Repair Manual

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Routine safety checks / Service intervals / Oil and filter change / Transmission oil check / Final drive oil change / Drive shaft oil change / Air filter change / Control cable lubrication / Periodic lubrication / Periodic maintenance / Tune-up / Valve clearance adjust / Compression test / Spark plugs / Idle speed and fuel injector throttle synchronization / Specifications

CHAPTER FOUR / ENGINES
Removal installation / Crankshaft cover, cylinder head cover and timing chain cover / Camshafts, timing chain and chain tensioner / Cylinder head / Valves and components / Oil water pump / Intermediate housing / Starter clutch and gears / Oil pan, lower crankcase half and output shaft / Pistons and connecting rods / Crankshaft / Cylinder block / Break-in / Specifications

CHAPTER FIVE / CLUTCH
Clutch release mechanism / Clutch cable / Specifications

CHAPTER SIX / TRANSMISSION AND GEARSHIFT MECHANISMS
Housing / Transmission shafts and gearshift mechanism / Specifications

CHAPTER SEVEN / FUEL INJECTION SYSTEM, EMISSION CONTROLS AND EXHAUST SYSTEM
Depressurizing the system / Fuel injectors and fuel supply pipe / Throttle housing and intake manifold / Pressure regulator / Air flow meter / Fuel injection control unit / Throttle valve switch / Air filter case / Throttle cable / Choke cable / Fuel pump / Fuel filler cap / Fuel tank / Fuel gauge sensor / Fuel level sender / Crankcase breather system / Evaporative emission control system / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Charging system / Alternator / Voltage rectifier / Ignition systems / Hall transmitter unit / Ignition control unit / Ignition coils / Spark plug secondary wires / Starting system / Starter / Starter relay / Lighting system / Switches / Electrical connectors / Instrument cluster / Relays / Horn / Fuses / Chassis wiring harness / Wiring diagrams / Specifications

CHAPTER NINE / COOLING SYSTEM
Hoses and clamps / Pressure check / Radiator / Cooling fan / Thermostat / Connector pipe / Coolant recovery tank / Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Wheel and hub / Handlebar / Steering head and stem / Steering head bearing race / Front fork / Specifications

CHAPTER ELEVEN / REAR SUSPENSION AND FINAL DRIVE
Wheel and hub / Shock absorber / Swing arm and drive shaft / Final drive unit / Pinion gear-to-ring gear adjustment / Taper roller bearing preload / Specifications

CHAPTER TWELVE / BRAKES
Brake pad / Master cylinder / Front rear caliper / Disc brake / Rear brake pad / Brake hose and line non-ABS models / ABS brake system / Brake hose and line ABS models / Pressure modulator and mounting bracket / Trigger sensor / Bleeding the system / Rear brake pedal / Specifications

CHAPTER THIRTEEN / FRAME AND BODY

CHAPTER FOURTEEN / SUPPLEMENT

INDEX

WIRING DIAGRAMS