QUICK REFERENCE DATA
GENERAL INFORMATION
TROUBLESHOOTING
LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule intervals / Periodic lubrication Oil and filter change / Oil pressure check / Battery / Tune-up / Air filter / Spark plugs / Engine compression test / Ignition timing / Valve clearance adjustment
ENGINE
Cylinder head covers / Camshafts / Cam sprockets / Cylinder heads / Valves and valve components/ Removal installation / Crankcase breather cover / Alternator cover / Stator and pickup coils / Flywheel / Starter clutch / Starter gears / Oil pan / Oil pump / Main oil gallery / Piston connecting rod assembly / Pistons and rings / Crankcase / Crankshaft and cam chain / Balancer shaft / Break-in
CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch bleeding and draining / Clutch cover / Master and slave cylinder / External shift mechanism / Hose replacement
TRANSMISSION, MIDDLE GEAR AND INTERNAL SHIFT MECHANISM
Shift pedal / Middle gearcase cover / Internal shift mechanism / Middle drive gear assembly / Middle gear backlash adjustment / Rounding shim thickness measurements / Middle gear alignment / Middle driven gear assembly
AIR/FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Fuel tank / Fuel filter / Fuel pump / Fuel pump relay / Fuel pump testing / Air box / Carburetor operation / Carburetor / Carburetor cleaning and inspection / Carburetor adjustments / Throttle cable / Throttle cable adjustment / V-Boost assembly / V-Boost servomotor / V-Boost control unit / V-Boost adjustment / V-Boost testing / Evaporative emission control system / Exhaust system
ELECTRICAL SYSTEM
Electrical connectors / Battery terminal / Frame neck / Electrical bracket / Charging system / Stator / Voltage regulator/rectifier / Ignition system / Ignition coil / Pickup coil / Spark plug cap / Diode / Pressure sensor / Ignitor unit / Ignition timing / Starting system / Starter / Starter relay / Starting circuit cutoff relay / Lighting system / Headlight / Meter assembly / Taillight / Signal system / Brake light / Turn signals / Flasher relay / Horn / Indicator lights / Switches / Wiring connectors / Fuses
COOLING SYSTEM
Hoses and clamps / Cooling system check / Water pump / Thermostat housing and drain cock assembly / Coolant reservoir / Coolant manifold / Radiator / Fan assembly / Thermoswitch / Temperature sender
WHEELS AND TIRES
Front and rear wheel / Front and rear hub / Wheel balance / Tire repair / Tire changing
FRONT SUSPENSION AND STEERING
Front fork / Handlebar / Steering head / Steering head bearing races / Lower bearing inner race replacement
REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Swing arm / Final gearcase
BRAKES
Brake bleeding and draining / Brake pad replacement / Front brake caliper / Front brake master cylinder / Rear brake caliper / Rear brake master cylinder / Footpeg/brake level assembly / Brake disc / Brake hose replacement
BODY
Top cover / Front side cover / Side cover / Rider footpeg / Passenger footpeg / Rider seat / Passenger seat / Front fender / Rear fender
INDEX
COLOR WIRING DIAGRAMS
