- 2Contents
- 4General Information/safety
- 5Service Rules
- 6Model Identification
- 7Specifications
- 9Lubrication/fuel System Specification
- 10Cooling System, Cylinder Head/valves Specifications
- 11Clutch/gearshift Linkage, Alternator/starter Clutch, Crankcase/piston/cylinder Specifications
- 12Crankshaft/transmission Specification
- 13Front, Rear Wheel/suspension/steering Specification
- 14Hydraulic Brake/battery/charging System Specifications
- 15Ignition System/electric Starter/lights/meters/switches Specifications
- 16Torque Values
- 20Tools
- 22Lubrication and Seal Points
- 25Cable and Harness Routing
- 38Secondary Air Supply System Routing
- 39Emission Control Systems
- 39Source of Emissions
- 39Crankcase Emission Control System
- 40Evaporative Emission Control System/noise Emission Control System
- 41Exhaust Emission Control System (Pulse Secondary Air Injection System)
- 42Emission Control Information Labels
- 42Vehicle Emission Control Information Update Label
- 42Vacuum Hose Routing Diagram Label
- 43Body Panel Locations
- 44Frame/body Panels/exhaust System: Contents, Service Information, Troubleshooting
- 45Seat/fuel Tank Removal
- 46Seat/fuel Tank Installation
- 46Pillion Seat/side Cover Removal
- 48Seat/side Cover Installation
- 49Middle/lower Cowl Removal
- 50Middle/lower Cowl Installation
- 50Upper Cowl Rearview Mirror Removal
- 51Upper Cowl Removal
- 53Windscreen Replacement
- 54Upper Cowl Installation
- 55Rearview Mirror Installation
- 56Front Fender Removal/installation
- 57Rear Fender Removal
- 58Rear Fender Installation
- 58Seat Rail Removal
- 59Seat Rail Installation
- 59Muffler/Exhaust Pipe Removal
- 60Muffler/Exhaust Pipe Installation
- 62Maintenance: Contents, Service Information
- 64Maintenance Schedule
- 65Fuel Line
- 65Throttle Operation
- 66Carburetor Choke
- 66Air Cleaner
- 66Spark Plug
- 67Spark Plug Inspection
- 67Reusing/replacing a Spark Plug
- 68Valve Clearance Inspection
- 71Valve Clearance Adjustment
- 72Engine Oil/oil Filter
- 72Oil Level Inspection
- 73Engine Oil and Filter Change
- 74Carburetor Synchronization
- 76Engine Idle Speed
- 76Radiator Coolant
- 77Cooling System
- 77Secondary Air Supply System
- 78Evaporative Emission Control System
- 78Drive Chain Slack Inspection
- 79Drive Chain Slack Adjustment, Cleaning and Lubrication
- 80Sprockets Inspection, Replacement
- 82Brake Fluid
- 82Front/rear Brake
- 83Brake Pad Wear
- 83Brake System Inspection
- 83Front/rear Brake Pads
- 84Brake Light Switch
- 84Headlight Aim
- 84Brake Lever/pedal Height Adjustment
- 85Clutch System
- 86Side Stand
- 86Front Suspension Inspection/adjustment
- 87Rear Suspension Inspection
- 88Nuts, Bolts, Fasteners
- 88Rear Suspension Adjustment
- 89Wheels/tires
- 89Steering Head Bearings
- 91Lubrication System Diagram
- 92Lubrication System: Contents, Service Information
- 93Lubrication System: Troubleshooting
- 94Oil Pressure Inspection
- 95Oil Strainer/pressure Relief Valve Removal, Inspection
- 96Oil Strainer/pressure Relief Valve Installation
- 97Oil Pump Removal, Disassembly
- 98Oil Pump Inspection
- 99Oil Pump Assembly
- 100Oil Pump Installation
- 101Oil Cooler Removal
- 102Oil Cooler Inspection, Installation
- 105Fuel System Overview
- 106Fuel System: Contents, Service Information
- 108Fuel System: Troubleshooting
- 109Air Cleaner Housing Removal/installation
- 110Carburetor Removal
- 111Carburetor Separation
- 112Carburetor Disassembly
- 112Air Funnel
- 113Starting Enrichment Valve
- 113Diaphragm/vacuum Piston
- 114Float and Jets
- 116Carburetor Assembly
- 120Carburetor Combination
- 124Carburetor Installation
- 125Pilot Screw Adjustment
- 125Idle Drop Procedure
- 126High Altitude Adjustment
- 127Secondary Air Supply System Inspection
- 128Fuel Auto Valve Inspection
- 128Diaphragm Replacement
- 129Fuel Strainer Cleaning
- 131Cooling System Flow Pattern
- 132Cooling System: Contents, Service Information
- 133Cooling System: Troubleshooting
- 134Cooling System Testing
- 134Radiator Cap/system Pressure Inspection
- 135Coolant Replacement Preparation/replacement/air Bleeding
- 136Thermostat Removal
- 137Thermostat Inspection
- 138Thermostat Installation
- 139Radiator Removal, Disassembly
- 140Radiator Assembly
- 142Radiator Installation
- 142Water Pump
- 142Mechanical Seal Inspection
- 143Water Pump Removal/installation
- 145Radiator Reserve Tank Removal/installation
- 147Engine Removal/installation
- 148Engine Removal/installation: Contents, Service Information
- 149Engine Removal
- 153Engine Installation
- 159Cylinder Head/valves Overview
- 160Cylinder Head/valves: Contents, Service Information
- 162Cylinder Head/valves: Troubleshooting
- 163Cylinder Compression Test
- 163Cylinder Head Cover Removal
- 164Camshaft Removal
- 166Camshaft Inspection
- 167Camshaft Oil Clearance
- 168Cylinder Head Removal
- 169Cylinder Head Disassembly
- 170Cylinder Head Inspection
- 171Cam Chain Tensioner/cam Chain Guide
- 171Valve Spring/lifter
- 172Valve Lifter Bore, Valve Guide
- 173Valve Guide Replacement
- 174Valve Sear Inspection/refacing
- 176Cylinder Head Assembly
- 178Cylinder Head Installation
- 179Camshaft Installation
- 183Cylinder Head Cover Installation
- 184Cam Chain Tensioner Lifter Removal
- 185Cam Chain Tensioner Lifter Installation
- 187Clutch/gearshift Linkage Overview
- 188Clutch/gearshift Linkage: Contents, Service Information
- 189Clutch/gearshift Linkage: Troubleshooting
- 190Right Crankcase Cover Removal
- 190Clutch Lifter Inspection
- 191Clutch Removal
- 193Clutch Inspection
- 195Clutch Outer Needle Bearing Replacement/installation
- 198Gearshift Linkage Removal
- 199Gearshift Linkage Inspection
- 199Shift Drum/shift Fork Removal
- 200Shift Drum/shift Fork Inspection
- 201Shift Drum/shift Fork Installation
- 202Gearshift Linkage Installation
- 203Right Crankcase Cover Installation
- 205Alternator/starter Clutch Overview
- 206Alternator/starter Clutch: Contents, Service Information, Troubleshooting
- 207Alternator Cover Removal
- 208Stator Removal/installation
- 209Flywheel Removal
- 210Starter Clutch Inspection/disassembly
- 211Starter Clutch Assembly
- 212Flywheel Installation
- 213Alternator Cover Installation
- 215Crankcase/piston/cylinder Overview
- 216Crankcase/piston/cylinder: Contents, Service Information
- 217Crankcase/piston/cylinder: Troubleshooting
- 218Crankcase Separation
- 219Piston/connecting Rod Removal
- 220Piston Inspection
- 221Cylinder Inspection
- 222Connecting Rod/crankpin Bearing Inspection
- 223Crankpin Bearing Selection
- 224Crankpin Bearing Selection Table
- 225Piston Assembly, Installation
- 227Crankcase Combination
- 229Crankshaft/transmission Overview
- 230Crankshaft/transmission: Contents, Service Information
- 231Crankshaft/transmission: Troubleshooting
- 232Crankshaft Removal
- 233Primary Drive Sub-gear Removal/installation
- 234Starter Clutch Needle Bearing Replacement
- 235Starter Clutch Needle Bearing Inspection
- 235Main Journal Bearing
- 236Main Journal Bearing Selection
- 237Main Journal Bearing Installation
- 238Transmission Removal/disassembly
- 240Bearing Replacement
- 241Bearing Assembly
- 242Bearing Installation
- 243Front Wheel/suspension/steering Overview
- 244Front Wheel/suspension/steering: Contents, Service Information
- 245Front Wheel/suspension/steering: Troubleshooting
- 246Handlebars Removal
- 248Handlebars Installation
- 248Handlebar Weight Replacement
- 251Front Wheel Removal
- 252Front Wheel Inspection
- 254Front Wheel Disassembly/assembly
- 255Front Wheel Installation
- 257Fork Removal
- 258Fork Disassembly
- 260Fork Inspection
- 261Fork Tube/slider/piston
- 261Fork Tube Bushing
- 261Compression Adjuster
- 262Fork Tube Assembly
- 265Fork Tube Installation
- 266Steering Stem Removal
- 273Steering Stem Installation
- 275Steering Head Bearing Pre-load
- 277Rear Wheel/suspension Overview
- 278Rear Wheel/suspension: Contents, Service Information
- 279Rear Wheel/suspension: Troubleshooting
- 280Rear Wheel Removal, Inspection
- 281Rear Wheel Disassembly
- 282Drive Flange Bearing Removal
- 283Rear Wheel Assembly
- 283Wheel Bearing Removal
- 284Driven Flange Bearing Installation
- 285Rear Wheel Installation
- 286Shock Absorber Removal, Disassembly
- 287Shock Absorber Inspection
- 288Shock Absorber Disposal Procedure
- 288Lower Joint Needle Bearing Replacement
- 291Suspension Linkage Removal/disassembly
- 292Suspension Linkage Installation
- 292Shock Link Needle Bearing Replacement
- 293Swingarm Removal
- 295Swingarm Disassembly/inspection
- 296Pivot Bearing Replacement
- 298Swingarm Assembly
- 298Shock Link Pivot Bearing Replacement
- 299Swingarm Installation
- 303Hydraulic Brake Overview
- 304Hydraulic Brake: Contents, Service Information
- 305Hydraulic Brake: Troubleshooting
- 306Brake Fluid Replacement/air Bleeding
- 307Brake Bleeding
- 308Brake Pads/discs
- 308Front Brake Pad Replacement
- 311Rear Brake Pad Replacement
- 312Brake Disc Inspection
- 313Front Master Cylinder Removal/disassembly
- 314Front Master Cylinder Inspection
- 315Front Master Cylinder Assembly
- 317Rear Master Cylinder Removal/disassembly
- 318Rear Master Cylinder Inspection
- 319Rear Master Cylinder Assembly
- 320Rear Master Cylinder Installation
- 321Front Brake Caliper Removal
- 322Front Brake Caliper Disassembly
- 323Front Brake Caliper Inspection, Assembly
- 324Front Brake Caliper Installation
- 325Rear Master Cylinder Removal
- 329Rear Brake Caliper Removal/disassembly
- 330Rear Brake Caliper Inspection
- 331Rear Brake Caliper Assembly
- 332Rear Brake Caliper Installation
- 332Brake Pedal Removal
- 337Battery/charging System Diagram
- 338Battery/charging System: Contents, Service Information
- 340Battery/charging System Troubleshooting
- 342Battery Removal/installation/charging
- 342Voltage Inspection
- 343Charging System Inspection
- 343Regulated Voltage Inspection
- 344Current Leakage Inspection
- 345Alternator Charging Coil Inspection
- 345Regulator/rectifier System Inspection
- 346Regulator/rectifier Removal and Installation
- 347Ignition System Diagram
- 349Ignition System: Contents, Service Information
- 350Ignition System: Troubleshooting
- 351Ignition System Inspection
- 351Ignition Coil Primary Peak Voltage
- 352Ignition Pulse Generator Peak Voltage
- 353Ignition Coil Removal/installation
- 354Ignition Pulse Generator Removal
- 355Ignition Pulse Generator Installation
- 357Throttle Sensor Inspection
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