1
Chapter One General Information
2
Chapter Two Troubleshooting
3
Chapter Three Periodic Lubrication, Maintenance and Tune-up
4
Chapter Four Engine
5
Chapter Five Clutch, Primary Drive and Starter Drive
6
Chapter Six Transmission
7
Chapter Seven Fuel, Exhaust and Emission Control Systems
8
Chapter Eight Electrical System
9
Chapter Nine Wheels, Hubs and Tires
10
Chapter Ten Front Suspension and Steering
11
Chapter Eleven Rear Suspension
12
Chapter Twelve Brakes
13
Supplement 1996-1998 Service Information
14
Index
15
Wiring Diagrams
CONTENTS
QUICK REFERENCE DATA ........................................................................................................ IX CHAPTER ONE GENERAL INFORMATION ............................................................................................................1 Manual organization Notes, cautions and warnings Safety first Service hints Serial numbers Parts replacement Torque specifications Fasteners Lubricants Sealant, cements and cleaners
Expendable supplies Basic hand tools Test equipment Precision measuring tools Other special tools Mechanic's tips Ball bearing replacement Oil seals Riding safety
CHAPTER TWO TROUBLESHOOTING....................................................................................................................36 Operating requirements Troubleshooting instruments Testing electrical components Emergency troubleshooting Engine performance Electric starting system Charging system Ignition system Fuel system
Engine noises Engine lubrication Clutch Transmission Electrical problems Excessive vibration Front suspension and steering Brake problems
CHAPTER THREE PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP ......................................................89 Routine safety checks Maintenance intervals Cleaning your motorcycle Tires and wheels Periodic lubrication
Periodic maintenance Tune-up Ignition service Idle speed adjustment
CHAPTER FOUR ENGINE .................................................................................................................................... 127 Service precautions Special tools Servicing engine in frame Engine Rocker arm cover and cylinder head Valves and valve components Cylinders Pistons and piston rings
Pushrods Lifters and lifter guides Oil pump Oil filter mount (1992-on) Gearcase cover and timing gears Crankcase and crankshaft Engine break-in
CHAPTER FIVE CLUTCH AND PRIMARY DRIVE............................................................................................. 210 Outer primary cover Clutch plates Clutch, compensating sprocket and primary drive chain removal and installation Clutch overhaul Primary chain and guide inspection
Primary chain alignment Compensating sprocket inspection Inner primary housing Starter jackshaft Clutch cable replacement
CHAPTER SIX TRANSMISSION....................................................................................................................... 238 Production gear changes Shifter adjustment Transmission top cover Shifter cam Shift forks Transmission side door
Transmission shafts Main drive gear Transmission case Transmission side cover Oil tank
CHAPTER SEVEN FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS..................................................... 275 Air filter backplate (all 1991-1995 domestic and 1991-1994 international models) Air filter backplate (1995 international models) Carburetor Throttle and idle cable replacement Enrichener cable replacement
Fuel tank Fuel valve Exhaust system Evaporative emission control system (California models) Evaporative emission control system service
CHAPTER EIGHT ELECTRICAL SYSTEM ........................................................................................................... 321 Battery Charging system Ignition system Ignition coil Vacuum operated electric switch Starter Starter solenoid Lighting system
Switches Horn Turn signal module Speedometer speed sensor (1995) Indicator lights Electric panel Starter relay switch replacement Circuit breakers
CHAPTER NINE WHEELS, HUBS AND TIRES...................................................................................................376 Front wheel Front hub Rear wheel Rear hub Driven sprocket assembly Secondary drive belt Drive sprocket
Wire spoke wheels Cast wheels Wheel balance Tires Tire repairs (tube-type tires) Tire repairs (tubeless type) Vehicle alignment
CHAPTER TEN FRONT SUSPENSION AND STEERING ................................................................................ 409 Handlebar Front forks Steering head and stem
Steering head bearing race Steering play adjustment
CHAPTER ELEVEN REAR SUSPENSION............................................................................................................... 427 Shock absorbers
Rear swing arm
CHAPTER TWELVE BRAKES................................................................................................................................... 439 Front brake pads Front brake caliper Front master cylinder Rear brake pads Rear brake caliper
Rear master cylinder Brake hose and line replacement Brake disc (front and rear) Bleeding the system
SUPPLEMENT 1996-1998 SERVICE INFORMATION....................................................................................478 Periodic lubrication Charging system Periodic maintenance Ignition system Ignition service Starter Clutch plates (1998 models) Switches Clutch overhaul Front master cylinder Battery
INDEX .....................................................................................................................................506 WIRING DIAGRAMS ..............................................................................................................510
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