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QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Oil Pressure test / Leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system (carbureted models) / Electronic diagnostic system / Electrical testing / Lighting system / Charging system / Ignition system / Starting system / Suspension and steering / Brake system
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
pre-ride check list / maintenance schedule / Tires and wheels / Battery / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Non-scheduled maintenance / Tune-up / Valve clearance / Compression test / Spark plugs / Ignition timing / Fuel System adjustment / Specifications
CHAPTER FOUR / ENGINE TOP END
цилиндр head cover caps / цилиндр Head covers / Rocker ARM assemblies / распредвалы / цилиндр head and цилиндр / цилиндр head / Valves and valve components / Camshaft Chain tensioner / цилиндр / поршни и поршневые кольца / Specifications
CHAPTER FIVE / Engine LOWER END
Engine removal and installation / Oil pump / Starter clutch and gears / Primary drive gear / Camshaft drive chains and drive sprockets / Secondary gear assembly / Crankcase / Crankshaft and connecting rods / Break-in / Specifications
CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Clutch cable / Clutch cover / Clutch release mechanism / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Internal shift mechanism / Transmission / Specifications
CHAPTER EIGHT / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (2001-2004 MODELS)
Carburetor / Pilot screw / Carburetor float height / Throttle position (TP) sensor / carburetor heater (U. K. models) / Throttle cable / Starter (choke) cable / Air box / Fuel tank / Fuel valve / Fuel pump / Pair (Air supply) system / Crankcase breather system / Evaporative emission control system (California models) / Exhaust system / Specifications
CHAPTER NINE / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (2005-ON MODELS)
Electronic Fuel injection (EFI) / Fuel delivery system tests / Fuel pump / Fuel Pump relay / Fuel Pressure regulator / Throttle cable / Air box / Throttle body / Fuel injectors / Crankshaft position (CKP) sensor / Throttle position (TP) sensor / Secondary throttle position (STP) sensor / Secondary throttle Valve actuator (STVA) / Fast idle speed / intake air pressure (IAP) Sensors / Engine coolant temperature (ECT) Sensor / intake air temperature (IAT) Sensor / heated Oxygen (ho2) Sensor / Tip-over (to) Sensor / Fuel Tank / Pair (Air Supply) System / EVAPORATIVE Emission Control System (California Models) / exhaust System / specifications
CHAPTER TEN / ELECTRICAL SYSTEM
Peak voltage and resistance testing / Electrical component replacement / Electrical connectors / Charging system / Voltage Controller / rectifier / Alternator / Electronic ignition system / Igniter / Electronic control module ECM / Starter system / Starter relay / Lighting system / Switches / Relay assembly / Speedometer / Horn / Cooling system / Fuses / Wiring diagrams / Specifications
Chapter ELEVEN / COOLING SYSTEM
Coolant reservoir / радиатор / Cooling fan / Thermostat / Water pump / Cooling Fan switch / Engine coolant temperature ECT switch / Specifications
CHAPTER TWELVE / WHEELS AND TIRES
Front wheel / Rear wheel / Front wheel hub / Rear wheel hub / Wheel service / Tires / Wheel balance / Specifications
CHAPTER THIRTEEN / FRONT SUSPENSION AND STEERING
Balancer weights / Handlebar / Handlebar left Hand grip replacement / Steering stem and head / Steering head bearing races / Front fork / Specifications
CHAPTER FOURTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Final drive and driveshaft / Swing arm / Shock linkage / Bearing replacement / Specifications
CHAPTER FIFTEEN / BRAKES
Brake fluid selection / Brake service / Front brake pads / Front Brake caliper / Front brake master цилиндр / Front Brake hose / Front Brake disc / brake bleeding / Rear drum brake / Rear brake pedal / Rear brake pivot lever / Specifications
CHAPTER SIXTEEN / BODY AND FRAME
Seats / Frame side covers / Frame head side covers / Toolbox / Sidestand / Front fender / Rear fender / Left footpeg / footrest / Right footpeg / Footrest / Specifications
COLOR WIRING DIAGRAMS