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QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization /Warning, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Special tools / Basic service methods / Storage
CHAPTER TWO / TROUBLESHOOTING
Engine operating principles / Engine operating principles / Starting the engine / Engine Spark test / Engine performance / Engine noises / Leakdown test / Fuel system / Clutch / External shift mechanism and transmission / Kickstarter / Drive train noise / Front suspension and steering / Rear suspension / Frame noise / Brakes
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Service intervals / Tune-up / Valve clearance / Pre-ride inspection / Engine lubrication / Oil and filter change / Transmission oil / Air filter / Engine compression check / Ignition timing / Spark plug / Engine top end inspection / Kickstarter pedal and shift pedal / Drive chain and sprockets / Wheel bearings / Steering / Fasteners / Specifications
CHAPTER FOUR AND FIVE / ENGINE
Cleanliness / Exhaust system / Exhaust manifold / циліндрична головка / циліндр / Exhaust valve system 1998-1999 models / Exhaust valve system 2000-on models / Piston, piston ring and connecting rod / Reed valve assembly / Engine break-in / Removal installation / Countershaft seal replacement / Left main bearing seal / Crankcase and Crankshaft / Crankcase Seal and Bearing / Engine break-in / Specifications
CHAPTER SIX / CLUTCH
Right crankcase cover / exhaust Valve governor and Valve linkage / Clutch cover / Clutch / Clutch lifter lever / Primary drive gear / Kickstarter and kick idle gear / Gearshift linkage / Clutch Cable replacement / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation / Transmission troubleshooting / Transmission / Service notes / Mainshaft / Countershaft / Transmission inspection / Internal shift mechanism / Specifications
CHAPTER EIGHT / FUEL SYSTEM
Carburetor 1998-1999 models / Carburetor 2000-2001 models / Carburetor 2002 models / float height adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Throttle cable / Air box / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Flywheel / Stator / Ignition coil / Ignition Coil module ICM / Engine Stop switch / Ignition system testing / Ignition timing / Wiring diagrams / Specifications
CHAPTER TEN / COOLING SYSTEM
Safety precautions / Hoses and Hose clamps / Cooling system inspection / Water pump mechanical seal inspection / pressure testing / радіатор / Water pump / Specifications
CHAPTER ELEVEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel / Rear wheel / Front and rear hubs / Wheel service / Drive chain / Sprocket replacement / Tire changing / Specifications
Chapter TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Handlebar grips / Steering head / Steering play check and adjustment / Steering head bearing races / Front fork / Front fork service 1998-1999 models / Front fork service 2000-on models / Fork inspection all models / Fork oil change and oil Level adjustment all models / Front fork adjustment / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Rear suspension operation / Shock absorber / Shock linkage / Rear swing arm / Rear Suspension adjustment / Specifications
CHAPTER FOURTEEN / BRAKES
Гальмівна служба / передні гальмівні колодки / передній гальмівний супорт / передній Головний циліндр / задня гальмівна накладка Заміна / Задній гальмівний супорт / задній Головний циліндр / Заміна гальмівного шланга / гальмівний диск / дренажна Гальмівна рідина / гальмівне кровотеча / задня гальмівна педаль / Specifications
CHAPTER FIFTEEN / BODY
Seat / Side covers / Heatsink shrouds / Number plate / Front fender / Rear fender / Footpegs / Subframe / Specifications
INDEX
WIRING DIAGRAMS