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TABLE OF CONTENTS
General Information ...................................................... 2
General Information.................................................................2
Torque Specifications ..............................................................2
Torque Conversions (ft-lb/N-m) ...............................................3
Break-In Procedure .................................................................3
Gasoline - Oil - Lubricant ........................................................4
Genuine Parts .........................................................................4
Preparation For Storage ..........................................................4
Preparation After Storage........................................................5
Periodic Maintenance ................................................... 6
Periodic Maintenance Chart ....................................................6
Lubrication Points ....................................................................7
Air Filter ...................................................................................7
Valve/Tappet Clearance...........................................................7
Testing Engine Compression...................................................9
Spark Plugs .............................................................................9
Muffler/Spark Arrester .............................................................9
Engine/Transmission Oil - Filter ............................................10
Liquid Cooling System...........................................................11
Front Differential/Rear Drive Lubricant ..................................12
Nuts/Bolts/Cap Screws..........................................................12
Headlights/Taillight-Brakelight ...............................................12
Shift Lever .............................................................................14
Hydraulic Brake Systems ......................................................14
Burnishing Brake Pads ..........................................................16
Checking/Replacing V-Belt ....................................................16
Steering/Frame/Controls ............................................ 19
Front Body Panel/Side Panels...............................................19
Rear Body Panel/Rack ..........................................................22
LCD Gauge ...........................................................................23
Steering Post/Tie Rods .........................................................23
Handlebar Grip ......................................................................26
Throttle Control......................................................................27
Steering Knuckles .................................................................28
Measuring/Adjusting Toe-Out ................................................29
Shift Lever .............................................................................31
Front Rack .............................................................................31
Front Bumper Assembly ........................................................31
Footrests ...............................................................................32
Belly Panel ............................................................................32
Exhaust System ....................................................................32
Taillight Assembly..................................................................32
Seat .......................................................................................33
Troubleshooting .....................................................................33
Engine/Transmission .................................................. 34
Specifications ........................................................................34
Troubleshooting .....................................................................35
Removing Engine/Transmission ............................................37
Servicing Engine ...................................................................41
Installing Engine/Transmission ..............................................85
Fuel/Lubrication/Cooling............................................ 89
Electronic Fuel Injection ........................................................89
Throttle Cable Free-Play .......................................................90
Gas Tank ...............................................................................91
Oil Filter/Oil Pump................................................................. 91
Testing Oil Pump Pressure ................................................... 91
Oil Cooler .............................................................................. 92
Liquid Cooling System .......................................................... 92
Electric Fuel Pump/Fuel Level Sensor .................................. 94
Troubleshooting..................................................................... 96
Electrical System ........................................................97
Electrical Connections .......................................................... 97
Battery .................................................................................. 97
RPM Limiter .......................................................................... 98
Testing Electrical Components.............................................. 98
Accessory Receptacle/Connector......................................... 98
Brakelight Switch (Auxiliary).................................................. 98
Brakelight Switch (Handlebar Control) .................................. 99
Engine Coolant Temperature (ECT) Sensor ....................... 100
Fan Motor............................................................................ 100
Power Distribution Module (PDM) ....................................... 100
Ignition Coil ......................................................................... 101
EFI Sensors/Components................................................... 102
Speed Sensor ..................................................................... 102
Electronic Power Steering (EPS) ........................................ 103
Ignition Switch..................................................................... 105
Handlebar Control Switches ............................................... 106
Drive Select Switch ............................................................. 107
Front Drive/Differential Lock Actuator ................................. 107
Stator Coil/Crankshaft Position (CKP) Sensor .................... 108
Starter Relay ....................................................................... 108
Starter Motor ....................................................................... 109
Electronic Control Module (ECM) ....................................... 109
Regulator/Rectifier .............................................................. 110
Headlights ........................................................................... 110
Taillight - Brakelight ............................................................. 110
Ignition Timing..................................................................... 110
Tilt Sensor........................................................................... 111
Throttle Position Sensor (TPS) ........................................... 112
EFI Diagnostic System........................................................ 112
Troubleshooting................................................................... 114
Drive System/Brake System.....................................116
Front Drive Actuator/Differential Lock ................................. 116
Front Differential.................................................................. 117
Drive Axles.......................................................................... 129
Rear Gear Case.................................................................. 132
Hub ..................................................................................... 135
Hand Brake Lever/Master Cylinder Assembly..................... 136
Hydraulic Brake Caliper ...................................................... 138
Troubleshooting Drive System ............................................ 141
Troubleshooting Brake System ........................................... 141
Suspension ................................................................142
Shock Absorbers................................................................. 142
Front A-Arms....................................................................... 143
Rear A-Arms ....................................................................... 145
Wheels and Tires ................................................................ 147
Troubleshooting ................................................................... 148
