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TABLE OF CONTENTS
General Information........................................................... 2
General Specifications.................................................. 2
Torque Specifications.................................................... 3
Torque Conversions (ft-lb/N-m)..................................... 3
Break-In Procedure ...................................................... 3
Gasoline - Oil - Lubricant .............................................. 4
Genuine Parts............................................................... 5
Preparation For Storage ............................................... 5
Preparation After Storage ............................................. 5
Periodic Maintenance/Tune-Up......................................... 6
Periodic Maintenance Chart ......................................... 6
Lubrication Points ......................................................... 7
Air Filter ........................................................................ 7
Valve/Tappet Clearance ................................................ 8
Testing Engine Compression ........................................ 9
Spark Plug .................................................................... 9
Muffler/Spark Arrester ................................................ 10
Engine Oil - Filter ........................................................ 10
Transmission Lubricant ............................................... 11
Drive Chain ................................................................. 11
Headlight/Taillight-Brakelight ...................................... 12
Shift Lever................................................................... 12
Brake Systems............................................................ 13
Burnishing Brake Pads (Rear) .................................... 15
Checking/Replacing V-Belt ......................................... 15
Steering/Body/Controls ................................................... 17
Body ........................................................................... 17
Steering Post Cover/Instrument Pod .......................... 18
Steering Post/Tie Rods............................................... 18
Measuring/Adjusting Toe-In/Toe-Out .......................... 20
Front Brake Lever ....................................................... 21
Throttle Control ........................................................... 22
Troubleshooting .......................................................... 23
Engine/Transmission....................................................... 24
Removing Engine/ Transmission ................................ 24
Top-Side Components ................................................ 26
Removing Top-Side Components ............................... 27
Servicing Top-Side Components ................................ 28
Installing Top-Side Components ................................. 32
Left-Side Components ................................................ 34
Removing Left-Side Components............................... 34
Servicing Left-Side Components ................................ 35
Installing Left-Side Components................................. 39
Right-Side Components ............................................. 40
Removing Right-Side Components ............................ 40
Servicing Right-Side Components.............................. 42
Installing Right-Side Components .............................. 43
Disassembling Crankcase Half................................... 46
Servicing Center Crankcase Components ..................47
Assembling Crankcase Half ........................................49
Installing Engine/Transmission ....................................52
Troubleshooting ...........................................................54
Fuel/Lubrication/Cooling .................................................57
Carburetor ...................................................................57
Throttle Cable Free-Play .............................................61
Engine RPM (Idle) .......................................................61
Gas Tank .....................................................................61
Gas Tank Valve ...........................................................62
Gas/Vent Hoses ..........................................................62
Oil Flow Chart .............................................................62
Oil Pump .....................................................................62
Troubleshooting ...........................................................63
Electrical System..............................................................64
RPM Limiter ................................................................64
Testing Electrical Components ....................................64
Electrical Connections.................................................64
Switches ......................................................................64
Battery.........................................................................64
Brakelight Switch.........................................................65
Fuse Holder.................................................................66
Ignition Coil .................................................................66
LCD Gauge Assembly.................................................67
Ignition Switch .............................................................68
Handlebar Control Switches........................................68
Magneto Coils .............................................................69
Starter Motor ...............................................................69
Starter Relay ...............................................................70
CDI Unit.......................................................................70
Regulator/Rectifier ......................................................70
Start-in-Gear Relay .....................................................70
Headlights ...................................................................71
Taillight - Brakelight .....................................................71
Ignition Timing .............................................................71
Troubleshooting ...........................................................72
Drive System.....................................................................74
Rear Drive Axle ...........................................................74
Rear Brake Lever/Master Cylinder Assembly..............76
Troubleshooting Drive System.....................................77
Suspension .......................................................................78
Front Shock Absorbers................................................78
Rear Shock Absorber ..................................................78
Swing Arm...................................................................79
Front A-Arms ...............................................................80
Wheels and Tires ........................................................82
Troubleshooting ...........................................................83
