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TABLE OF CONENTS
General Information ............................................................. 2
General Specifications............................................................ 2
Torque Specifications ............................................................. 3
Torque Conversions (ft-lb/N-m)............................................... 4
Break-In Procedure ................................................................ 4
Gasoline - Oil - Lubricant........................................................ 4
Genuine Parts......................................................................... 5
Preparation For Storage ......................................................... 5
Preparation After Storage ....................................................... 6
Periodic Maintenance .......................................................... 7
Periodic Maintenance Chart ................................................... 7
Lubrication Points ................................................................... 8
Air Filter .................................................................................. 8
Valve/Tappet Clearance.......................................................... 9
Testing Engine Compression ................................................ 10
Spark Plug ............................................................................ 10
Liquid Cooling System.......................................................... 11
Muffler/Spark Arrester .......................................................... 11
Adjusting Throttle Cable ....................................................... 11
Adjusting Engine RPM (Idle) ................................................ 12
Engine/Transmission Oil - Filter ........................................... 12
Front Differential/Rear Drive Lubricant ................................. 13
Tires...................................................................................... 13
Driveshaft/Coupling .............................................................. 14
Nuts/Bolts/Cap Screws ......................................................... 14
Ignition Timing ...................................................................... 14
Lights .................................................................................... 14
Shift Lever............................................................................. 16
Frame/Welds/Racks.............................................................. 16
Hydraulic Brake Systems...................................................... 16
Burnishing Brake Pads ......................................................... 18
Checking/Replacing V-Belt .................................................. 18
Engine/Transmission.......................................................... 21
Troubleshooting .................................................................... 22
Removing Engine/Transmission ........................................... 24
Top-Side Components .......................................................... 25
Removing Top-Side Components ......................................... 26
Servicing Top-Side Components .......................................... 29
Installing Top-Side Components ........................................... 36
Left-Side Components.......................................................... 39
Removing Left-Side Components......................................... 40
Servicing Left-Side Components .......................................... 42
Installing Left-Side Components........................................... 44
Right-Side Components ....................................................... 46
Removing Right-Side Components ...................................... 46
Servicing Right-Side Components........................................ 49
Installing Right-Side Components ........................................ 50
Center Crankcase Components ........................................... 52
Separating Crankcase Halves .............................................. 52
Disassembling Crankcase Half............................................. 53
Servicing Center Crankcase Components ........................... 54
Assembling Crankcase Half.................................................. 59
Joining Crankcase Halves .................................................... 61
Installing Engine/Transmission ............................................. 62
Fuel/Lubrication/Cooling .................................................... 64
Electronic Fuel Injection ....................................................... 64
Throttle Body ........................................................................ 64
Throttle Cable Free-Play....................................................... 64
Gas Tank .............................................................................. 65
Oil Filter/Oil Pump ................................................................ 66
Testing Oil Pump Pressure ................................................... 66
Liquid Cooling System ..........................................................67
Electric Fuel Pump/Fuel Level Sensor ..................................69
Troubleshooting .....................................................................71
Electrical System ................................................................72
Electrical Connections...........................................................72
Battery...................................................................................72
RPM Limiter ..........................................................................73
Testing Electrical Components..............................................73
Accessory Receptacle/Connector .........................................73
Brakelight Switch (Pressure) .................................................73
Fan Motor ..............................................................................74
Fuse Block/Power Distribution Module..................................75
Ignition Coil ...........................................................................75
Speed Sensor .......................................................................76
Ignition Switch .......................................................................77
Handlebar Control Switches..................................................77
Front Drive Selector Switch...................................................78
Front Drive Selector Actuator ................................................78
Gear Position Switch .............................................................78
Stator Coil .............................................................................79
Starter Relay .........................................................................79
Starter Motor .........................................................................80
Electronic Control Unit (ECU) ...............................................80
Regulator/Rectifier ................................................................80
Lights.....................................................................................81
Ignition Timing.......................................................................82
Tilt Sensor .............................................................................82
Throttle Position Sensor (TPS)..............................................83
Diagnostic Trouble Codes (DTC) ..........................................85
Troubleshooting .....................................................................87
Drive System ......................................................................88
Front Drive Actuator ..............................................................88
Front Differential....................................................................89
Drive Axles ............................................................................99
Rear Gear Case ..................................................................101
Hub......................................................................................101
Hand Brake Lever/Master Cylinder Assembly.....................102
Hydraulic Brake Caliper.......................................................102
Troubleshooting Drive System.............................................105
Troubleshooting Brake System............................................106
Suspension.......................................................................107
Shock Absorbers .................................................................107
Front A-Arms .......................................................................107
Rear A-Arms .......................................................................108
Wheels and Tires ................................................................109
Troubleshooting ...................................................................110
Steering/Frame/Controls ..................................................111
Steering Post/Tie Rods .......................................................111
LCD Gauge .........................................................................112
Handlebar Grip....................................................................113
Throttle Control ...................................................................113
Steering Knuckles ...............................................................114
Measuring/Adjusting Toe-Out..............................................116
Front Rack...........................................................................116
Front Bumper Assembly......................................................117
Front Body Panel/Fender ....................................................117
Exhaust System ..................................................................118
Rear Body Panel/Rack ........................................................119
Seat.....................................................................................120
Troubleshooting ...................................................................121
