Buell S1 Lightning Workshop Manual Download Page 261 | Manualshive

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6-17

CLEANING, INSPECTION
AND REPAIR

Thoroughly clean transmission compartment with cleaning
solvent. Blow parts dry with compressed air. Inspect parts to
determine if any must be replaced. Replace all parts that are
badly worn or damaged.

Neutral Indicator Switch

See

The neutral indicator switch is threaded into

the transmission portion of the right crankcase half. See

NEUTRAL INDICATOR SWITCH

in Section 7 for testing,

removal and installation procedures.

Figure 6-14. Countershaft Retainer

Retainer

TORX screw

3557

Figure 6-15. Shifter Shaft Assembly

Figure 6-16. Neutral Indicator Switch

7.

Bolt (5)

8.

Washer (5)

9.

Detent plate

10. Retaining ring
11. Washer (2)

b0153x6x

3 11

5

6

10

9

4

1

2

7,8

7,8

1.

Spring

2.

Post

3.

Locknut (2)

4.

Detent arm screw

5.

Pawl

6.

Shifter shaft assembly

Neutral indicator

switch

3553

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Summary of Contents for S1 Lightning

Page 1: ...ews 4 3 Fluid Requirements 6 4 Clutch 7 5 Rear Preload Adjustment 8 6 Ignition Timing 9 This section explains procedures unique to 1997 model S1 Lightnings Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual Part No 99490 96Y ...

Page 2: ...2 NOTES ...

Page 3: ...ns 15 14 Reserve 0 6 gallons 2 27 Oil tank 2 0 quarts 1 89 Transmission 1 0 quart 0 95 WEIGHT LBS KG S1 shipping weight 446 202 GVWR 820 372 GAWR Front 340 154 GAWR Rear 480 218 ENGINE Number of cylinders 2 Type 4 Cycle 45 Degree V Type Bore 3 498 in 88 849 mm Stroke 3 8125 in 96 838 mm Piston displacement 73 4 cu in 1203 cc Compression ratio 10 0 to 1 Horsepower RPM 91 5800 Torque ft lb RPM 87 52...

Page 4: ... 8 Right front turn signal 9 Headlamp 10 Front brake caliper 11 Timer cover 12 Rear shock absorber 13 Rear brake pedal 14 Rider footrest 15 Belt guard s 16 License plate light 1 Rear axle adjuster nut 2 Rear sprocket and secondary drive belt 3 Ignition module 4 Fuse block and spare fuse 5 Turn signal flasher 6 Remote idle adjuster 7 Front brake master cylinder 8 Front brake hand lever 9 Front brak...

Page 5: ...op lamp 9 Left rear turn signal 10 Rear brake caliper 11 Passenger footrest 12 Rider footrest 13 Gear shift lever 14 Exhaust muffler 15 Oil filter 5 4 5809 6 8 4 2 3 1 7 11 12 13 14 10 5 9 15 1 Steering head lock 2 Instruments 3 Clutch hand lever 4 Ignition coil 5 Enrichener knob 6 Starter relay 7 Oil filler plug dipstick 8 Oil tank 9 Rear brake caliper 10 Rear axle adjuster nut 11 Oil tank drain ...

Page 6: ...ASE Part No 99855 89 BRAKE FLUID 1WARNING D O T 5 SILICONE HYDRAULIC BRAKE FLUID can cause eye irritation In case of contact with eyes flush with plenty of water and get medical attention KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Use only D O T 5 SILICONE HYDRAULIC BRAKE FLUID Part No 99902 77 FRONT FORK OIL Use only WP FORK OIL 5 WEIGHT FUEL Use a good quality leaded or unleaded gasoline 91 p...

Page 7: ... the new style clutch release ramp introduced on late 1996 vehicles The clutch adjustment and lever freeplay procedures remain the same The change was made to provide additional clear ance between the coupler and the primary cover Figure 5 Ramp Change New style Old style 5671 ...

Page 8: ...he seat to be sure the suspen sion is free and not binding 7 With the help of an assistant take the same measure ment with the vehicle fully loaded rider passenger lug gage cargo The assistant should help balance the motorcycle so the rider can keep both feet on the foot rests 8 Subtract the second measurement from the first The dif ference which is the squat should be 0 25 0 75 in 6 4 19 1 mm If ...

Page 9: ...his adjuster it is no longer necessary to use the CARBURE TOR IDLE ADJUSTMENT TOOL Part No HD 33413 and TIP SNAP ON Part No TMP23A to adjust engine idle speed NOTE The new idle adjuster changes Step 4 of IGNITION TIMING INSPECTION in Section 1 the 1996 manual See REMOTE IDLE ADJUSTER on page 21 for more infor mation Figure 8 Remote Idle Adjuster 5853 ...

Page 10: ...10 NOTES ...

Page 11: ...fication Number 13 2 Front Wheel 14 3 Front Brake Caliper 15 4 Swingarm 16 This section explains procedures unique to 1997 model S1 Lightnings Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual Part No 99490 96Y ...

Page 12: ...12 NOTES ...

Page 13: ...de of the crankcase NOTE Always give the V I N or abbreviated V I N when ordering parts or making inquiries about your Buell motorcycle Figure 9 Vehicle Identification Number V I N 00001 20000 World 20001 25000 California 4 MZ SS 11 J V 32 00001 Varies can be 0 thru 9 or X Sample V I N as it appears on the steering head 4MZSS11J1V3200001 Sample abbreviated V I N as it appears on the left side cran...

Page 14: ...ges Step 4 of FRONT WHEEL REMOVAL and Step 2 of FRONT WHEEL ASSEM BLY in the 1996 manual REMOVAL INSTALLATION 1 See Figure 10 Remove and discard the clip 2 2 Remove the wave washer 3 3 Remove the drive pin 1 Repeat this procedure for the other five fasteners to separate the carrier 4 from the rotor 5 4 Assemble in reverse order Use new clips upon assembly Figure 10 1997 Rotor to Carrier Fastener 5...

Page 15: ...ts 1WARNING When using air pressure to remove pistons from caliper pistons may be ejected with considerable force Wear safety glasses and heavy gloves to prevent personal injury 1CAUTION Exercise care to avoid dropping piston on hard surface Any damage requires piston replacement 2 If removing pistons from outside caliper half place a gloved finger over the banjo bolt hole 3 See Figure 13 Apply lo...

Page 16: ...oat bearing components with WHEEL BEARING GREASE Part No HD 99855 89 and assemble 3 Install a new swingarm seal 3 flush to the swingarm 4 Slide swingarm assembly into position NOTE See Figure 14 The left side bearing adjustment bolt 6 has additional internal threads 5 Install both bearing adjustment bolts 2 6 and the threaded rod 1 Insert the rod from the air cleaner side of the motorcycle 6 Tight...

Page 17: ...17 SECTION III ENGINE All engine procedures in the 1996 S1 Lightning Service Manual Part No 99490 96Y apply to 1997 models ...

Page 18: ...18 NOTES ...

Page 19: ...T PAGE NO 1 Remote Idle Adjuster 21 2 Air Cleaner 22 This section explains procedures unique to 1997 model S1 Lightnings Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual Part No 99490 96Y ...

Page 20: ...20 NOTES ...

Page 21: ...tine cable strap over adjuster c Run cable strap through the other side of the slot Strap should be tight enough that the adjuster turns easily 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 3 Install fuel tank and seat See FUEL...

Page 22: ...s and snorkel plate 6 Remove snorkel 7 See Figure 23 Remove screw with spacer and gasket 8 Remove backplate a See Figure 24 Remove two bolts 1 washers 2 and nuts 3 b Draw rear breather hose through backplate c Remove front breather bolt Detach backplate from motorcycle 9 If necessary remove air cleaner support ring a Detach breather hose from rear cylinder head breather bolt b Loosen rear bolt c S...

Page 23: ...through backplate 3 See Figure 23 Apply LOCTITE THREADLOCKER 242 blue to screw Install ring with screw through backplate Tighten to 7 9 ft lbs 9 5 12 2 Nm 4 See Figure 22 Apply LOCTITE THREADLOCKER 242 blue to screws Fasten snorkel tube with ring and two screws Tighten to 6 8 ft lbs 8 1 10 8 Nm 5 Connect snorkel hose to snorkel tube 6 See Figure 20 Check air cleaner filter Place filter inside filt...

Page 24: ...24 NOTES ...

Page 25: ...R SUBJECT PAGE NO 1 Starting System Diagnosis 27 This section explains procedures unique to 1997 model S1 Lightnings Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual Part No 99490 96Y ...

Page 26: ...26 NOTES ...

Page 27: ...th Starter Button Pressed Check for Ground at Relay Terminal 85 Ground Present Inspect Starter Interlock Circuit or Correct Relay Ground Check for Battery Voltage to Starter Button W BK Wire Battery Voltage Present Replace Starter Button NO Repair Wiring to Starter Button YES YES Repair Wiring From Starter Button to Relay NO YES YES NO NO 1 Perform Voltage Drop Tests Between Battery and Relay Term...

Page 28: ...OT Pressed Replace Starter Button Replace Starter Relay Replace Solenoid YES NO NO YES NO NO YES Perform Voltage Drop Test Between Battery Neg and Starter Studs or Bolts Is Voltage Greater than 1 Volt Clean Ground Connections NO YES Perform Voltage Drop Tests from Battery Pos to Starter Battery Terminal Crank Engine IsVoltage Greater than 1 Volt YES NO Repair Connection Between Battery and Starter...

Page 29: ...29 SECTION VI DRIVE TRANSMISSION All drive transmission procedures in the 1996 S1 Lightning Service Manual Part No 99490 96Y apply to 1997 models ...

Page 30: ...30 NOTES ...

Page 31: ... Switches 33 2 Starter Interlock System 34 3 Horn 36 4 Wiring Harness 37 This section explains procedures unique to 1997 model S1 Lightnings Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual Part No 99490 96Y ...

Page 32: ...32 NOTES ...

Page 33: ... starter switch Left Handlebar Switch See Figure 26 The left handlebar switch P6 contains Passing lamp switch Headlamp dimmer switch headlamp HIGH or LOW beam Turn signal switch Horn switch Figure 25 Right Handlebar Switch P1 Figure 26 Left Handlebar Switch P6 GY W BK W BK BK R 1 3 2 4 GN BK W R BE Y R P1 P2 BRAKE SWITCH RIGHT HANDLEBAR SWITCH CONNECTOR 1 2 O W O W R Y R Y TO STOPLIGHT ACC POWER I...

Page 34: ...resent if test light illuminates or if voltmeter shows 12 VDC 1 0 VDC NO YES Place motorcycle in first gear Press starter button on right handlebar Is current present Check neutral switch and circuit See NEUTRAL INDI CATOR SWITCH in Section 7 of the 1996 manual Repeat entire interlock circuit test when finished NO Disengage clutch lever by pulling lever in fully Press starter button on right handl...

Page 35: ...rrent present YES Check neutral switch See NEUTRAL INDICATOR SWITCH in Section 7 of the 1996 manual Repeat entire ignition portion of interlock circuit test when fin ished NO Check side stand switch See STARTER INTERLOCK in Section 7 of the 1996 manual Repeat entire ignition portion of interlock circuit test when finished YES Extend side stand Pull in clutch lever Is current present NO Check clutc...

Page 36: ...d bracket from frame INSTALLATION 1 See Figure 28 Attach horn assembly to frame using bolt 1 lockwasher 2 and washer 3 2 Connect horn wires a Attach Y BK power wire 5 b Attach BK ground wire 6 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and pers...

Page 37: ...tilock front brake switch P3 12 place Amp Multilock instruments and indicator lamps P4 4 place Amp Multilock headlamp P5 2 place Amp Multilock clutch switch P6 8 place connector left handlebar switch housing horn turn signals lights P7 2 place Deutsch vacuum operated electric switch P8 4 place PED ignition headlamp switch P9 4 slot fuse block four 15 amp fuses ignition instruments lights and acces...

Page 38: ... 30 BK R R BK 86 87 87A GN TN GN STARTER RELAY P13 BK R GN R BK TN GN VIEW FROM FUSE INSERTION SIDE GY O BE O W O W O O R BK R BK R BK R GY INSTRUMENTS 15A LIGHTS 15A 15A ACCESSORIES 15A IGNITION FUSE BLOCK P9 REAR PLUG FRONT PLUG COIL PK PK W BK 85 30 86 87 87A GY O GY O TN W TN W GY IGNITION RELAY GY O GY O P12 S14 S15 TN W TN W TN GN GY BK 1 2 BK TN GN R BE P6 P5 CLUTCH SWITCH LOW BEAM HIGH BEA...

Page 39: ...ly explosive Always stop the engine when refueling or servicing the fuel system Do not smoke or allow open flame or sparks near the work site Inadequate safety precautions may result in personal injury Good preparation is very important for efficient service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and will reduce the in...

Page 40: ...r personal injury whether to yourself or others 1CAUTION A CAUTION indicates that vehicle damage can occur 1WARNING Proper service and repair is important for the safe reliable operation of all mechanical products The service procedures recommended and described in this Service Manual are effective methods for performing service operations Some of these service operations require the use of tools ...

Page 41: ...are given in this section Repair Disassembly Assembly Replace Removal Installation All special tools and torque values are noted at the point of use All required parts or materials can be found in the appropriate PARTS CATALOG Safety Safety is always the most important consideration when performing any job Be sure you have a complete understanding of the task to be performed Use common sense Use t...

Page 42: ...or removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Never use...

Page 43: ...commended accessories with proper capacity ratings Do not exceed air pressure ratings of any power tools Bits should be placed against work surface before air hammers are operated Disconnect the air supply line to an air hammer before attaching a bit Never point an air tool at yourself or another person Protect bystanders with approved eye protection Wrenches Never use an extension on a wrench han...

Page 44: ...lace parts individually ratchets should be rebuilt with the entire contents of service kit Never hammer or put a pipe extension on a ratchet or handle for added leverage Always support the ratchet head when using socket extensions but do not put your hand on the head or you may interfere with the action of its reversing mechanism When breaking loose a fastener apply a small amount of pressure as a...

Page 45: ... 4 0 gallons 15 14 Reserve 0 6 gallons 2 27 Oil tank 2 0 quarts 1 89 Transmission 1 0 quart 0 95 WEIGHT LBS KG S1 shipping weight 446 202 GVWR 820 372 GAWR Front 340 154 GAWR Rear 480 218 ENGINE Number of cylinders 2 Type 4 Cycle 45 Degree V Type Bore 3 498 in 88 849 mm Stroke 3 8125 in 96 838 mm Piston displacement 73 4 cu in 1203 cc Compression ratio 10 0 to 1 Horsepower RPM 91 5800 Torque ft lb...

Page 46: ...adlamp 10 Front brake caliper 11 Timer cover 12 Rear shock absorber 13 Rear brake pedal 14 Belt guard s 15 License plate light 5745 5 6 4 7 11 12 13 14 9 10 1 8 3 2 15 1 Rear axle adjuster nut 2 Rear sprocket and secondary drive belt 3 Ignition module 4 Fuse block and spare fuse 5 Turn signal flasher 6 Horn 7 Front brake master cylinder 8 Front brake hand lever 9 Front brake caliper 10 Oil pump 11...

Page 47: ...Fuel supply valve 8 Tail brake lamp 9 Left rear turn signal 10 Rear brake caliper 11 Gear shift lever 12 Exhaust muffler 13 Oil filter 5748 6 8 4 2 3 1 7 11 12 13 14 10 5 9 15 1 Steering head lock 2 Instruments 3 Clutch hand lever 4 Ignition coil 5 Enrichener knob 6 Starter relay 7 Oil filler plug dipstick 8 Oil tank 9 Rear brake caliper 10 Rear axle adjuster nut 11 Oil tank drain hose 12 Gear shi...

Page 48: ...RNING D O T 5 SILICONE HYDRAULIC BRAKE FLUID can cause eye irritation In case of contact with eyes flush with plenty of water and get medical attention KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Use only D O T 5 SILICONE HYDRAULIC BRAKE FLUID Part No 99902 77 FRONT FORK OIL Use only WP FORK OIL 5 WEIGHT FUEL Use a good quality leaded or unleaded gasoline 91 pump octane or higher Pump octane is ...

Page 49: ...k 1 2 quart 0 47 liter difference Oil capacity 2 0 quarts 1 9 liters Oil filter page 1 16 R R R R R R R R Hand tighten filter 1 2 3 4 turn after gasket contacts surface Brake fluid level and condition page 1 17 I I I I I I I I Fluid type D O T 5 SILICONE HYDRAULIC BRAKE FLUID Front master cylinder level Above LOW mark on sight glass or within 1 8 in 3 2 mm of molded boss when cover is removed Rear...

Page 50: ...ry chain page 1 22 I I I I I I I Chain freeplay with hot engine 1 4 3 8 in 6 4 9 5 mm Chain freeplay with cold engine 3 8 1 2 in 9 5 12 7 mm Inspection screws torque 40 60 in lbs 4 5 6 8 Nm Rear shock absorber page 1 24 I I I I I I I Check for bushing wear and loose mounting hardware Steering head bearing adjustment page 1 25 FRONT WHEEL SUPPORT STAND Part No B 41395 S1 ADAPTER B 41686 I I IL I IL...

Page 51: ...ichener cable Engine idle speed page 1 30 CARBURETOR IDLE ADJUSTMENT TOOL Part No HD 33413 TIP Snap on Part No TMP23A I I I I I I I I I I I I I I Fast idle all models 2000 RPM Regular idle 49 state models 950 1050 RPM Regular idle California models 1150 1250 RPM Ignition timing page 1 30 TIMING MARK VIEW PLUG Part No HD 96295 65D INDUCTIVE TIMING LIGHT Part No HD 33813 I I I I I I Ignition timing ...

Page 52: ...pment and switches Section 7 I I I I I I I I I I I I I I All fasteners except engine head bolts T T T T T T T Road test X X X X X X X X X X X X X X SERVICE OPERATIONS AND SPECIAL TOOLS P r e r i d e 5 0 0 mi 8 0 0 km 2 5 0 0 mi 4 0 0 0 km 5 0 0 0 mi 8 0 0 0 km 7 5 0 0 mi 1 2 0 0 0 km 1 0 0 0 0 mi 1 6 0 0 0 km 1 2 5 0 0 mi 2 0 0 0 0 km 1 5 0 0 0 mi 2 4 0 0 0 km 1 7 5 0 0 mi 2 8 0 0 0 km 2 0 0 0 0 m...

Page 53: ... problem test as described below 1 Remove battery from motorcycle See BATTERY REMOVAL on page 1 14 2 Test battery voltage using a multimeter 3 If battery voltage is below 12 66 Volts use a 1 100 Amp 12 Volt charger on battery See Table 1 3 Figure 1 5 Battery Warnings Figure 1 6 Open Circuit Voltage vs State of Charge No Charge Last 24 Hours Table 1 3 Charging Rates CHARGER OUTPUT CURRENT RATE OPEN...

Page 54: ...ways connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion resulting in personal injury 1CAUTION Connect cables to correct terminals of battery or serious damage to motorcycle electrical system will occur 2 Connect positive cable to positive battery terminal Then after positive cable ha...

Page 55: ...l should be between lower and upper dipstick level marks If oil level in tank is below lower mark of dip stick add oil to tank Install filler cap dipstick Recommended viscosity depends upon ambient temper ature See Table 1 4 NOTE Difference between upper and lower dipstick marks is 0 5 quart 0 47 liter 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position ...

Page 56: ...liter of clean oil into new filter when changing oil 8 Screw filter onto adapter until gasket contacts mounting plate surface Apply another 1 2 3 4 turn by hand 1WARNING Be sure no oil gets on tires when changing oil and filter Traction will be adversely affected which may lead to a loss of control and personal injury 9 Fill oil tank with an oil from Table 1 4 Oil tank capacity is 2 0 quarts 1 90 ...

Page 57: ...ded boss for front master cylinder reservoir b Bring fluid level between upper and lower marks for rear master cylinder reservoir 3 Depress and hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve about 1 2 turn counterclockwise brake fluid will flow from bleeder valve and through tub ing When brake lever pedal has moved 1 2 3 4 of its full range of travel close bleeder valve...

Page 58: ...en storing or removing the motorcycle for the season Check wheel bearings and axle spacers for wear and corro sion Excessive play or roughness indicates worn bearings Replace bearings in sets only SPEEDOMETER CABLE Check speedometer cable Inspect before every ride Lubricate at every 5000 mile 8000 km service interval Examine speedometer cable housing outer sheath for kinks or other damage Replace ...

Page 59: ... Do not damage or dislodge Quad ring from primary cover 1CAUTION Do not overfill the primary chaincase with lubricant Overfilling may cause rough clutch engagement and incomplete disengagement or clutch drag 6 Add SPORT TRANS FLUID Part No 98854 96 quart size Part No 98855 96 gallon size as required until lubricant is even with bottom of clutch diaphragm spring See Figure 1 16 7 Install clutch ins...

Page 60: ...kwise 1 4 turn Install lockplate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns 6 Squeeze clutch lever to maximum limit three times to set ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 1 16 1 8 in 1 6 3 2 mm freeplay at hand lever Adjust as...

Page 61: ...load See REAR PRE LOAD ADJUSTMENT on page 1 23 2 See Figure 1 22 Loosen rear axle nut metric if not already performed NOTE After you loosen the axle nut turn the axle and nut so the rear most flat on each side is parallel with the ends of the swingarm Check to be sure rear wheel axle is parallel with swingarm pivot shaft 3 See Figure 1 23 Measure each side from the flat to the end of the swingarm ...

Page 62: ...ghtest point in the drive as measured with specialized factory equipment If a chain has less than 1 4 in vertical freeplay with a cold engine adjust freeplay to the field specification of 3 8 1 2 in 9 5 12 7 mm The looser specification will avoid overtightening which might otherwise occur during adjustment using non factory equipment and methods 5 Install primary chain inspection cover Tighten scr...

Page 63: ...all items removed in Step 2 Load all cargo 6 Bounce a few times on the seat to be sure the suspen sion is free and not binding 7 With the help of an assistant take the same measure ment with the vehicle fully loaded rider passenger lug gage cargo The assistant should help balance the motorcycle so the rider can keep both feet on the foot rests 8 Subtract the second measurement from the first The d...

Page 64: ...e interval thereafter Inspect the rear shock absorber for loose mounting hardware leaks or rod to spring contact Tighten the front and rear mounts 40 45 ft lbs 54 2 61 0 Nm Table 1 8 Suspension Settings ADJUSTMENT RANGE IN CLICKS FACTORY SETTING SEE FIGURE Front fork compression 28 20 1 29 Front fork rebound 28 12 1 29 Rear shock rebound 7 3 1 30 Rear shock compression 11 5 1 31 Figure 1 29 Front ...

Page 65: ...ARING GREASE Part No 99855 89 See FORK STEM AND BRACKET ASSEMBLY in Section 2 for lubrication procedure ADJUSTMENT 1 Raise front wheel off floor using FRONT WHEEL SUP PORT STAND Part No B 41395 and S1 LIFT ADAPTER Part No B 41686 2 Turn front wheel to full right lock 3 See Figure 1 32 Hook spring scale into front axle hole Pull front wheel to center position It should take 3 5 5 5 lbs 1 6 2 5 kg t...

Page 66: ...juster Pull damper assembly through several full strokes to bleed air from the fork 5 With front fork fully compressed clamp vertically in FRONT FORK HOLDING TOOL Part No B 41177 6 Measure distance from fork oil surface to top of tube using PRO LEVEL OIL GAUGE Part No B 59000A Add or drain fork oil as needed until distance from top of fork tube to oil surface measures 4 33 in 110 mm See Figure 1 3...

Page 67: ... too lean a hot running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown pow dery deposit indicates balanced combustion Clean off spark plug deposits at regular inter...

Page 68: ...al injury Do not use gasoline or solvents to clean the filter ele ment Volatile flammable cleaning agents may cause an intake system fire which may result in personal injury 2 Wash element in luke warm water with a mild detergent Dry the filter element using low pressure 32 psi 221 kPa maximum compressed air Rotate element while moving air nozzle up and down the element interior Do not rap the ele...

Page 69: ...Twist throttle control grip to fully open position hold in position 6 Turn adjuster 3 on throttle control cable 1 until throttle cam stop 5 touches carburetor stop plate 6 Tighten jam nut on throttle control cable 1 adjuster 3 release throttle control grip 7 Turn handlebars fully to right Turn adjuster 3 on idle control cable 2 until end of cable housing just touches the carburetor cable guide 8 T...

Page 70: ...timing inspection hole If not see ADJUSTMENT on page 1 31 6 Set engine slow idle speed as described in Step 4 with engine running at normal operating temperature and with enrichener control knob pushed in fully NOTE Buells have an enrichener circuit that will cause the engine to idle at approximately 2000 RPM with the engine at normal operating temperature and the enrichener knob pulled out fully ...

Page 71: ...r screws 3 timer cover 2 and new outer cover rivets 1 6 Remove TIMING MARK VIEW PLUG from timing inspec tion hole Install hex socket timing plug Figure 1 44 Ignition System Components 1 2 1 Pop rivet 2 2 Timer cover 3 Screw 2 4 Inner cover 5 Ignition gasket 6 Timer plate stud 2 7 Bolt 8 Sensor assembly 9 Trigger rotor 10 Seal 11 Gearcase cover 12 Spark plug 2 13 Ignition coil 4 5 6 7 11 12 15 14 1...

Page 72: ...peed does not first decrease and then increase as described check V O E S wire connection to ignition module Ohmmeter and Vacuum Pump Method The V O E S can also be checked using an ohmmeter and a VACUUM PUMP Part No HD 23738 1 Remove V O E S from vehicle See VACUUM OPER ATED ELECTRIC SWITCH V O E S in Section 7 2 See Figure 1 45 Connect two ohmmeter leads to the two V O E S leads 3 Connect vacuum...

Page 73: ...emoved to access front clamp screws 1 Remove windscreen See WINDSCREEN in Section 2 2 Remove instrument support See SPEEDOMETER AND TACHOMETER in Section 2 3 See Figure 1 47 Loosen clamp screws 4 Move handlebar to desired position 5 Tighten clamp screws to 10 12 ft lbs 13 6 16 2 Nm NOTE Tighten front clamp screws first 6 Install instrument support See SPEEDOMETER AND TACHOMETER in Section 2 7 Inst...

Page 74: ...torcycle seat Weight of rider will compress vehicle suspension slightly 6 Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment directly forward 7 Turn ignition switch to IGN Set handlebar headlamp switch to HIGH beam position 8 Check light beam for proper height alignment Main beam of light broad flat pattern of light should be cen tered on hori...

Page 75: ... plugs 4 Adjust primary chain 5 Adjust secondary drive belt 6 Check tire inflation If the motorcycle will be stored for an extended period of time securely support the motorcycle under the frame so that all weight is off the tires 1WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and can result in an accident causing personal injury 7 Wash pa...

Page 76: ...nition not timed properly See dealer 9 Vapor vent valve plugged or carburetor fuel line closed off restricting fuel flow 10 Water or dirt in fuel system and carburetor 11 Enrichener valve inoperative 12 Air leak at intake manifold 13 Valves sticking Starts But Runs Irregularly or Misses 1 Spark plugs in bad condition or partially fouled 2 Spark plug cables in bad condition and shorting 3 Spark plu...

Page 77: ... Regulator rectifier module not functioning 2 Stator not functioning 3 Rotor not functioning 4 Weak battery 5 Loose connections FUEL Carburetor Floods 1 Excessive pumping of throttle control grip 2 Inlet valve sticking 3 Inlet valve and or valve seat worn or damaged 4 Dirt or other foreign matter between valve and its seat 5 Float misadjusted or filled with fuel TRANSMISSION Shifts Hard 1 Clutch d...

Page 78: ...ot be more than 0 080 in 2 03 mm 6 Rims and tires out of round or eccentric with hub tire runout should not be more than 0 090 in 2 29 mm 7 Irregular or peaked front tire tread wear 8 Tire and wheel unbalanced 9 Steering head bearings improperly adjusted Correct adjustment and replace pitted or worn bearings and races See FORK STEM AND BRACKET ASSEMBLY in Section 2 10 Shock absorber not functionin...

Page 79: ...at Height 29 5 749 CHASSIS IN MM Road Clearance 5 2 132 Front Wheel Travel 4 7 119 4 Rear Wheel Travel 4 9 124 5 Trail 3 9 99 Rake 25 degrees WEIGHT LBS KG S1 Shipping weight 446 202 GVWR 820 372 GAWR Front 340 154 GAWR Rear 480 218 CAPACITIES U S LITERS Fuel Tank including reserve 4 0 gallons 15 14 Reserve 0 6 gallons 2 27 Oil Tank 2 0 quarts 1 89 Transmission 1 0 quart 0 95 TIRE AND POSITION PRE...

Page 80: ...nt caliper banjo bolt 16 20 ft lbs 21 7 27 1 Nm page 2 21 page 2 22 Front caliper bleeder valve 4 6 ft lbs 5 4 8 1 Nm page 2 22 Front caliper center bolt 11 13 ft lbs 14 9 17 6 Nm page 2 21 Front caliper mounting bolt 30 33 ft lbs 40 7 44 7 Nm page 2 21 Front fork triple clamp screw 18 20 ft lbs 24 4 27 1 Nm LOCTITE ANTI SEIZE page 2 31 Front master cylinder banjo bolt 17 20 ft lbs 23 0 27 1 Nm me...

Page 81: ... 6 16 2 Nm metric page 2 24 page 2 27 Rear master cylinder mounting screw 8 10 ft lbs 10 8 13 6 Nm page 2 24 Rear master cylinder rod to brake pedal screw 10 12 ft lbs 13 6 16 2 Nm page 2 24 Rear shock mounting screw 40 45 ft lbs 54 2 61 0 Nm metric page 2 37 Sprocket bolt 55 65 ft lbs 74 6 88 1 Nm LOCTITE THREADLOCKER 272 red page 2 12 Sprocket cover mounting screw 12 17 in lbs 1 4 1 9 Nm page 2 ...

Page 82: ...the bead seat measured in inches The 17 0 is the normal diame ter of the rim in inches measured at the bead seat diameter DOT means that the rim meets Department of Transportation Federal Motor Vehicle Safety Standards See the tables below Table 2 1 Tire Fitment Tubeless Cast Marchesini Wheels WHEEL SIZE POSITION CONTOUR RIM SIZE RIM VALVE HOLE DIAMETER DUNLOP SPORTMAX RADIAL II TIRE SIZE 17 in Fr...

Page 83: ...rcycle Figure 2 1 Abbreviated V I N Location 5711 Figure 2 2 Vehicle Identification Number V I N 4 MZ SS 11 J T 3 20 0001 Varies can be 0 through 9 or X Sequential Number Manufacturer and Make Buell Motorcycle Company Sample V I N as it appears on the steering head 4MZSS11J1T3200001 Sample abbreviated V I N as it appears on the left side crankcase SS11T200001 NOTE Two market destination characters...

Page 84: ... ft lbs 89 5 98 9 Nm 2 Excessive side play or radial up and down play in wheel hubs Replace wheel hub bearings 3 Alignment of rear wheel in frame or with front wheel Check WHEEL BALANCING on page 2 17 or repair swingarm as described under SWINGARM on page 2 33 4 Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Replace rims See TIRES INSTALLATION on page 2 16 5 Rims and ...

Page 85: ...al injury 4 Tires and wheels are critical safety items Since the servicing of these components requires special tools and skills Buell recommends that you see your dealer for these services 1WARNING Excessively worn tires adversely affect motorcycle trac tion steering and handling and could result in personal injury At regular intervals of 5000 miles 8000 km or whenever han dling irregularities ar...

Page 86: ...ide of wheel remove right axle spacer 12 3 Remove wheel bearings 6 11 using BUSHING AND BEARING PULLER Part No HD 95760 69A and 3 4 in COLLET Part No HD 95767 69A 4 Remove six locknuts 14 washers 21 spring washers 20 screws 19 and brake drive pins 18 Remove brake rotor 17 5 Remove five screws 16 and front brake carrier 15 6 Remove tire See TIRES REMOVAL on page 2 15 CLEANING INSPECTION AND REPAIR ...

Page 87: ...ing suitable driver Press on outer race only 5 On the side of the wheel opposite the brake rotor insert left axle spacer 5 into hub until it seats in bore Spacer sleeve must not be cocked or tilted in bore 6 On the right side of the wheel insert right axle spacer 12 into hub until it seats in bore Spacer sleeve must not be cocked or tilted in bore 7 Install tire if removed See TIRES INSTALLATION o...

Page 88: ...l hub Push axle through speedometer drive speedometer drive spacer and left fork leg 4 Compress the front suspension to make sure it is free and not binding 5 See Figure 2 6 Apply LOCTITE THREADLOCKER 242 blue to axle nut Install washer 2 and axle nut 1 met ric over threaded end of axle Insert screwdriver or steel rod through hole in axle on right side of vehicle While holding axle stationary tigh...

Page 89: ...xle adjuster nuts Push wheel as far for ward as possible 6 Slip secondary drive belt from bottom of rear wheel sprocket and remove 7 See Figure 2 9 Remove rear axle nut 14 metric lock washer 13 and washer 12 Pull axle 3 and washer 4 out from left side and remove wheel Figure 2 8 Rear Wheel Mounting Axle adjuster nut Rear axle nut metric 5574 Figure 2 9 Rear Wheel 1 2 3 4 5 6 7 13 10 14 9 8 12 11 1...

Page 90: ...brake fluid bearing grease lubricants etc to contact brake rotor or reduced braking ability will occur possibly resulting in personal injury 1 See Figure 2 9 Verify that brake rotor 2 is thoroughly clean Apply LOCTITE THREADLOCKER 242 blue to each screw 1 metric Fasten rotor to hub with four screws Tighten to 35 40 ft lbs 47 5 54 2 Nm NOTE P M wheels use a nut not shown with each screw 1 2 Apply t...

Page 91: ...r brake caliper mount wheel assembly spacer 11 and right side of swingarm 4 Install washer 12 lockwasher 13 and axle nut 14 metric on right side of axle Do not fully tighten rear axle nut at this time 5 Install rear brake caliper See REAR BRAKE CALIPER INSTALLATION on page 2 26 6 Check for proper belt tension and wheel alignment See REAR BELT DEFLECTION in Section 1 7 Tighten rear axle nut 14 metr...

Page 92: ...t 1 See Figure 2 12 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 4 Table 2 4 Wheel Runout WHEEL TYPE MAXIMUM LATERAL RUNOUT MAXIMUM RADIAL RUNOUT Cast Marchesini 0 040 in 1 02 mm 0 030 in 0 7...

Page 93: ...t handling resulting in personal injury 4 If a bead breaker machine is not available attach RIM PROTECTORS Part No HD 01289 to the rim Using tire tools not sharp instruments start upper bead over edge of rim at valve Repeat all around rim until first bead is over rim 5 See Figure 2 14 Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side Pry bead over ri...

Page 94: ...RNING Do not inflate over 40 psi 2 8 bars to seat the beads Inflating the tire beyond 40 psi 2 8 bars to seat the beads can cause the tire rim assembly to burst with force sufficient to cause personal injury If the beads fail to seat to 40 psi 2 8 bars deflate and relubricate the bead and rim and reinflate to seat the beads but do not exceed 40 psi 2 8 bars 6 Apply air to stem to seat beads on rim...

Page 95: ...S Part No 43692 94Y which have special self adhesive backings The maximum weight permissible to accomplish balance is 1 oz 28 g total weight applied to the rim Wheels should be balanced to within 1 4 oz 7 g at 60 MPH 97 KM H These weights are applied to the flat surface of the wheel rim according to the following procedures 1 Make sure that area of application is completely clean dry and free of o...

Page 96: ...injury Buell recommends that all brake repairs be performed by a Buell dealer or other qualified mechanic Exercise caution when handling brake fluid Brake fluid can cause irritation of eyes and skin and may be harmful or fatal if swallowed If swallowed adminis ter two tablespoons of salt in a glass of warm water to induce vomiting Call a doctor immediately In case of contact with skin or eyes flus...

Page 97: ...e of the hydraulic brake line Install banjo bolt through gaskets and brake line fit ting into master cylinder Tighten banjo bolt 6 metric to 17 20 ft lbs 23 0 27 1 Nm 3 Attach brake lamp switch 7 with screw 10 lockwasher 9 and washer 8 4 Remove both master cylinder cover screws 3 and cover 5 With the master cylinder in a level position add D O T 5 SILICONE HYDRAULIC BRAKE FLUID Bring fluid level t...

Page 98: ...s 3 6 Free caliper from front brake rotor 7 Move caliper assembly to bench area 8 See Figure 2 20 Remove screws 13 14 to separate caliper halves 7 12 Remove O rings 11 and discard Figure 2 19 Front Brake Caliper Mounts 2 4 1 3 3 Caliper mounting bolts 4 Banjo bolt 5 Wire guide 1 Cotter and support pins 2 Center caliper bolt 5712 5 Figure 2 20 Front Brake Caliper 1 3 4 5 6 7 8 11 9 10 12 14 13 15 1...

Page 99: ...liper half 7 12 Install new O rings 9 in groove of piston bores 2 Install pistons 10 in each caliper piston bore 3 Tighten caliper halves together with four screws 13 14 Smallest screw 13 is placed on top next to bleeder valve 8 Tighten screws to 26 28 ft lbs 35 2 38 0 Nm INSTALLATION 1 Fit caliper on front brake rotor without brake pads 2 See Figure 2 20 Tighten both caliper mounting bolts 4 to 3...

Page 100: ...the brake line runs downward in front of the right handlebar where it turns inboard at the upper triple clamp Loosely install clamp 5 and screw 4 to attach front brake line to right side of lower triple clamp 3 Place brake line inside wire guide 6 on front fender 4 Position new gaskets 8 on each side of banjo fitting at free end of brake line Insert caliper banjo bolt 7 through gaskets Loosely ins...

Page 101: ...cylinder Discard gaskets 4 Remove two screws and locknuts 5 holding the rear brake master cylinder to frame 5 Remove reservoir hose clamp from rear master cylinder 6 Remove screw on reservoir assembly CLEANING INSPECTION AND REPAIR 1WARNING Clean brake system components using denatured alco hol Do not use mineral base cleaning solvents such as gasoline or paint thinner Use of mineral base solvents...

Page 102: ... cylinder and tighten to 10 12 ft lbs 13 6 16 2 Nm 4 See Figure 2 23 Place push rod into rear master cylinder Install male rod end behind brake pedal with screw and locknut Tighten screw to 10 12 ft lbs 13 6 16 2 Nm 5 Adjust brake pedal freeplay 6 See Figure 2 25 With the master cylinder in a level posi tion check that the brake fluid level is between the upper and lower marks on reservoir Add D O...

Page 103: ... signs of hydraulic fluid leakage or piston is not operating properly If piston must be removed proceed to Step 7 1WARNING When using air pressure to remove piston from caliper piston may be ejected with considerable force Wear safety glasses heavy gloves and hold caliper with heavy towel to prevent personal injury 1CAUTION Exercise care to avoid dropping piston on hard surface Any damage requires...

Page 104: ...ensure proper brake pad to brake rotor clearance when the caliper is installed piston must be pressed all the way into the bore whenever new brake pads are used 3 Install master brake pad 7 on piston 6 4 Install dust boots 12 13 and rear pad bracket 9 into rear caliper assembly 5 Install slave brake pad 8 INSTALLATION 1 With friction material facing brake rotor align rear caliper assembly on mount...

Page 105: ...m left side of vehicle feed new brake line from rear brake caliper mount forward to frame mount Thread brake line right to rear master cylinder 3 Install screw and clamp to secure rear brake line to frame Tighten clamp screw to 10 12 ft lbs 13 6 16 2 Nm 4 Attach brake line to clamp under oil tank 5 See Figure 2 28 Position new gaskets on each side of master cylinder banjo fitting Insert banjo bolt...

Page 106: ...ork cap 2 metric O ring 3 and washer 4 4 Reduce spring pressure and remove both retaining clips 5 5 Remove preload shim s 6 and steel washer 7 6 Remove fork spring 8 7 Invert fork and drain fork oil 8 Clamp fork outer tube 9 horizontally using FRONT FORK HOLDING TOOL Part No B 41177 Loosen fork seal retaining ring 14 and spacer ring 13 9 Using ROBINAIR HEAT GUN Part No HD 25070 heat bottom of oute...

Page 107: ...pacer ring 14 Retaining ring 15 Retaining cap red 16 DU bushing upper 17 Washer 18 Inner tube 19 Copper washer 20 Bolt metric 21 Bolt 2 metric 22 Damper assembly b0033a2x 1 20 19 21 11 13 2 3 5 4 6 7 8 9 22 NOTE Quantities are listed per individual fork leg Left leg controls rebound damping Right leg controls compression damping Number of preload shims 6 may vary between fork assemblies 10 12 14 1...

Page 108: ...ur face of the inner tubes 5 Clamp outer tube 9 upside down using FRONT FORK HOLDING TOOL Part No B 41177 6 See Figure 2 34 Place inner tube assembly inside outer tube Using bushing side of FRONT FORK BUSHING SEAL INSTALLER Part No B 41176 drive in DU bush ings until fully seated 7 Reverse FRONT FORK BUSHING SEAL INSTALLER Part No B 41176 Seat fork oil seal with seal side of tool Drop seal retaini...

Page 109: ...ree threads of all five front fork triple clamp pinch screws Tighten screws to 18 20 ft lbs 24 4 27 1 Nm 4 Position headlamp bracket 2 375 in 60 3 mm above lower triple clamp Tighten headlamp bracket screws 5 Install front fender See FENDERS REMOVAL INSTAL LATION on page 2 54 6 Install front wheel See FRONT WHEEL INSTALLATION on page 2 10 7 Install front brake caliper See FRONT BRAKE CALI PER INST...

Page 110: ... dam age Replace damaged fork stem ASSEMBLY INSTALLATION 1 See Figure 2 36 If removed install new bearing cups 5 into frame steering head using STEERING HEAD BEAR ING RACE INSTALLER Part No HD 39302 2 Liberally coat the bearing cones 4 with grease using WHEEL BEARING PACKER TOOL Part No HD 33067 Work the grease into the rollers 3 Place lower bearing dust shield 3 over fork stem Find a section of p...

Page 111: ... crankcase Avoid pushing tie bar assembly upward 15 Place a crating strap between the engine cylinders and around the lift Tighten crating strap until snug 16 Detach tie bars from frame mounts in the following sequence Do not remove tie bars from engine a Rear tie bar Use a swivel socket b Top tie bar c Front tie bar and clutch cable clamp 17 See Figure 2 37 Remove isolator screws 9 and wash ers o...

Page 112: ...rough mount block and swingarm Install the opposing bearing adjustment bolt 1 using PIVOT SHAFT BEARING ADJUSTER Part No B 41175 8 Tighten one pinch screw 8 into swingarm mount block Do not tighten the other pinch screw 8 at this time INSTALLATION 1 Adjust swingarm preload Using a scale as shown in Fig ure 2 40 Preload should measure 3 5 5 5 lbs 1 6 2 5 kg 2 Remove both pinch screws 8 Apply LOCTIT...

Page 113: ...parks may cause a battery explo sion resulting in personal injury and or property damage 1CAUTION Hold battery cable when tightening battery terminal hard ware Failure to hold cable may cause battery damage 15 Connect battery cables positive cable first 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle ope...

Page 114: ...ng shock absorber 7 Loosen rear reservoir clamp 2 8 Remove shock absorber assembly DISASSEMBLY 1WARNING The following steps require using a press Wear eye pro tection and make certain set up is stable The force involved could cause parts to flyout at great speeds causing personal injury 1 See Figure 2 42 Place rear shock absorber in a hydrau lic press with REAR SHOCK COMPRESSING TOOL Part No B 411...

Page 115: ... in mounts and loosely install front allen screw and locknut 4 metric 3 Loosely install rear allen screw and locknut 1 metric Tighten reservoir clamp hardware 2 3 4 Tighten front and rear allen screws 1 4 metric to 40 45 ft lbs 54 2 61 0 Nm 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and st...

Page 116: ...com pression and rebound damping as well as spring preload See Figure 2 46 The front suspension uses WP Suspension inverted forks that adjust for compression and rebound damp ing These forks offer strength and stiffness for improved slid ing action better shock absorption and compliance with the road If the preload adjustment is correct and you have the rebound and compression damping set at the f...

Page 117: ...all items removed in Step 2 Load all cargo 6 Bounce a few times on the seat to be sure the suspen sion is free and not binding 7 With the help of an assistant take the same measure ment with the vehicle fully loaded rider passenger lug gage cargo The assistant should help balance the motorcycle so the rider can keep both feet on the foot rests 8 Subtract the second measurement from the first The d...

Page 118: ... exhibits mini mum rebound damping At this setting the shock will have a very fast rebound Position 7 sets the rear shock to maxi mum rebound damping The factory recommended setting is Position 3 Front Suspension Adjustments See Table 2 6 The fork compression damping adjuster on right fork leg has 28 positions Position 20 is the factory rec ommended setting The fork rebound adjuster on the left fo...

Page 119: ...e Rear occurs when you are accelerating out of a corner This problems occurs in two varieties 1 The first type has a movement with a long stroke and a high frequency 2 The second version has a movement with a short stroke and high frequency 1 The shock is too soft Increase compression damping If the adjuster is already set to the maxi mum add more preload to the spring one turn maximum 2 In this c...

Page 120: ...ted for the rider s size and weight For information on setting rear shock preload see SUSPENSION ADJUSTMENTS REAR SHOCK PRELOAD in this section DATE FRONT FORK REBOUND FRONT FORK COMPRESSION REAR SHOCK COMPRESSION REAR SHOCK REBOUND RESULTS Position 12 Position 20 Position 5 Position 3 Factory recommended settings ...

Page 121: ... be at 12 o clock 4 Position housings on right handlebar by engaging locat ing pin 10 on front housing with hole in handlebar Attach housings with screws 1 metric Tighten to 12 17 in lbs 1 4 1 9 Nm 5 Route idle and throttle control cables a Cables must be routed forward from throttle control grip forward of upper triple clamp and down and to the left b Continue between side of frame steering head ...

Page 122: ... lever and hold c Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar NOTE The individual parts of the clutch switch are not serviceable Replace switch upon failure 2 Remove bolt 2 metric and nut 6 metric 3 Remove handlever from clutch clamp 5 Detach clutch cable from handlever 4 Slide clutch cable out of wire guide 10 on right fork leg 5 Remove cl...

Page 123: ...tch clamp 5 as follows a Slide clamp over handlebar b Install left switchgear housing See HANDLEBAR SWITCHES in Section 7 c Place clamp next to switchgear housing Fasten to handlebar with screw 4 metric Tighten screw to 30 35 in lbs 3 4 4 0 Nm d Install mirror parallel to handlebars Mirror mount has metric left hand threads e Install a new left handgrip See HANDLEBAR INSTALLATION on page 2 49 2 Co...

Page 124: ...nut 5 washer 6 and odometer reset cable 3 Pull indicator lights assembly 4 out towards the head lamp Pull bezel 19 out towards the tail lamp 4 Remove two screws 7 5 Remove instrument support INSTALLATION Speedometer 1 See Figure 2 55 If removed install instrument support 8 Slide speedometer into instrument support 2 Attach ground wire with screw and lockwasher 3 Connect wire terminals on back of s...

Page 125: ...d nut 6 Washer 7 Screw 2 8 Instrument support 9 Odometer reset cable 10 Cotter pin 11 Rubber cushion 2 12 Speedometer cover 13 Tachometer cover 14 Lockwasher 3 15 Nut 2 16 Wire guide 17 Speedometer drive 18 Speedometer cable 19 Indicator lamp bezel b0214x2x 1 2 3 4 19 5 6 8 9 11 10 12 14 15 14 15 11 13 16 17 7 18 ...

Page 126: ...ive unit 5 Carefully wipe off old lubricant from inner cable Inspect cable coils for bends bulges discoloration or other defects Replace entire cable assembly if any damage or defect is noted 6 Apply a good quality graphite grease to entire length of inner cable Wipe off excess grease 7 Insert inner cable fully into its housing rotating inner cable somewhat to allow its lower end to engage with sp...

Page 127: ...8 lockwashers 7 and washers 6 Tighten to 30 33 ft lbs 40 7 44 7 Nm 2 Install clutch control See CLUTCH CONTROL ASSEM BLY INSTALLATION on page 2 45 3 Install handlebar 3 using upper handlebar clamp 2 and four screws 1 Tighten screws to 10 12 ft lbs 13 6 16 2 Nm 4 Install instrument support See SPEEDOMETER AND TACHOMETER on page 2 46 5 Install left and right handlebar switch housings See HANDLEBAR S...

Page 128: ...m b Fasten muffler support 15 to crankcase with bolts 5 washers 7 and locknuts 10 Tighten to 30 33 ft lbs 40 7 44 7 Nm c Install front muffler mounts 25 and mount spacer 3 Coat inside of muffler inlet with PERMATEX ULTRA COPPER HIGH TEMP RTV SILICON GASKET material 4 Place a new muffler clamp 14 over slotted end of muf fler Place muffler and clamp on end of exhaust header Loosely tighten clamp NOT...

Page 129: ...asher 4 7 Washer 5 8 Nut 4 9 Locknut 5 10 Locknut 2 11 Locknut 12 Exhaust header 13 Muffler 14 Muffler clamp 15 Muffler support 16 Exhaust port gasket 2 17 Exhaust clamp retaining ring 2 18 Exhaust header clamp 2 19 Muffler support 2 20 Mount spacer 3 21 Washer 4 22 Heat shield 23 Heat shield clamp 2 24 Rear muffler mount 2 25 Front muffler mount 2 26 Header tiebar 27 Washer 2 ...

Page 130: ...ghten bolts 2 so footrests are tight but not binding 2 If removed install footrest mounts 5 a Assemble brake pedal with bushing 8 on the inside and thrust washer 6 on the outside Fasten brake pedal to frame with bolt 10 washer 9 and footrest mount b Assemble shift lever with bushing on the inside and thrust washer on the outside Fasten shift lever to frame with bolt washer and footrest mount 3 Ins...

Page 131: ... Figure 2 60 If removed attach sprocket cover to swingarm drive support with two screws 9 Tighten screws to 12 17 in lbs 1 4 1 9 Nm 2 Install sprocket cover assembly with screw 5 washer 6 and spacer 8 Tighten screw to 4 6 ft lbs 5 4 8 6 Nm 3 Install screws 3 Tighten to 20 25 ft lbs 27 1 33 9 Nm 4 Install nut 1 and washer 2 Tighten nut to 30 35 ft lbs 40 7 47 4 Nm Figure 2 60 Sprocket Cover 1 Nut 2...

Page 132: ...ctor 10 2 Remove screws 13 and nylon washers 2 on right side to detach lower belt guard 11 3 Remove shoulder bolts 7 washers 8 and grommets 9 on left side 4 Remove rear fender 6 from swingarm 5 Install in reverse order Frame Heat Shield 1 Remove seat and tail section See TAIL SECTION REMOVAL on page 2 55 2 See Figure 2 62 Remove screws 1 nylon washers 2 and locknut 4 3 Remove frame heat shield 5 4...

Page 133: ... 2 See Figure 2 63 Install two screws 4 and nylon wash ers 3 NOTE If fuel tank was removed see FUEL TANK INSTALLATION in Section 4 3 Tighten screw 6 to 9 11 ft lbs 12 2 14 9 Nm 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 4 Pl...

Page 134: ...ousing and headlamp brackets INSTALLATION 1 If removed install the three windscreen brackets a See Figure 2 65 Install center bracket using nut b Install left and right brackets between headlamp housing and headlamp brackets Tighten headlamp adjusting screws metric 6 8 ft lbs 8 1 10 8 Nm 2 Align windscreen on right left and center brackets Attach windscreen to center bracket velcro strip 3 See Fig...

Page 135: ...b on the underside of the seat into the opening on the motorcycle 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 2 See Figure 2 66 Fasten seat to frame with wing screw Tighten securely Figure 2 66 Seat Wing Screw Figure 2 67 Sea...

Page 136: ...ll side stand using pivot pin 8 and retaining clip 7 4 Connect spring 6 to side stand and spring pin 5 1WARNING If the side stand is not in the full forward position when vehicle weight is rested on it the vehicle could fall over possibly causing personal injury Always park motorcycle on a level firm surface Vehicle weight could cause motorcycle to fall over possibly causing personal injury Be sur...

Page 137: ...see NEW COMPONENTS ITEM NEW COMPONENTS SERVICE WEAR LIMITS VALVE Fit in guide Exhaust 0 0015 0 0033 in 0 038 0 084 mm 0 0040 in 0 102 mm Intake 0 008 0 0026 in 0 020 0 066 mm 0 0035 in 0 089 mm Seat width 0 040 0 062 in 1 02 1 57 mm 0 090 in 2 29 mm Stem protrusion from cylinder valve pocket 1 975 2 011 in 50 17 51 08 mm 2 031 in 51 59 mm OUTER VALVE SPRING Free length 2 105 2 177 in 53 47 55 30 m...

Page 138: ...25 mm Head gasket surface flatness 0 006 in total 0 15 mm total 0 006 in total 0 15 mm total CYLINDER Taper 0 002 in 0 05 mm Out of round 0 003 in 0 08 mm Warpage gasket surfaces Top 0 006 in 0 15 mm Base 0 008 in 0 20 mm Bore diameter 0 0002 in OS over size Standard 3 4978 in 88 844 mm 3 5008 in 88 920 mm 0 005 OS 3 502 in 88 95 mm 3 505 in 89 03 mm 0 010 OS 3 507 in 89 08 mm 3 510 in 89 15 mm 0 ...

Page 139: ...0 000 0 002 in 0 00 0 05 mm 0 002 in 0 05 mm End play 0 001 0 005 in 0 025 0 13 mm 0 005 in 0 13 mm SPROCKET SHAFT BEARING Outer race fit in crankcase tight 0 0004 0 0024 in 0 010 0 061 mm Bearing inner race fit on shaft tight 0 0002 0 0015 in 0 005 0 038 mm PINION SHAFT BEARINGS Pinion shaft jounal diameter 1 2496 1 2500 in 31 740 31 750 mm 1 2496 in min 31 375 mm min Outer race diameter in right...

Page 140: ...lter adapter 8 12 ft lbs 11 16 Nm LOCTITE THREADLOCKER 242 blue page 3 37 Oil pressure signal light switch 5 7 ft lbs 7 9 Nm page 3 37 Oil pressure switch wire nut 4 10 in lbs 0 4 1 1 Nm page 3 37 Oil pump cover screws 125 150 in lbs 14 1 16 9 Nm page 3 36 Oil pump mounting screws 125 150 in lbs 14 1 16 9 Nm page 3 36 Pinion shaft nut 35 45 ft lbs 47 61 Nm LOCTITE THREAD LOCKER 262 red page 3 46 R...

Page 141: ...xture in the rear cylinder FUEL Gasoline alcohol Blends Buell motorcycles were designed to obtain the best perfor mance and efficiency using unleaded gasoline 91 pump octane or higher Some fuel suppliers sell gasoline alcohol blends as a fuel The type and amount of alcohol added to the fuel is important DO NOT USE GASOLINES CONTAINING METHANOL Using gasoline methanol blends will result in starting...

Page 142: ... the process of elimination to indicate any one of the above components is worn it is best to give attention to all of the cylinder head and cylinder parts Compression Test Procedure Combustion chamber leakage can result in unsatisfactory engine performance A compression test can help determine the source of cylinder leakage Use CYLINDER COMPRES SION GAUGE Part No HD 33223 1 A proper compression t...

Page 143: ...rear brake 7 Following the manufacturer s instructions perform a cyl inder leakage test on the front cylinder Make a note of the percent leakdown Any cylinder with 12 leakdown or more requires further attention 8 Listen for air leaks at carburetor intake exhaust head gasket and timing inspection hole See Table 3 2 NOTE If air is escaping through valves check push rod length 9 Repeat procedure on r...

Page 144: ...nd the lift Attach straps to frame and hoist Raise hoist until straps tighten 4 Detach clutch cable from handgrip 5 Remove REAR FENDER LOWER BELT GUARD and SPROCKET COVER See Section 2 6 Remove rear caliper See REAR BRAKE CALIPER in Section 2 7 Detach belt from rear sprocket and remove rear wheel See REAR WHEEL in Section 2 8 Drain oil tank and remove oil filter See ENGINE LUBRI CATION SYSTEM in S...

Page 145: ...e SWINGARM in Section 2 24 If necessary detach swingarm mount block from power train by removing bolts 3 4 washers and locknuts Figure 3 2 Supporting the Engine b0251x3x Crating strap Figure 3 3 Rear Tie Bar Assembly Figure 3 4 Front Tie Bar Assembly 1 Ground strap 2 Rear isolator 3 Swingarm mount block bolts 2 upper 4 Swingarm mount block bolts 2 lower 5 Rubber isolator 2 6 Lockwashers 2 7 Isolat...

Page 146: ...ount block 14 Attach clutch cable to handlebar lever 15 Remove strap from between engine cylinders Using a floor hoist lift motorcycle by the frame and remove the wooden cradle from underneath the crankcase 16 Install rear shock See REAR SHOCK ABSORBER INSTALLATION in Section 2 Remove floor hoist straps 17 Install rear wheel and attach secondary drive belt See REAR WHEEL INSTALLATION in Section 2 ...

Page 147: ...asteners with unhardened parts Do not reuse fiber cover seals These actions may result in accelerated wear and increased noise 2 Remove top 4 and middle 5 sections of rocker box Remove and discard gaskets 6 7 and 8 Figure 3 5 Rocker Arm Cover 1 Screws 4 2 Fiber seal 4 3 Umbrella Valve 2 4 Upper rocker cover 5 Middle rocker cover 6 Gasket 7 Gasket 8 Gasket 9 Rocker arm shafts 10 Rocker arm 11 Rocke...

Page 148: ...h 8 See Figure 3 5 Remove rocker arms 10 11 mark them for reassembly in their original locations 1CAUTION Distortion to the head cylinder and crankcase studs may result if head screws are not loosened or tightened gradually in the sequence shown in Figure 3 8 9 See Figure 3 8 Loosen each head screw 1 8 turn follow ing the sequence shown 1CAUTION See Figure 3 7 Do not attempt to remove the front is...

Page 149: ...or mount attached 13 See Figure 3 10 Remove socket screws 11 washers 13 and retainers 9 Remove push rod covers 7 seals 8 O rings 10 and push rods 12 Mark the loca tion and orientation top and bottom of each push rod 14 Remove socket screw 5 washer 14 and plate 4 Remove O rings 3 from ends of pins 2 Grasp pins 2 and pull from crankcase Use a pliers if necessary Remove lifter from crankcase bore 15 ...

Page 150: ...See Figure 3 12 and Figure 3 13 Measure rocker arm shaft diameter at the positions where shaft fits in lower rocker arm cover and where rocker arm bushings ride Record the measurements 6 See Figure 3 14 and Figure 3 15 Measure rocker arm shaft bore diameter in lower rocker cover and rocker arm bushing inner diameter Record the measurements 7 Check the clearances and measurements obtained in Steps ...

Page 151: ...s 17 See Figure 3 16 Check free length and compression force of each spring Compare with SPECIFICATIONS If spring length is shorter than specification or if spring compression force is below specification replace spring 18 Examine push rods particularly the ball ends Replace any rods that are bent worn discolored or broken 19 See Figure 3 17 Check head gasket surface on head for flatness Machine o...

Page 152: ... the tool touches the machined surface surrounding the guide At this point the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 025 mm of final size using VALVE GUIDE REAMER Steel Part No HD 39932 or Carbide Part No HD 39932 CAR Use REAMER LUBRICANT Part No HD 39964 or lib eral amounts of suitable cutting oil to prevent reamer chatter 6 See Figure 3 20 Apply ...

Page 153: ...Always grind valves before cutting seats 1 Cut 46 or grind 45 valve seat angle first Use cutting oil to avoid chatter marks Cut or grind only enough to clean up the seat 2 Apply a small amount of lapping compound to the valve face Rotate valve against seat using VALVE LAPPING TOOL Part No HD 96550 36A 3 See Figure 3 21 Check the contact pattern on valve face It should be 0 040 0 062 in 1 02 1 57 m...

Page 154: ...ort side Lapping Valve Faces and Seats NOTE If valve faces and seats have been smoothly and accurately refaced very little lapping will be required to complete the seating operation 1 See Figure 3 23 Apply a light coat of fine lapping com pound to valve face Insert valve in guide Position one rubber cup end of VALVE LAPPING TOOL Part No HD 96550 36A onto head of valve Holding lapping tool as shown...

Page 155: ...e seal will be damaged Do not remove valve after seal is installed Other wise sharp edges on keeper groove will damage seal 7 See Figure 3 24 Tap the seal onto the guide using the VALVE SEAL INSTALLATION TOOL Part No HD 34643A and DRIVER HANDLE Part No HD 34740 The seal is completely installed when the tool touches the lower collar 4 8 See Figure 3 9 Install valve springs 5 6 and upper col lar 8 9...

Page 156: ...TAGE See Figure 3 26 Mark cylinder head and head screw shoulder with a line as shown View A Tighten each screw a 1 4 turn 90 View B 12 See Figure 3 10 Rotate engine so that both tappets 6 from the cylinder being serviced will be installed on the base circle lowest position of the cam 13 Apply a liberal amount of engine oil to tappet assembly especially roller needles for smooth initial operation 1...

Page 157: ...bs 20 24 Nm See Table 3 5 NOTES Tubular frame prohibits direct access to bolt 12 on right rear cylinder Use TORQUE ADAPTOR SNAP ON Part No FRDH 181 and TORQUE COMPUTER Part No SS 306G to correctly assemble 21 Place new gasket 7 middle rocker cover 5 with breather valve on intake side new gasket 6 and upper rocker cover 4 on lower rocker box Install screws 1 with new fiber seals 2 Tighten screws 1 ...

Page 158: ...ightest bend could cause a stress riser and lead to stud failure 7 Install a 6 in 150 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each stud This will protect the studs and the pistons 1WARNING The next step covers removing the piston pin retaining rings These rings are highly compressed in the ring groove and may fly out with considerable force when pried out of the groove Safety gl...

Page 159: ...ored 5 Check piston pin bushing to see that it is not loose in connecting rod grooved pitted or scored A piston pin properly fitted to upper connecting rod bushing has a 0 00125 to 0 00175 in 0 0317 0 0444 mm clearance in bushing If piston pin to bushing clearance exceeds 0 00200 in 0 0508 mm replace worn parts See CON NECTING ROD BUSHING on page 3 26 6 Clean piston pin retaining ring grooves 7 Ex...

Page 160: ...t bottom of ring path Record readings This process will determine if cylinder is out of round or egged and will also show any cylinder taper or bulge 5 See Table 3 6 If cylinder is not scuffed or scored and is within service limit see FITTING CYLINDER TO PIS TON on page 3 25 NOTE If piston clearance exceeds service limit cylinders should be rebored and or honed to next standard oversize and refitt...

Page 161: ...ines See Figure 3 31 Piston rings are of two types compression and oil control The two compression rings are positioned in the two upper piston ring grooves The dot on the second compression ring must face upward Ring sets are available to fit standard and oversize pistons Piston ring sets must be properly fitted to piston and cylinder 1 See Figure 3 32 Place piston in cylinder about 1 2 in 12 7 m...

Page 162: ...nnecting rod place new bushing between connecting rod and driver NOTE The driver must be attached facing the opposite direction as it was for removal of the bushing 8 Clean up and size bushing to 0 0010 0 0005 in 0 025 0 013 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 0317 mm clearance can result in a bushing loos ening and or seized pin in rod 9 Hone ...

Page 163: ... PISTON PIN RETAINING RING INSTALLER Part No HD 34623A Make sure the ring groove is clean and that the ring is fully seated in the groove with the gap away from the slot at the bottom 4 See Figure 3 34 Make sure the piston ring end gaps are properly positioned as shown 5 Lubricate cylinder wall piston pin and rod bushing with engine oil 6 Turn engine until piston is at top dead center 7 Compress t...

Page 164: ...other gases and particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase breather system A moderately driven vehicle making short runs may not be able to vacat...

Page 165: ... oil pump The feed hose attaches to the rear most oil pump fitting the return hose connects forward and above After diverging from the feed and return hoses the vent hose is routed beneath the starter The vent hose continues on to the right side of the motorcycle and goes behind the gearcase cover assembly where it connects to an elbow fitting Figure 3 38 Oil Tank Hoses Figure 3 39 Oil Pump Connec...

Page 166: ...and lockwashers 1 at all four mounting points NOTE Starting at the top mounting points will simplify installation 2 Connect the four oil tank hoses Tighten new clamps 5 8 and 10 using HOSE CLAMP PLIERS Part No HD 41137 NOTE Worm clamp 3 may be reused on feed hose 4 3 Fill oil tank See ENGINE LUBRICATION SYSTEM CHANGING ENGINE OIL AND FILTER in Section 1 4 Install rear fender See FENDERS in Section...

Page 167: ... will warm up and become less viscous oil pressure decreases When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use OIL PRESSURE GAUGE Part No HD 96921 52A and OIL PRESSURE GAUGE ADAPTER Pa...

Page 168: ...from the crankcase air collects and passes through a small drain hole 2 where it eventually returns to the crankcase The crankcase air is routed through a passage in each cylinder head The crankcase air then travels through each air cleaner breather bolt 4 into a hose leading into the air cleaner Figure 3 43 Crankcase Breathing System Typical Cylinder 1 Push rod cover 2 2 Oil drain hole 3 Umbrella...

Page 169: ...n intersecting passage in the gearcase cover Oil flow is then routed to the crankshaft area 10 Oil enters a hole in the end of the pinion gear shaft and travels to the right flywheel where it is routed through the flywheel to the crankpin Oil is forced through the crank pin to properly lubricate the rod bearing assembly 11 Oil flows up passages in the push rods to the rocker arm shafts and bushing...

Page 170: ... from the oil tank enters the pump through fitting 5 It is forced by gerotor set 7 through a hose to the oil filter Return oil from the flywheel compartment is drawn back into the pump and is forced by gerotor set 9 back to the oil tank See INTERNAL ENGINE PASSAGES for oil passages within the engine The oil pump seldom needs servicing Before you disassem ble an oil pump suspected of not producing ...

Page 171: ...r 6 off body 12 Remove and discard O ring 14 7 Slide both pieces of feed gerotor set 7 separator plate 8 and both pieces of scavenge gerotor set 9 off gear shaft 11 8 Remove and discard retaining ring 16 Remove thrust washer 15 and gear shaft 11 Figure 3 45 Oil Pump Hardware 3 2 1 1 2 4 5 1 Mounting screw and washer 2 2 Cover screw and washer 2 3 Feed hose connection 4 Return hose connection 5 Oil...

Page 172: ... to complete scavenge set 9 4 Position separator plate 8 into case and line up slots on perimeter with tabs inside oil pump body 12 5 Place feed gerotor set 7 over gear shaft 11 6 Install a new O ring 14 into groove in cover 6 Place cover onto pump body Install cover screws 2 with washers 3 Tighten cover screws 2 to 125 150 in lbs 14 1 16 9 Nm 7 Place new mounting gasket 10 in position 8 See Figur...

Page 173: ...242 blue to the threads on that end of the oil filter adapter 1 which is installed into oil filter mount 4 Do not apply LOCTITE to adapter threads on oil filter element side NOTE The oil filter adapter 1 has identical ends either end may be installed into the oil filter mount 3 Place spring 3 and check ball 2 into threaded hole at center of mount 4 Push adapter 1 against ball to compress spring In...

Page 174: ... Lift retainer 9 and seal 8 upward a few inches on push rod cover 7 Push upward on push rod cover while pulling bottom of cover 7 clear of crankcase Remove cover 7 4 Remove screw 5 washer 14 and plate 4 Pull O rings 3 off ends of pins 2 and discard Grasp ends of pins 2 and pull outward free of crankcase A pliers is a handy tool to free pins 2 With a thin bladed screwdriver in the retainer groove a...

Page 175: ...2 4 Nm 5 Slide new seal 8 and place retainer 9 over top of push rod cover 7 Position new O ring 10 at top of push rod cover Hold cover at an angle and insert top through hole in cylinder head Push up on cover while aligning bottom of cover with tappet bore in crankcase Lower retainer 9 with seal 8 onto crankcase aligning locating pin 15 with hole in retainer 6 Insert screw 11 with washer 13 throug...

Page 176: ... any parts that will interfere with gearcase disas sembly i e exhaust header footrest air cleaner etc 3 Remove push rods as described under CYLINDER HEAD REMOVAL on page 3 11 4 Remove tappets See VALVE TAPPETS REMOVAL on page 3 38 Figure 3 51 Gearcase and Valve Train Components 1 Rear exhaust cam gear 2 Rear intake cam gear 3 Front intake cam gear 4 Front exhaust cam gear 5 Pinion gear 6 Seal 7 Fr...

Page 177: ... 15 cams on 1996 models See Figure 3 53 Measure the gear diameter with a microme ter over 0 108 in 2 74 mm diameter gauge pins on opposite sides of the gear The pins are of the proper size to fit between the contacting surfaces of the gear teeth Gear diameter should be measured in at least two places 90 apart Use GAUGE PIN SET Part No HD 38361 when mea suring pinion and cam gear sizes Cam and pini...

Page 178: ...8 323 48 333 2 4031 2 4035 61 038 61 049 1 9015 1 9019 48 298 48 308 1 9025 1 9029 48 323 48 333 1 2745 1 2748 32 372 32 380 WHITE 1 9020 1 9024 48 310 48 321 1 9020 1 9024 48 310 48 321 2 4036 2 4040 61 051 61 061 1 9020 1 9024 48 310 48 321 1 9020 1 9024 48 310 48 321 1 2741 1 2744 32 362 32 369 GREEN 1 9025 1 9029 48 323 48 333 1 9015 1 9019 48 298 48 308 2 4041 2 4045 61 064 61 074 1 9025 1 90...

Page 179: ... There is no need to orient these particular bushings in any specific position of rotation within gearcase cover bores 2 After you install a new bushing in gearcase cover line ream the bushing to correct size See BUSHING REAM ING on page 3 44 REAR INTAKE CAM GEAR BUSHING IN GEARCASE COVER 1 See Figure 3 51 Rear intake cam gear bushing 15 must be installed in its gearcase cover 17 bore using an arb...

Page 180: ...n flat surface with gearcase side upward Bushing to be reamed must be oriented as shown in Figure 3 57 2 See Figure 3 59 Position CAMSHAFT BUSHING REAMER PILOT Part No HD 38871 onto gearcase side of crankcase half upper right and lower left indexing holes in pilot must be placed over dowels in crankcase half Insert two bolts supplied with pilot through two remaining holes in pilot and into threade...

Page 181: ... through bushing in gearcase cover until reamer bottoms Then give reamer one com plete clockwise turn to size the bushing Continue turning reamer clockwise while extracting reamer from bushing 5 Separate gearcase cover from right crankcase half Inspect bushing for proper cam gear shaft fit Repeat line reaming operation if necessary 6 Thoroughly clean gearcase cover removing all metal chips shaving...

Page 182: ...nstall a new seal 6 and new dry gas ket 9 on gearcase cover 17 5 Install gearcase cover over all gears and onto right crankcase half 10 Secure cover to crankcase half with 11 socket head screws Tighten screws evenly to 80 110 in lbs 9 0 12 4 Nm according to the torque sequence shown in Figure 3 63 6 Check cam gear end play for each cam gear as follows a Turn engine over until lobe of cam gear bein...

Page 183: ...INSTALLATION on page 3 39 8 Install ignition system See Section 7 9 Install any components removed to gain access to gear case i e exhaust system components air cleaner etc Figure 3 63 Gearcase Cover Mounting Screw Torque Sequence b0064a3x 7 3 1 11 10 9 4 2 5 6 8 ...

Page 184: ...haft while reading dial indicator Then rotate and pull on sprocket shaft while reading dial indicator If difference end play in indicator readings is not 0 001 0 005 in 0 025 0 13 mm bearing inner spacer shim item 6 Figure 3 68 must be replaced Choose spacer from Table 3 11 Use a thinner spacer for less end play use a thicker spacer for more end play DISASSEMBLY Crankcase Halves 1 Remove cylinder ...

Page 185: ...set up is stable The force involved could cause parts to fly out and cause per sonal injury 10 See Figure 3 66 Mount the left case half and flywheel assembly on a press table supporting crankcase on par allel bars Press on end of sprocket shaft with arbor press until flywheel assembly is free from case half Do not drive flywheel assembly from case half as flywheels may be knocked out of alignment ...

Page 186: ... a short length of pipe or tubing so connecting rods 3 may be slipped off bearings then remove bearing assembly Secure bearings 4 together in set until they are washed and refitted to crank pin 3 Remove crank pin nut 9 then tap crank pin 6 out of flywheel and remove key 7 CLEANING INSPECTION 1 Wash all parts in solvent and blow dry with compressed air Examine crank pin for wear grooving and pittin...

Page 187: ...el recess and is secured originally by punching flywheel metal tight against the washer at several points It is usu ally necessary to drill a small hole 1 8 in 3 2 mm or smaller at the outer edge of the washer to permit prying with a pointed tool NOTE Drill hole only slightly deeper than thickness of washer Avoid removing more material than necessary 2 Before installing a new washer scrape outer e...

Page 188: ...d be trued and sized with CONNECTING ROD LAPPING ARBOR Part No HD 96740 36 1 Clean lap before using 2 See Figure 3 71 Clamp lap into lathe chuck carefully load lap with 220 grit grinding compound mixed with oil Adjust lathe to turn at approximately 150 200 RPM 3 Carefully slide connecting rod over lap Adjust lap to a dragging but free fit in rod race NOTE A loose lap will BELL MOUTH bearing races ...

Page 189: ... ers from dropping out of the cage Only one size replacement bearing set standard either red or blue coding is sold Oversize bearings are not available Bearing clearance or fit is controlled by the connecting rod race inside diameters and the crank pin diameter Two oversize crank pins are available 1 See Figure 3 73 Measure inside diameter ID of lapped connecting rod races with a dial bore gauge t...

Page 190: ...ECIFICATIONS are also met CONNECTING ROD SPECIFICATION Rear Difference in ID of two races must not exceed 0 0001 in 0 0025 mm Front and rear Difference in ID of races in front and rear connecting rods must not exceed 0 0002 in 0 005 mm Front and rear Races must be round within 0 00025 in 0 0064 mm Difference between largest and smallest ID mea surement in any race must not exceed 0 00025 in 0 0064...

Page 191: ... See Figure 3 76 Installed inner races are identified at the fac tory as shown See Figure 3 77 Outer races are identified at the factory as shown Figure 3 75 Pulling Pinion Shaft Inner Race 1 Puller Part No HD 97292 61 2 Center cap Part No HD 95652 43A 3 Bearing separator Snap On Part No CJ950 1 3106a 3 2 Figure 3 76 Factory Inner Race Sizes Figure 3 77 Factory Outer Race Sizes Paint dot on end of...

Page 192: ...ING RACES on page 3 58 Race must be lapped until all wear marks are removed 5 Measure ID of race at four places and record the mea surements 6 Check measurements against these specifications Largest ID measured 1 5672 in 39 807 mm or less Roundness of ID within 0 0002 in 0 005 mm Taper within 0 0002 in 0 005 7 If lapping increased bore ID to larger than 1 5672 in 39 807 mm go to Step 8 If roundnes...

Page 193: ... See Table 3 13 With a 1 5651 in ID outer race and a 1 2499 in 31 747 mm OD inner race a blue bearing is required NOTE Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings Table 3 13 Pinion Shaft Bearing Selection FACTORY STAMPED NUMBER OUTER RACE ID BEARING SIZE AS IDENTIFIED BY COLOR CODING over 1 5672 in 39 807 mm Service Wear Limit...

Page 194: ...eel components using a non petroleum based solvent such as LOCTITE CLEANING SOLVENT or electrical contact cleaner Thoroughly dry all components 2 See Figure 3 70 Apply two drops of LOCTITE 620 RETAINING COMPOUND to the crank pin threads and apply no more than two drops to the nut bearing faces 1CAUTION Do not apply any LOCTITE THREADLOCKER COM POUND or RETAINING COMPOUND to shaft tapers Any materi...

Page 195: ...n with lead or copper mallet 13 When wheels are both out of true as indicated in B drive a hardwood wedge between the wheels opposite the crank pin and lightly tap the rims near the crank pin with a lead or copper mallet 14 When wheels are out of true as indicated in C strike the rim of the wheel a firm blow at about 90 from crank pin on high side 15 When wheels are out of true in a combination of...

Page 196: ... pin assembled with oil on tapers and nut over tightened Disassemble clean and reassemble b New flywheel washers installed and not fully seated Disassemble inspect replace deepest seating fly wheel or crank pin As last resort grind down width of forked rod c Taper holes enlarged as a result of having been taken apart several times Replace deepest seating wheel d Cracked flywheel at tapered hole Re...

Page 197: ...right outer race 5 and into installer base 1 Press race into bore until firmly seated against retaining ring 3 NOTE See Figure 3 88 Use SPROCKET SHAFT BEARING SEAL INSTALLATION TOOL 1 8 Part No HD 37047A to install sprocket shaft tapered roller bearings and seal 8 See Figure 3 89 Place bearing cone 3 small end upward over end of sprocket shaft Position spacer 2 over sprocket shaft with radius roun...

Page 198: ...aring cage Remove the driver handle and seal spacer driver 1CAUTION Do not remove the spacer after installation or the new seal will have to be discarded and the procedure repeated 14 Apply a thin coat of DOW CORNING SILASTIC or 3 M 800 sealant to crankcase joint faces Figure 3 88 Sprocket Shaft Bearing Seal Installation Tool Figure 3 89 Installing Bearing Cone 6 7 8 5 4 3 2 1 1 Nut driver 2 Space...

Page 199: ...See Figure 3 65 Install crankcase in chassis using hard ware shown 22 Install transmission mainshaft sprocket See TRANSMIS SION INSTALLATION AND SHIFTER PAWL ADJUST MENT in Section 6 23 Install starter See STARTER INSTALLATION in Section 5 24 Install primary drive components clutch and clutch release mechanism See PRIMARY DRIVE CLUTCH in Section 6 25 Apply two or three drops of LOCTITE THREADLOCKE...

Page 200: ...tall cylinder heads See CYLINDER HEAD INSTAL LATION on page 3 20 30 Install cam gears gearcase cover tappet guides and tappets See GEARCASE COVER AND CAM GEARS ASSEMBLY INSTALLATION on page 3 46 31 Refer to INSTALLING THE ENGINE on page 3 10 and perform the applicable steps 32 Install ignition system and check adjust engine ignition timing See IGNITION SYSTEM in Section 7 ...

Page 201: ...RETURN OIL FEED OIL RETURN OIL FEED OIL INTERNAL ENGINE PASSAGES ...

Page 202: ...crew 6 8 ft lbs 8 1 10 8 Nm page 4 19 Air cleaner front support screw 3 5 ft lbs 4 1 6 8 Nm LOCTITE THREADLOCKER 242 blue page 4 19 Canister clamp screws 6 8 ft lbs 8 1 10 8 Nm page 4 25 Cylinder head breather bolts 10 15 ft lbs 13 6 20 3 Nm HYLOMAR page 4 19 Fuel cap flange screws 22 25 in lbs 2 5 2 8 Nm special pattern to tighten page 4 21 Fuel supply valve screws 34 37 in lbs 3 8 4 2 Nm page 4 ...

Page 203: ...ting by procedures other than specified in this section may be in violation of Federal or State regula tions This system partially compensates for changes in the mixture that are normally caused by changes in altitude Because atmospheric pressures drop as altitude increases the pres sure difference in the upper and lower chambers is reduced this results in less fuel being delivered to the engine t...

Page 204: ...mp output Remedy 1 Limit system use 2 Adjust clean or replace 3 Clean or replace as required 4 Correct restricted hose Replace vapor vent valve 5 Modify riding habits 6 Adjust operating idle speed 7 Tighten jets 8 Adjust float tab for correct fuel level 9 Clean and clear passages 10 Replace needle or needle jet 11 See Vacuum Piston Troubleshooting on page 4 4 12 Clean clear and correct as required...

Page 205: ...act 5 Dirty or damaged air cleaner element 6 Plugged bowl vent or overflow 7 Worn or damaged needle or needle jet 8 Vacuum piston assembly malfunction 9 Loose or plugged main jets or passages 10 Improper fuel level 11 Accelerator pump inoperative Remedy 1 Clean or replace 2 Adjust clean or replace 3 Correct restricted hose Replace vapor vent valve 4 Correct and clean restriction 5 Clean or replace...

Page 206: ...ROTTLE IS CLOSED Pull enrichener knob to full out position 6 Press electric starter switch to operate starter After starting the motorcycle proceed as follows 1 After initial 15 30 second warm up ride for 5 minutes or 3 miles with enrichener knob in full out position 2 After 5 minutes or 3 miles push enrichener knob in to the 1 2 way position Ride 2 minutes or 2 miles 3 After 2 minutes or 2 miles ...

Page 207: ...osing the valve and stopping fuel flow to the float chamber When fuel is used by the running engine the fuel level in the float chamber drops this lowers the float and inlet valve thereby causing the valve to open and the fuel flow to resume The float chamber is vented to atmosphere through an air passage in the carburetor body The opening for the float chamber vent passage is next to the carburet...

Page 208: ...chener valve opens the air fuel passage to the low pressure carbure tor venturi Fuel in the float bowl at atmospheric pressure flows upward through a metering enrichener jet and then through a passage to the lower pressure enrichener valve chamber Air in the enrichener air inlet at atmospheric pres sure also flows into the lower pressure enrichener valve chamber and mixes with the incoming fuel Th...

Page 209: ...el of the carburetor During the transition period from idle speed to mid range the idle and transfer ports also supply some fuel to the carburetor barrel this allows for a smoother transition The venturi opening is reduced by the low position of the vac uum piston This enables initial air stream velocities to be higher than normally attainable with fixed venturi carburetors The higher air stream v...

Page 210: ...proportion to the pressure difference between the chambers The tapered needle moves upward with the vacuum piston thereby opening the needle jet With the needle jet open the main bleed tube is exposed to the lower pressure of the car buretor venturi This causes fuel in the float bowl at atmo spheric pressure to flow through the main jet and into the main bleed tube Air from the main air jet at atm...

Page 211: ...olume of air are simultaneously increased and metered to the proportions of engine demand by the variable venturi and needle lift With the vacuum piston fully upward the venturi opening is fully enlarged and the needle jet opening exposure to the air stream is at its maximum Air and fuel supplies are now available in quantities sufficient to meet maximum engine demand Figure 4 7 High Speed Circuit...

Page 212: ...ess the accelerator pump diaphragm This forces fuel in the pump to flow through a fuel passage which has a one way check valve through the pump nozzle and then into the venturi When the throttle closes the pump rod lifts up and away from the pump diaphragm a spring below the diaphragm pushes the diaphragm upward thereby causing the lower pump cavity to refill with fuel from the float bowl The chec...

Page 213: ... on float while measuring The measurement must be 0 413 0 453 in 10 49 11 51 mm If measurement is not within given dimension remove float and carefully bend tab in order to reposition float at proper level 3 Install float and recheck setting 4 Install float bowl Install carburetor as described in CAR BURETOR INSTALLATION on page 4 17 OPERATION CHECK VACUUM PISTON Opening Malfunction 1WARNING While...

Page 214: ...etor Float Adjustment Base Correct float position 15 to 20 Incorrect float position Start float position Pin Fuel inlet valve XLH0404 Float Float 0 413 0 453 in 10 49 11 51 mm Pin return spring collapsed Float Greater than 20 ...

Page 215: ...able adjusters metric Remove throttle cables at carburetor 8 Pull carburetor free of intake manifold 9 Disconnect fuel drain hose from drain fitting On Califor nia models disconnect canister vent hose Carburetor Manifold 1 Remove carburetor as described above 2 Remove fuel tank See FUEL TANK REMOVAL on page 4 20 3 Remove ignition key switch bracket a Remove bolt and locknut to detach top tie bar f...

Page 216: ...n needle jet 9 Replace if damaged 12 Clean all internal fuel air passages and jets Check that all passages and jets are open and free of obstruction 13 Check needle jet holder 10 Clean bleed tube orifices Replace holder if damaged 14 Check float 16 for cracks or other leaks Replace if damaged 15 Clean main jet 11 with carburetor cleaner and inspect for damage Replace if damaged Accelerator Pump 1 ...

Page 217: ... bracket 25 Screw 26 Screw and lockwasher 27 Idle speed adj screw 28 Spring 29 Washer 2 30 Drain hole 31 Drain hose 32 Clip 33 Washer 34 Cotter pin 2 35 Washer 3 36 Washer 37 Lever 38 Float bowl 39 E clip 40 Accelerator pump nozzle 41 Spring 42 Pump housing 43 Spring 44 Diaphragm 45 O ring 46 O ring 47 Drain screw 48 Lockwasher 3 49 Screw 3 50 Boot 51 Accelerator pump rod 52 Collar 53 Float bowl O...

Page 218: ...n key switch bracket a Fasten bracket to cylinder heads with two TORX screws and washers Tighten to 25 30 ft lbs 33 9 40 7 Nm b Attach top tie bar to bracket Tighten locknut to 30 33 ft lbs 40 7 44 7 Nm c Secure ignition wires to main wiring harness using a new cable strap Carburetor 1 Attach throttle cables to carburetor a Install idle control cable into longer inboard cable guide on carburetor b...

Page 219: ...4 See Figure 4 17 Remove two screws and snorkel plate 5 Remove snorkel and filter box 6 See Figure 4 18 Remove screw with spacer and gasket 7 See Figure 4 19 Remove screw under air cleaner sup port NOTE Step 7 may require a cut down allen wrench 8 Draw breather hoses through backplate Remove back plate 9 If necessary remove air cleaner support ring a Detach breather hoses from cylinder head breath...

Page 220: ...e Figure 4 18 Apply LOCTITE THREADLOCKER 242 blue to screw Install ring with screw through backplate Tighten to 7 9 ft lbs 9 5 12 2 Nm 5 See Figure 4 17 Apply LOCTITE THREADLOCKER 242 blue to screws Fasten snorkel tube with ring and two screws Tighten to 6 8 ft lbs 8 1 10 8 Nm 6 Check air cleaner filter See AIR CLEANER FILTER in Section 1 Attach filter box with filter to snorkel tube 7 Connect bre...

Page 221: ...r Gasoline can be extremely flammable and highly explosive Inadequate safety precautions may result in personal injury 2 Remove fuel hose and hose clamp from fuel supply valve NOTE Fuel tank can be removed from motorcycle without being drained Drain tank only when necessary 3 Drain fuel from tank a Attach an additional length of hose to fuel supply valve Place free end of drain hose into a proper ...

Page 222: ...esult in personal injury Clean tank interior with commercial cleaning solvent or a soap and water solution Plug fuel tank openings Shake tank to agi tate the cleaning agent Thoroughly flush fuel tank after clean ing Allow tank to air dry Carefully inspect fuel hose for damage wear or general deterioration Replace as necessary INSTALLATION 1 See Figure 4 21 Place fuel tank on frame Install fuel tan...

Page 223: ...end of drain hose into a proper clean con tainer of adequate size Turn supply valve to reserve RES Drain gasoline from tank into container Remove temporary drain hose 1WARNING Even with the fuel tank completely drained a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed Thoroughly wipe up any spilt fuel immediately and dispose of rags in a suitable m...

Page 224: ...hose These vapors pass through the carburetor and are burned as part of normal combustion in the engine The large diameter canister to air cleaner hose canister clean air inlet hose supplies the canister with fresh air from the air cleaner TROUBLESHOOTING 1WARNING Verify that the evaporative emissions vent hoses do not contact hot exhaust or engine parts The hoses contain flammable vapors that can...

Page 225: ...to detach mounting plate 2 from clamps 1 5 Remove countersunk screws and locknuts 4 to sepa rate bracket 3 from mounting plate 2 INSTALLATION Vent Valve 1WARNING Verify that the fuel tank vapor vent hose does not contact hot exhaust or engine parts The hose contains flamma ble vapors that can be ignited if damaged thereby result ing in personal injury 1 See Figure 4 26 Screw vent valve 2 into fuel...

Page 226: ...r Hose Routings 1 See Figure 4 25 Connect one end of the canister clean air inlet hose to the carbon canister 2 Connect overflow vent hose and canister vent hose to fit tings on carbon canister Canister vent hose attaches to top fitting Route both hoses towards fresh air hose on rear of canister 3 Cable strap the three hoses where the hose connector attaches the two pieces of fresh air hose 4 Rout...

Page 227: ...4 V Stall torque 8 1 ft lbs 11 0 Nm min 2 4 V SERVICE WEAR LIMITS IN MM Brush length minimum 0 433 11 0 Commutator diameter minimum 1 141 28 98 5 ITEM TORQUE NOTES Battery terminal hardware 30 40 in lbs 3 4 4 5 Nm hold cable when loosening tightening page 5 17 Starter mounting bolts 13 20 ft lbs 17 6 27 1 Nm page 5 17 ...

Page 228: ...attery current to flow into the pull in winding and also into the hold in winding to ground The magnetic forces of the pull in and hold in windings in the sole noid push the plunger causing it to shift to the left This action engages the pinion gear with the clutch ring gear At the same time the main solenoid contacts are closed so battery current flows directly through the field windings to the a...

Page 229: ...gear Clutch ring gear Overrunning clutch Hold in winding Pull in winding Plunger Main contacts Start circuit See wiring diagram Ball bearing Brush Armature Battery Field winding Idler gear Pinion gear Clutch ring gear Overrunning clutch Hold in winding Pull in winding Plunger Main contacts Start circuit See wiring diagram Ball bearing Brush Armature ...

Page 230: ... O INSTRUMENTS 15A LIGHTS 15A 15A ACCESSORIES 15A IGNITION FUSE BLOCK P9 85 30 86 87 87A GY O GY O TN W TN W GY IGNITION RELAY GY O GY O P12 S14 S15 TN W TN W TN GN GY BK 1 2 BK TN GN R BE P5 CLUTCH SWITCH TO GROUND FROM IGN RLY TN TN GN TN GN TN GN S11 S10 S12 S13 TN S1 GY BK R 4 2 3 1 BE Y O P1 TO STARTER IGN POWER LT BE LIGHT BLUE CABLE COLOR BE COLOR CODE BK BN GN GY O BLUE BLACK BROWN GREEN G...

Page 231: ...by burnt contact 1 4 2 Contact plate removed 1 4 3 Pull in winding open or short circuited 1 4 4 Hold in winding open 1 4 1 Polish contact surface or replace solenoid assembly 1 4 2 Repair 1 4 3 Replace solenoid assembly 1 4 4 Replace solenoid assembly 1 5 Starting motor 1 5 1 Poor contact condition of brushes 1 5 2 Commutator burnt 1 5 3 Commutator high mica 1 5 4 Field winding grounded 1 5 5 Arm...

Page 232: ...3 2 Pinion teeth worn out 2 3 3 Pinion does not run in overrunning direction 2 3 4 Poor sliding condition of spline teeth 2 3 5 Reduction gears damaged 2 3 1 Replace overrunning clutch 2 3 2 Replace overrunning clutch 2 3 3 Replace overrunning clutch 2 3 4 Remove foreign materials dirt or replace overrunning clutch 2 3 5 Replace overrunning clutch and idler gear 2 4 Ring gear 2 4 1 Excessively wor...

Page 233: ...arter components RUN ON Sticky starter button Contaminated switch water in button Sticking relay STARTER SPINS BUT DOES NOT ENGAGE Starter clutch failure Replace starter clutch Damaged gear armature Replace starter INOPERATIVE Nothing clicks Relay clicks Solenoid clicks Perform voltage drop tests between battery and solenoid relay ter minals less than 1 volt High voltage YES Back track to pinpoint...

Page 234: ...t breaker VDC Starter Solenoid Battery Start switch ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT b0157x5x Relay Ignition circuit breaker Ignition switch Main circuit breaker Starter Solenoid Battery Start switch OV VDC Relay Ignition circuit breaker Ignition switch Main circuit breaker VDC Starter Solenoid Battery Start switch Relay Ignition circuit breaker Ignition switch Main circuit ...

Page 235: ...l the voltage dropped and the entire difference in potential displayed on the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage dropped...

Page 236: ...e fully charged Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 See Figure 5 7 Verify that transmission is in neutral Dis connect spark plug wires from spark plug terminals 2 Clamp induction ammeter over positive battery cable next to starter 3 With ignition key switch ON turn engine over by pressing starter switch while taking a reading on th...

Page 237: ...starter and gasket from right side of motorcycle TESTING ASSEMBLED STARTER Starter Solenoid NOTE Do not disassemble solenoid Before testing disconnect field wire from terminal C as shown in Figure 5 9 1CAUTION Each test should be performed for only 3 5 seconds to prevent damage to solenoid NOTE The solenoid Pull in Hold in and Return tests must be per formed together in one continuous operation Al...

Page 238: ...r specified at the end of the previous SOLENOID HOLD IN TEST disconnect solenoid 50 terminal battery positive test lead at either end If pinion returns to its original posi tion the solenoid is working properly If pinion does not return to its original position solenoid should be replaced DISASSEMBLY INSPECTION AND REPAIR 1 See Figure 5 14 Remove field wire 22 2 See Figure 5 12 Remove thru bolts 3...

Page 239: ... Drive housing mounting bolt and lockwasher 2 10 Drive housing 11 Solenoid housing 12 Drive assembly overrunning clutch 13 Idler gear 14 Idler gear roller 5 15 Idler gear bearing cage 16 O ring 17 Return spring 18 Ball 19 Gasket 20 Washer 2 21 Mounting bolt 2 22 Field wire 23 O ring 2 b0004o5x 8 6 3 23 7 5 23 4 3 2 1 22 9 21 20 19 10 16 12 15 13 14 18 17 11 ...

Page 240: ...d and check runout of commutator Commutators with more than 0 016 in 0 41 mm of runout should be replaced or machined on a lathe Commutators should be replaced when diameter is less than 1 141 in 28 98 mm Figure 5 15 Removing Brush Holder Brush holder 3540a Figure 5 16 Undercutting Mica Separators Mica must not be left with a thin edge next to segments Right way Mica Undercutting mica with piece o...

Page 241: ... to any commutator segment Touch the other probe to the armature core There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures 11 See Figure 5 19 Check for OPEN ARMATURE with an ohmmeter or continuity tester Check for continuity between all commutator segments There should be con tinuity 0 ohms at all test points No continuity at a...

Page 242: ...replace if necessary 16 See Figure 5 23 Remove two drive housing mounting screws with washers and lockwashers Remove drive housing from solenoid housing 17 See Figure 5 24 Remove drive 1 idler gear 2 idler gear bearing 3 and O ring 4 from drive housing O ring is located in drive housing groove ASSEMBLY 1 See Figure 5 24 Clean inspect and lubricate drive assembly components Lubricate parts with hig...

Page 243: ...he starter mounting bolts and washers Tighten mounting bolts to 13 20 ft lbs 17 6 27 1Nm 4 Install primary cover See PRIMARY CHAIN in Section 6 5 Fill primary chaincase transmission with proper lubricant See CLUTCH TRANSMISSION FLUID in Section 1 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks m...

Page 244: ...ver 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 25 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing Install clip 2 and screws 1 Figure 5 25 Starter Solenoid 1 Screw 3 2 Clip 3 Cover 4 Gasket 5 Plunger 6 Solenoid housing 7...

Page 245: ...1 43 5 180 Fourth Gear 1 18 4 269 Fifth High Gear 1 00 3 615 PRIMARY DRIVE ENGINE TO TRANSMISSION Engine sprocket 35 teeth Clutch sprocket 56 teeth Ratio 1 60 1 FINAL DRIVE TRANSMISSION TO REAR WHEEL Transmission sprocket 27 teeth Rear wheel sprocket 61 teeth Secondary drive belt 128 teeth Ratio 2 26 1 6 NOTE Service wear limits are given as a guideline for measuring components that are not new Fo...

Page 246: ...e 6 4 Primary chain adjuster locknut 20 25 ft lbs 27 34 Nm on exterior of chaincase page 6 4 Primary chain inspection cover screws 40 60 in lbs 4 5 6 8 Nm page 6 3 Primary cover bolts 80 110 in lbs 9 0 12 4 Nm 3 lengths page 6 5 Rear shock mounting bolts 40 45 ft lbs 47 5 61 0 Nm metric page 6 7 Shift lever pinch screw 100 120 in lbs 11 3 13 6 Nm page 6 5 Shifter shaft assembly nuts 90 110 in lbs ...

Page 247: ...able first If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion producing personal injury 1 Raise rear wheel off floor using REAR WHEEL SUPPORT STAND Part No B 41174 2 Remove muffler See EXHAUST SYSTEM in Section 2 3 See Figure 6 1 Place a drain pan under the engine Remove drain plug 9 and drain lubricant from primary dr...

Page 248: ...e must be slid off plate toward closed or blind side of shoe Remove locknut 4 and plate 5 INSTALLATION Primary Chain Adjuster 1 See Figure 6 3 If shoe 6 is badly worn replace it or adjust assembly 2 Install plate 5 over top of chain adjuster screw 3 Place spacer 7 over top of adjuster screw next to plate Secure plate and spacer to adjuster screw by threading on locknut 4 Tighten locknut to 10 12 f...

Page 249: ... FLUID in Section 1 8 Adjust clutch See CLUTCH ADJUSTMENT in Section 1 9 Adjust primary chain tension See PRIMARY CHAIN ADJUSTMENT in Section 1 10 Install rubber washer 13 and shift lever assembly 12 Shift lever must bisect primary chain inspection cover See Figure 6 5 Tighten pinch screw to 100 120 in lbs 11 3 13 6 Nm 11 Install muffler See EXHAUST SYSTEM in Section 2 1WARNING Always connect posi...

Page 250: ...ve rear caliper See REAR BRAKE CALIPER REMOVAL DISASSEMBLY in Section 2 6 Remove lower belt guard and sprocket cover See SPROCKET COVER and FENDERS in Section 2 7 Remove seat fuel tank and tail section See TAIL SEC TION REMOVAL in Section 2 8 Remove air cleaner assembly See AIR CLEANER REMOVAL in Section 4 9 Detach belt from rear sprocket a Loosen rear axle nut metric b Loosen both rear axle adjus...

Page 251: ...ngarm and crank case 7 Attach rear shock to swingarm with bolt metric and nut Tighten to 40 45 ft lbs 47 5 61 0 Nm 8 Remove floor hoist straps from frame 9 Connect and fill lubrication system See ENGINE LUBRI CATION SYSTEM in Section 1 10 Install muffer and exhaust header See EXHAUST SYS TEM in Section 2 11 Align belt and rear wheel See REAR BELT DEFLEC TION in Section 1 12 Install rider footrests...

Page 252: ... plates to the clutch hub 23 As long as the transmission is set in a for ward gear power from the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate 17 is pulled outward by clutch cable action against the diaphragm spring 11 thereby compressing the diaphragm spring With the pressure plate retracted strong inward...

Page 253: ...cket surfaces of inner and outer ramps for wear pitting surface breakdown and other damage Replace parts as necessary 3 Check hub fit of inner 15 and outer 6 ramps Replace ramps if excessively worn 4 Check clutch cable for frayed or worn ends Replace cable if damaged or worn 5 Change or add transmission fluid if necessary See CLUTCH TRANSMISSION FLUID in Section 1 ASSEMBLY 1 See Figure 6 8 Apply m...

Page 254: ...COMPRESSING TOOL Part No HD 38515 A CLUTCH SPRING FORCING SCREW Part No HD 38515 91 and proper eye protection Otherwise the highly compressed diaphragm spring could fly out with great force possibly causing personal injury 2 Thread the CLUTCH SPRING FORCING SCREW Part No HD 38515 91 item 1 Figure 6 10 onto the clutch adjusting screw item 16 Figure 6 9 Place the bridge item 2 Figure 6 10 of SPRING ...

Page 255: ...e 14 Retaining ring 15 Bearing 16 Adjusting screw 17 Pressure plate 18 Friction plate 8 19 Steel plate 6 20 Spring plate 21 Mainshaft nut 22 Washer 23 Clutch hub 24 Retaining ring 25 Bearing 26 Clutch shell 27 Retaining ring 1 8 6 7 9 3 2 5 19 18 17 16 15 14 13 12 11 10 21 20 25 24 23 22 27 26 4 b0009b6x NOTE Depending upon vehicle production date configuration of items 4 and 5 may vary See CLUTCH...

Page 256: ...es 18 steel plates 19 and spring plate 20 is the only ser vice work to be performed perform ASSEMBLY Steps 2 5 6 7 and 8 only and then proceed to INSTALLATION NOTE Observe all 1WARNING and 1CAUTION statements which apply to the steps specified 1 See Figure 6 9 If the assembly of the clutch hub 23 and shell 26 was disassembled press new bearing 25 in clutch shell secure bearing with a new retaining...

Page 257: ...ck friction plates 18 steel plates 19 and spring plate 20 was the only ser vice work performed perform INSTALLATION Step 5 only 1 Install the engine sprocket clutch assembly and primary chain as a unit into primary chaincase 2 Install SPROCKET LOCKING LINK Part No HD 38362 Apply two or three drops of LOCTITE THREAD LOCKER 262 red onto threads of sprocket shaft Install the engine sprocket nut Tight...

Page 258: ...r which transmits the force through a gear shifter shaft The shifter shaft actuates a pawl and a shifter fork drum The shifter fork drum moves shifter forks which slide a series of shifter clutch gears on the mainshaft and countershaft into and out of mesh with the other gears LUBRICATION Drain transmission and refill to correct level with fresh clean lubricant at least once each year or every 500...

Page 259: ...1 3 2 5 4 1 3 2 5 Neutral Power flow Sliding member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In 2nd Gear Countershaft Mainshaft In 3rd Gear Countershaft Mainshaft Out In 5th Gear Countershaft Mainshaft Out In 4th Gear Countershaft Mainshaft In Out XLH transpower flow ...

Page 260: ...ads To pre vent damage turn nut clockwise to loosen and remove from main drive gear shaft 7 Remove transmission sprocket nut 3 from main drive gear shaft 1 8 Remove secondary drive belt from transmission sprocket 2 Remove transmission sprocket from main drive gear shaft 1 9 Remove primary cover See PRIMARY CHAIN on page 6 3 10 Remove clutch assembly primary chain and engine sprocket See PRIMARY DR...

Page 261: ...ch is threaded into the transmission portion of the right crankcase half See NEUTRAL INDICATOR SWITCH in Section 7 for testing removal and installation procedures Figure 6 14 Countershaft Retainer Retainer TORX screw 3557 Figure 6 15 Shifter Shaft Assembly Figure 6 16 Neutral Indicator Switch 7 Bolt 5 8 Washer 5 9 Detent plate 10 Retaining ring 11 Washer 2 b0153x6x 3 11 5 6 10 9 4 1 2 7 8 7 8 1 Sp...

Page 262: ... pins 4 Figure 6 17 Shifter Mechanism 1 Shifter fork 3rd and 5th gear 2 Shifter fork 1st and 2nd gear 3 Shifter fork 4th gear 4 Cotter pin 5 Pin shifter fork 6 Pin neutral indicator 7 Shifter fork drum 8 Plate shifter drum locating 9 Plate reinforcing 10 Nut 2 11 Shifter shaft assembly 12 Nut 13 Plate detent 14 Washer 15 Bowed snap ring 16 Detent arm 17 Spring 18 Screw detent 19 Bearing mainshaft ...

Page 263: ...tion Insert the pin end of drum shaft 7 through the hubs of shifter forks 1 2 and 3 and through the bearing in access cover 5 Align the hole through the top of each shifter fork with the appropriate cam groove in the shifter drum Lubricate pins 5 with SPORT TRANS FLUID Drop pins 5 through the holes in shifter forks With a small screw driver press on the pins while manipulating the forks back and f...

Page 264: ... this rea son it is important that each component be reinstalled in its original location and facing its original direction 3 See Figure 6 21 As each component is removed place it on a clean surface in the exact order of removal See Figure 6 22 Using RETAINING RING PLIERS Part No J 5586 remove and discard retaining ring 5 next to counter shaft 5th gear 12 Slide countershaft 5th 12 mainshaft 2nd 22...

Page 265: ...l oil 16 Spacer belt drive 17 Ring Quad 18 Ring retaining 19 Bearing ball 20 Bearing needle 21 Gear mainshaft 5th 22 Gear mainshaft 2nd 23 Gear mainshaft 3rd 24 Gear mainshaft 1st 25 Gear mainshaft 4th 26 Spacer 27 Mainshaft 28 Bearing 29 Ring retaining 30 Seal 31 Retention collar 32 Torx screw 33 Ring retaining 34 Nut mainshaft 35 Washer spring 36 Bushing 37 Bearing closed shifter shaft 14 b0129x...

Page 266: ... slide off end of shaft 7 See Figure 6 25 Place COUNTERSHAFT GEAR SUP PORT PLATE Part No HD 37404 under countershaft 4th gear 4 Place assembly on press with suitable metal blocks under the support plate Place a socket or man drel smaller than inside diameter of bearing and press countershaft free of access cover Slide mainshaft 1st gear 24 off mainshaft 8 See Figure 6 26 Remove beveled spacer 3 an...

Page 267: ...on the gears Replace the gears if dogs are rounded cracked battered chipped or dimpled 4 Discard all retaining rings that were removed ASSEMBLY 1CAUTION During assembly the split bearings 7 and the internal bores of the gears must be lubricated with SPORT TRANS FLUID prior to assembly Leaving these parts dry could accelerate wear at start up 1 Find a section of pipe that matches the inner race of ...

Page 268: ...shaft first gear 8 Gear 8 has a ring groove at one side of the gear Install gear 8 over split bearing 7 7 Install thrust washer 6 and retaining ring 5 next to gear 8 8 Locate countershaft 4th gear 4 This gear is splined and has a single radial groove at one side Position gear next to retaining ring 5 Place beveled washer 3 over end of shaft with beveled side away from gear 4 9 See Figure 6 31 Stan...

Page 269: ...tall countershaft 2nd gear 11 over bearing 7 16 Install mainshaft 2nd gear 22 onto shaft 17 Install countershaft 5th gear 12 18 Expand retaining ring 5 and slide into groove next to countershaft 5th gear 12 19 See Figure 6 34 At outside of access door position retention collar 31 next to end of countershaft with bev eled side facing outward Apply a few drops of LOCTITE THREADLOCKER 242 blue to the...

Page 270: ... pressed out against the resistance of the bearing inner race With out any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 5 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tighten nut 6 until 5th gear 3 is free Figure 6 35 Main Drive Gear Assembly 1 Main drive ...

Page 271: ...on the gear when the correct depth is reached INSTALLATION 1 Replace main drive gear bearing See ACCESS DOOR BEARINGS INSTALLATION on page 6 28 2 Use MAIN DRIVE GEAR REMOVER AND INSTALLER TOOL See Figure 6 39 Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt From inside of case insert bolt and main drive gear through inner race of ball bearing 3 Insert threaded end of b...

Page 272: ...downward 2 Lay bearing squarely over bore with printed side of bear ing upward Place section of pipe or tubing slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retaining ring with beveled side facing away from bearing Shift Drum Bushing 1 Lay access door on press with outside surface of door downward 2...

Page 273: ...ove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 From the outside of the case place the needle bearing open end first next to the bearing bore Hold the driver squarely against the closed end of the bearing and tap the bearing into place The bearing...

Page 274: ...ly bottom nut 1 first to 90 110 in lbs 10 2 12 4 Nm Then tighten shifter shaft assembly top nut 1 to the same torque Remove drill bit 7 See Figure 6 23 Place new quad ring 17 over threaded end of fifth gear 21 and position next to the gear taper Install spacer 16 over threaded end of fifth gear with chamfered end toward quad ring Slide spacer up against bearing 19 8 Coat lips of seal 15 with SPORT...

Page 275: ...l screw holes align 13 Install two socket head screws 5 through aligned holes of lockplate and into tapped holes of sprocket Tighten screws to 90 110 in lbs 10 2 12 4 Nm NOTE The original equipment socket head screws 5 have thread locking compound applied to them Since this compound remains effective for about three removal installation cycles the original screws may be reused up to three times Af...

Page 276: ...STANCE Primary winding 2 5 3 1 Ohms Secondary winding 10 000 12 500 Ohms ELECTRICAL SYSTEM AMPERES Main circuit breaker 30 Ignition fuse 15 Light fuse 15 Accessory fuse 15 Instrument fuse 15 BULB CHART Lamp Description All Lamps 12 V Number Of Bulbs Required Specifications Headlamp High low replaceable bulb 1 60 W 55 W Position lamp 1 14 W Marker lamps Tail stop lamp 1 5 W 21 W Turn signal lamp fr...

Page 277: ... 90 110 in lbs 10 2 10 4 Nm LOCTITE THREADLOCKER 242 blue page 7 30 Spark plugs 11 18 ft lbs 14 9 24 4 Nm page 7 1 Stator mounting screws 30 40 in lbs 3 4 3 5 Nm T 27 Torx with retaining compound replace after removal page 7 30 Switchgear housing screws left side 25 33 in lbs 2 8 3 7 Nm metric page 7 40 Switchgear housing screws right side 12 17 in lbs 1 4 1 9 Nm metric page 7 39 Timer plate studs...

Page 278: ...e ignition module has two functions First it computes the spark advance for proper ignition timing Second it opens and closes the low voltage circuits between the battery and igni tion coil to produce high voltage discharge to the spark plugs Figure 7 1 Ignition System Components 1 2 1 Pop rivet 2 2 Timer cover 3 Screw 2 4 Inner cover 5 Ignition gasket 6 Timer plate stud 2 7 Bolt 8 Sensor assembly...

Page 279: ...plate See IGNITION TIMING in Section 1 The ignition module contains all the solid state components used in the ignition system The dwell time for the ignition coil is also calculated by the microprocessor and is dependent upon engine speed The programmed dwell is an added fea ture to keep battery drain to a minimum and to adequately charge the coil at all speeds The ignition module has added prote...

Page 280: ...IEW FROM FUSE INSERTION SIDE GY O R BK R BK R BK INSTRUMENTS 15A LIGHTS 15A 15A ACCESSORIES 15A IGNITION FUSE BLOCK P9 REAR PLUG FRONT PLUG COIL PK W BK 85 30 86 87 87A GY O GY O TN W TN W GY IGNITION RELAY GY O GY O P12 S14 S15 TN W TN W TN GN GY BK 1 2 BK TN GN R BE P5 CLUTCH SWITCH TO GROUND FROM IGN RLY TN TN GN TN GN TN GN S11 S10 S12 S13 TN S1 S8 GY W BK W BK BK R 4 2 3 1 GN BK W R BE Y O P1...

Page 281: ...heck spark See STEP 3 b0078x7x STEP 3 1 Pink module wire disconnected 2 Ignition switch on 3 Jumper wire connect capacitor wire to pink wire terminal 4 Connect both wires to common ground 5 Momentarily touch ground wire to pink wire terminal When you remove the wire there should be a spark at plug If spark occurs proceed to STEP 4 Jumper IF NO SPARK Replace coil b0079x7x STEP 4 1 Reconnect pink wi...

Page 282: ...e from battery positive terminal to white wire 4 Operate vehicle to see if problem is eliminated NOTE Vehicle no longer has an engine stop switch Engine must be stopped by removing jumper wire PROBLEM NOT ELIMINATED Problem is vibration possibly loose connections at safety switches or defective ignition relay in starter circuit b0224x7x Intermittent Ignition Problem Vibration Sensor IF ENGINE KILL...

Page 283: ...m Check harness for opens See next page If harness checks OK replace module B A C V W Chassis ground 1 Ignition sensor plate 2 Ignition module 3 Ignition coil 4 Spark plug 2 5 Vacuum operated electric switch V O E S b0080b3x 2 1 3 4 4 5 1CAUTION If a resistance test is performed on a live circuit the multimeter will be damaged Turn off ignition and disconnect the battery before doing a resistance ...

Page 284: ...Good More than 1 Ohm Repair broken wire or loose dirty connection IGNITION MODULE CONNECTOR P10 PIN NO 1 2 3 4 5 6 7 8 COLOR CODE W BK W R PK GN V W BK open f1143b8x TEST CONDITIONS Engine stop switch on right handlebar must be in OFF position and 8 place ignition module connector P10 and 3 place sensor connector P16 must be disconnected for these tests Shake or wiggle the harness to detect any br...

Page 285: ...7 to main wiring harness 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 3 Install fuel tank and seat See FUEL TANK INSTALLA TION in Section 4 Figure 7 4 V O E S Connector P7 b0225x7x P7 WIRE TERMINATION 1 Ignition module 2 Splic...

Page 286: ...K REMOVAL in Section 4 1WARNING To avoid accidental start up of vehicle and possible per sonal injury disconnect the battery cables before pro ceeding Always disconnect the negative cable first If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion producing personal injury 1CAUTION Hold battery cable when loosening batter...

Page 287: ...battery explo sion producing personal injury 1CAUTION Hold battery cable when tightening battery terminal hard ware Failure to hold cable may cause battery damage 5 Install battery cables positive cable first 6 Install fuel tank and seat See FUEL TANK INSTALLA TION in Section 4 1WARNING Check for proper headlamp operation before riding motorcycle Visibility is a major concern for motorcy clists Fa...

Page 288: ...ws and washers 2 See Figure 7 8 Attach ignition module connector P10 to main wiring harness 3 Secure main wiring harness to frame member with a new cable strap 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion producing personal injury and or property damage 1CA...

Page 289: ...e first If the positive cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion producing personal injury 1CAUTION Hold battery cable when loosening battery terminal hard ware Failure to hold cable may cause battery damage 1 Disconnect battery cables negative cable first Figure 7 9 Ignition Components 1 2 1 Pop rivet 2 2 Timer cover 3 Scre...

Page 290: ...uted too far to the rear of this position they could contact the moving secondary drive belt and or sprocket resulting in damage to sensor plate wiring 4 Route sensor plate wiring leads a Downward through hole 7 o clock position in timer bore of gearcase cover 11 b Upward through bottom opening between right crankcase half and rear of gearcase cover c Route wiring around tower shaft behind gearcas...

Page 291: ...ark plug the spark jumps from the center electrode to the outer electrode but on the other plug the spark jumps in the reverse direction from the outer electrode to the center elec trode TROUBLESHOOTING Follow the troubleshooting procedures listed under IGNITION SYSTEM if the engine will not start is difficult to start or runs roughly Also check condition of spark plug cables Insulation on cables ...

Page 292: ...mounting plate 3 Tighten screws 1 to 4 6 ft lbs 5 4 8 Nm 2 Connect ring terminal of pink wires to forward post Con nect ring terminals of white wires to rear post Secure wires with nuts and lockwashers 3 Connect spark plug cables to ignition coil Longer cable attaches to rear post and rear cylinder spark plug 1WARNING After installing seat pull upward on front of seat to be sure it is locked in po...

Page 293: ... the cable portion itself Pulling on the cable will damage the cable s carbon core Disconnect spark plug cables from ignition coil and spark plug terminals INSPECTION 1 Inspect spark plug cables Replace cables that are worn or damaged a Check for cracks or loose terminals b Check for loose fit on ignition coil and spark plugs 2 Check cable boots caps for cracks or tears Replace boots caps that are...

Page 294: ...aging the clutch and grounding through the clutch lever switch Note that the ignition circuit allows operation in gear with the side stand extended if the clutch is disengaged However if the motorcycle is in gear with the side stand extended and the clutch is released the ignition ground is lost and the igni tion system is turned off This system will prevent operation of the vehicle if forward mot...

Page 295: ... VIEW FROM FUSE INSERTION SIDE GY O R BK R BK R BK INSTRUMENTS 15A LIGHTS 15A 15A ACCESSORIES 15A IGNITION FUSE BLOCK P9 REAR PLUG FRONT PLUG COIL PK W BK 85 30 86 87 87A GY O GY O TN W TN W GY IGNITION RELAY GY O GY O P12 S14 S15 TN W TN W TN GN GY BK 1 2 BK TN GN R BE P5 CLUTCH SWITCH TO GROUND FROM IGN RLY TN TN GN TN GN TN GN S11 S10 S12 S13 TN S1 S8 GY W BK W BK BK R 4 2 3 1 GN BK W R BE Y O ...

Page 296: ...tch is closed clutch disengaged the switch should show 0 ohms or little resistance 3 Replace the assembly with a new switch if necessary a Remove small Phillips screw b Depress clutch lever and hold c Detach switch by depressing switch trigger button and pulling switch towards the end of the handlebar d Install new switch Diodes The main wiring harness contains two diodes along the left side frame...

Page 297: ...oil tank See STARTER SYSTEM TESTING in Section 5 Main Circuit Breaker See Figure 7 16 Attached to the frame above the battery the main circuit breaker is between the ignition key switch and the battery The main circuit breaker can be removed as follows 1 Remove seat and fuel tank See FUEL TANK REMOVAL in Section 4 2 Remove battery negative terminal from frame 3 Remove nuts and wire leads from circ...

Page 298: ...rging system fails or does not charge at a satis factory rate it is recommended that the following checks be made Battery Check for a weak or dead battery See BATTERY in Section 1 Battery must be fully charged in order to perform any electrical tests Wiring Check for corroded or loose connections in the charging cir cuit See Figure 7 19 Voltage Regulator Inspection The voltage regulator base must ...

Page 299: ...W TEST before proceeding Inspect rotor Replace stator Perform AC OUTPUT TEST Replace regulator Perform VOLTAGE OUTPUT TEST Damaged or slipping rotor Perform CURRENT OUTPUT TEST System tests good up to this point Suspect 1 Accessories on for long periods when vehicle is parked and not running 2 Accessories on when vehicle is ridden very slowly for long periods 3 Battery self discharge and or acces ...

Page 300: ... BK BK VOLTAGE REGULATOR BK BK BK BK STATOR BATTERY LT BE LIGHT BLUE CABLE COLOR BE COLOR CODE BK BN GN GY O BLUE BLACK BROWN GREEN GRAY ORANGE PINK RED TAN VIOLET WHITE YELLOW PK R TN V W Y STRIPE COLOR XX XX PIN CONNECTOR SOCKET CONNECTOR NO CONNECTION CONNECTION DIODE b0240x7x ...

Page 301: ... for a long time NOTE A battery with a surface discharge condition could suffer a static drain Correct by cleaning battery case Total Current Draw Test See Figure 7 21 If battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system To check for this condi tion place load tester induction pickup or current probe pickup over batt...

Page 302: ...or more than 20 seconds or overheating and tester damage are possible Stator Check 1 Turn ignition to LOCK 2 Disconnect stator wiring from voltage regulator wiring at connector P17 3 See Figure 7 23 Connect an ohmmeter on the RX1 scale between crankcase and either stator socket Test for continuity a A good stator will show no continuity ohms across either test point b Any other reading indicates a...

Page 303: ...M The AC output should be 38 52 volts AC 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under Current and Voltage Output Test Figure 7 25 Check Stator AC Voltage Output 5685a ...

Page 304: ...or to engine sprocket 2 See Figure 7 26 Position blocking under rotor Press sprocket free of rotor NOTE Resistance to sprocket rotor disassembly is due in part to the magnetic force of the permanent rotor magnets Stator 1 See Figure 7 27 Disconnect stator wiring 4 from volt age regulator wiring at connector 5 P17 2 Remove cable straps holding stator wire to frame 3 Withdraw stator wiring 4 from be...

Page 305: ...orarily attach a thin flexible feed or mechanic s wire to the connector end of the stator wiring to assist in the routing of the wiring 5 Route stator wiring upward along side of frame upright Connect stator wiring connector P17 to voltage regulator 6 Secure stator wiring along with any other wires and hoses routed in the same location to frame using cable straps 7 See Figure 7 28 Attach rotor to ...

Page 306: ...eaker 4 See Figure 7 30 Remove screws 1 3 washers 2 and lockwasher 5 Detach and remove groundstrap from long screw 1 5 Remove and discard voltage regulator 3 INSTALLATION 1 See Figure 7 30 Install new voltage regulator with longer screw 1 next to battery Attach groundstrap under voltage regulator mount 2 Connect voltage regulator connector P17 to alternator stator wiring 3 Route charging wire to g...

Page 307: ...hield or goggles when working near a battery or acid KEEP BATTERIES AND ACID OUT OF THE REACH OF CHIL DREN See Figure 7 31 The battery is below the seat in the center of the vehicle The battery can be removed from the left side of the motorcycle without removing the tail section or fuel tank NOTE The battery requires no additional fluid at any time See BAT TERY in Section 1 for removal installatio...

Page 308: ...ank See FUEL TANK REMOVAL in Section 4 4 See Figure 7 34 Cut as many cable straps as necessary to access headlamp connector P4 along right side frame tube Detach connector P4 from wiring harness 5 Remove headlamp housing from vehicle 6 Remove headlamp brackets a Remove front turn signals See TURN SIGNALS REMOVAL on page 7 37 b Remove windscreen mounting brackets c See Figure 7 32 Remove four bolts...

Page 309: ...e proper headlamp operation could lead to personal injury 6 Check ignition headlamp switch for proper operation Headlamp and Bulbs 1WARNING The bulb contains Halogen gas under pressure Handle bulb careful and wear eye protech to avoid possible per sonal injury 1CAUTION Never touch the bulb with your fingers Fingerprints will etch the glass and cause the bulb to fail Always wrap the bulb in paper o...

Page 310: ...l reflectors 8 2 Install tail lamp with washers 6 and locknuts 7 metric 3 Install turn signals See TURN SIGNALS INSTALLA TION on page 7 37 4 Attach bracket 5 to frame with bolt 4 and seat wing screw 9 5 Use new cable straps to secure tail lamp wiring harness to rear frame Attach connector P11 to main wiring har ness See Figure 7 36 6 Install tail section and seat See TAIL SECTION INSTAL LATION in ...

Page 311: ...o have proper lamp operation could lead to personal injury 4 Check tail lamp and turn signals for proper operation 5 Use new cable straps to bundle the tail lamp wiring har ness under the tail section Figure 7 36 Tail Lamp Connector P11 Figure 7 37 Tail Lamp Bulb Wires RIGHT REAR TURN SIGNAL 1 2 3 4 5 6 7 8 P11 BK BK BK V R Y BN V O W BK BK R Y V BK BK 1 2 P15 BE BE Y BK BK BK LICENSE PLATE LIGHT ...

Page 312: ...ARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could lead to personal injury 4 Check turn signals for proper operation Rear 1 See Figure 7 38 Install turn signals using screws 9 metric and nuts 6 metric NOTE Install turn signal with lens drain hole facing downward 2 Attach bullet c...

Page 313: ...es INSTALLATION 1 See Figure 7 39 Connect both wires to flasher 2 Place flasher inside clamp so prongs on flasher face inside and down 3 Install on flasher and clamp on frame with screw 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could lead to personal injury 4 Check turn sign...

Page 314: ...LLATION in Section 2 2 Position housings on right handlebar by engaging stud on front housing with hole in handlebar Fasten housings with two screws metric Tighten to 12 17 in lbs 1 4 1 9 Nm 3 See Figure 7 40 Route switch housing wiring harness between front forks and along right side frame tube Attach connector P1 to wiring harness Fasten wiring harness to frame with new cable straps 4 Install fu...

Page 315: ...operations before riding motorcycle Handlebar switches not operating properly could lead to personal injury 4 Check handlebar switch for proper operation Figure 7 41 Left Handlebar Switch Connection P6 BK 1 2 BK TN GN R BE P6 P5 CLUTCH SWITCH LEFT HANDLEBAR SWITCH CONNECTOR LOW BEAM HIGH BEAM RIGHT TURN LIGHT POWER LEFT TURN FROM FLASHER HORN POWER HORN TO GROUND FROM IGN RLY 1 3 4 5 6 7 8 2 W Y O...

Page 316: ...ctory charge and wiring appears to be in good condition check for the following a Poor ground to frame through mounting hardware or ground wire see Steps 3 5 below b Inoperative horn switch see Steps 3 5 below 3 Remove terminal clips from connections 4 Connect a voltmeter as follows a Positive lead to wire terminal b Negative lead to ground 5 Turn ignition switch to IGN Depress horn switch If bat ...

Page 317: ...mp switch is turned to LOCK 2 Remove sprocket cover See SPROCKET COVER in Section 2 3 See Figure 7 43 Place transmission in first gear Remove two socket head screws 7 and lockplate 6 1CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Transmission sprocket nut will be damaged if turned counterclockwise to remove 4 Remove trans...

Page 318: ...The main circuit breaker is on the frame beneath the tail section The main circuit breaker is rated at 30 amperes Circuit breakers prevent electrical overload of a circuit The circuit breaker electrical contacts remain closed completing the circuit as long as current amperage flowing through the circuit does not exceed the ampere rating of the breaker If the circuit current exceeds the breaker amp...

Page 319: ...tilock headlamp page 7 34 P5 2 place Amp Multilock clutch switch page 7 21 P6 8 place Amp Multilock left handlebar switch housing horn turn signals lights page 7 40 P7 2 place Deutsch vacuum operated electric switch page 7 10 P8 4 place PED ignition headlamp switch page 7 12 P9 4 slot fuse block four 15 amp fuses for ignition instruments lights and accessories page 7 43 P10 8 place Deutsch ignitio...

Page 320: ...ition coil 17 Instruments P3 18 Headlamp P4 19 Clutch switch P5 20 Ignition switch P8 21 Ignition relay P12 22 Master circuit breaker 23 Battery negative cable 24 Turn signal flasher 25 Ignition module P10 26 Tail lamp and turn signals P11 27 Rear right turn signal 28 Tail lamp 29 Rear left turn signal 30 Fuse block 31 Rear brake lamp switch 3 4 5 8 7 9 10 14 15 16 12 13 11 20 21 22 23 17 19 18 6 ...

Page 321: ...n the socket housing and holds the terminal latches tightly closed NOTE The conical secondary locking wedge of the 3 pin con nector must be installed with the arrow pointing toward the external latch See Figure 7 48 If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals a...

Page 322: ...lead removing 5 32 in 4 0 mm of insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remo...

Page 323: ...e Figure 7 51 With the flat edge against the terminal insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick away from the terminal and gently tug on wire to pull terminal from chamber Do not tug on the wire until the tang is released or the termi nal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the ste...

Page 324: ...on the same side as the crimp tails must face upward Up and down can be deter mined by the position of the release button used to separate the pin and socket halves the button always being the top of the connector 2 Gently tug on wire end to verify that the terminal is locked in place and will not back out of chamber 3 Rotate the hinged secondary lock inward until tabs fully engage latches on both...

Page 325: ...nsert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 See Figure 7 52 Inspect the qua...

Page 326: ... LOCK OFF IGN 85 30 BK R R BK 86 87 87A GN TN GN STARTER RELAY P13 BK R GN R BK TN GN VIEW FROM FUSE INSERTION SIDE GY O BE O W O W O O R BK R BK R BK R GY INSTRUMENTS 15A LIGHTS 15A 15A ACCESSORIES 15A IGNITION FUSE BLOCK P9 REAR PLUG FRONT PLUG COIL PK PK W BK 85 30 86 87 87A GY O GY O TN W TN W GY IGNITION RELAY GY O GY O P12 S14 S15 TN W TN W TN GN GY BK 1 2 BK TN GN R BE P6 P5 CLUTCH SWITCH L...

Page 327: ... B 41174 2 Replacement Pad Part No B 41175 Pivot Shaft Bearing Adjuster Part No B 41176 Front Fork Bushing Seal Installer Part No B 41177 Front Fork Holding Tool Part No B 41178 A Rear Shock Compressing Tool Part No B 41395 Front Wheel Support Stand and Part No B 41686 S1 Lift Adapter Part No B 42079 Brake Caliper Piston Remover A ...

Page 328: ...rt No HD 01289 Rim Protectors Part No HD 21000 Tire Spreader Part No HD 23738 Vacuum Pump Part No HD 25070 Robinair Heat Gun Part No HD 28700 Tire Bead Expander Part No HD 33067 Wheel Bearing Packer Part No HD 33223 1 Cylinder Compression Gauge ...

Page 329: ...418 Universal Puller Forcing Screw Part No HD 33446A Cylinder Torque Plates and Torque Plate Bolts Part No HD 33446 86 Part No HD 33813 Inductive Timing Light Part No HD 34623A Piston Pin Retaining Ring Installer Part No HD 34643A Shoulderless Valve Guide Seal Installer Part No HD 34723 Valve Guide Hone 8 mm ...

Page 330: ...river Handle and Remover Used with HD 34643A and HD 34731 Part No HD 34751 Nylon Valve Guide Brush Part No HD 34813 Rowe Flywheel Rebuilding Jig Part No HD 34816 Oil Pressure Switch Wrench Part No HD 35102 Wrist Pin Bushing Hone 20 mm Part No HD 35316 A Main Drive Gear Remover Installer and Main Drive Gear Bearing Installer ...

Page 331: ...ndb n CYLINDER LEAKDOWN TESTER Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pffb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pklhb odlbndpob npdb n...

Page 332: ...rminal Crimp Tool Sealed and non sealed connectors Part No HD 38125 7 Packard Terminal Crimp Tool Sealed connectors Part No HD 38125 8 Packard Terminal Crimp Tool Part No HD 38361 Cam Gear Gauge Pin Set 0 108 in 2 74 mm Diameter Part No HD 38362 Sprocket Locking Link Part No HD 38515 A Clutch Spring Compressing Tool and Part No HD 38515 91 Forcing Screw ...

Page 333: ...39301A Steering Head Bearing Race Remover Part No HD 39302 Steering Head Bearing Race Installer Part No HD 39458 Sprocket Shaft Bearing Outer Race Installer Part No HD 39565 Engine Sound Probe Part No HD 39617 Inductive Amp Probe Use with HD 35500A Part No HD 39621 Electrical Terminal Repair Kit T S P O R S T E R 1 3 C C 4 0 ...

Page 334: ... 39782 Cylinder Head Support Part No HD 39786 Cylinder Head Holding Fixture Part No HD 39800 Oil Filter Crusher Small Part No HD 39823 Oil Filter Crusher Large Part No HD 39847 Universal Ratcheting Tap Reamer Handle Part No HD 39932 Steel or HD 39932 CAR Carbide Intake and Exhaust Valve Guide Reamer ...

Page 335: ...o HD 39965 Deutsch Terminal Crimp Tool Part No HD 39969 Ultra Torch UT 100 Part No HD 39994 Paint Repair Kit Part No HD 41025 Tool Organizational System Part No HD 41137 Hose Clamp Pliers Part No HD 41155 VHS Video Shelf Part No HD 41183 Shrink Attachment ...

Page 336: ...Hose Cutter Part No HD 41215 Oil Filter Wrench Part No HD 41321 Sprocket Holding Tool Part No HD 41496 Main Drive Gear Seal Installer Part No HD 41506 Crankshaft Locking Tool Part No HD 41609 Amp Terminal Crimp Tool Part No HD 41675 Oil Pressure Sending Unit Wrench ...

Page 337: ...nshaft Locknut Wrench Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots 600 200 Made in USA PP 9606 0001 Part No HD 94803 67 Rear Intake Camshaft Bushing Reamer Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 94812 1 Pinion Shaft Bushing Reamer Use with HD 94812 87 Part No HD 94812 87 Pinion Shaft Reamer Pilot Use with HD 94812 1 ...

Page 338: ...h HD 95635 46 Part No HD 95760 69A Bushing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 95952 33A Connecting Rod Clamping Tool Part No HD 95970 32C Piston Pin Bushing Tool Part No HD 96215 49 Small Internal Retaining Ring Pliers Part No HD 96295 65D Timing Mark View Plug Use with HD 33813 ...

Page 339: ...ol Part No HD 96650 80 Flywheel Truing Stand Part No HD 96710 40B Crankcase Main Bearing Lapping Tool Part No HD 96718 87 Pinion Bearing Outer Race Lapping Kit Part No HD 96740 36 Connecting Rod Lapping Arbor Part No HD 96796 47 Valve Spring Tester Part No HD 96921 52A Oil Pressure Gauge ...

Page 340: ...l Pressure Gauge Adapter Use with HD 96921 52A Part No HD 97087 65B Hose Clamp Pliers Part No HD 97292 61 Two Claw Puller Part No HD 99500 80 Wheel Truing and Balancing Stand Part No J 5586 Transmission Shaft Retaining Ring Pliers ...

Page 341: ...7 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9 15 16 1 1 1 16 1 1 ...

Page 342: ...que figures are listed in ft lbs except those marked with an asterisk which are listed in in lbs In the metric table figures are listed in Newton meters 1WARNING The quality fasteners used on Buell motorcycles have specific strength finish and type requirements to perform properly in the assembly and the operating environment Use only genuine Buell replacement fasteners tightened to the proper tor...

Page 343: ...46 STUDS Use SAE 2 5 and 8 values when grade is known with nut of sufficient strength Table B 3 Metric Torque Values FASTENER TYPE MINIMUM TENSILE STRENGTH MATERIAL BODY SIZE OR OUTSIDE DIAMETER number mm millimeters 2 3 4 5 6 8 10 6 4 7 9 9 5 11 1 12 7 14 3 15 9 19 1 22 2 25 4 SAE 2 STEEL 5 202 kg cm2 LOW CARBON 8 3 16 6 27 7 44 3 65 0 95 4 132 8 214 4 283 5 428 7 SAE 5 STEEL 8 436 kg cm2 MEDIUM ...

Page 344: ...ructions and system requirements see the README file accompanying your software Click one of the following topics to go to an explanation of that topic How to use this online guide About Adobe Acrobat The Acrobat Reader window Status bar Preferences Using links Using notes Displaying documents in full screen mode Reading an article How to upgrade Thi d t t d ith F M k 4 0 4P2 ...

Page 345: ...ious location Click the Next Page button in the tool bar to go to the next page of the guide Click the First Page button in the tool bar to return to the opening screen of this guide Click the bookmark name to go to the topic marked by that book mark Click the triangle to the left of a bookmark to show and hide subordinate bookmarks The bookmarks for this guide provide a complete list of topics Cl...

Page 346: ...robat Reader for Macintosh Windows DOS and UNIX Acrobat Pro Acrobat 2 0 plus Acrobat Distiller Acrobat Distiller converts any PostScript language file into PDF Set up Acrobat Distiller to convert Post Script files on a local Macintosh or Windows computer or to monitor directories on a network file server which provides Distiller conversion services to any number of network users Acrobat for Workgr...

Page 347: ...of the window is the tool bar at the bottom left of the window is the status bar At the right of the window is a vertical scroll bar that enables you to scroll up and down through a document The overview area of the window includes an independent scroll bar that you can use to scroll through bookmarks or thumbnails See these topics for more information about the Acrobat Reader window Status bar fi...

Page 348: ... the overview area of the window Click the Bookmarks and Page button to open the overview area and display bookmarks created for the document Click a bookmark s name to go to the location marked by that bookmark Click the Thumbnails and Page button to open the overview area and display thumbnail images of each document page Click a thumbnail to go to the page marked by that thumbnail Use the hand ...

Page 349: ...ct graphics in a document The browse buttons advance the document to the first or last page of a document or forward or back one page at a time Use the Go Back and Go Forward buttons to retrace your steps in a document moving to each view in the order visited Go Back also returns you to the original document after you click a link to another document Click the Actual Size button to display the pag...

Page 350: ... the page width to fill the width of the window Pressing this button and the Option Macintosh or Control Windows key fills the window with only the visible text and graphics on the page The find tool searches for part of a word a complete word or multiple words in a document ...

Page 351: ...areas The page number box displays the current page number and lets you go to a specified page in a multi page document Click the page number box to display the Go to Page dialog box The magnification box displays the current page magnification and lets you select various magnifications Choose Other from the menu to display the Zoom To dialog box The page size box shows the size of the current pag...

Page 352: ...ble Magnification is the maximum magnification for Fit Visible and for viewing articles Display Large Images displays large images without replacing them as gray boxes A large image is an image that requires many bytes of storage and that takes a long time to display Use Page Cache may reduce the amount of time it takes to page through a document Greek Text below _____ pixels displays the size of ...

Page 353: ... Startup Maximize Application on Opening Windows only the application window is maximized to fill the entire display Full Screen preferences The Preferences Full Screen dialog box provides these options Change pages specifies mouse and keyboard control or automatic advance ment every specified number of seconds Loop displays the document continuously looping from the first page to the last Backgro...

Page 354: ...en preferences for more information The cursor remains active during full screen mode so that viewers can click links and open notes Thumbnails and bookmarks are not accessible in full screen mode The following tools and commands are accessible through their command key shortcuts All View menu commands except Page Only Bookmarks and Page and Thumbnails and Page Tools menu hand Zoom in and Zoom out...

Page 355: ...part of a PDF document to another PDF document or to another application file such as a spreadsheet or movie To use a link Click any text or graphics that is identified as a hypertext link The pointer changes to a pointing finger when positioned over a link To return from a link Click Go Back or choose Go Back from the View menu to return to the previous page view ...

Page 356: ...er a note in a PDF document double click it to open the note window To find the next note in the document choose Find Next Note from the Tools menu To close the note window click the close box in the upper left corner of the note Macintosh users can also press Command W ...

Page 357: ...ct the article you want to read from the title list and click View to go directly to the beginning of the article or click the beginning of the article with the hand tool Place the hand tool cursor on any box in the article If you start at the first article box the cursor changes to Read Article and the status bar shows Read Article Click or press Enter to follow the article To return to the previ...

Page 358: ... Return Go to another article or page Click Shift Option Macintosh or Shift Ctrl Click Windows Note If you exit an article by going to a specific page using Go To Page or the toolbar buttons the page is displayed with the Default Magnification prefer ence setting The magnification in effect while you read the article is not used ...

Page 359: ...des Acrobat Exchange and PDF Writer for creating your own PDF files Acrobat Search for full text search and retrieval of files indexed with Acrobat Catolog Acrobat Reader for Macintosh Windows DOS and UNIX to view and print your PDF files In North America To order or locate the Adobe Authorized Reseller nearest you call 1 800 521 1976 Please mention offer number 9 02 02 9 Print or fax the order fo...

Page 360: ...ogram Price 195 U S Adobe Acrobat 2 0 for Macintosh Acrobat 2 0 includes Acrobat Exchange and the PDF Writer driver for creating my own PDF files Acrobat Search which lets me quickly find detailed information contained in any document indexed with Acrobat Catalog and Acrobat Reader 2 0 which I can send FREE to anyone to enable them to view and print my PDF files All for just 195 U S Purchase order...

Page 361: ...ed which may be registered in certain jurisdictions Microsoft is a registered trademark and Windows is a trademark of Microsoft Corporation Pentium is a trademark of Intel Corporation All other products or name brands are trademarks of their respective holders 1994 This software includes software licensed from RSA Data Security Inc Written and designed at Adobe Systems Incorporated 1585 Charleston...

Page 362: ......

Page 363: ...brication System 1 15 Brakes 1 17 Tires and Wheels 1 18 Clutch 1 19 Rear Belt Deflection 1 21 Primary Chain 1 22 Rear Preload Adjustment 1 23 Suspension 1 24 Front Fork 1 25 Spark Plugs 1 27 Air Cleaner Filter 1 28 Carburetor 1 29 Ignition Timing 1 30 Vacuum Operated Electrical Switch V O E S 1 32 Handlebars 1 33 Headlamp 1 34 Storage 1 35 Troubleshooting 1 36 ...

Page 364: ...ne 2 22 Rear Brake Master Cylinder 2 23 Rear Brake Caliper 2 25 Rear Brake Line and Switch 2 27 Front Fork 2 28 Fork Stem and Bracket Assembly 2 32 Swingarm 2 33 Rear Shock Absorber 2 36 Suspension Theory 2 38 Suspension Adjustments 2 39 Throttle Control 2 43 Clutch Control 2 44 Speedometer and Tachometer 2 46 Handlebars 2 49 Exhaust System 2 50 Footrests 2 52 Sprocket Cover 2 53 Fenders 2 54 Tail...

Page 365: ...ylinder Head 3 11 Cylinder and Piston 3 22 Lubrication System 3 28 Oil Hose Routing 3 29 Oil Tank 3 30 Oil Pressure Signal Light Switch 3 31 Crankcase Breathing System 3 32 Oiling System Color Foldout 3 33 Oil Pump 3 34 Oil Filter Mount 3 37 Valve Tappets 3 38 Gearcase Cover and Cam Gears 3 40 Crankcase 3 48 ...

Page 366: ...FUEL SYSTEM Specifications 4 1 Carburetor 4 2 Air Cleaner 4 18 Fuel Tank 4 20 Fuel Supply Valve 4 22 Evaporative Emissions Control California Models 4 23 ...

Page 367: ...ELECTRIC STARTER Specifications 5 1 Electric Starter System 5 2 Diagnostics Troubleshooting 5 9 Starter System Testing 5 10 Starter 5 11 Starter Solenoid 5 18 ...

Page 368: ...tch Release Mechanism 6 9 Primary Drive Clutch 6 10 Transmission 6 14 Transmission Case 6 16 Shifter Forks and Drum 6 18 Mainshaft and Countershaft 6 20 Main Drive Gear 6 26 Access Door Bearings 6 28 Right Transmission Case Bearings 6 29 Transmission Installation and Shifter Pawl Adjustment 6 30 ...

Page 369: ...il 7 16 Spark Plug Cables 7 18 Starter Interlock 7 19 Charging System 7 23 Alternator 7 29 Voltage Regulator 7 31 Battery 7 32 Headlamp 7 33 Tail Lamp 7 35 Turn Signals 7 37 Turn Signal Flasher 7 38 Handlebar Switches 7 39 Horn 7 41 Neutral Indicator Switch 7 42 Fuses and Circuit Breakers 7 43 Electrical Connectors 7 44 Deutsch Electrical Connectors 7 46 Amp Multilock Electrical Connectors 7 48 ...

Page 370: ...1997 INFORMATION Maintenance 1 Chassis 11 Engine 17 Fuel System 19 Electric Starter 25 Drive transmission 29 Electrical 31 ...

Page 371: ...APPENDIX Tools A 1 Metric Conversion B 1 ...

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