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15-4

6999-0003 7/15/99

BRAKES

(StepNumber)

FRONT MASTER CYLINDER

REMOVAL

Loosen the mirror lock nut and remove the right mirror.

Loosen the turn signal gimbal nut and remove the turn

signal assembly.

Disconnect the brake light wire harness.

Remove the banjo bolt, brake hose, and sealing washers.

Discard the sealing washers.

Remove the screws from the handlebar clamp and

remove the master cylinder assembly.

1. MIRROR LOCK NUT
2. GIMBAL NUT
3. BRAKE LIGHT WIRE
4. BANJO BOLT

5. BRAKE HOSE
6. SEALING WASHER
7. HANDLEBAR CLAMP

DISASSEMBLY

Clean the area around the reservoir cap and remove the

reservoir cap, plate, and diaphragm. Empty the reservoir of
any remaining hydraulic fluid.

Remove the lever bolt and lever.

Remove the brake light switch.

1. CAP
2. PLATE
3. DIAPHRAGM

4. LEVER BOLT
5. LEVER
6. BRAKE LIGHT SWITCH

Clamp the master cylinder securely in a padded vise.

Carefully remove and discard the dust boot.

Use a retaining ring pliers to remove and discard the

piston retaining ring.

Pull the piston assembly and the piston return spring

from the cylinder bore and discard.

1. DUST BOOT
2. RETAINING RING

3. PISTON ASSEMBLY
4. RETURN SPRING

Содержание HCX 1999

Страница 1: ......

Страница 2: ...out incurring any obligation to make the same or similar changes to motorcycles previously built EXCELSIOR HENDERSON MOTORCYCLE MANUFACTURING COMPANY 805 HANLON DRIVE BELLE PLAINE MINNESOTA 56011 TELE...

Страница 3: ...l attention to information in the Handbook that begins with this symbol The following terms have special meaning in the Handbook Be certain you understand the meaning of each term as the terms communi...

Страница 4: ...Notice Use genuine Excelsior Henderson replace ment parts and lubricants or substitute parts and or lubricants recommended by Excelsior Henderson Special tools should be used as service procedures rec...

Страница 5: ...FOREWORD 6999 0003 7 15 99 iii...

Страница 6: ...L SYSTEM 4 ENGINE REMOVAL INSTALLATION 5 CYLINDER HEAD CAM DRIVE 6 CYLINDER PISTON 7 CRANKCASE CRANKSHAFT 8 PRIMARY DRIVE 9 CLUTCH 10 TRANSMISSION 11 WHEELS 12 FRONT SUSPENSION STEERING 13 REAR SUSPEN...

Страница 7: ...6999 0003 7 15 99 v...

Страница 8: ...1 0 6999 0003 7 15 99 ROUTINE MAINTENANCE 1...

Страница 9: ...3 DRIVE BELT 1 3 CHECK TENSION 1 4 ADJUST TENSION 1 4 THROTTLE CABLES 1 5 FUEL HOSE RAIL 1 5 EMISSION CONTROL SYSTEM 1 5 OXYGEN SENSOR 1 6 HYDRAULIC CONTROLS 1 6 FLUID LEVEL 1 6 LEVERS AND PEDAL 1 6...

Страница 10: ...1 2 6999 0003 7 15 99 ROUTINE MAINTENANCE TROUBLESHOOTING MAINTENANCE INTERVALS...

Страница 11: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 3 StepNumber StepNumber StepNumber ENGINE OIL 1 2 AIR FILTER ELEMENT 1 2 DRIVE BELT Check the drive belt condition 1 2...

Страница 12: ...4 Push the plunger upward until the small O ring touches the tension gauge body Make sure the tension gauge is seated squarely against the drive belt and move the large O ring until it aligns with th...

Страница 13: ...nuts 4 Tighten the rear axle castle nut Torque 111 ft lbs 5 Install a new rear axle cotter pin Caution Always use a new cotter pin when installing the rear axle nut 1 COTTER PIN 2 CASTLE NUT 3 ADJUST...

Страница 14: ...istency 1 2 HYDRAULIC CONTROLS inspect all hoses and connections Make sure the front and rear brake light switches 1 2 FLUID LEVEL StepCaptionHold For demonstration only StepCaptionHold These are BLIN...

Страница 15: ...PADS StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 SPARK PLUGS 1 2 STEERING HEAD BEARINGS Turn bars side...

Страница 16: ...monstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 WHEELS AND SPOKES 1 2 SIDESTAND StepCaptionHold For demonstration only StepCaption...

Страница 17: ...AINTENANCE 6999 0003 7 15 99 1 9 StepNumber StepNumber ROAD TEST 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consist...

Страница 18: ...1 10 6999 0003 7 15 99 ROUTINE MAINTENANCE...

Страница 19: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 11...

Страница 20: ...ROUTINE MAINTENANCE NOTES 6999 0003 7 15 99 1 12...

Страница 21: ...ROUTINE MAINTENANCE 6999 0003 7 15 99 1 13...

Страница 22: ...2 0 6999 0003 7 15 99 BODY EXHAUST 2...

Страница 23: ...can explode Insufficient safeguards when handling gasoline can result in severe personal injury death and or property damage TORQUE VALUES Rear fender strut bolts Exhaust header flange nut Muffler cl...

Страница 24: ...2 2 6999 0003 7 15 99 BODY EXHAUST TROUBLESHOOTING Excessive exhaust noise Broken exhaust system components Exhaust leak Poor performance Dents of kinks in exhaust header Exhaust leak Plugged muffler...

Страница 25: ...e post at the rear of the fuel tank Install the tandem saddle posts and fasten the rider s saddle screws Torque 18 ft lbs 2 Slide the tandem saddle into the posts at the rear of the rider s saddle and...

Страница 26: ...hose from the fuel pump 1 FUEL HOSE 6 Connect a drain hose to the fuel tank at the fuel pump connection 7 Run the drain hose into a suitable container up to 6 5 gallons 8 Be sure to secure the hose wh...

Страница 27: ...ifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish 6 Lift the rear of the fuel tank two or three inches to expose the fue...

Страница 28: ...ion Stop the fuel pump before it runs dry Running the fuel pump without fuel will damage the pump REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Open the right g...

Страница 29: ...e disconnection point to prevent fuel spray 9 Wrap a rag around the fuel hose connection point and disconnect the hose from the fuel pump Wipe up any spilled fuel 1 FUEL HOSE 10 Remove the two nuts an...

Страница 30: ...sor Tuck the connectors under the tank electrical connectors 8 Install the instrument cluster see INSTRUMENT CLUSTER INSTALLATION page 18 23 9 Install the rear fuel tank screw and isolator 10 Tighten...

Страница 31: ...ssembly aside 1 BRAKE HOSE 2 CALIPER ROD MOUNT 3 BRAKE CALIPER ASSEMBLY 4 RIGID FORK Wrap a clean cloth around the lower portion of each strut spring Cover the inner surface of each strut below the fe...

Страница 32: ...e are BLIND white text StepCaptionHold Used to hold table height consistency 1 BRAKE HOSE 2 BRAKE CALIPER ASSEMBLY 3 CALIPER ROD MOUNT 4 RIGID FORK Install both suspension rockers Torque Remove any cl...

Страница 33: ...ve the spacers For additional tail lamp service information see TAIL LAMP page 18 14 For additional turn signal lamp service information see TURN SIGNAL LAMPS page 18 16 1 FENDER SUPPORT 2 MOUNTING SC...

Страница 34: ...DN 7 15 Remove rear exhaust header flange nuts Support the rear muffler and remove the muffler mounting bolts Remove the rear exhaust assembly by sliding the assembly rearward off of the exhaust studs...

Страница 35: ...flange over the exhaust studs Start the header mounting nuts onto the exhaust studs Start the muffler mounting bolts into the muffler 1 EXHAUST GASKET 2 EXHAUST STUD Slide the rear exhaust assembly o...

Страница 36: ...place any wire ties previously removed Notice Make sure all wires are secure from vibration and direct contact to high temperature surfaces Install all exhaust system heat shields and tighten the heat...

Страница 37: ...BODY EXHAUST 6999 0003 7 15 99 2 15...

Страница 38: ...3 0 6999 0003 7 15 99 LUBRICATION SYSTEM 3 10732...

Страница 39: ...ifters and cam chains of both cylinders The oil then drains through the cam chain tunnel into the timing gear area of the crankcase where it is drawn into the outer scavenge pump The scavenge pump ret...

Страница 40: ...lve stuck open Pressure pump gerotor pin sheared Pressure pump drive gear s damaged Worn or damaged pressure pump gerotor Oil draining from air cleaner Oil level too high Oil pressure too high Pressur...

Страница 41: ...e indicator lamp does not illuminate at startup inspect the oil pressure switch see OIL PRESSURE SWITCH INSPECTION page 18 22 If the low pressure indicator lamp remains lit while the engine is running...

Страница 42: ...MP COVER 2 PUMP 7 Remove the timing gear cover screws and the timing gear cover 8 Remove and discard the cover gasket and O rings 9 Pull the idler shaft from the crankcase and discard the O ring 10 Re...

Страница 43: ...es should rotate smoothly and quietly Replace any worn or damaged components 1 IDLER SHAFT 2 IDLER GEAR 3 SPACER 4 NEEDLE BEARING RELIEF VALVE 1 Push in the relief valve plunger to make sure it moves...

Страница 44: ...actly as they were removed from the oil pump housing Notice Coat all components with clean engine oil before assembly 1 RETAINING RING 2 OIL PUMP SHAFT 3 BACKPLATE 2 Install the dowel pin into the oil...

Страница 45: ...e timing cover and tighten the mounting screws Torque 8 ft lbs 1 TIMING GEAR COVER 2 IDLER SHAFT 3 IDLER GEAR 7 Place a new O ring in the pump port 8 Install the pump and tighten the mounting screws T...

Страница 46: ...G RING 4 Remove the gerotor assemblies Caution The georotor assemblies must be reinstalled exactly as it was removed from the oil pump Use a permanent marker to identify the inner and outer surfaces o...

Страница 47: ...moved from the oil pump housing Notice Coat all components with clean engine oil before assembly 1 RETAINING RING 2 PUMP SHAFT 3 BACKPLATE 2 Install the first dowel pin into the oil pump shaft 3 Place...

Страница 48: ...13 1 TIMING GEAR COVER CRANKCASE REED VALVE REMOVAL 1 Remove the inner primary cover see INNER PRIMARY COVER REMOVAL page 9 6 2 Remove the starter idler gear 3 Remove the starter crankshaft gear 4 Re...

Страница 49: ...LUBRICATION SYSTEM NOTES 6999 0003 7 15 99 3 11...

Страница 50: ...4 0 6999 0003 7 15 99 ENGINE CONTROL SYSTEM 4...

Страница 51: ...pump has a built in pressure regulator and filter SERVICE INFORMATION 4 1 TROUBLESHOOTING 4 3 SYSTEM OPERATION 4 4 DIAGNOSING FAULTS 4 11 ENGINE CONTROL MODULE 4 122 FUEL TANK 4 124 FUEL PUMP FILTER 4...

Страница 52: ...t switch screw 5 ft lbs Idle air control screw 26 in lbs Spark plug 15 ft lbs SPECIFICATIONS Unit inch ITEM STANDARD SERVICE LIMIT Air temperature sensor resistance 820 120 F 1210 100 F 1830 80 F 2840...

Страница 53: ...function Fuel injector malfunction Faulty crankshaft position sensor Closed throttle position needs resetting EFI fuse open Oxygen sensor contaminated Engine Stalls Hard to Start Rough Idle Intake air...

Страница 54: ...n to the ECM which it uses to make adjustments to these basic parameters The ECM generates signals that drive the devices that do the work such as the fuel pump fuel injectors and ignition coils The E...

Страница 55: ...ed to be reset periodically as parts wear and seat together Use the Examinator diagnostic tool to reset the closed throttle position The throttle body is equipped with an idle air control IAC valve an...

Страница 56: ...uel On California models an emissions canister captures the fuel vapors and passes them through a purge valve to the throttle body While the engine is not running vapor pressure that builds in the fue...

Страница 57: ...essure of 48 psi The ECM applies a voltage to the fuel injector solenoid for a specific time period opening the valve and releasing fuel into the intake port The engine tem perature sensor enables the...

Страница 58: ...he crankcase This generates voltage pulses that the ECM uses to calculate engine speed To determine piston position in the 4 cycle com bustion process the ECM matches injection timing and the rapid de...

Страница 59: ...al for high oxygen content 0 5V or a rich signal for low oxygen content 0 5V The ECM compensates by increasing or decreasing the injection duration based on these signals This causes the calculated ai...

Страница 60: ...ult P0117 Engine Temperature Sensor Short to Ground P0352 Ignition Coil 2 Circuit Fault P0118 Eng Temp Sensor Open Circuit Short to Power P1352 Ignition Coil 1 Open Circuit Short to Ground P0119 Engin...

Страница 61: ...er as labeled on the connector For example power to the throttle position sensor is applied to pin P7A A The Examinator diagnostic tool displays a variety of engine data that can help you determine th...

Страница 62: ...LT HISTORY DATA Make note of the air pressure value INSPECT AIR PRESSURE SENSOR TUBE Remove and inspect the ECM vent tube Is the tube clogged Caution Do not apply compressed air to the vent tube or th...

Страница 63: ...ground Temperature above 160 F INSPECT AIR TEMPERATURE SENSOR Is the connector P8 fastened Is the air temperature sensor probe tip intact Yes Continue No Fasten the connector Replace the air temperat...

Страница 64: ...lt reoccurs continue MEASURE COMPONENT RESISTANCE Measure the resistance across the sensor terminals Is the value in range Standard 820 120 F 1210 100 F 1830 80 F 2840 60 F 3500 50 F Yes Continue No R...

Страница 65: ...between Air Temp and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs contact dealer service No Contact dealer service TEST FOR...

Страница 66: ...T HISTORY DATA Make note of the air temperature DISPLAY SENSOR DATA Make note of the air temperature sensor voltage INSPECT AIR TEMPERATURE SENSOR Is the connector P8 fastened Is the air temperature s...

Страница 67: ...lt reoccurs continue MEASURE COMPONENT RESISTANCE Measure the resistance across the sensor terminals Is the value in range Standard 820 120 F 1210 100 F 1830 80 F 2840 60 F 3500 50 F Yes Continue No R...

Страница 68: ...tinuity between Air Temp and P8B 1 between Sensor Gnd and P8B 2 Yes Continue No Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR SHO...

Страница 69: ...the air temperature sensor voltage greater than 5 5 volts Yes Trace air temperature sensor signal wiring Gn W for a short to 12 volts Repair wiring Reconnect the harness clear the fault codes and run...

Страница 70: ...gine temperature condition Possible short to ground INSPECT ENGINE TEMPERATURE SENSOR Is the engine temperature sensor fastened properly Is the connector P5 intact and fastened properly Yes Continue N...

Страница 71: ...and continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 1...

Страница 72: ...tinuity between Engine Temp and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR INTERNAL SHORT Di...

Страница 73: ...wer source DISPLAY FAULT HISTORY DATA Make note of the engine temperature DISPLAY SENSOR DATA Make note of the engine temperature sensor voltage INSPECT ENGINE TEMPERATURE SENSOR Is the engine tempera...

Страница 74: ...d continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 160...

Страница 75: ...re sensor P5 Is there continuity between Engine Temp and P5B 1 between Sensor Gnd and P5B 2 Yes Continue No Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault re...

Страница 76: ...engine temperature sensor voltage greater than 5 5 volts Yes Trace engine temperature sensor signal wiring Pk Y for a short to 12 volts Repair wiring Reconnect the harness clear the fault codes and r...

Страница 77: ...mperature condition Possible short to a 5 volt power supply INSPECT ENGINE TEMPERATURE SENSOR Is the engine temperature sensor fastened properly Is the connector P5 intact and fastened properly Yes Co...

Страница 78: ...and continue MEASURE COMPONENT RESISTANCE Disconnect the harness from the engine temperature sensor P5 Measure the resistance across the sensor terminals Is the value in range Standard 150 230 F 422 1...

Страница 79: ...leaving the ECM disconnected then continue TEST FOR INTERNAL SHORT Disconnect the harness from the engine temperature sensor P5 Is there continuity between Engine Temp and Sensor Gnd Yes Repair wiring...

Страница 80: ...A Make note of the throttle position value DISPLAY SENSOR DATA Make note of the throttle position and throttle position sensor voltage values INSPECT THROTTLE POSITION SENSOR Is the throttle position...

Страница 81: ...e throttle position sensor P7 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the harness clear the fault codes and run the engine If the fault reoccurs disconnec...

Страница 82: ...Is there continuity between Throttle and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CI...

Страница 83: ...EST FOR INTERNAL SHORT Is there continuity between Throttle and Sensor Gnd Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs contact dealer service...

Страница 84: ...Make note of the throttle position value DISPLAY SENSOR DATA Make note of the throttle position sensor voltage with the throttle closed and open INSPECT THROTTLE POSITION SENSOR Is the throttle positi...

Страница 85: ...e throttle position sensor P7 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the harness clear the fault codes and run the engine If the fault reoccurs disconnec...

Страница 86: ...isconnected then continue TEST FOR SHORT TO 5V Is there continuity between Throttle and Sensor 5V Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs...

Страница 87: ...mber DESCRIPTION Calculated fuel demand has reached the maximum limit Possible causes Incorrect engine tune Engine tune variables out of range Intake or exhaust air leak Insufficient fuel flow Sensor...

Страница 88: ...isplay the engine tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes...

Страница 89: ...ly Yes Continue No Secure sensor and connector Clear the fault codes and run the engine If the fault reoccurs continue Start the engine and allow it to warm to closed loop operation Use the Examinator...

Страница 90: ...ving the ECM disconnected then continue TEST FOR SHORT TO GROUND Disconnect the harness from the oxygen sensor P4 Is there continuity between Oxygen and motorcycle ground Yes Repair wiring Reconnect t...

Страница 91: ...needed INSPECT THROTTLE BODY Remove the air cleaner cover and inspect the air cleaner Clean or replace the air cleaner if necessary Open the throttle bore and inspect the butterfly valve the injector...

Страница 92: ...leaks around the injectors and the intake collar seals Are repairs needed Yes Make repairs Reset closed throttle position long term fuel trim and IACV adaption Clear the fault codes and run the engin...

Страница 93: ...e position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair complete MEASURE CYLINDER COMPRESSION Measure compre...

Страница 94: ...r DESCRIPTION Calculated fuel demand has reached the minimum limit Possible causes Incorrect engine tune Engine tune variables out of range Insufficient air flow Excess fuel flow Sensor malfunction Fa...

Страница 95: ...tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine...

Страница 96: ...volt Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue REPLACE OXYGEN SENSOR Replace the oxygen sensor Reconnect the harness c...

Страница 97: ...ndard 45 51 psi Yes Replace the fuel pump Clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT INTAKE MANIFOLD Remove the intake manifold and inspect for obstruc...

Страница 98: ...load the current engine tune Reset closed throttle position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair co...

Страница 99: ...StepNumber DESCRIPTION Calculated air demand has reached the maximum limit Possible causes Incorrect engine tune Engine tune variables out of range Insufficient air flow Excess fuel flow Sensor malfun...

Страница 100: ...he engine tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run...

Страница 101: ...arness clear the fault codes and run the engine If the fault reoccurs continue No Continue REPLACE OXYGEN SENSOR Replace the oxygen sensor Reconnect the harness clear the fault codes and run the engin...

Страница 102: ...ndard 45 51 psi Yes Replace the fuel pump Clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT INTAKE MANIFOLD Remove the intake manifold and inspect for obstruc...

Страница 103: ...load the current engine tune Reset closed throttle position long term fuel trim and IACV adaption values Run the engine Does the fault reoccur Yes Reinstall the original ECM and continue No Repair co...

Страница 104: ...pNumber StepNumber DESCRIPTION Calculated air demand has reached the minimum limit Possible causes Incorrect engine tune Engine tune variables out of range Excess air flow Insufficient fuel flow Senso...

Страница 105: ...tune Is the correct engine tune loaded Yes Continue No Load the correct engine tune Reset closed throttle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine...

Страница 106: ...he fault reoccurs continue Start the engine and allow it to warm to closed loop operation Use the Examinator diagnostic tool to monitor the short term fuel trim Raise the engine speed to 2000 RPM for...

Страница 107: ...Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from the oxygen sensor P4 Is there...

Страница 108: ...hrottle position long term fuel trim and IACV adaption values Clear the fault codes and run the engine No Continue Remove the throttle body assembly Inspect for air leaks around the butterfly valve th...

Страница 109: ...d fastened properly Yes Continue No Secure fuel injectors and connectors Clear the fault codes and run the engine If the fault reoccurs continue REPLACE FUEL INJECTORS Replace the fuel injectors Recon...

Страница 110: ...epair complete MEASURE CYLINDER COMPRESSION Measure compression on both cylinders Is the value in range Standard 185 205 psi Yes Continue No Make necessary repairs Clear the fault codes and run the en...

Страница 111: ...of the injector pulse time INSPECT FUEL INJECTOR 1 Is fuel injector 1 fastened properly Is the connector P10 intact and fastened properly Yes Continue No Secure fuel injector 1 and connector Clear th...

Страница 112: ...the harness from injector 1 P10 Measure the resistance across the injector terminals Is the value in range Standard 11 75 12 25 68 F Notice Use an ohmeter with sufficient accuracy for this measuremen...

Страница 113: ...and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from fuel...

Страница 114: ...5 68 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic tool Yes Reconnect the harness clear the fault codes and run the engine If the fault reo...

Страница 115: ...ing the ECM disconnected TEST FOR SHORT TO 12V Disconnect the harness from injector 1 P10 Is there continuity between Injector 1 and Power Relay Output Yes Repair wiring Reconnect the harness clear th...

Страница 116: ...ote of the injector pulse time INSPECT FUEL INJECTOR 2 Is injector 2 fastened properly Is the connector P11 intact and fastened properly Yes Continue No Secure the injector 2 and connector Clear the f...

Страница 117: ...esistance between across the injector terminals Is the value in range Standard 11 75 12 25 68 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic...

Страница 118: ...and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from fuel...

Страница 119: ...8 F Notice Use an ohmeter with sufficient accuracy for this measurement instead of the Examinator diagnostic tool Yes Reconnect the harness clear the fault codes and run the engine If the fault reoccu...

Страница 120: ...ut box leaving the ECM disconnected TEST FOR SHORT TO 12V Disconnect the harness from injector 2 P11 Is there continuity between Injector 2 and Power Relay Output Yes Repair wiring Reconnect the harne...

Страница 121: ...note of the Ignition Timing and the Target Dwell values INSPECT CRANKSHAFT SENSOR Is the crankshaft position sensor fastened properly Is the connector P6 intact and fastened properly Yes Continue No...

Страница 122: ...t reoccurs continue MEASURE COMPONENT RESISTANCE Disconnect the crankshaft position sensor from the harness P6 Measure the resistance across the sensor terminals Is the value in range Standard 532 588...

Страница 123: ...inue TEST FOR SHORT TO GROUND Disconnect the harness from the crankshaft sensor P6 Is there continuity between Crankshaft Pos and motorcycle ground between Crankshaft Neg and motorcycle ground Yes Rep...

Страница 124: ...epair or replace the crankshaft position sensor cable Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR INTERNAL SHORT Is there continuity between...

Страница 125: ...Is the crankshaft position gear free from damage and debris Is the clearance between the sensor and the timing tooth in range Standard 0 039 inches Yes Contact dealer service Yes Clean or replace cran...

Страница 126: ...OIL 1 Is ignition coil 1 fastened properly Is the connector P12 intact and fastened properly Yes Continue No Secure the ignition coil 1 and connector Clear the fault codes and run the engine If the fa...

Страница 127: ...the harness from ignition coil 1 Measure the resistance across the ignition coil terminals Is the value in range Standard 0 8 1 5 Notice Use an ohmeter with sufficient accuracy for this measurement i...

Страница 128: ...ycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from ignition coil...

Страница 129: ...ult codes and run the engine If the fault reoccurs continue MEASURE COIL 1 RESISTANCE Disconnect the harness from ignition coil 1 Measure the resistance across the ignition coil terminals Is the value...

Страница 130: ...e harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from the ignition coil P12 Is there con...

Страница 131: ...OIL 2 Is ignition coil 2 fastened properly Is the connector P13 intact and fastened properly Yes Continue No Secure the ignition coil 2 and connector Clear the fault codes and run the engine If the fa...

Страница 132: ...the harness from ignition coil 2 Measure the resistance across the ignition coil terminals Is the value in range Standard 0 8 1 5 Notice Use an ohmeter with sufficient accuracy for this measurement i...

Страница 133: ...l 2 and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect the harness from...

Страница 134: ...t codes and run the engine If the fault reoccurs continue MEASURE COMPONENT RESISTANCE Disconnect the harness from ignition coil 2 Measure the resistance across the ignition coil terminals Is the valu...

Страница 135: ...he harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from ignition coil 2 P13 Is there cont...

Страница 136: ...cycle INSPECT PURGE VALVE Is the purge valve fastened properly Is the connector P3 intact and fastened properly Yes Continue No Secure the purge valve and connector Clear the fault codes and run the e...

Страница 137: ...P3 Measure the resistance between across the purge valve terminals Is the value in range Standard 26 Yes Continue No Replace the purge valve Reconnect the harness clear the fault codes and run purge v...

Страница 138: ...d run purge valve component test If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Disconnect harness from the purge valve P3 Is there continuity between Purge and P3B 2 between Power R...

Страница 139: ...engine If the fault reoccurs continue MEASURE PURGE VALVE RESISTANCE Disconnect the harness from the purge valve P3 Measure the resistance between across the purge valve terminals Is the value in rang...

Страница 140: ...the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Disconnect the harness from the purge valve P3 Is there cont...

Страница 141: ...of road speed value INSPECT ECM CONNECTORS Are the ECM connectors fastened properly Yes Continue No Fasten the ECM connectors Clear the fault codes and run the engine If the fault reoccurs continue 1...

Страница 142: ...etween Speedometer and motorcycle ground Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue TEST FOR OPEN CIRCUIT Is there cont...

Страница 143: ...or Clear the fault codes and run the engine If the fault reoccurs continue INSPECT COMPONENT CONNECTOR Disconnect the harness from road speed sensor P37 Are the pins and sockets intact and secure Yes...

Страница 144: ...PLAY SENSOR DATA Make note of the IACV Stepper Position value INSPECT IAC VALVE Is the IAC valve fastened properly Is the connector P9 intact and fastened properly Yes Continue No Secure the sensor an...

Страница 145: ...NT RESISTANCE Disconnect the harness from the IAC valve P9 Measure the resistance between P9A A and P9A D and between P9A B and P9A C Are the values in range Standard 47 7 58 3 73 F Yes Continue No Re...

Страница 146: ...l C and ground between Idle Air Control D and ground Yes Repair wiring Reconnect the harness and clear the fault code Run the IAC valve component test If the fault reoccurs continue No Continue TEST F...

Страница 147: ...between Idle Air Control B and P9B B Is there continuity between Idle Air Control C and P9B C between Idle Air Control D and P9B D Yes Contact dealer service No Repair wiring Reconnect the harness an...

Страница 148: ...cable terminals if necessary Measure the battery voltage Is the voltage 11 14 volts Yes Make note of the voltage and continue No Charge or replace the battery Clear the fault codes and run the engine...

Страница 149: ...Is the value less than the measured battery voltage Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue INSPECT MAIN SWITCH With...

Страница 150: ...continue No Move the main switch to the Off position Reconnect connector P40 and continue MEASURE ENGINE STOP RUN SWITCH VOLTAGE Disconnect the harness from the right handle bar controls P25 Move the...

Страница 151: ...P2B to the breakout box leaving the ECM disconnected then continue MEASURE SYSTEM VOLTAGE Move the main switch to the On position Move the engine stop run switch to Run Measure the voltage between Ki...

Страница 152: ...asure the alternator output voltage Is the voltage acceptable Yes Contact dealer service No Repair alternator Clear the fault codes and run the engine If the fault reoccurs contact dealer service 1023...

Страница 153: ...fuse Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue TEST FOR CONTINUITY Disconnect the harness from the fuel pump P18 Is there continuity between P18B 1...

Страница 154: ...reoccurs continue CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected TEST FOR SHORT TO GROUND Disconnect the harnes...

Страница 155: ...pair wiring Reconnect the harness clear the fault codes and run the fuel pump prime component test If the fault reoccurs contact dealer service MEASURE FUEL PUMP FUSE VOLTAGE Measure the voltage at th...

Страница 156: ...ay fuel pump fuse and fuse connector cover Clear the fault codes and run the engine If the fault reoccurs continue MEASURE IGNITION RELAY VOLTAGE Move the main switch to the On position Measure the vo...

Страница 157: ...des and run fuel pump prime test If the fault reoccurs continue TEST FOR SHORT TO POWER Measure the voltage between the fuel pump signal line P18B 2 and motorcycle ground under the following condition...

Страница 158: ...10 seconds any voltage indicates a short with a switched power circuit other than the fuel pump power circuit Main switch On Engine stop run switch Run Any voltage indicates a short with the ECM powe...

Страница 159: ...he tachometer work DISPLAY FAULT HISTORY DATA Make note of the Engine Speed value INSPECT ECM CONNECTORS Are the ECM connectors fastened properly Yes Continue No Fasten the ECM connectors Clear the fa...

Страница 160: ...air wiring Reconnect the harness clear the fault codes and run the tachometer component test If the fault reoccurs repair or replace the instrument cluster No Repair or replace instrument cluster Disc...

Страница 161: ...gine Speed value INSPECT INSTRUMENT CLUSTER CONNECTOR Disconnect the harness from the instrument cluster P20 Are the pins and sockets intact and secure Yes Continue No Repair connector Reconnect the h...

Страница 162: ...ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then continue TEST FOR SHORT TO 12V Is there continuity between Tachometer and the potential power sources on the ins...

Страница 163: ...Y SENSOR DATA Make note of the Sensor Reference Voltage CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout box leaving the ECM disconnected then con...

Страница 164: ...e No Continue MEASURE SENSOR VOLTAGE Attach the breakout box Y cable female connectors to the ECM Move the main switch to the On position Move the Engine Stop Run switch to the Run position Measure th...

Страница 165: ...lace or secure the fuses Clear the fault codes and run the engine If the fault reoccurs continue INSPECT INSTRUMENT CLUSTER CONNECTOR Is the instrument cluster connector P20 intact and fastened proper...

Страница 166: ...and the check engine lamp bulb Repair wiring or replace the bulb Reconnect the harness clear the fault codes and run the engine If the fault reoccurs continue INSPECT ECM CONNECTORS Are the ECM connec...

Страница 167: ...arness from the instrument cluster Is there continuity between the check engine lamp P20A 3 and ground P20A 7 Yes Repair wiring Reconnect the harness clear the fault codes and run the engine If the fa...

Страница 168: ...alue 11 14 volts Yes Continue No Repair wiring and continue MEASURE RELAY COIL VOLTAGE Move the main switch to Acc Measure the voltage at the relay coil input P16B 86 Is the value 11 14 volts Yes Move...

Страница 169: ...sconnect the harness from the main switch Move the main switch to Acc Measure the voltage at the accessory output P29B B Is the value 11 14 volts Yes Contact dealer service No Repair wiring Reconnect...

Страница 170: ...Fasten the ECM connectors Clear the fault codes and run the engine If the fault reoccurs continue CONNECT BREAKOUT BOX Disconnect the harness from the ECM P1 and P2 Connect P1B and P2B to the breakout...

Страница 171: ...onnect the harness clear the fault codes and run the engine If the fault reoccurs continue No Continue Is there continuity between P20A 2 and the potential power sources on the instrument cluster conn...

Страница 172: ...lt guard see Chapter 2 BODY EXHAUST 1 UPPER BELT GUARD 4 Remove the four screws and washers that secure the electronics guard 5 Remove the electronics guard between the rear fender and the wheel d tab...

Страница 173: ...the two screws Torque 22 in lbs Caution Do not apply grease to the ECM connectors Grease prevents moisture from escaping the connector body This can cause corrosion of the pins and sockets leading to...

Страница 174: ...uel tank and the fuel hose may retain some residual pressure WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always work in a well ventilated area Keep sparks and...

Страница 175: ...8 Be sure to secure the hose while running the pump to prevent the hose from coming out of the container 1 DRAIN HOSE 9 Connect the Examinator diagnostic tool to the diagnostic connector on the wirin...

Страница 176: ...he tank Caution Lifting the fuel tank too high will bring the front of the fuel tank in contact with the triple clamp possibly damaging the finish 6 Lift the rear of the fuel tank two or three inches...

Страница 177: ...top the fuel pump before it runs dry Running the fuel pump without fuel will damage the pump REMOVAL 1 Disconnect the battery beginning with the negative battery cable see Chapter 16 BATTERY CHARGING...

Страница 178: ...ver the disconnection point to prevent fuel spray 9 Wrap a rag around the fuel hose connection point and disconnect the hose from the fuel pump Wipe up any spilled fuel 1 FUEL HOSE 10 Remove the two n...

Страница 179: ...ctor through the hole and connect it 7 Connect the wiring harness to the fuel pump and the fuel level sensor Tuck the connectors under the tank electrical connectors 8 Install the instrument cluster s...

Страница 180: ...4 124 Be sure the battery is well charged Run the fuel pump for 15 seconds and measure the volume of fuel Multiply the measured value by four to obtain gallons per minute If the flow volume is out of...

Страница 181: ...cross the input P18B 1 and output P18B 2 terminals of the fuel pump If there is no continuity replace the fuel pump Test for continuity between the ground terminal P18B 3 and the fuel pump casing If t...

Страница 182: ...ot pour from the fuel level sensor opening 4 Remove the five screws from the fuel level sensor 5 Carefully remove the fuel level sensor and rubber gasket 1 FUEL LEVEL SENSOR INSPECTION Inspect the fue...

Страница 183: ...alve 3 Disconnect the vent tubes from the purge valve 4 Remove the purge valve 1 PURGE VALVE 2 VENT TUBES INSPECTION While installed on the motorcycle the purge valve should be oriented so that the ar...

Страница 184: ...he canister vent tube from the canister 3 Disconnect the rollover vent tube from the canister 4 Remove the screw on the canister strap lift the strap and remove the canister 1 PURGE VENT TUBE 2 CANIST...

Страница 185: ...Discard the clip 1 DRAIN TUBE INSPECTION Inspect the rollover valve openings for obstructions Hold the valve with the inlet up Blow air low pressure through the inlet Air should flow freely If not rep...

Страница 186: ...ake manifold 1 CLIP 2 FUEL RAIL WARNING There may be a small amount of fuel in the fuel hose and fuel rail Use a rag when removing the fuel rail to absorb any fuel 5 Using the fuel rail mounting stem...

Страница 187: ...TALLATION 1 Install a new injector o ring Lubricate the o ring with a small amount of silicon grease 2 Install the injector into the intake manifold Be sure the collar is in place 3 Using the fuel rai...

Страница 188: ...es from the throttle body 5 Remove the cable retainer underneath the switch assembly 6 Separate the halves of the right hand switch control and remove the throttle grip 1 CABLE ADJUSTERS 2 JAM NUTS IN...

Страница 189: ...Turn the cable adjuster on the throttle opening cable out until the throttle free play is between 1 16 and 3 16 1 CABLE ADJUSTERS 2 JAM NUTS 4 Hold the throttle control grip at the fully closed posit...

Страница 190: ...s Torque 8 ft lbs THROTTLE BODY REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2 Remove the four nuts on the air cleaner backplate 3 Pull the air cleaner backplate from the mounti...

Страница 191: ...for proper operation Notice On California models inspect the vent tube and coupling for cracks Repair or replace as needed INSTALLATION 1 Fit the throttle body with a new throttle body seal 2 Install...

Страница 192: ...ank see FUEL TANK REMOVAL page 4 127 2 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 3 Remove throttle body see THROTTLE BODY REMOVAL page 4 140 WARNING There may be a small amount of fuel...

Страница 193: ...Install the fuel tank see FUEL TANK INSTALLATION page 4 128 AIR TEMPERATURE SENSOR REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2 Remove the four nuts on the air cleaner backpla...

Страница 194: ...ss 2 Install the air cleaner backplate on the mounting studs and fasten the four nuts Torque 8 ft lbs 3 Install the air cleaner see AIR CLEANER INSTALLATION page 4 140 CRANKSHAFT POSITION SENSOR REMOV...

Страница 195: ...and the crankshaft position gear Standard 0 039 inches Measure the resistance across the sensor terminals If the value is not in range replace the crankshaft position sensor Standard 532 588 68 F INS...

Страница 196: ...nect the wiring harness from the engine temperature sensor 2 Remove the engine temperature sensor from the front cylinder head 1 ENGINE TEMPERATURE SENSOR INSPECTION Inspect the engine temperature sen...

Страница 197: ...or OXYGEN SENSOR REMOVAL 1 Disconnect the wiring harness from the oxygen sensor 2 Remove the oxygen sensor from the rear exhaust pipe INSPECTION Inspect the oxygen sensor and connector for damage Repa...

Страница 198: ...the output sprocket cover and remove the cover 1 OUTPUT SPROCKET 3 Remove the three screws from the electronics cover and remove the cover 4 Disconnect the wiring harness from the road speed sensor 5...

Страница 199: ...screws and grommets Torque 22 in lbs 5 Install the exhaust and muffler system see Chapter 2 BODY EXHAUST THROTTLE POSITION SENSOR REMOVAL 1 Remove the air cleaner see AIR CLEANER REMOVAL page 4 139 2...

Страница 200: ...nstall the air cleaner see AIR CLEANER INSTALLATION page 4 140 4 Install the fuel tank see FUEL TANK INSTALLATION page 4 128 5 Reset the closed throttle position Tool Examinator Diagnostic Tool 6999 0...

Страница 201: ...or a tilt angle greater than 60 If the values are not in range replace the tilt switch Standard Within 60 11 14 volts Greater than 60 0 8 volts INSTALLATION 1 Install the tilt switch and fasten the tw...

Страница 202: ...o ring 1 IDLE AIR CONTROL 2 O RING INSPECTION Remove the air cleaner and inspect the valve movement while running the idle air control valve component test See the Examinator Handbook for information...

Страница 203: ...8 5 Use the Examinator diagnostic tool to reset the idle air control valve adaption and the long term fuel trim Tool Examinator Diagnostic Tool 6999 0009 IGNITION COILS SPARK PLUGS REMOVAL 1 Remove th...

Страница 204: ...Both spark plugs should have light or medium tan color deposits on the insulator around the electrode tip The spark plug electrode tip and bridge should have sharp square edges Damaged electrodes can...

Страница 205: ...erminals If the value is not in range replace the ignition coil Standard 0 8 1 5 INSTALLATION 1 Install the spark plug in to the cylinder head Thread by hand then tighten Torque 15 ft lbs 2 Install th...

Страница 206: ...5 0 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION 5...

Страница 207: ...sembly should be removed and installed from the right side of the motorcycle TORQUE VALUES TOOLS Engine lift fixture EH 6999 0101 Engine stand adapter EH 6999 0102 SERVICE INFORMATION 5 1 TROUBLESHOOT...

Страница 208: ...5 2 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION TROUBLESHOOTING...

Страница 209: ...em over the top tube of the frame 8 Disconnect the main switch wire 9 Remove the switch bracket screws and the main switch assembly 10 Remove the output sprocket see OUTPUT SPROCKET REMOVAL page 11 14...

Страница 210: ...AFT POSITION SENSOR 24 Remove the air cleaner cover and the air cleaner element 25 Remove the air cleaner backplate and gasket 26 Disconnect the crankcase breather hose 27 Disconnect the air temperatu...

Страница 211: ...KET 4 DIAGNOSTIC CONNECTOR 5 BATTERY BOX 39 Disconnect the engine ground wires 1 GROUND WIRE 40 Support the engine from underneath 41 Remove the front engine mount nuts 42 Remove both front mount scre...

Страница 212: ...lift fixture EH 6999 0101 Notice Make sure the engine lift fixture is securely installed on the engine lift 1 LIFT FIXTURE 48 Raise the engine until it clears the lower frame rail 49 Tip the engine s...

Страница 213: ...e support Notice Make sure the drive belt is not pinched behind the engine during engine installation 7 Remove the engine lift fixture Install Motor Mounts and Regulator 8 Install one of the rear engi...

Страница 214: ...cknut from the engine isolator bracket lower stud and tighten the lower stud locknut to a torque of 20 ft lb 1 REMOVE LOCKNUT 2 UPPER STUD 3 LOWER STUD 9 Install the right front engine isolator bracke...

Страница 215: ...solator mounting bracket 18 Align the hole in the left rubber engine mount with the alignment pin on the left engine isolator mounting bracket 19 Install the left front engine mounting bracket Install...

Страница 216: ...torque of 20 ft lb 1 ENGINE MOUNT COVER NUTS Install Brake Pedal 1 Align the brake pedal with the brake mounting bracket 2 Insert the brake pedal pivot bolt and tighten hand tight 3 Tighten the brake...

Страница 217: ...the oil pressure switch 1 OIL PRESSURE SWITCH 2 OIL PRESSURE CONNECTOR Connect the Road Speed Sensor 1 Attach the road speed connector to the road speed sensor 1 ROAD SPEED SENSOR 2 ROAD SPEED CONNEC...

Страница 218: ...X 2 WIRING TRAY 3 MOUNTING BOLTS 4 FLANGE NUTS 1 Insert the wiring tray into it s installation location 2 insert the battery box into it s installation location 3 From the battery box side insert one...

Страница 219: ...NGE NUTS 7 Plug In the electrical connectors for the fuse holders 8 Install the small mounting bolts 9 Install the battery spacer 1 ELECTRICAL CONNECTOR 2 SMALL MOUNTING BOLTS 3 BATTERY SPACER Install...

Страница 220: ...h a constant belt tension Notice Do not finish tighten the axle adjustment locknuts axle nut or drive pulley nut this will be completed in later procedures 1 MOVE REAR WHEEL BACK 2 REAR WHEEL ADJUSTER...

Страница 221: ...play as necessary to achieve 1 16 in to 3 16 in of free play 1 RUBBER COVERS 2 CABLE ADJUSTER JAM NUT 3 CABLE ADJUSTER 4 CABLE GUIDES 5 THROTTLE OPENING CABLE 6 THROTTLE CLOSING CABLE Install the Sta...

Страница 222: ...l the fuel injector electrical connector labeled 2 on the front 2 cylinder 1 1 FUEL INJECTOR CONNECTOR 2 FRONT 1 CYLINDER 3 2 FUEL INJECTOR CONNECTOR 4 REAR 2 CYLINDER ENGINE TEMPERATURE SENSOR 4 Conn...

Страница 223: ...ect the crankshaft sensor wire 1 CRANKSHAFT SENSOR VOLTAGE REGULATOR 5 Connect the voltage regulator plug connector 1 VOLTAGE REGULATOR 2 VOLTAGE REGULATOR PLUG CONNECTOR ALTERNATOR 8 Connect the alte...

Страница 224: ...the wires for the air temperature in between the cylinders They will need to be available at the bottom right of the throttle body support bracket 2 Install the throttle body onto the four 4 manifold...

Страница 225: ...AIR CONTROL VALVE 2 THROTTLE BODY 3 AIR CLEANER BACKPLATE 4 AIR TEMPERATURE SENSOR 5 BREATHER LINE AIR CLEANER BACKING PLATE 6 Slide the backplate onto the manifold studs 7 Install the four 4 hex fla...

Страница 226: ...lave Supply Line 1 Remove the acorn nut This acorn nut is from the shifter linkage rear bolt that is covering the clutch slave cylinder supply line banjo bolt 2 Install new crush washers Notice Anytim...

Страница 227: ...ng 5 Close bleeder and repeat steps 1 thru 4 6 Remove the plastic tube wipe up any excess fluid 7 Install the clutch access cover and fasteners when complete 8 Tighten the fasteners to a torque of 8ft...

Страница 228: ...OUNTING FASTENERS 4 OIL DIPSTICK Oil Filter 1 Using a new oil filter apply a light coating of oil to the gasket surface of the oil filter 2 Thread the oil filter onto the oil filter adaptor stem 3 Tur...

Страница 229: ...e 5 Install the two 2 exhaust flange fasteners and tighten hand tight Always replace the exhaust sealing gaskets whenever the exhaust pipes are removed from the engine 1 FRONT HEAD PIPE 2 EXHAUST SEAL...

Страница 230: ...to a torque of 55 ft lb 16 Tighten the muffler mounting bracket bolts to a torque of 30 ft lb 17 Position heat shields and tighten them to a torque of 8ft lb 1 EXHAUST FLANGE NUTS 2 MUFFLER MOUNTING B...

Страница 231: ...instrument pod bolts 8 Install the front gas tank isolator mounts and mounting bolts tighten the front and rear tank mounting bolts handtight 9 Tighten the front and rear tank mounting bolts to a torq...

Страница 232: ...nter along the rod until pointer tip rests in the center dimple of the rear axle Tighten the pointer thumb screw 3 Move the alignment gauge to the opposite location on the other side of the motorcycle...

Страница 233: ...own directly over the 10 lb mark on the plunger 5 Have an assistant complete steps 6 9 6 Place the base of the tension gauge bracket squarely against the lower strand of the drive belt at the front of...

Страница 234: ...sion and install a new rear axle cotter pin WARNING Do not reuse a cotter pin because it may fail causing the wheel to loosen and you to lose control of the motorcycle 1 COTTER PIN 2 CASTLE NUT 3 ADJU...

Страница 235: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 29...

Страница 236: ...5 30 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Страница 237: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 31...

Страница 238: ...5 32 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Страница 239: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 33...

Страница 240: ...5 34 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Страница 241: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 35...

Страница 242: ...5 36 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Страница 243: ...ENGINE REMOVAL INSTALLATION 6999 0003 7 15 99 5 37...

Страница 244: ...5 38 6999 0003 7 15 99 ENGINE REMOVAL INSTALLATION...

Страница 245: ...ENGINE REMOVAL INSTALLATION NOTES 6999 0003 7 15 99 5 39...

Страница 246: ...6 0 6999 0003 7 15 99 CYLINDER HEAD CAM DRIVE 6...

Страница 247: ...self adjusting hydraulic lifters to open the valves Notice To gain access to the cylinder head valves camshafts and cam drive components the engine must be removed from the frame see Chapter 5 ENGINE...

Страница 248: ...EH 6999 0062 Idler bearing remover installer EH 6999 0056 Universal driver EH 6999 0043 SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Cylinder compression Pressure 125 175 psi Variance 0 10 Cylinder hea...

Страница 249: ...seat Burnt or bent valve Valve stuck open Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Compression too high Carbon build up on piston or combustion chamber...

Страница 250: ...n with air 4 Remove the spark plugs 5 Connect a compression gauge to the front cylinder 1 COMPRESSION GAUGE 6 Make sure the transmission is in neutral 7 Make sure the engine Run Stop switch is set to...

Страница 251: ...body see THROTTLE BODY REMOVAL page 4 140 Notice Mark all components during disassembly so they can be installed in their original location 1 Blow the area around the spark plug clean with air and rem...

Страница 252: ...and the idler shaft O ring 1 TIMING COVER 2 COVER O RING 3 IDLER SHAFT O RING 11 Remove the oil scavenge pump 12 Remove and discard the input and output port O rings 13 Remove idler bearing carrier 1...

Страница 253: ...R IDLER GEAR 2 REAR LOWER IDLER GEAR 20 Remove the cam chain tunnel bolts 21 Loosen the cylinder head bolts gradually 1 8 1 4 turn increments in a cross pattern and remove them 22 Separate and remove...

Страница 254: ...remove the valve keepers and remove the valve keepers Tool Valve spring compressor EH 6999 0026 1 VALVE SPRING COMPRESSOR 3 Remove the valve spring retainer spring spring seat and valve 4 Remove the...

Страница 255: ...hold table height consistency 1 STRAIGHT EDGE 2 FEELER GAUGE 3 Inspect the lifter bores for wear or damage 4 Blow clean all oil passages making sure they are not plugged 1 OIL PASSAGE VALVE SPRING 1 M...

Страница 256: ...take 0 0030 in Exhaust 0 0045 in 1 VALVE STEM 2 If the valve to valve guide clearance exceeds the service limit determine if a new valve guide with standard dimensions would bring the clearance within...

Страница 257: ...rea 1 UNEVEN SEAT WIDTH 2 FACE DAMAGE 3 CONTACT AREA LOW 4 CONTACT AREA HIGH 8 Measure the valve seat width Notice Valve seat width should be even all the way around the valve Service Limit 0 045 in 9...

Страница 258: ...ginal location Tighten the bearing cap screws gradually and evenly in a diagonal pattern Torque 90 in lbs Notice Do not rotate the camshaft while using plastigauge 1 PLASTIGUAGE 2 CAMSHAFT JOURNAL 3 B...

Страница 259: ...e wear or damage or if any measurements are past the service limits see CAMSHAFT GEAR REPLACEMENT page 6 21 5 Inspect the cam gear teeth for wear and damage Replace if necessary see CAMSHAFT GEAR REPL...

Страница 260: ...ar and idler gear 1 GEAR TEETH 2 THICKNESS 8 Measure and record the gap between the idler gear bosses of the cylinder head 9 Subtract the idler gear thickness from the boss gap to determine the idler...

Страница 261: ...TENSIONER 1 Inspect the cam chain tensioner and its spring for wear or damage 2 Release the ratchet and check that the rod moves freely in the housing 3 Replace if necessary 1 SPRING 2 RATCHET 3 ROD 4...

Страница 262: ...etaining ring to remove a bearing from the bearing carrier Use the following tools to remove the inner bearings from the engine case Tool Inner idler bearing remover EH 6999 0063 Tool Transmission end...

Страница 263: ...o avoid injury use insulated gloves when handling a heated cylinder head 3 Drive the old valve guides out from the combustion chamber side of the cylinder head Tool Valve guide driver EH 6999 0025 1 1...

Страница 264: ...the seat Refinish the seat to the specified seat width with a 45 finish cutter Caution Grind the seat only as much as necessary to obtain the desired specification 2 Lap valve seat see LAPPING VALVE...

Страница 265: ...Caution Grind the seat only as much as necessary to obtain the desired specification 7 Lap valve seat see LAPPING VALVE SEAT page 6 19 1 NEW SEAT WIDTH LAPPING VALVE SEAT 1 Apply lapping compound to t...

Страница 266: ...m oil solution and carefully insert the valves into the valve guides Caution To avoid damaging the valve seal rotate the valve slowly while inserting 1 VALVE STEM 4 Install the valve spring and valve...

Страница 267: ...from cam lobe Rear intake 90 degrees from cam lobe 1 INTAKE CAM LOBE 2 FRONT CAM DOWEL POSITION 3 REAR CAM DOWEL POSITION Front exhaust in line with cam lobe Rear exhaust 70 degrees from cam lobe 5 In...

Страница 268: ...CHAIN TUNNEL BOLTS 2 9 Tighten the head bolts in the order shown to the initial torque Torque 10 ft lbs 10 Continue tightening the head bolts in the order shown to the intermediate torque Torque 20 ft...

Страница 269: ...move any slack in the cam chain and check the alignment of the timing index marks Adjust idler gear in the cam chain if necessary 1 IDLER GEAR TIMING MARK 2 INDEX MARK 22 Reset the cam chain tensioner...

Страница 270: ...ll the camshaft bearing caps and tighten the mounting bolts evenly in a diagonal sequence Torque 90 in lbs Notice To aid in returning the camshaft bearing caps to their original location they are cast...

Страница 271: ...e any slack in the cam chain and check the alignment of the timing index marks Adjust idler gear in the cam chain if necessary 1 IDLER GEAR TIMING MARK 2 INDEX MARK 39 Reset the cam chain tensioner by...

Страница 272: ...ring caps to their original location they are cast with a number that matches a number location cast in the cylinder head The arrow head near the number on the bearing cap should point toward the cams...

Страница 273: ...gasket and install the upper cam cover Tighten the mounting bolts in a crisscross pattern starting in the center Torque 12 ft lbs 56 Install spark plugs and ignition coils see IGNITION COILS SPARK PLU...

Страница 274: ...7 0 6999 0003 7 15 99 CYLINDER PISTON 7...

Страница 275: ...s of the cylinder or the piston during disassembly or assembly When servicing cylinders and pistons mark the disassembled parts to ensure they are reinstalled in their original location When reassembl...

Страница 276: ...000 in Standard 0 000 in 010 inch Oversize 0 000 in 020 inch Oversize Piston outer diameter 0 000 in Cylinder to piston clearance 0 000 in Piston ring clearance Compression ring 0 008 in Oil ring 0 00...

Страница 277: ...e Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and or piston Compression too high Carbon build up on piston or combustion chamber Excessive exhaust smoke Worn...

Страница 278: ...tionHold Used to hold table height consistency 4 Remove the fixed and movable cam chain guides Notice Mark all components during disassembly Front or Rear so they can be installed in their original lo...

Страница 279: ...in guide for deformed mounting holes and posts Replace as required 2 Inspect the tensioner pad portion of the movable cam chain guide for deformation Replace as required 1 MOUNTING HOLE 2 MOUNTING POS...

Страница 280: ...volatile cleaning solvent 1 GASKET MATERIAL 2 MACHINED SURFACES 3 CYLINDERS 3 Inspect the cylinder bore for burned spots scoring grooves scratches scuffing or uneven wear in the ring path area 1 INSP...

Страница 281: ...bore and or hone the cylinder to the next larger standard piston size This also requires refitting the cylinder with the next standard size piston and piston rings 1 Measure from front to rear and fro...

Страница 282: ...ead bolt Insert the feeler gauge between the metal scale and the cylinder base surface Repeat this measurement for each pair of adjacent head bolts Service Limit 0 008 in 1 CYLINDER BASE SURFACE 2 MET...

Страница 283: ...ls hone the bore to create an angular crosshatch pattern of 60 Caution An improper crosshatch pattern or too fine a hone may result in high engine oil consumption and piston seizure 1 Coat the cylinde...

Страница 284: ...n clips Caution Do not reuse piston pin clips The removal process can weaken them causing them to break or dislodge resulting in engine damage 5 Using the piston pin puller remove the piston pin from...

Страница 285: ...ing or melting burning and scoring 2 Inspect the edges of the piston domes for nicks or burrs Remove any defects with a light filing of the edge of the piston dome and buff smooth with a steel wool pa...

Страница 286: ...te text StepCaptionHold Used to hold table height consistency 1 OIL RING 2 COMPRESSION RING 1 3 COMPRESSION RING 2 4 Use a piston to press each piston ring squarely into the cylinder bore Remove the p...

Страница 287: ...ameter from the piston pin hole inner diameter Service Limit 0 000 in 1 PISTON PIN HOLE 2 PISTON PIN CONNECTING ROD PISTON PIN BUSHING 1 Measure and record the inner diameter of the piston pin bushing...

Страница 288: ...new piston pin bushing into the connecting rod and install the piston pin bushing tool into the connecting rod 3 Press in the new piston pin bushing 4 Drill 7 64 inch oil holes in top of bushing 5 Re...

Страница 289: ...xpander ring into the third ring groove StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 COMPRESSION RINGS 2 OI...

Страница 290: ...onHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 MOVABLE CAM CHAIN GUIDE 2 DOWEL PINS 3 CYLINDER BASE GASKET 7 Apply clean engine oil to the cylinder walls and...

Страница 291: ...are properly seated 11 Install the cylinder heads see CYLINDER HEAD CAM DRIVE INSTALLATION page 6 21 1 STATIONARY CAM CHAIN GUIDE StepCaptionHold For demonstration only StepCaptionHold These are BLIND...

Страница 292: ...8 0 6999 0003 7 15 99 CRANKCASE CRANKSHAFT 8...

Страница 293: ...L TORQUE VALUES TOOLS TROUBLESHOOTING SERVICE INFORMATION 8 1 TROUBLESHOOTING 8 1 Remove all fasteners from the left side of the crankcase holding the crankcase halves together 8 3 CRANKSHAFT 8 11 CON...

Страница 294: ...onsistency 1 ROAD SPEED SENSOR 2 CRANKSHAFT POSITION SENSOR 3 NEUTRAL SWITCH CRANKCASE SEPERATION Remove all fasteners from the right side of the crankcase holding the crankcase halves together Remove...

Страница 295: ...the way around the crankcase to loosen the bond between the mating surfaces of the crankcases to separate the crankcase halves StepCaptionHold For demonstration only StepCaptionHold These are BLIND wh...

Страница 296: ...kshaft Disassemble the rods from the crankshaft 1 OUTER SIDE RIGHT ROD 2 OUTER SIDE RIGHT ROD Install the rod cap onto the same rod immediately after removal with dimple on rod in alignment with dimpl...

Страница 297: ...need to be replaced 1 V BLOCKS 2 CRANKSHAFT 3 DIAL INDICATOR AND FREE STANDING BASE INSPECTION MAIN BEARING CRANKSHAFT Inspect the primary drive Left Case side crankshaft main bearing journal for scr...

Страница 298: ...damaged it will need to be turned down or replaced 1 12 AND 6 POSITION 2 3 AND 9 POSITION INSPECTION MAIN BEARING CRANKCASE Inspect the crankcase primary drive Left Case side main bearing for scratche...

Страница 299: ...mit or has scratches wear or is damaged it will need to be replaced and new bearings installed 1 TELESCOPING GAUGE 2 MICROMETER 3 2 AND 8 POSITION 4 4 AND 11 POSITION REPLACEMENT MAIN BEARING CRANKCAS...

Страница 300: ...RING REMOVER 2 UNIVERSAL DRIVER 3 HAND TORCH 4 PRESS OR HAMMER REPLACEMENT MAIN BEARING CRANKCASE INSTALLATION PRIMARY OR CAM DRIVE BEARING Caution The Crankshaft Bearing Installer has two different d...

Страница 301: ...ORT 2 MAIN BEARING Install the crankshaft bearing installer onto the universal handle driver Using a small hand torch heat the crankcase casting area around the bearing for approximately 4 to 5 minute...

Страница 302: ...cratches wear or is damaged it will need to be turned down or replaced and new bearings installed Rod bearings are available in the following sizes 0 00 in Standard 0 10 in 0 20 in 1 MICROMETER 2 12 A...

Страница 303: ...old Used to hold table height consistency 1 2 MAIN BEARING REPLACEMENT StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consi...

Страница 304: ...8 12 6999 0003 7 15 99 CRANKCASE CRANKSHAFT StepNumber StepNumber StepNumber StepNumber INSPECTION 1 2 CAM GEAR REPLACEMENT 1 2 OIL PUMP GEAR REPLACEMENT 1 2 INSTALLATION 1 2...

Страница 305: ...er StepNumber StepNumber CONNECTING RODS REMOVAL 1 2 INSPECTION OIL CLEARANCE 1 2 WRIST PIN CLEARANCE StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold...

Страница 306: ...NKCASE CRANKSHAFT StepNumber StepNumber StepNumber StepNumber INSTALATION 1 2 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table h...

Страница 307: ...6999 0003 7 15 99 8 15 StepNumber StepNumber StepNumber StepNumber 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height cons...

Страница 308: ...9 0 6999 0003 7 15 99 PRIMARY DRIVE 9 10794...

Страница 309: ...tion see Chapter 17 STARTER For additional Alternator service information see Chapter 16 BATTERY CHARGING SYSTEM For additional Clutch service information see Chapter 10 CLUTCH Caution Cleanliness is...

Страница 310: ...ator Remove the cable tie if necessary 7 If servicing the hydraulic clutch system remove the banjo bolt clutch hose and sealing washers Discard the sealing washers 8 Remove the outer primary cover scr...

Страница 311: ...see STATOR INSTALLATION page 16 9 1 INSERT INSTALLATION 1 Clean any remaining gasket material from the inner and outer primary covers 2 Make sure the two alignment pins are in position 3 Using a new...

Страница 312: ...0 3 10 Adjust the clutch freeplay see ADJUSTING CLUTCH FREEPLAY page 10 4 11 Install gear shifter assembly see GEAR SHIFTER INSTALLATION page 11 4 12 Fill the engine case with oil see ENGINE OIL page...

Страница 313: ...driven ramps Each ramp face should have a smooth gradual slope without ridges grooves or steps 2 Position the driven ramp on the crankshaft sleeve The ramp should rotate smoothly and evenly around th...

Страница 314: ...the four compensator springs are identical they must be installed in the orientation shown 5 Using an impact wrench install the spring retainer Tool Torsional compensator socket EH 6999 0041 Torque 80...

Страница 315: ...the engine case and inner primary cover 2 Make sure the two alignment pins are in position 3 Using new gaskets install the inner primary cover and tighten the cover mounting screws Torque 8 ft lbs No...

Страница 316: ...10 0 6999 0003 7 15 99 CLUTCH 10 10758...

Страница 317: ...the hydraulic system can damage brake system componants Do not use mineral based products to clean clutch cylinder parts Use only denatured alcohol DOT 5 hydrau lic fluid or a solvent specifically rec...

Страница 318: ...ufficient fluid in the master cylinder Contaminated hydraulic fluid System leak Clutch freeplay out of adjustment Clutch lever feels spongy when applied Air in the hydraulic system Contaminated hydrau...

Страница 319: ...ESERVOIR CAP 2 PLATE 3 DIAPHRAGM 5 Remove the clutch cover 6 Push one end of a piece of 3 16 I D clear tubing over the slave cylinder bleed valve Place the other end of the tube in a container filled...

Страница 320: ...esistance is felt piston is against outer retaining ring 5 Hold the inner jam nut and turn the adjustment screw counter clockwise until the inner jam nut is captured by the slave cylinder Continue tur...

Страница 321: ...PLATE 3 DIAPHRAGM 4 LEVER BOLT 5 LEVER ASSEMBLY 6 DUST BOOT 7 PUSH ROD 8 RETAINING RING 9 PISTON ASSEMBLY 10 RETURN SPRING INSPECTION 1 Clean all cylinder parts and blow out all fluid ports with compr...

Страница 322: ...ush the piston past the retaining ring groove in the cylinder bore 5 Install a new retaining ring with retaining ring pliers Notice Make sure the retaining ring is completely seated in the cylinder bo...

Страница 323: ...to the left side steering stop Adjust the turn signal assembly to the desired position and tighten the gimbal nut 6 Bleed the clutch system see BLEEDING CLUTCH SYSTEM page 10 3 1 GIMBAL NUT 2 BANJO B...

Страница 324: ...caliper housing with great force resulting in damage to the piston or personal injury Point the caliper away from you or others and wear heavy gloves or wrap the caliper housing in a heavy towel befor...

Страница 325: ...d port the clutch hose and both ends of the supply tube The machined surfaces must be absolutely free of damage If any damage is observed replace the component 1 CYLINDER BORE 2 PISTON 3 FLUID PORT 4...

Страница 326: ...system operation always use new sealing washers 5 Tighten the supply tube hex nut Torque 35 ft lbs Notice Make sure the head of the slave cylinder supply tube is properly seated in the outer primary c...

Страница 327: ...1 With the clutch collar installed in the clutch basket compress the diaphragm springs Tool Valve spring compressor EH 6999 0026 Tool Clutch compression adaptors EH 6999 0027 2 Remove the spring retai...

Страница 328: ...asteners for wear cracks or damage Replace components as necessary LIFT PLATE BEARING 1 Turn the inner race of the lift bearing with your finger The bearing should turn smoothly and quietly without ex...

Страница 329: ...ISC CLUTCH PLATES 1 Inspect the clutch plates for scoring and discoloration 2 Use a surface plate and a feeler gauge to measure the plate warpage Service Limit 008 in 3 Measure the clutch plate thickn...

Страница 330: ...tached to the clutch basket 1 COLLAR 2 CLUTCH BASKET 3 CLUTCH GEAR 5 Inspect the clutch basket dogs for scoring nicks notches or abnormal wear caused by the friction discs Replace components as necess...

Страница 331: ...tch basket 1 THRUST WASHER 2 HUB 3 CLUTCH BASKET 4 FRICTION DISC BROWN TAB 5 CLUTCH PLATE 6 FRICTION DISC GREEN TAB 7 FRICTION DISC BLUE TAB 8 SHALLOW DOG 11 Install the pressure plate spring seat and...

Страница 332: ...the belleville washer should contact the spring retainer 3 Hold the clutch basket stationary and install the clutch mounting nut Tool Clutch basket wrench EH 6999 0030 Torque 90 ft lbs 1 MOUNTING NUT...

Страница 333: ...CLUTCH NOTES 6999 0003 7 15 99 10 17...

Страница 334: ...11 0 6999 0003 7 15 99 TRANSMISSION 11 10822...

Страница 335: ...and cause serious eye injury To Avoid injury when removing or installing retaining rings always use the correct size and type retaining ring pliers and be sure the tips are not worn or damaged Notice...

Страница 336: ...ller EH 6999 0061 Shift shaft bearing tool EH 6999 0060 Output shaft seal installer EH 6999 0057 TROUBLESHOOTING Excessive noise Worn seized or damaged transmission gear Worn or damaged transmission b...

Страница 337: ...KET DISASSEMBLY 1 Remove the pinch screw from the front shift lever and remove the shift lever 2 Remove the shifter shaft from the pivot bracket 3 Remove the pinch screws from the foot peg levers and...

Страница 338: ...ker Torque 8 ft lbs 1 FOOT PEG LEVER 2 SHIFT SHAFT 3 FRONT SHIFT LEVER INSTALLATION 1 Install the rear shift lever on the transmission shift shaft as shown 2 Install the pinch screw with one drop of L...

Страница 339: ...ever and remove the shift lever 1 ACORN NUT 2 BALL JOINT 3 SHIFT LEVER 4 PINCH SCREW 8 Remove the transmission cassette plate screws 9 Carefully tap on the end of the output shaft with a wooden or pla...

Страница 340: ...from the output shaft 8 Remove the retaining ring needle bearing and washer from the input shaft 9 Remove the retaining ring washer and 5th gear from the input shaft 1 5TH GEAR OUTPUT 2 RETAINING RING...

Страница 341: ...transmission parts in solvent prior to inspection BEARINGS 1 Inspect the input end bearing race in right side engine case and the output end bearing race in cassette plate for grooves scoring or gall...

Страница 342: ...PUT MAIN BEARING 2 BEARING RETAINER 5 Inspect the shift drum bearing The inner race should turn smoothly and quietly and the shift drum should slide easily into the bearing without excess play 6 The o...

Страница 343: ...Output 3rd gear somethingO3 1 DOG 2 DOG HOLE 3 SPLINE 4 MEASURE I D SHAFTS 1 Check the spline grooves bearing surfaces and gear shoulders for damage and abnormal wear 2 Measure the shaft diameter in t...

Страница 344: ...Limit something 3 Inspect the shift fork shafts for deformation and abnormal wear Replace components as necessary 1 SHIFT CLAW 2 SHIFT DRUM PIN SHIFT MECHANISM 1 Inspect the stop stud detent arm all...

Страница 345: ...3 OUTER RETAINER 4 INNER RETAINER 5 CASSETTE PLATE Notice Coat the bearing surface of all gears bearings shafts and the shift drum grooves prior to assembly 5 Install 3rd gear the washer and the reta...

Страница 346: ...1 5TH GEAR OUTPUT 2 RETAINING RING 3 NEEDLE BEARING 4 WASHER 5 RETAINING RING 6 WASHER 7 5TH GEAR INPUT 15 Install the shift drum bearing Notice The shift drum bearing has a slip fit and should not re...

Страница 347: ...nput shaft and output shaft with an assembly lubricant 3 Carefully slide the transmission assembly into the engine case and install the cassette plate screws Torque 18 ft lbs Notice Make sure the cass...

Страница 348: ...ely 4 Remove the lower belt guard 1 SPROCKET COVER 2 LOWER BELT GUARD 5 Remove and discard the rear axle cotter pin 6 Loosen the castle nut 7 Loosen the rear axle adjuster jam nuts and turn the adjust...

Страница 349: ...ves scratches and pitting Replace components as necessary 1 SPLINES 2 SIDE PLATE 3 TEETH 4 SPACER 5 Inspect the sprocket cover grommets for cracks and brittleness Replace grommets as necessary 1 COVER...

Страница 350: ...2 ADJUSTER COLLAR 9 Install the lower belt guard Torque 5 ft lbs 10 Install the sprocket cover Torque 8 ft lbs 11 Install the exhaust system see EXHAUST SYSTEM INSTALLATION page 2 13 1 SPROCKET COVER...

Страница 351: ...unt aligned 8 Remove the right side mount spacer and mount 9 Remove the drive belt 1 NUT 2 SCREW 3 SHAFT 4 SPACER 5 MOUNT INSTALLATION 1 Place the drive belt on the front sprocket and feed it out the...

Страница 352: ...12 0 6999 0003 7 15 99 WHEELS 12 10736...

Страница 353: ...n those used on the front WARNING Riding on damaged wheels or tires impairs safe operation of this vehicle For brake system service see Chapter 15 BRAKES SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 2...

Страница 354: ...ed tire and wheel Loose axle fasteners Faulty swing cage pivot bearings see Chapter 14 REAR SUSPENSION Wheel rotation difficult Faulty wheel bearings Bent axle Brake drag see Chapter 15 BRAKES SPECIFI...

Страница 355: ...pacers and caliper bracket Notice Do not operate the front brake while the front wheel is removed Doing so will cause difficulty reinstalling the brake rotor between the brake pads 1 AXLE PINCH SCREW...

Страница 356: ...Standard Lateral 0 00 0 08 1 DIAL INDICATOR RADIAL 2 DIAL INDICATOR LATERAL BRAKE ROTOR 1 Place the wheel in a truing stand and measure the brake rotor runout Spin the wheel slowly and read the runou...

Страница 357: ...remove the spokes and rim from the hub 1 STAMPED TEXT 2 PUNCH ASSEMBLY 1 If hub was removed from wheel see LACING WHEEL page 12 12 2 Install a new bearing in the stamped text side of the hub with the...

Страница 358: ...pads during front wheel installation 3 Coat the axle with a thin film of molybdenum grease 4 Slide the axle all the way through the bevel washer rockers spacers bracket and wheel from the left side o...

Страница 359: ...cause difficulty reinstalling the brake rotor between the brake pads 10 Support the rear wheel from underneath and carefully push or pull the axle out to the right 11 Hold the caliper bracket in posit...

Страница 360: ...ateral 0 00 0 08 1 DIAL INDICATOR RADIAL 2 DIAL INDICATOR AXIAL BRAKE ROTOR 1 Place the wheel in a truing stand and measure the brake rotor runout Spin the wheel slowly and read the runout using a dia...

Страница 361: ...remove the spokes and rim from the hub 1 STAMPED TEXT 2 PUNCH ASSEMBLY 1 If hub was removed from wheel see LACING WHEEL page 12 12 2 Install a new bearing in the stamped text side of the hub with the...

Страница 362: ...he brake caliper bracket slot is in position on the swing cage tab 3 Place the axle spacers in position on the wheel Lift the rear wheel and spacers into the swing cage from behind Support the wheel f...

Страница 363: ...GAUGE 2 POINTER 3 Move the alignment gauge to the opposite location on the other side of the motorcycle 4 Without moving the alignment gauge pointer turn the rear axle adjuster in or out until the ce...

Страница 364: ...flange inner spokes counterclockwise as far as possible 3 Insert an outer spoke in each remaining lower flange spoke hole Swing all lower flange outer spokes clockwise as far as possible 1 STAMPED TEX...

Страница 365: ...hat point inward toward each other 1 RIM 2 SPOKE HOLE GROUP 10 9 Lace a lower flange outer spoke through the one hole in a spoke hole group that points toward the spoke 10 Lubricate the threads and sc...

Страница 366: ...age 12 14 1 UPPER FLANGE OUTER SPOKE HOLE 2 SPOKE HOLE GROUP 10 TRUING WHEEL 1 Mark the center of one of the ten spoke groups with a piece of tape 2 Mark the center of the spoke group directly across...

Страница 367: ...for all four marked spoke groups 1 SPOKE HOLE GROUP 2 SPOKES TO STAMPED TEXT FLANGE 9 Adjust the truing stand gauge to the tire bead seat 10 Spin the rim slowly If the rim contacts the gauge near a ma...

Страница 368: ...t the valve stem hole lubricate and tighten the remaining spoke nipples one turn at a time Torque 40 in lbs 1 GAUGE R Caution Do not tighten spokes too tight or damage to rim hub spokes or nipples may...

Страница 369: ...langes with a tire lubricant or liquid soap 5 Using tire irons and rim protectors start the upper bead over the edge of the rim at the valve stem Continue all around rim until first bead is entirely o...

Страница 370: ...sidewall it is the tire balance mark heaviest point and should be located next to the valve stem when the tire is mounted 4 Beginning at the valve stem hole place the first bead into the rim well Work...

Страница 371: ...is within the specified tolerance the tire is at fault and should be replaced 1 GAUGE LATERIAL RUNOUT 1 Mount the wheel assembly in a truing stand Slowly turn the wheel assembly and measure the amount...

Страница 372: ...p properly attached 2 Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel 3 Repeat this procedure two or three times to verify the heaviest area If the wheel is balanced it...

Страница 373: ...WHEELS NOTES 6999 0003 7 15 99 12 21...

Страница 374: ...13 0 6999 0003 7 15 99 FRONT SUSPENSION STEERING 13...

Страница 375: ...5 00 ft lbs Caliper rod mount screws 6 00 ft lbs Brake hose banjo bolt 7 00 ft lbs Suspension rocker bolts 8 00 ft lbs Steering stem lock nut 9 00 ft lbs Top triple clamp acorn nut 10 00 ft lbs Fork...

Страница 376: ...not track straight Damaged or loose steering head bearings Bent front fork Bent front struts Bent front axle Front wheel installed incorrectly Bent frame Worn or damaged front wheel bearings Worn or...

Страница 377: ...turn both cable adjusters to create slack in the cables Disconnect the cables from the hand grip and slide the hand grip off the handlebar Carefully allow the control assembly to hang by the throttle...

Страница 378: ...d or personal injury StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 RISER 2 HANDLEBAR KNURLED AREA 3 CLAMP Ti...

Страница 379: ...adequate travel Failure to insure proper operation could result in damage to the motorcycle and or personal injury 1 CABLE RETAINER 2 LEFT CONTROL ASSEMBLY 3 CLUTCH LEVER ASSEMBLY STRUTS REMOVAL Remov...

Страница 380: ...1 STRUT 2 FENDER MOUNTING SCREWS 4 3 TAPE Remove one of the strut axle end bolts Support the strut assembly opposite the remaining strut axle end bolt Pull the strut axle out only enough to release t...

Страница 381: ...TAINER 3 DAMPER UNIT HEAD 4 UPPER STRUT COVER 5 UPPER SPRING ISOLATOR Remove the lower spring isolator Stabilize the lower strut Use the flats at the base of the damper unit to unscrew it from the low...

Страница 382: ...ring isolator for cracks tears and brittleness Replace as needed 1 FREE LENGTH STRUT AXLE Place the strut axle in V blocks and measure the runout Notice Actual runout is 1 2 the total indicator readin...

Страница 383: ...ng upper spring isolator and upper strut cover Slide the spring retainer between upper spring cover and the damper unit head Decompress the strut spring 1 STRUT SPRING 2 SPRING RETAINER 3 DAMPER UNIT...

Страница 384: ...height consistency 1 STRUTS 2 RIGID FORK 3 TAPE 4 FENDER MONTING SCREWS 4 Install the brake caliper assembly by attaching the caliper rod mount to the rigid fork Torque Caliper rod mount screws 6 00 f...

Страница 385: ...tion only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 FORK Release any headlamp wire retainers and disconnect the headlamp wire from the main wir...

Страница 386: ...G HEAD INSPECTION TOP TRIPLE CLAMP Inspect the top triple clamp bushings Blow the bushings clean and dislodge any abrasive particles imbedded in the bushings A straight strut axle should pass easily t...

Страница 387: ...rests squarely on the spacers Measure the distance from the work surface to the bottom of one fork leg at the fork bearing center Label this dimension D1 Measure the remaining fork in the same manner...

Страница 388: ...uced vehicle control resulting in personal injury Hold the retaining nut and tighten the lock nut Tool Retaining nut socket XXXX XXX6 Torque Steering stem lock nut 9 00 ft lbs Check that the bearing p...

Страница 389: ...ary Inspect the lower bearing and lower bearing race for signs of wear such as cracks galling flat spots and metal filings mixed with the bearing grease Replace the lower bearing and race if necessary...

Страница 390: ...alent tool Be careful not to damage the fork or steering stem 1 ACORN NUT 2 STEERING STEM 3 LOWER TRIPLE CLAMP 4 LOWER BEARING SEAL 5 CHISEL INSTALLATION Pack the new lower bearing seal with wheel bea...

Страница 391: ...g head Contact only the outer race of the bearing pressing it squarely into the head until it seats Tool Bearing driver XXXX XXX3 StepCaptionHold For demonstration only StepCaptionHold These are BLIND...

Страница 392: ...14 0 6999 0003 7 15 99 REAR SUSPENSION 14...

Страница 393: ...999 0003 7 15 99 14 1 SERVICE INFORMATION GENERAL TORQUE VALUES TOOLS TROUBLESHOOTING SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 1 SHOCK ABSORBER 14 2 SWING CAGE 14 3 SPECIFICATIONS Unit inch ITEM ST...

Страница 394: ...epCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistency 1 2 REMOVAL StepCaptionHold For demonstration only StepCaptionHold...

Страница 395: ...Number StepNumber StepNumber StepNumber ASSEMBLY 1 2 INSTALLATION StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consistenc...

Страница 396: ...N StepNumber StepNumber StepNumber StepNumber PIVOT BEARING REPLACEMENT 1 2 INSTALLATION StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold...

Страница 397: ...999 0003 7 15 99 14 5 StepNumber StepNumber StepNumber StepNumber 1 2 StepCaptionHold For demonstration only StepCaptionHold These are BLIND white text StepCaptionHold Used to hold table height consis...

Страница 398: ...14 6 6999 0003 7 15 99 REAR SUSPENSION StepNumber 1 2...

Страница 399: ...REAR SUSPENSION 6999 0003 7 15 99 14 7...

Страница 400: ...15 0 6999 0003 7 15 99 BRAKES 15...

Страница 401: ...nation Use only DOT 5 silicone based hydraulic fluid from a sealed clean container Using the wrong hydraulic fluid or allowing contaminants into the hydraulic system can damage brake system componants...

Страница 402: ...ot yet seated Caliper piston seized or sticking Excessive brake pedal or lever travel Air in the hydraulic system Insufficient fluid in the master cylinder Contaminated hydraulic fluid System leak Act...

Страница 403: ...push one end of a piece of 3 16 I D clear tubing over the bleed valve Place the other end of the tube in a container filled with enough hydraulic fluid to cover the end of the tube 6 Pump the brake p...

Страница 404: ...4 BANJO BOLT 5 BRAKE HOSE 6 SEALING WASHER 7 HANDLEBAR CLAMP DISASSEMBLY 1 Clean the area around the reservoir cap and remove the reservoir cap plate and diaphragm Empty the reservoir of any remaining...

Страница 405: ...Clamp the master cylinder securely in a padded vise 2 Insert a new piston return spring into the master cylinder with the larger windings toward the brake hose port Caution For proper master cylinder...

Страница 406: ...w sealing washers 3 Connect the brake light wire harness 4 Install the turn signal assembly and tighten the turn signal gimbal nut finger tight 5 Install the mirror 6 Rotate the master cylinder assemb...

Страница 407: ...G PIN 4 BRAKE PAD 6 Inspect the brake rotor A heavily scored rotor should be replaced 7 Measure the thickness of the rotor in the brake pad contact area Replace the rotor if it has worn beyond the min...

Страница 408: ...ousing screws 5 Remove the caliper from the padded vise and separate the caliper housing 6 Remove the anti rattle spring 7 Remove and discard the cross port O ring StepCaptionHold For demonstration on...

Страница 409: ...re If there is evidence or scoring pitting or corrosion replace the caliper assembly 3 Inspect each piston If there is evidence of scoring pitting or corrosion replace the piston set 4 Inspect the bra...

Страница 410: ...r bore 2 Install a new dust seal in each cylinder bore 3 Lubricate each piston with clean DOT 5 hydraulic fluid and with the cupped end facing toward the brake pad carefully press the piston into the...

Страница 411: ...E 3 SEALING WASHER 4 CALIPER ROD 5 CALIPER ASSEMBLY REAR MASTER CYLINDER REMOVAL 1 Remove the front right foot support assembly 2 Remove the brake pedal clevis pin and cotter pin Discard the cotter pi...

Страница 412: ...UST SEAL 3 RESERVOIR CONNECTOR 4 RETAINING RING 5 SUPPLY PORT O RING 7 Remove the spring bellows 8 While compressing the spring loosen the jam nut and remove the rod clevis 9 Remove the clevis end spr...

Страница 413: ...aphragm piston dust boot and bellows for cuts tears and deterioration Replace items if necessary 1 SUPPLY PORT 2 BRAKE HOSE PORT 3 BRAKE HOSE FITTING 4 DIAPHRAGM 5 DUST BOOT 6 BELLOWS ASSEMBLY 1 Clamp...

Страница 414: ...er cylinder 14 Install a new retaining ring with retaining ring pliers 15 Install a new dust seal and connector O ring 16 Attach the diaphragm plate and cap to the fluid reservoir StepCaptionHold For...

Страница 415: ...the hose or caliper could occur 2 Use a large flat blade screwdriver or small pry bar against the old brake pads and spread the caliper pistons as far apart as possible 3 Remove the retaining ring and...

Страница 416: ...ting screws and slide the caliper forward and off of the brake rotor 1 BANJO BOLT 2 BRAKE HOSE 3 SEALING WASHER 4 MOUNTING SCREWS DISASSEMBLY 1 Clean brake dust from the caliper 2 Clamp the caliper se...

Страница 417: ...careful not to scratch the cylinder bore when removing the piston seals 10 Remove the bleed valve cover and the bleed valve 1 DUST SEAL 2 WIPER SEAL INSPECTION 1 Clean all caliper parts and blow out...

Страница 418: ...n procedures see REAR WHEEL DISASSEMBLY page 12 8 and see REAR WHEEL ASSEMBLY page 12 9 ASSEMBLY 1 Install a new wiper seal in each cylinder bore 2 Install a new dust seal in each cylinder bore 3 Lubr...

Страница 419: ...tall the two mounting screws Torque 35 ft lbs 2 Install the banjo bolt brake hose and new sealing washers Torque 18 ft lbs Caution For proper brake system operation always use new sealing washers 3 Bl...

Страница 420: ...16 0 6999 0003 7 15 99 BATTERY CHARGING SYSTEM 16...

Страница 421: ...ttery specifically designed for use in the Super X motorcycle Follow manufacturers instructions for proper preparation of the battery before installation WARNING The battery contains sulfuric acid whi...

Страница 422: ...current leakage and locate short if readings are high Test regulated voltage Test alternator output and inspect alternator stator and rotor if readings are low Test current balance Battery overchargin...

Страница 423: ...R 3 NEGATIVE CABLE 4 POSITIVE CABLE INSPECTION 1 Inspect the battery for leaks cracks or damage to the case Replace the battery if necessary Notice Over time the ends of the battery case may bow inwar...

Страница 424: ...w the battery to sit 1 2 hours before checking the charge Use a voltmeter to check the charge Repeat the charging cycle if the charge is less than the minimum Standard 12 8 V or more 1 BATTERY CHARGER...

Страница 425: ...RNATOR OUTPUT page 16 5 1 DC VOLTMETER 2 POSITIVE TERMINAL 3 NEGATIVE TERMINAL ALTERNATOR OUTPUT 1 Disconnect the wiring harness from the voltage regulator connector 2 Check the connector for corrosio...

Страница 426: ...ative battery cable 5 Connect the negative probe of the ammeter to the negative battery terminal Caution When using an ammeter set it to a high range initially Current that is higher than the selected...

Страница 427: ...ickup over the alternator wire 13 Start the engine run it at 3000 rpm Increase the load on the load tester as required to obtain a constant 13 0 volts 14 Record the current output The current output s...

Страница 428: ...nets 4 Clean the rotor using a petroleum based solvent and a clean dry cloth 1 ROTOR INSIDE 2 ROTOR TAPERED BORE ROTOR INSTALLATION 1 Slide the rotor onto the crankshaft WARNING When installing the ro...

Страница 429: ...sistance see ALTERNATOR STATOR page 16 6 1 STATOR STATOR INSTALLATION 1 Position the stator on the outer primary cover and route the stator wire above the stator as shown 2 Install the stator mounting...

Страница 430: ...bracket and install the mounting screws and locknuts Torque 8 ft lbs 2 Connect the regulator to the alternator and to the wire harness 3 Secure the connectors to the bottom frame tube with a new cable...

Страница 431: ...BATTERY CHARGING SYSTEM NOTES 6999 0003 7 15 99 16 11...

Страница 432: ...17 0 6999 0003 7 15 99 STARTER 17 10722...

Страница 433: ...starts the crankshaft accelerates and overtakes the starter crankshaft gear disen gaging the sprag clutch WARNING Disconnect the battery before servicing the starter motor or the starter relay TORQUE...

Страница 434: ...pen circuit Faulty ground Starter motor runs slowly Low battery voltage Faulty starter motor connection Faulty starter relay connection Faulty engine ground connection Faulty starter motor Starter mot...

Страница 435: ...n the starter motor while observing the ammeter Ignore the initial peak current value If the value is out of range a starter malfunction is likely Remove and inspect the starter motor see STARTER MOTO...

Страница 436: ...NDING BRUSHES INSPECTION Make sure no engine oil is present inside the starter motor casing COMMUTATOR 1 Clean with crocus cloth if needed Measure the diameter of the commutator in the brush contact a...

Страница 437: ...continuity between the brush holder base and each of the two field winding brush housings If the test fails replace the brush holder Standard No continuity 1 BRUSH HOLDER BASE 2 INSULATOR 3 FIELD WIN...

Страница 438: ...that the transmission is in neutral and remove the ignition coils from the spark plugs 4 Move the engine run stop switch to the Run position and the main switch to the On position 5 Press the starter...

Страница 439: ...cables and wiring harness to the starter relay 3 Install the electronics cover and mounting screws Torque 5 ft lbs 4 Install the muffler and exhaust assembly see EXHAUST SYSTEM INSTALLATION page 2 13...

Страница 440: ...ree of grooves or brinelling chatter marks 2 Inspect the sprag cams They should move freely in all directions The sprag housing should retain the cams at all times 1 SPRAG INNER RACE 2 SPRAG OUTER RAC...

Страница 441: ...PIN 3 GASKET 4 INNER PRIMARY COVER 5 If removed assemble the starter gear and sprag outer race if required and fasten the screws Torque 55 in lbs 6 Lightly lubricate the sprag cams with an assembly lu...

Страница 442: ...install the starter gear sprag clutch assembly on the crankshaft 8 Install the clutch see CLUTCH INSTALLATION page 10 16 9 Install the torsional compensator see TORSIONAL COMPENSATOR INSTALLATION page...

Страница 443: ...STARTER NOTES 6999 0003 7 15 99 17 11...

Страница 444: ...18 0 6999 0003 7 15 99 LIGHTS GAUGES SWITCHES 18...

Страница 445: ...LATION 18 14 TAIL LAMP 18 14 BULB REPLACEMENT 18 14 REMOVAL 18 14 INSTALLATION 18 15 TURN SIGNAL CONTROL MODULE18 15 REMOVAL 18 14 INSTALLATION 18 16 TURN SIGNAL LAMPS 18 16 BULB REPLACEMENT 18 16 FRO...

Страница 446: ...g screw 35 ft lbs Tail lamp mounting screw 7 ft lbs Front turn signal gimbal nut 10 ft lbs Rear turn signal mounting screw 20 ft lbs Horn cover nut 8 ft lbs Horn mounting screw 22 in lbs Neutral switc...

Страница 447: ...not work Faulty horn Blown horn fuse Faulty wiring Turn signals do not work Faulty bulb Faulty turn signal control module Faulty wiring Fault turn signal switch Tail lamp does not work Faulty bulb Blo...

Страница 448: ...DLEBAR CONTROL REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Remove the fuel tank see FUEL TANK REMOVAL page 4 127 3 Remove the handlebar wire clips and steerin...

Страница 449: ...for continuity between the switch input P25A C and ground P25A D with the switch set to Run and Stop If the test fails replace the right handlebar control Standard Run Continuity Stop No Continuity 1...

Страница 450: ...Install the control body on the handlebar and fasten the screws Torque 20 in lbs Notice Place the tab on the control body into the hole in the handlebar 1 ALIGNMENT HOLE 2 Route the handlebar control...

Страница 451: ...als Horn button powered through the horn fuse and controls power to the horn REMOVAL 1 Disconnect the battery negative cable first see BATTERY REMOVAL page 16 3 2 Remove fuel tank see FUEL TANK REMOVA...

Страница 452: ...beam Switch power P23B A Low beam output P23B C If the test fails replace the left handlebar control Standard Continuity 1 LOW BEAM 2 HIGH BEAM TURN SIGNAL SWITCH Test for continuity between the foll...

Страница 453: ...fasten the harness P clip 3 Connect the wiring harness to the left handlebar control left turn signal and head lamp dimmer switch 1 HARNESS ROUTING 4 Move handlebars from stop to stop to verify free...

Страница 454: ...sion or damage Clean or repair as needed 3 Test for continuity Switch position Off If the test fails replace the main switch Switch power P29B A and Accessory P29B B Switch power P29B A and On P29B C...

Страница 455: ...r The front brake switch is powered by the Lights fuse and controls the brake lamp REMOVAL 1 Disconnect the two wires from the brake switch 2 Remove the screw that secures the switch to the front brak...

Страница 456: ...ake lines Add brake fluid or bleed the brakes if necessary see BLEEDING BRAKE SYSTEM page 15 3 1 With the switch mounted on the motorcycle disconnect the two wires Test for continuity between the swit...

Страница 457: ...5 feet away from a wall 2 Turn the motorcycle main switch to On and the headlamp dimmer switch to high beam 3 The headlamp beam should shine straight ahead with the top of the beam even with the cente...

Страница 458: ...or is located under the seat BULB REPLACEMENT 1 Remove the lens screws and lens from the brake lamp housing 2 Remove the tail lamp bulb or license plate lamp bulb 3 Install the new tail lamp bulb Stan...

Страница 459: ...ail lamp housing Torque 7 ft lbs 2 Route the tail lamp harness and fasten it to the wire clips 3 Assemble the tail lamp connector Install the pins and the locking wedge Pin 1 Blue tail lamp Pin 2 Yell...

Страница 460: ...3 Install the fuel tank see FUEL TANK INSTALLATION page 4 123 4 Connect the battery positive cable first see BATTERY INSTALLATION page 16 4 TURN SIGNAL LAMPS The front turn signal lamps are combinatio...

Страница 461: ...rn signal gimbal nut and remove the turn signal Remove harness ties as needed under the fuel tank and remove the turn signal lamp 1 TURN SIGNAL 2 TURN SIGNAL CONNECTOR INSTALLATION 1 Install the turn...

Страница 462: ...n 3 Violet left turn signal Pin 6 Black left turn signal ground Pin 4 Violet right turn signal taped Pin 5 Black right turn signal ground taped 1 PIN 3 VIOLET 2 PIN 4 VIOLET 3 PIN 5 BLACK 4 PIN 6 BLAC...

Страница 463: ...STALLATION page 2 11 6 Connect the battery positive cable first see BATTERY INSTALLATION page 16 4 HORN REMOVAL 1 Disconnect the wiring harness from the horn 2 Remove the screws that secure the horn a...

Страница 464: ...e and inspect the neutral switch see NEUTRAL SWITCH INSPECTION page 18 20 If the neutral indicator lamp does not illuminate inspect the instrument cluster wiring and the neutral indicator lamp bulb se...

Страница 465: ...closed and the low oil pressure indicator lamp is illuminated As the oil pressure rises to normal operating levels the switch opens and extinguishes the indicator lamp While the engine is running if...

Страница 466: ...cator lamp does not illuminate inspect the oil pressure switch wiring and the indicator bulb see INSTRUMENT CLUSTER BULB REPLACEMENT page 18 23 INSTALLATION 1 Install the oil pressure switch Torque 12...

Страница 467: ...ANSI 1061 Fuel gauge lighting Standard ANSI 1061 Low Fuel Indicator Standard ANSI 1063 4 Install the instrument cluster see INSTRUMENT CLUSTER INSTALLATION page 18 23 1 SPEEDOMETER 2 INDICATOR LAMPS 3...

Страница 468: ...t secure the electronics cover and remove the cover 4 Open the circuit breaker boot and disconnect the circuit breaker wires Clean ring connectors and breaker posts as needed 5 Remove the screws that...

Страница 469: ...tach the fuse block to the frame 5 Install the tandem and rider s saddle see SADDLE INSTALLATION page 2 3 1 FUSE BLOCK COVER 2 LIGHTS 15A 3 HORN 10A 4 IGNITION 5A 5 AUXILIARY LIGHTS 10A 6 FUEL PUMP 10...

Страница 470: ...12 volts remove the accessory relay and perform a continuity test see RELAYS CONTINUITY TEST page 18 27 1 MAIN SWITCH 2 LIGHTS FUSE IGNITION RELAY 1 With the engine stop run switch in the Stop positio...

Страница 471: ...witch input pin 30 and the output pin 87 If there is no continuity replace the relay INSTALLATION 1 Apply a small amount of silicon grease to the terminals and insert the relay in the connector 2 Inst...

Страница 472: ...18 28 6999 0003 7 15 99 LIGHTS GAUGES SWITCHES...

Страница 473: ...Light Brake Light Turn Signal Left Turn Signal Right Ground D4 A1 A2 B1 B2 B3 B4 D1 G1 E1 E2 E3 E4 F1 F2 F4 H4 G4 H1 H2 H3 D2 A1 A2 B2 C4 D1 E1 F3 G3 H4 G4 H1 1 2 3 1 2 A B C D 86 87 85 30 K J H G F E...

Страница 474: ...WIRING SCHEMATIC NOTES 19 2 6999 0003 7 15 99...

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