Cable and Chassis Lubrication 138

General 1-38

Cables and Hand Levers 1 -38

Jiffy Stand 1-38

1.21 Throttle Cables 1-39

Cable Inspection, Lubrication and Adjustment 1-39

Inspection and Lubrication 1-39

Adjustment 1 -39

Fuel System Lines and Fittings 1-39

1.22 Valve Lash 1-40

Lash Measurement 1-40

Verify Cam Timing 1-44

Lash Adjustment 1-44

1.23 Secondary Cam Chain 1-50

General 1-50

Adjustment 1 -50

1.24 Headlamp Alignment 1-53

Inspection 1-53

1.25 Critical Fasteners 1-54

Inspection 1-54

1.26 Storage 1-55

Preparation for Storage 1-55

Removal from Storage 1-56

1.27 Troubleshooting 1-57

General 1-57

Engine 1-57

Starter Motor Does Not Operate/Turn Over 1-57

Engine Turns Over But Does Not Start 1-57

Starts Hard 1-57

Starts But Runs Irregularly or Misses 1-57

A Spark Plug Fouls Repeatedly 1-58

Pre-lgnition or Detonation (Knocks or Pings) 1-58

Overheating 1-58

Valve Train Noise 1-58

Excessive Vibration 1-58

Check Engine Light Illuminates During Operation 1-58

Lubrication System 1-58

Engine Uses Oil or Smokes Excessively 1-58

Engine Leaks Oil from Cases, Hoses, Etc 1-58

Low Oil Pressure 1-59

High Oil Pressure 1-59

Electrical System 1 -59

Alternator Does Not Charge 1 -59

Alternator Charge Rate Is Below Normal 1-59

Speedometer Operates Erratically 1-59

Transmission 1-59

Shifts Hard 1-59

Jumps Out of Gear 1-59

Clutch Slips 1-59

Clutch Drags or Does Not Release 1-59

Clutch Chatters 1-59

Handling 1-60

Irregularities 1-60

Brakes 1-60

Brake Does Not Hold Normally 1-60

SECTION 2-CHASSIS

2.1 Specifications 2-1

2.2 Torque Values 2-2

2.3 Vehicle Identification Number (V.I.N.) 2-5

General 2-5

2.4 Frame/Lower Frame Rails 2-6

General 2-6

Removal 2-7

Installation 2-7

2.5 Front Engine Mount 2-8

Replacement 2-8

2.6 Front Engine Mount Assembly 2-9

Removal 2-9

Disassembly and Assembly 2-9

Installation 2-9

2.7 Exhaust System 2-11

Removal 2-11

Installation 2-12

2.8 Rear Engine Mounts 2-13

Removal 2-13

Installation 2^13

2.9 Engine Replacement 2-14

General 2-14

Removal 2-14

Installation 2-20

2.10 Jiffy Stand 2-23

Cleaning 2-23

Removal 2-24

Installation 2-24

2.11 Footrests/Foot Controls 2-25

Rider Footrests 2-25

Removal 2-25

Installation 2-25

Passenger Footrests 2-25

Removal 2-25

Installation 2-25

2.12 Throttle Cables 2-27

Removal/Disassembly 2-27

Cleaning and Inspection 2-27

Assembly and Installation 2-28

2.13 Clutch Master Cylinder/Reservoir 2-29

General 2-29

Removal 2-29

Disassembly 2-30

Assembly 2-31

Installation 2-31

2.14 Clutch Hand Lever 2-32

installation 2-32

2.15 Clutch Fluid Line 2-33

Removal 2-33

Installation 2-33

2.16 Secondary Clutch Actuator 2-34

Removal 2-34

Disassembly 2-34

Assembly 2-34

Installation 2-35

2.17 Front Brake Master Cylinder/Reservoir 2-36

General 2-36

Removal and Disassembly 2-37

Cleaning and Inspection 2-38

Assembly 2-38

Installation 2-39

2.18 Front Brake Calipers 2-40

Removal 2-40

Disassembly 2-41

Cleaning, Inspection and Repair 2-42

Assembly 2-42

Installation 2-43

2.19 Rear Brake Master Cylinder/Reservoir 2-45

Removal 2-45

Disassembly 2-47

Cleaning and Inspection 2-48

Assembly 2-48

Installation 2-50

2.20 Rear Brake Caliper 2-51

Removal 2-51

Disassembly 2-51

Cleaning, Inspection and Repair 2-53

Assembly 2-54

Installation 2-55

2.21 Handlebars 2-56

Removal 2-56

Installation 2-57

2.22 Front Wheel 2-58

General 2-58

Preliminary Inspection - Brake Discs 2-58

Preliminary Inspection - Wheel/Tire 2-58

Removal 2-59

Disassembly 2-60

Cleaning and Inspection 2-60

Assembly 2-60

Installation 2-61

2.23 Rear Wheel 2-62

General 2-62

Preliminary Inspection - Brake Disc 2-62

Preliminary Inspection - Wheel/Tire 2-62

Removal 2-63

Disassembly 2-64

Cleaning and Inspection 2-64

Assembly 2-65

Installation 2-66

2.24 Sealed Wheel Bearings 2-67

General 2-67

Inspection - Lateral End Play 2-67

Removal 2-68

Installation 2-69

2.25 Disc Rim Runout 2-70

General 2-70

Lateral Runout 2-70

Radial Runout 2-70

2.26 Tires 2-71

General 2-71

Demounting Tires 2-71

Cleaning and Inspection 2-72

Tire Replacement 2-72

Mounting Tires 2-73

Tire Runout 2-74

Lateral Runout 2-74

Radial Runout 2-74

Wheel Balancing 2-75

2.27 Front Fender 2-76

Removal 2-76

Installation 2-76

2.28 Front Fork 2-77

Removal 2-77

Disassembly 2-77

Cleaning and Inspection 2-78

Assembly 2-80

Installation 2-81

2.29 Steering Head 2-82

Removal 2-82

Cleaning and Inspection 2-83

Lower Fork Stem Bearing 2-83

Steering Head Bearing Race 2-83

Assembly 2-84

Installation 2-84

2.30 Fork Lock 2-85

General 2-85

Removal 2-85

Installation 2-85

2.31 Belt Guard/Debris Deflector 2-86

Removal 2-86

Belt Guard 2-86

Debris Deflector 2-86

Installation 2-86

Belt Guard 2-86

Debris Deflector 2-86

2.32 Rear Shock Absorbers 2-87

Removal 2-87

Installation 2-87

2.33 Rear Fork 2-89

Removal 2-89

Disassembly 2-90

Assembly 2-90

Installation 2-91

2.34 Seat Latch 2-92

Replacement 2-92

2.35 Seat 2-93

Removal 2-93

Cleaning and Inspection 2-93

Installation 2-94

2.36 Rear Fender/Supports 2-95

Removal 2-95

Installation 2-96

Installation 2-96

SECTION 3-ENGINE

3.1 Specifications 3-1

3.2 Service Wear Limits 3-6

General 3-6

3.3 Torque Values (table) 3-7

General 3-8

3.5 Oil Pressure 3-12

Oil Pressure Indicator Lamp 3-12

Checking Oil Pressure 3-12

3.6 How To Use This Section 3-13

Top End Repair 3-13

Bottom End Repair 3-13

Typical Symptoms 3-13

3.7 Troubleshooting 3-14

Diagnosing Valve Train Noise 3-14

Compression Test 3-14

Cylinder Leakage Test 3-15

Diagnosing Smoking Engine or High Oil Consumption 3-15

Check Prior to Cylinder Head Removal 3-15

Check After Cylinder Head Removal 3-15

3.8 Stripping Motorcycle For Service ..3-16

General 3-16

Engine Cradle and Stand 3-17

3.9 Throttle Body 3-18

Removal 3-18

Installation 3-19

3.10 Top End Disassembly 3-20

Cam Drive Removal 3-20

3.11 Cylinder Head Service 3-26

General 3-26

Removal and Disassembly 3-26

Procedure for Using the Neway Valve Seat Cutter 3-32

Head Assembly 3-34

3.12 Oil Pump 3-36

Replacement 3-36

3.13 Clutch 3-38

Removal 3-38

Disassembly 3-42

Cleaning and Inspection 3-43

Assembly 3-43

Installation 3-47

3.14 Upper and Lower

Crankcase Service 3-50

Disassembly 3-50

Shift Drum Removal 3-55

Assembly 3-57

3.15 Counterbalancer Bearing Replacement 3-65

Removal 3-65

Installation 3-68

3.16 Crankshaft Bearing Replacement 3-71

General 3-71

Alternator Side 3-71

Clutch Side 3-72

3.17 Shift Shaft and Seal 3-73

General 3-73

Removal 3-73

Installation 3-74

3.18 Crankshaft, Piston and

Cylinder Liner 3-75

General 3-75

3.19 Oil Filter Mount 3-89

Replacement 3-89

3.20 Cam Drive 3-90

Assembly 3-90

3.21 Cylinder Heads 3-93

General 3-93

Installation 3-93

3.22 Installing and Timing the Cams... 3-95

Procedure 3-95

SECTION 4-FUEL SYSTEM

4.1 Specifications 4-1

Torque Values 4-1

4.2 Fuel Pump/Filters/Fuel Level Sender Assembly 4-2

Removal 4-2

Installation 4-4

Suction Side Fuel Filter 4-5

Pressure Side Fuel Filter 4-5

Removal 4-5

Installation 4-5

Fuel Pump 4-6

General 4-6

Removal 4-6

Installation 4-6

Fuel Level Sender 4-6

Removal 4-6

Installation 4-6

4.3 Fuel Tank 4-7

Removal 4-7

Cleaning and Inspecting 4-7

Installation 4-8

4.4 Vapor Valve 4-9

General 4-9

Replacement 4-9

Resistive Plug 4-9

4.5 Evaporative Emissions Control-CA Models 4-10

General 4-10

Purge Solenoid 4-11

Removal 4-11

Installation 4-11

Vapor Valve 4-11

Charcoal Canister 4-12

Removal/Inspection 4-12

Installation 4-12

Hose Routing 4-13

SECTION 5-ELECTRIC STARTER

5.1 Specifications 5-1

Torque Values 5-1

5.2 Electric Starter System 5-2

General 5-2

Wiring Diagrams 5-2

Starter Relay 5-2

Starter 5-2

Starter Solenoid 5-2

Operation 5-2

5.3 Starter Relay 5-4

Removal 5-4

Installation 5-5

5.4 Starter 5-6

Removal 5-6

Installation 5-6

5.5 Starter Solenoid 5-7

General 5-7

Removal 5-7

Installation 5-7

SECTION-6 COOLING SYSTEM

6.1 Specifications 6-1

Torque Values 6-1

Torque Values 6-2

6.2 Coolant Flow 6-2

General 6-2

Description 6-2

Troubleshooting 6-4

Low Engine Temperature 6-4

High Engine Temperature 6-4

Coolant Leaks 6-4

Pressure Cap 6-4

Pressure Cap Test 6-5

System Pressure Test 6-6

Leak Detection Dye Test 6-7

Tests for Blown Gasket 6-7

6.3 Engine Coolant 6-8

General 6-8

Changing Coolant 6-8

6.4 Thermostat 6-10

General 6-10

Removal 6-10

Installation 6-11

6.5 Water Pump 6-12

Removal 6-12

Installation 6-13

6.6 Coolant Pipes and Hoses 6-14

Removal 6-14

Disassembly 6-14

Assembly 6-16

Installation 6-16

6.7 Oil Line Fittings 6-17

Removal 6-17

Installation 6-17

6.8 Radiator/Oil Cooler 6-18

General 6-18

Removal 6-18

Installation 6-20

6.9 Oil Cooler 6-21

Removal 6-21

Installation 6-21

SECTION 7-TRANSMISSION

7.1 Specifications 7-1

Torque Values 7-1

7.2 Output Shaft 7-2

General 7-2

Disassembly - 2nd Gear End 7-2

Bearing Removal - 2nd Gear End 7-2

Bearing Installation - 2nd Gear End 7-3

Assembly - 2nd Gear End 7-6

Bearing Removal - 1st Gear End 7-7

Bearing Installation - 1st Gear End 7-7

Assembly - 1st Gear End 7-9

7.3 Input Shaft 7-11

Disassembly - 2nd Gear End 7-11

Bearing Removal - 2nd Gear End 7-11

Bearing Installation - 2nd Gear End 7-11

Assembly - 2nd Gear End 7-14

Disassembly -1 st Gear End 7-16

Bearing Removal - 1st Gear End 7-16

Assembly -1 st Gear End 7-16

Bearing Installation - 1st Gear End 7-16

SECTION 8-ELECTRICAL

8.1 Specifications 8-1

Torque Values 8-2

8.2 Bulb Requirements 8-3

General 8-3

8.3 Relay/Fuse Block 8-4

General 8-4

Relay/Fuse Block Removal 8-4

Fuse Replacement 8-4

Relay Replacement 8-4

Relay/Fuse Block Installation 8-5

8.4 Crank Position Sensor: CKP 8-6

General 8-6

Removal 8-6

Installation 8-6

8.5 Maxi-Fuse 8-7

Replacement 8-7

8.6 Ignition/Light Switch 8-8

General 8-8

Replacement 8-8

8.7 Alternator 8-9

General 8-9

Removal 8-9

Installation 8-10

8.8 Voltage Regulator 8-11

General 8-11

Removal 8-11

Installation 8-12

8.9 Battery 8-13

General 8-13

Battery Electrolyte Antidote (table) 8-13

Battery Testing 8-13

Voltmeter Test (table) 8-13

Battery Disconnection And Removal 8-14

Cleaning And inspection 8-15

Battery Charging 8-15

Safety Precautions 8-15

Charging Battery 8-15

Battery Charging Rates/Times (table) 8-16

Battery Installation And Connection 8-16

Battery Storage 8-17

8.10 Battery Cables 8-18

General 8-18

Negative Cable Replacement 8-18

8.11 Headlamp 8-19

General 8-19

Headlamp Bulb 8-20

Removal 8-20

Installation 8-20

Headlamp Lens\ 8-20

Removal 8-20

Installation 8-20

8.12 Tail Lamp 8-21

Removal 8-21

Installation 8-22

8.13 Turn Signals/Running Lights 8-23

Bulb Replacement 8-23

Lamp Replacement 8-23

General 8-23

Front Turn Signals 8-23

Rear Turn Signals 8-24

8.14 Turn Signal Security Module:

TSSM 8-25

General 8-25

Removal 8-25

Installation 8-25

8.15 Instrument Cluster 8-26

General 8-26

Removal 8-26

Installation 8-27

8.16 Vehicle Speed Sensor: VSS 8-28

General 8-28

Removal 8-28

Installation 8-28

8.17 Neutral Switch 8-29

General 8-29

Removal 8-29

Installation 8-29

8.18 Oil Pressure Switch 8-30

General 8-30

Removal 8-30

Installation 8-31

8.19 Stop Light Switch 8-32

General 8-32

Removal 8-32

Installation 8-32

8.20 Horn 8-33

Inspection 8-33

Replacement 8-33

8.21 Cooling Fans 8-34

General 8-34

Removal 8-34

Installation 8-35

SECTION 9-FUEL INJECTION

9.1 Specifications 9-1

Torque Values 9-2

9.2 Electronic Fuel Injection: EFI 9-3

General 9-3

Troubleshooting 9-3

9.3 Electronic Control Module: ECM 9-5

General 9-5

Removal 9-5

Installation 9-5

9.4 Throttle Position Sensor: TP 9-6

General 9-6

Removal 9-6

Installation 9-6

9.5 Intake Air Temperature Sensor: IAT.9-7

General 9-7

Removal 9-7

Installation 9-7

9.6 Engine Coolant Temperature Sensor: ECT 9-8

General 9-8

Removal 9-8

Installation 9-8

9.7 Idle Air Control: IAC 9-9

General 9-9

Removal 9-9

Installation 9-10

9.8 Manifold Absolute Pressure Sensor: MAP 9-11

General 9-11

Removal 9-11

Installation 9-11

9.9 Fuel Rail/Fuel Injectors 9-12

General 9-12

Removal 9-12

Disassembly 9-12

Fuel Injectors 9-12

Fuel Pressure Regulator 9-12

Fuel Tubes 9-12

Assembly 9-13

Fuel Injectors 9-13

Fuel Pressure Regulator 9-13

Fuel Tubes 9-13

Installation 9-13

9.10 Fuel Pressure Test 9-14

General 9-14

Testing 9-14

9.11 Intake Leak Test 9-16

General 9-16

Leak Tester 9-16

Parts List 9-16

Tester Assembly 9-16

Intake Leak Testing 9-17

APPENDIX A-TOOLS

APPENDIX B-WIRING

B.1 Amp Multilock Electrical Connectors B-1

Removing Socket/Pin Terminals B-1

Installing Socket/Pin Terminals B-1

Crimping Instructions B-4

B.2 Deutsch Electrical Connectors B-5

General B-5

Removing/Disassembling B-5

Removing/Installing Sockets B-5

Removing/Installing Pins B-6

Assembling/Installing B-7

Crimping Instructions B-8

B.3 Mini-Deutsch Connectors B-10

General B-10

Crimping Instructions B-10

B.4 Sealed Butt Splice Connectors B-12

Installation B-12

B.5 Packard Electrical Connectors B-13

General B-13

Pull-to-Seat Terminals B-14

Push-to-Seat Terminals B-14

Crimping Instructions B-15

B.6 Packard ECM Connector B-17

Crimping Instructions B-18

B.7 Connector Locations B-19

B.8 Index To Wiring Diagrams B-21

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