General Information

MOTORCYCLE IDENTIFICATION 1-1

VEHICLE IDENTIFICATION NUMBER 1-1

MODEL LABEL 1-1

FEATURES 1-2

OUTLINE OF FI SYSTEM 1-2

FI SYSTEM 1-3

INSTRUMENT FUNCTION 1-4

IMPORTANT INFORMATION 1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-7

REPLACEMENT PARTS 1-7

GASKETS, OIL SEALS AND O-RINGS 1-7

LOCK WASHERS/PLATES AND COTTER PINS 1-8

BEARINGS AND OIL SEALS 1-8

CIRCLIPS 1-8

CHECKING THE CONNECTIONS 1-9

SPECIAL TOOLS 1-10

CHAPTER 2 SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1

ENGINE SPECIFICATIONS 2-2

CHASSIS SPECIFICATIONS 2-11

ELECTRICAL SPECIFICATIONS 2-15

CONVERSION TABLE 2-18

GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-18

TIGHTENING TORQUES 2-19

ENGINE TIGHTENING TORQUES 2-19

CHASSIS TIGHTENING TORQUES 2-22

LUBRICATION POINTS AND LUBRICANT TYPES 2-24

ENGINE 2-24

CHASSIS 2-25

COOLING SYSTEM DIAGRAMS 2-26

ENGINE OIL LUBRICATION CHART 2-30

LUBRICATION DIAGRAMS 2-31

CABLE ROUTING 2-37

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 3-1

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM 3-1

GENERAL MAINTENANCE AND LUBRICATION CHART 3-1

SEATS 3-3

FUEL TANK 3-4

REMOVING THE FUEL TANK 3-5

REMOVING THE FUEL PUMP 3-5

INSTALLING THE FUEL PUMP 3-6

INSTALLING THE FUEL TANK 3-6

COWLINGS 3-7

INSTALLATION 3-8

AIR FILTER CASE 3-9

ADJUSTING THE VALVE CLEARANCE 3-10

SYNCHRONIZING THE THROTTLE BODIES 3-16

ADJUSTING THE ENGINE IDLING SPEED 3-18

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-19

CHECKING THE SPARK PLUGS 3-21

MEASURING THE COMPRESSION PRESSURE 3-22

CHECKING THE ENGINE OIL LEVEL 3-24

CHANGING THE ENGINE OIL 3-25

MEASURING THE ENGINE OIL PRESSURE 3-27

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-29

CLEANING THE AIR FILTER ELEMENT 3-30

CLEANING THE AIR INTAKE SYSTEM SURGE TANKS 3-31

CHECKING THE THROTTLE BODY JOINTS 3-31

CHECKING THE FUEL AND BREATHER HOSES 3-32

CHECKING THE CRANKCASE BREATHER HOSE 3-32

CHECKING THE EXHAUST SYSTEM 3-33

CHECKING THE COOLANT LEVEL 3-33

CHECKING THE COOLING SYSTEM 3-34

CHANGING THE COOLANT 3-35

CHASSIS 3-39

ADJUSTING THE FRONT BRAKE 3-39

ADJUSTING THE REAR BRAKE 3-40

CHECKING THE BRAKE FLUID LEVEL 3-41

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-42

CHECKING THE FRONT AND REAR BRAKE PADS 3-43

CHECKING THE FRONT AND REAR BRAKE HOSES 3-43

BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-44

ADJUSTING THE SHIFT PEDAL 3-45

ADJUSTING THE DRIVE CHAIN SLACK 3-46

LUBRICATING THE DRIVE CHAIN 3-47

CHECKING AND ADJUSTING THE STEERING HEAD 3-48

CHECKING THE FRONT FORK 3-50

ADJUSTING THE FRONT FORK LEGS 3-51

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-53

CHECKING THE TIRES 3-55

CHECKING THE WHEELS 3-57

CHECKING AND LUBRICATING THE CABLES 3-58

LUBRICATING THE LEVERS AND PEDALS 3-58

LUBRICATING THE SIDESTAND 3-58

LUBRICATING THE REAR SUSPENSION 3-58

ELECTRICAL SYSTEM 3-59

CHECKING AND CHARGING THE BATTERY 3-59

CHECKING THE FUSES 3-64

REPLACING THE HEADLIGHT BULBS 3-66

ADJUSTING THE HEADLIGHT BEAMS 3-67

CHAPTER 4 CHASSIS

FRONT WHEEL AND BRAKE DISCS 4-1

REMOVING THE FRONT WHEEL 4-3

CHECKING THE FRONT WHEEL 4-3

CHECKING THE BRAKE DISCS 4-5

INSTALLING THE FRONT WHEEL 4-6

ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7

REAR WHEEL AND BRAKE DISC 4-9

REAR WHEEL 4-9

REAR BRAKE DISC AND REAR WHEEL SPROCKET 4-10

REMOVING THE REAR WHEEL 4-12

CHECKING THE REAR WHEEL 4-13

CHECKING THE REAR WHEEL DRIVE HUB 4-13

CHECKING AND REPLACING THE REAR WHEEL

SPROCKET 4-13

INSTALLING THE REAR WHEEL 4-14

ADJUSTING THE REAR WHEEL STATIC BALANCE 4-15

FRONT AND REAR BRAKES 4-16

FRONT BRAKE PADS 4-16

REAR BRAKE PADS 4-17

REPLACING THE FRONT BRAKE PADS 4-18

REPLACING THE REAR BRAKE PADS 4-21

FRONT BRAKE MASTER CYLINDER 4-23

REAR BRAKE MASTER CYLINDER 4-26

DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . 4-28

DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . 4-28 CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDERS 4-29

ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER

CYLINDER 4-30

ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-32

FRONT BRAKE CALIPERS 4-34

REAR BRAKE CALIPER 4-36

DISASSEMBLING THE FRONT BRAKE CALIPERS 4-38

DISASSEMBLING THE REAR BRAKE CALIPER 4-39

CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-40

ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPERS 4-41

ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER . 4-43

FRONT FORK 4-45

FRONT FORK LEGS 4-45

REMOVING THE FRONT FORK LEGS 4-48

DISASSEMBLING THE FRONT FORK LEGS 4-49

CHECKING THE FRONT FORK LEGS 4-50

ASSEMBLING THE FRONT FORK LEGS 4-51

INSTALLING THE FRONT FORK LEGS 4-56

HANDLEBARS 4-58

REMOVING THE HANDLEBARS 4-59

CHECKING THE HANDLEBARS 4-59

INSTALLING THE HANDLEBARS 4-60

STEERING HEAD 4-63

UNDER BRACKET 4-63

REMOVING THE UNDER BRACKET 4-65

CHECKING THE STEERING HEAD 4-65

INSTALLING THE STEERING HEAD 4-66

REAR SHOCK ABSORBER ASSEMBLY 4-68

HANDLING THE REAR SHOCK ABSORBER AND GAS

CYLINDER 4-70

DISPOSING OF A REAR SHOCK ABSORBER AND GAS

CYLINDER 4-70

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-71

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND

GAS CYLINDER 4-71

CHECKING THE CONNECTING ROD AND RELAY ARMS 4-72

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-72

SWINGARM AND DRIVE CHAIN 4-73

REMOVING THE SWINGARM 4-75

REMOVING THE DRIVE CHAIN 4-76

CHECKING THE SWINGARM 4-76

CHECKING THE DRIVE CHAIN 4-77

INSTALLING THE SWINGARM 4-79

CHAPTER 5 OVERHAULING THE ENGINE

DRIVE SPROCKET 5-1

EXHAUST PIPE 5-2

LEADS AND HOSES 5-3

INSTALLING THE ENGINE 5-6

CAMSHAFTS 5-8

CYLINDER HEAD COVER 5-8

CAMSHAFTS 5-9

REMOVING THE CAMSHAFTS 5-10

CHECKING THE CAMSHAFTS 5-11

CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,

AND TIMING CHAIN GUIDES 5-13

CHECKING THE TIMING CHAIN TENSIONER 5-13

INSTALLING THE CAMSHAFTS 5-14

CYLINDER HEAD 5-18

REMOVING THE CYLINDER HEAD 5-19

CHECKING THE CYLINDER HEAD 5-19

INSTALLING THE CYLINDER HEAD 5-20

VALVES AND VALVE SPRINGS 5-21

REMOVING THE VALVES 5-23

CHECKING THE VALVES AND VALVE GUIDES 5-24

CHECKING THE VALVE SEATS 5-26

CHECKING THE VALVE SPRINGS 5-28

CHECKING THE VALVE LIFTERS 5-29

INSTALLING THE VALVES 5-29

STARTER CLUTCH AND GENERATOR 5-31

STATOR COIL ASSEMBLY 5-31

REMOVING THE GENERATOR 5-33

REMOVING THE STARTER CLUTCH 5-34

CHECKING THE STARTER CLUTCH 5-35

INSTALLING THE STARTER CLUTCH 5-35

INSTALLING THE GENERATOR 5-36

SHIFT SHAFT 5-38

SHIFT SHAFT AND STOPPER LEVER 5-38

CHECKING THE SHIFT SHAFT 5-40

CHECKING THE STOPPER LEVER 5-40

INSTALLING THE SHIFT SHAFT 5-40

CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 5-41

REMOVING THE PICKUP ROTOR 5-43

INSTALLING THE PICKUP ROTOR 5-43

CLUTCH 5-45

CLUTCH COVER 5-45

CLUTCH 5-47

REMOVING THE CLUTCH 5-48

CHECKING THE FRICTION PLATES 5-48

CHECKING THE CLUTCH PLATES 5-49

CHECKING THE CLUTCH SPRINGS 5-49

CHECKING THE CLUTCH HOUSING 5-50

CHECKING THE CLUTCH BOSS 5-50

CHECKING THE PRESSURE PLATE 5-50

CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-51

INSTALLING THE CLUTCH 5-51

OIL PAN AND OIL PUMP 5-54

REMOVING THE OIL PAN 5-57

CHECKING THE OIL PUMP 5-57

CHECKING THE RELIEF VALVE 5-58

CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 5-58

CHECKING THE OIL STRAINER 5-58

CHECKING THE OIL NOZZLES 5-58

ASSEMBLING THE OIL PUMP 5-59

INSTALLING THE OIL PUMP 5-59

INSTALLING THE OIL STRAINER 5-60

INSTALLING THE OIL PAN 5-60

CRANKCASE 5-61

DISASSEMBLING THE CRANKCASE 5-63

CHECKING THE CRANKCASE 5-64

CHECKING THE BEARINGS AND OIL SEALS 5-64

CHECKING THE TIMING CHAIN 5-64

ASSEMBLING THE CRANKCASE 5-64

CONNECTING RODS AND PISTONS 5-66

REMOVING THE CONNECTING RODS AND PISTONS 5-67

REMOVING THE CRANKSHAFT ASSEMBLY 5-68

CHECKING THE CYLINDER AND PISTON 5-68

CHECKING THE PISTON RINGS 5-69

CHECKING THE PISTON PINS 5-70

CHECKING THE BIG END BEARINGS 5-71

INSTALLING THE CONNECTING ROD AND PISTON 5-74

CRANKSHAFT 5-78

CHECKING THE CRANKSHAFT 5-79

CHECKING THE CRANKSHAFT JOURNAL BEARINGS 5-79

INSTALLING THE CRANKSHAFT 5-82

TRANSMISSION 5-83

TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT

FORKS 5-83

REMOVING THE TRANSMISSION 5-89

CHECKING THE SHIFT FORKS 5-89

CHECKING THE SHIFT DRUM ASSEMBLY 5-90

CHECKING THE TRANSMISSION 5-90

INSTALLING THE TRANSMISSION 5-91

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