Contents
1. Operating instructions
Operation component locations ...................... 1-1
Fuel ............................................................ 1-2
Coolant ....................................................... 1-2
Basic Operation ............................................ 1-2
Shifting gears .............................................. 1-4
Braking ....................................................... 1-4
Parking ........................................................ 1-5
Controls ...................................................... 1-5
2. Service data
Specifications .............................................. 2-1
Service data ................................................. 2-2
Torque Values .............................................. 2-5
Tools .......................................................... 2-7
Lubrication & Seal Points ............................... 2-8
Cable & Harness Routing ............................... 2-11
3. Service and maintenance
Maintenance schedule ................................... 3-1
Pre-ride Inspection ........................................ 3-1
Warming-up Inspection .................................. 3-2
Ride Inspection ............................................. 3-2
After Ride Inspection .................................... 3-2
Replacement Parts ........................................ 3-2
Fuel Line ..................................................... 3-3
Air Cleaner .................................................. 3-3
Spark Plug ................................................... 3-4
Valve Clearance ........................................... 3-4
Engine Oil/Oil Filter ....................................... 3-6
Engine Idle Speed ......................................... 3-8
Transmission Oil ........................................... 3-8
Coolant ....................................................... 3-9
Clutch System ............................................. 3-10
Exhaust Pipe And Muffler .............................. 3-10
Drive Chain .................................................. 3-11
Drive Chain Slider ......................................... 3-11
Drive/Driven Sprockets .................................. 3-12
Brake Fluid .................................................. 3-13
Brake Pad Wear ............................................ 3-14
Brake System ............................................... 3-14
Handlebar And Steering Head Bearings ............ 3-15
Wheels And Tires ......................................... 3-15
Front Suspension .......................................... 3-16
Fork ........................................................... 3-16
Rear Suspension ........................................... 3-17
Cleaning ...................................................... 3-18
Storage ....................................................... 3-18
4. Engine servicing
Oil Pressure Relief Valve ................................ 4-1
Oil Pump ..................................................... 4-1
Fuel Line Inspection ...................................... 4-4
Fuel Tank/Fuel Pump ..................................... 4-6
Injector ....................................................... 4-9
Throttle Body ............................................... 4-10
Water Seal And Bearing Replacement .............. 4-12
Radiator Removal/Installation ......................... 4-14
Cylinder Compression ................................... 4-17
Cylinder Head Removal ................................. 4-20
Cylinder Head Disassembly ............................ 4-22
Cylinder Head Inspection ............................... 4-23
Valve Guide Replacement .............................. 4-24
Valve Seat Inspection/Refacing ...................... 4-25
Cylinder Head Assembly ................................ 4-28
Cylinder/Piston ............................................. 4-29
Cylinder Head Installation .............................. 4-34
Right Crankcase Cover .................................. 4-37
Clutch Slave Cylinder .................................... 4-38
Clutch ......................................................... 4-40
Kickstarter ...................................................
4-43
Gearshift Linkage .......................................... 4-44
Left Crankcase Cover .................................... 4-46
Flywheel ..................................................... 4-49
Crankcase Separation/Disassembly ................. 4-51
Crankshaft/Transmission Inspection ................ 4-53
Crankcase Bearing Replacement ..................... 4-53
Transmission Assembly ................................. 4-55
Crankcase Combination ................................. 4-56
5. Frame servicing
Front Wheel ................................................. 5-1
Fork ............................................................ 5-3
Steering stem .............................................. 5-12
Rear Wheel .................................................. 5-15
Shock Absorber ............................................ 5-16
Shock Linkage .............................................. 5-19
Swingarm ....................................................
5-20
Brake pad replacement .................................. 5-23
Front brake caliper ........................................ 5-25
Rear brake caliper ......................................... 5-26
Front master cylinder .................................... 5-26
Rear master cylinder ..................................... 5-27
Brake pedal .................................................. 5-28
Clutch master cylinder .................................. 5-29
6. Electrical servicing
Charging system inspection ........................... 6-1
Ignition system inspection ............................. 6-3
PGM-FI System inspection ............................. 6-5
PGM-FI ........................................................ 6-6
PGM-FI Self-diagnosis malfunction
indicator lamp (mil) failure codes .................... 6-7
Bank angle sensor inspection ......................... 6-8
Engine stop switch inspection ........................ 6-9
Cooling fan system inspection ........................ 6-9
Wiring diagram ............................................ 6-10
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