Contents
1. Operating Instructions
Operation Component Locations ..................... 1-1
Fuel ............................................................ 1-2
Coolant ....................................................... 1-2
Basic Operation ............................................ 1-2
Steering Lock ............................................... 1-4
Shifting Gears ............................................. 1-4
Braking ....................................................... 1-5
Parking ........................................................ 1-5
Controls ...................................................... 1-6
2. Service Data
Specifications .............................................. 2-1
Service Data ................................................ 2-2
Torque Values .............................................. 2-6
Tools .......................................................... 2-8
Lubrication & Seal Points ............................... 2-9
Cable & Harness Routing ............................... 2-12
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 (3E) ..................................................... 3-16
Fork (4E) ..................................................... 3-17
Rear Suspension ........................................... 3-18
Cleaning ...................................................... 3- 19
Storage ....................................................... 3-19
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 .............................................. 5-20
Swingarm .................................................... 5-21
Brake Pad Replacement ................................. 5-25
Front Brake Caliper ....................................... 5-28
Rear Brake Caliper ........................................ 5-29
Front Master Cylinder .................................... 5-30
Rear Master Cylinder ..................................... 5-31
Brake Pedal .................................................. 5-31
Clutch Master Cylinder .................................. 5-32
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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