A Few Words About Safety Service Information The service and repair Inlorrnatlon contained in this manual is intended lor use by qualified, prolessional technicians, Attempting service or repairs wlthcut the proper training. tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsale condition. This manual describes the proper methods and procedures lor perlorming service. maintenance. and repairs, Some procedures require the use of specially designed tools and dedimted equipment. Any persen mid intends to use a replacement part. service procedure or a tool that is not recommended by Honda. must determine the risks to their personal safety and the safe operation 01 Me vehicle. It you need to replace a part. use genuine Honda parts with the correct pan number or an equivalent part. We strongly recommended that you do not use replacement pans of inferior quality, For Vour Customer‘s safety Proper service and maintenance are essentlal to the customer‘s safety and the reliability oi the vehicle. Any error or oversight while servldnga vehicle can result In laulty operation. damage to the vehicle. or injury to others. For Your Safety Because this manual is intended lor the professional service technician. we do not provide warnings about many basic shop salety practices (2. 9. Hot parts » wear gloves). It you have nol received shop satety training or do not test confident about your knowledge or sale servicing practice, we recommended that you do not attempt to perform the procedures described in this manual. Some of the most important general service salety precautions are given below. However. we cannot warn you cl every conceivable hazard that can arise in parlorming service and repair procedures. Only you ran decide whether or not you should perform a given task. Important Sat-ty Precautions “WARNING improper service or repairs can create an unsale onnd'llon that In cause your customer or others to be seriously him or killed. Follow the procedures and precautions in this manual and other service materials carefully. “WARNING Failure to property follow Instructions and precautions can cause you to be seriously nun or ltllled. Follow the procedures and precautions In this manual careluliy. Make sure you have a clear understanding of all basic shcp satety practices and that you are wearing appropriate clothing and using safety equipment. When perfonnlng any service task. he espedally carelul ol the following: . Read all of the instructions before you begin. and make sure you have the tools. the replacement or repair parts. and the skills required to perlcmi the tasks safely and completely. - Protect your eyes by using proper safety glasses, goggles or lace shields any time you hammer. drill. grind. pry or work around pressurized air or liquids. and springs or other storedrerlergy components it there is any doubt, put on eye protection. . Use other piotecltve wear when necessary. for example gluves or safety slices Handling hat or sharp parts can cause severe burns at cuts, Before you grab scmelhing that looks like it can hurt you. stop and put an gloves. . Protect yourseli and others whenever you rave the vehicle up in the air. Any lime you III! the vehicle, either with a holsl or a jack. make sure that It is always securely supponed. Use Jack stands. Make sure Ihe engine is ON oetore you begin any servicing procedures, unless the Instruction tells you to do otherwise. This will help eliminate several potential hazards: . Inlury from moving parts. lithe Instruction tells you In run the engine. be sure your hands, fingers and clothing are out ottne way. Gasoline vapors and hydrogen gases from batteries are explosive To reduce the possibility at a fire or explosion. be carelul when working around gasoline 0' batteries. - Use only a nanflammable solvent. not gasolli's. to clean parts . Never drain or store gasoline in an open container. . Keep all cigarettes sparks and flames away from the battery and all fuel-related pans, Vour saiely. and the saiety at others. is very important. To help you make lniotmed decisions we have provided salety messages and other lniormatlun lhroughout this manual. of course. It Is not practical or possible to warn you about all the hazards associated with servicing this vehicle. You must use your own good judgment. you will find impona n! safely lnrormaiion in a van», of forms Including: . Saiely Labels - on the vehicle . Satsiy Messages preceded by a safety aisn symbol [A and one o1 three signal words. DANGER. WARNING. or CAUTION Those signal words mean: . You WILL be KILLED or SERIOUSLY HURT II you don't [allow A DANG ER Instructions. You CAN be KILLED 0t SERIOUSLV HURT it you don‘t Iollow A WA R N I N G instructions. A AUTIO You CAN be HURT it you don't Iollow instructions. . Instructions - on how to service this vehicle correctly and sately. As you mad this manual. you will find InIcrmalion Ihat is preceded by a NOTICE symbol. The purpose of lhis message is to help prevent damage to your vehicle. other property. or the environment ALL INFORMA'HONV ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE 11ME OF APPROVAL FOR PRINTING. HONDA MOTOR CO.. LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAV BE REFRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCVCLES. MOTOR SCOOTERS OR ATVS. CONTENTS GENERAL INFORMATION I I MAINTENANCE W LUBRICATION SYSTEM ll FUEL SYSTEM a ENGINE REMOVAL/INSTALLATION ENGINE AND DRIVE TRAIN U ‘CVLINDER HEADNALVES CVUNDEHIPISTON CLWCHIGEARSHIFI’ LINKAGE ALTERNATOR/STARTER CLUTCH CflANKSHAFT [TRANSMISSION ‘ 31m wuaeumu/susnusmu I E: uvomuuc same I" umnwmnsma SVSTEM ' Icumou SYSTEM 7 7 7' I3 sLscnuc sum-5n In . LIGHTS/METER/SWITCHES U U cunsszs ELECTRICAL JUUU wmmc mew ' TROUBLESHOOTING mozx SYMBOLS T‘h- tymboll und numughnux mi: manual show specific service proceduru. ll :upplumonuw iulmmnlun in llquir‘d unlining In mm lvmbnlm it would be eleinod amine-fly In [he llxl wilbout tho Mn 0' KM lymboll. Rooms lho DIM!) WWI 03w Out“) War: mummy. U33 "commended angina oil. uni.“ nah-Mm :miliodv Us. molvbdonum all uoluflon (minuro o' (h. Origin. oil and molybdonum all”. in n Ink: 0' I : I). “In mulfi—purpnsn all“. (leium baud muIII-narpolo (Ir-m NLGI U2 0' Iquivlllm). Uu molyhdlnum dixumdu gum (connlnlng men than 3% molyhdonumalmlfinn. NLGI fl 0' Iquivlllnl). Elamnda: Mulvkolt’ Eli-2 pin- mlnufulurod by Dow Corning, USA, Mum—puma.- M-l mlnulmurlfl by Miuubiwi Oil Jlnln U“ molvbavnum dlsulfido flmll (Cumming mull thin 37- molybdlnun‘ fliwmdm NLGI n m “NW-I'm). Example: Molykm.‘ am pm. manufmurod by Dow Coming. u.s.A, Hund- Mony so (u, A om) Row! ASP mum-mm by le Lunar-d, U.K. mm Fm- mnmmma by Sumico Luhdunl. J-pon u- aillconl gum. Amy . lacking ag-nl. u.- . middle nunqm lacuna agent mum mherwm specifiad. Apply mlml. Uh huh fluid. DOT 4. Us. “ll mcommended brake fluid‘ uni!” omnwise IMlflod. l-‘QHA Q éhJ-M U- Foal or Sumnlion Fluid. 1. GENERAL INFORMATION GENERAL SAFETV 1~1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 14 TORQUE VALUES 1-12 TOOLS 1-14 LUBRICAI'ION & SEAL POINTS 1-16 CABLE l: HARNESS ROUTING 1-1! EMISSION DON'TROL SYSTEMS 1-28 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) 1-2! GENERAL SAFETY canon monoxne n ma mam. mun be running to an mm. wort. mm sun m- am i! well vnnl In Neva! um um angml in .n mum-a nu Li . mmncmnxpmmxmmmmum unnuulaun/noucioautuulmladhl—h. Run me angina in m npln am or wim .n Ixhsuu avlc~ union Ivmm in an enema: mu. am wm in . nu "mil-1m Ina. Kay sign-tum mm“ cu man my m I» work m. m mm nnallnn il not“, ___—_ . saw-mm Indhnpbllwnlhrw— in m, an our or mm or (mum, WW8 _— - En‘iu lul «than! unu: pm. pm... ury m: u: mM/wxmmmnlhunflubm Warm UBED ENGINE OI. _— - mad-mew", mum marl/Wit; lun- mxmmuujwmmm‘mma Woblnhlmkuflllulaflmlbflyhuflllirnil mama. to "um-m; ml you 1mm .1:- m, "l mnmnnpmwm,nuoamsrour or mum at cmuumv. WK! mm Navor w- ." uIr has: or dry '2th to mm [ho hum nmmblin Us. an OSHA-appmm muum alarm 91 mm.“ mahod mom-d by OSHA. magma m mlni» mlu m Mum uund by Almanac mum 'Ib-rl. - lMM/Mshnhmj-ndhm'nlplnlmy firm-Ileana. IMKE mum CAUTION - Emilia] [mm on palnud. pku'm' or mum- mm wIII damn mm Plate a dam shop um: um mm [mm warm" I»: lymm u mw'mi KEEP OUT OF REACH OF CHILDREN mghwnnv‘ilnlflflllnflulllml , hm mow klon hum-3 mm m. 1-1 GENERAL INFORMATION ”HEIV HYDROGEN GAS In ELECTROLYTE “— "K hue/y Hm on «'1»an gum, , rpllkx. [ll-u ml (lg-um .wq. inn-u. «Aqua mat-du- when dun-hm - nu ma ("lulu "link and «lawn. Cum NM! m. at my my mu mm hm Wm mam Min, .na . In. Wall. — llgkrvalyle mu u. mluAbIJl-ul m. war. _l/derlmlylrgm “yearly".flmh rm. wen/n:- mu aim:- and mu . yum-m lav-Mina. Ekdmlyu L1 phantom. — 1/le Mn: iuu gum: a; mm or null and/oi- low an inn vii-1mm. .7 mm: Mm: nu . phyn" um KF 'r our 0r nsncu or cmwnsiv. SERVICE RULES . u“ guanine HONDA or HDNDA~rIcommlndqd will Ind lulu m. m mm Iquivnhms. Pm: mu mm in... Hounn duign lmifiminns mny uuu 4mm In m. malulcvcla. 2. u:- m. spat: look dniunnd In! this gradual to lvaid dummy: and incnnacl lsumhlvl 3. UK only mic Incl: when servicing Illa motarcvcle. Metric bum. nun and screws are nol inlflchanqelhle mlh English fut-null. I. lnmll nlw ankml things. can r plum me luck plum when reuumblinu. s. when llghlanlnp balls or nun, bogin Mm lhI lug-r di-malu on inner boll dim Thnn lighlen m m. poem-fl lam»- onally in lmomnnul slip: unleu - pluicullr uqu-nu is :pccifind. 5. cl n plmin clu inn sow-m upon dismnmblv Lubriclm Iny nliuing aim-c balm vummblvl 7. Mm maumblm chock all nan: fur mono! install-non and operation. an Rum: ail almvical wire: a: shw on man Ha lnrougn 145, mm and Names: Ruining GENERAL INFORMATION MODEL IDENTIFICATION '95 A 2000 Shawn, Afiev 200a sumIIar In Tm. Irumu sanal number Is sIampad an m. ugh: we of ma manng haad ..( x . . .I2I VEHICLE IDENTIFICATION NUMBER (3) ENGINE SERIAL NUMBER 12) The vahIcla Idennhnauon numbar (VIN) i‘ anachad '3) Th. engme sarIaI number Is sumpau on [ha Iowa! on the Inn svda 0' ma down luba as shwn Ion sun: 0! mo crankcaia (5‘ COLOR LABEL ‘ _ . A'CARBURETOR IDENTIFICATION NUMBERI u) The cerhuvsmr Idenhlmahon numbers are slumped 45) Thu :aIar Iabnl I5 attachad Ia m a" cleaner housing on mum We nhhe camuremr body cova! as thawn When uvdenng colcrrcodsu purl: always specv'vxha assugnaxed color cudu, 1-3 3“ INFORMATION SPECIFICATIONS ‘ ENERAL rl'EM 85mm DIMENSIONS Ovmll mm 2,115 mm (Lu in) 0mm wimh mm (32.9 in) am." mm mm mm (42.51": wvmtbm mm mm m1 In) San mm as mm (20.5 In) Pom mam zoo mm (118 In) Ground durum I50 nun-(5.91m orymIgm Inugmnw cm weight In: kg (m lbs) Modmummigm Emplunmlypl mammal») umdtv Can-do lypl 151 kg (as my FRAME FrImo m- Sum] mu. uldl. Fm “amnion 1.1—:me 1m From VIII—I lrlvul nu mm (4.: In) um um Swing-rm nurwhul ml n mm (23 in) Fromflr- nu 3.004341? nur II:- uu 130m - Iswc as! 11:. mm (emu-non.) From: unsun- 65m Inunlnpn Front: F1 IIR-lr: 321 me huh war-u II: IIngll hm. mar brak- Int-mil .mmlm .m- cmm snub 30- w run Imam 11: mm [m In) Full unk anew Fucl tank mm. nip-cm 10.0 III-r (23‘ us sol, 2.20 Imp ill} 2.7 “tn (0." US fllI, 0.99 Imp all) ENGINE Bor- lnd fink. Dhaka-«um Communion mlo VIN. min lmlh vllv. om doul Elm-all VIM 090m do“. Lubrication Wu OII WV WIN WIN! WM All flItt-llnn Grimm-II typo 2mm. my wow ovum“ Irranwvnm s: x 51mm (1.1 x m In) 2:» cm’ (14.3 w-In) 9.2 : I cum am. um um: um. rook-r mu —5- BTDC 35' AIDE 35' nsoc —5' A‘IDC Fonz-d prawns uni wn me Tmuhold Alr cool-d Plpu Inter Ammo Ivo- zu in (nu nu) vamI Mn. mun-I GENERAL INFORMATDON — GENERAL (Oom‘dl ‘ ITEM W110" unaunnon Cnrbul-lnr wp. Cnnmnl vllncily nngla :Irbunlur ”rt-mm: bovu 2: mm no Inl DRIVE TRAIN Clutch mum Mum-pun. wul Clulch apomion Iylum Mwhlnical type Trummislion Colman: moon. 54mm! Primary muucmm 1931 199/19) Hnul Inductlon 1.357 mm: 6w min In ‘ 2 345437113) 1nd L777 mus) m L33: (23/21) a» was (16m: in» mm (21/13: Gulnhiflpmnm unmmmvnmm,1.N—z-J-t—5 ELECTRICAL lgnninn Iymm AC~CDI SDHMO IMO!" Shem: nlflll manl Chlwlng mum nipln pm» output mum-nu nuuulorhmnm SCH Ihnrlldllrlplu mm m mu nuifiauou uqung Ivlum snow 1-5 GENERAL INFORMA‘HON _ Luanmmou SYSTEM “““2 ""“ "“’ "EM WWW SERVICE WIT Enginu an annuity At mar-mg 1.5 nm (1.5 us qu.1,3lmp m» — A! ditmombly LB II!" (1.! US My 1.6 lmv Q” — Rmmmlndld angina all HONDA 5N4 Mum all m ‘ Iquiv-lofn mm: on _ ‘ _ AP| “WIN cllfllfinmn SF at 5‘5 VLlculky: SAE 1W - ‘0 Oil pump Inlof “D slur-nee 0.15 (0.000) 0.20 (0.008) M Eli-rims “‘15 -0.ZI (EMS - .009) 0.15 (IMHO) End cluum 0.05 - . . J ink inms") _ FUEL svs‘rEM "9" B'ECIFICATION Clrhurum («unification number ‘5 m: WP. VESSC Calilnmil lyn- vsua cu tvpl vzasu Mlln ill a In SM ]n 0 31: PM" 1mm lniu'll mulling 1-3/1 [um] um NIgh Imam “lung z-m turns on mu Iml 135 mm (0.1: In) Idle lpfid 1‘00: ‘00 mm mm: gripfrauplly 2—ammu/12-m In) 1-6 GENERAL INFORMATION — cvuunin HEADNALVES ”"'“ ""“ “"’ nan sum same: um (mm nompnu‘mn 1,100 m (11.2 kgllcm’, 150 p11) .1 _ coo rpm mum-awn. — 0.1010004) v.10. um \uM | v-m dunno. wax 0.00— 0.10 (0.002 — 0.004) — “"‘d' ‘ Vfiw mm 0.0. m 0,000- 5.005 (0.1100 - 011521 5.42 (0.113) :x 5.030 » 5.445 (0.2130 — 02144) 5.00 (0.21:) VIIVI lfllfll ID. IN I 5.175 -§.‘5 (01150-01150) 5.0010217) EX 5.4154405 (03150- 011501 ( 550 (0.217) sum-MIMI!!! dour-m 1N 0.010 - 0.N510.w - 11W”) I 0.” (0.0031 ex 0.0004055100012400”) 0.100000) VIIVI ”It WW IN/EX 1.0 - 1.1 (0.038 - 0.013) 1.510.071 VOW. Iprillfl Inn-1 lN/EX 3311.181 ”.0 (1.10 'm “"I‘" 001.: INIEX 00.2 (1.50) 01.011») Ml! nrm Ml! ll‘m LD lN/EX 10.000 - 10.01510” - 0.39") 10.10 (0.390) m .m. m 0.0 )wzx 0.012 - 0.001 (0.3020 — 0.3032) 9.91 (0300) Rod“ lim-Io—Ihlk Ell-m 0.013 ‘ 0.00: 10.0005 - 0.M17) 0.05 10.001] can-nun Cam lob. 11.1.»: N 2100347502 (1.0701 » 1.0044) 27.1 (101) EX 21000-27300 (1.0712- 1.07151 ' 27.0 (1.00) RUN-W1 — 0.05 10.002] Journal 0.0. 10001— 10300101001 41.7000) 10.02 (0.704) 110.10... (.0. 20.000—20.0o0(0.7009—0.7007) 20.20 (0.700) _ ”ma/PISTON I mm: mm (1..) nan ‘ I'l’ANDMD lame: um mm 1.0. [ um - 00.010 (2.0000— 2.0070) 501012.001) 001 «1 round —- 0.05 (0002) You: — 0.0510002) Wupm — 0.05 (0.002) m", plmn Pinon mm dlrlnion 'IN' mm «mm. m0 m0 lnuh an. — "nu Pinon 00 52.010 - 52.000 (2.0004 » 200021 52.00 (2.003) Pinon 0.0. moi-um m 10 mm (0.1 01) 1mm mm m nkin — Plnon 11in hon 1.0. 15.002 - 15.000100000- 0.0000) 15.05 (0.501) PInun yin OD. ILQI >150N0105903 - 0.5906) ‘ “.98 (0.5.“ nmn-m-pimn n17! dour-nu 0.002 — 0.010 (0.0001 - 0.0000) 0.07 (0.000) Pinon finnvlo-iing Tap 0.015 ~ 0.0‘5 (0.0006 - 0.0018] 0.1010004) “m ”mm" 5000110 0015 — 0050100000 - 0.0020) 0.10 (0.004) M" Vlllfi Ind DID Tap 0.15 — 03010.00! - 0.012) 0.46 (0.018) 5000110 0.30 - 15(1012 r 0.015) 0.5010111” 00 um. um 02— 0.1 (0.01 — 0.00) 0.9010025) CylinduAm-pinofl nlullnol 0.010 » 0.000 (0.0000 — 0.0010) 010(0001) Cumming rod mull Md LD. 15.010—1503.103912‘05319) 15.“ (0.505) 6011110011110 mum" pin elm-m 0.010 - 0.000 (0.0000 - 0.0010) t 0.10 (0.000) 1-7 GENflAL WHOM — amen/emu“ nuns: ”'"t """ “"’ HEM "m names I”? Gulchlm'mphy 10-20lll5-3I‘) — Clutch lpving lrll llrlfllh 37.8 (1‘9) 3.0 (1J2) Dunn din: 011cm.” 1.01 - 3.0: (0.115 — 0.121) 18(010) Cinch uln- w-m-n- — 91° (0‘0") mumh om-r LB. 10000 - 20.011 (1.023 -1.02“) 20.05 (1.025) mm" W“, ouldo |.D. moon - 2mm (0.13“ — mam mus «1.753) 0.0. 15.060 — 26.“ (1.0220- 1.022!) 15.” (1.010) — ALTERNATOR/swam cw'm-I ”M“ '“"‘ “"’ ITEM "M sums LIIT 5mm 671V." [m . LD- 21.010 - 22.022 (onus - 0.5510) 32.00 10-”) r 30' OD. ”.975 - 31.000114567-1JW) 339011.453) — camxsuArrrrnmsmssIou W" "'"‘ ""’ "EM [rm m 1."? tun-w I “Mm...“ md M, 5m. dumm- n.m - 0.40 (0.004 - mm) on (out) w flldill ell-(m OM‘ - 0.011 (0.0002 - 0.00%) 0.“ (0.“) i Runwl A: be": um- — um moon Ax baring hum-r —— 0.05 mom) Tunlmhilon Gut LD. M5 20.020 - 20.011 (0.7882 - 0.70”) 20.00 (0.101) C1 20.000 - 20.0.1 (0.7H1 - 0.75”) 20400 (0.701) {:0 20.020 ~ 20.041 (0.7”: - 0-7“) 20% (0-791) G“! [WM 0.0. C1 11' 20.000 (0.7”! - 0.7"") 10.03 (0.7!) G“! bushing LD. C1 10.510 - 1033‘ (0.0502 — mason) 10.5! (0.”) Gear-[obtaining door-nu C1 0.020 - 1m mom - 0.0024) 0.10 (0.00‘) Mlinshlfl 0.0. Mi 10.059 - 10.000 (0.138 - 0.7“) 15.01 (0.704) Counmhnfl 0.0. C1 10.“ - 10.404 (0.005 - 05000) 13." (0.0“) CO 19.950 - (9.5501015! - 0.7“) 18.91 (0.704) GIIVAIDMII" slur-ma M5 0.010 - 0.032 [0.0010 — 0.0131) 0.10 (0.“) C‘ 0.0“) - 0.m(0.W10 - 0.0032) 0.101000.) amingvxmm flair-m C1 0032 - 003310.001: - 0.0027) 0.101000.) Shift folk, ‘ Fork LD. 12.000 -12.010(0.l714 — 0.0731) 12.13 (0.11.) mm Cl-w minim.- tBS—SJJO (MSG—0 m an «mam ) Fork mm 0.0. ".010 - 1130‘ (0.5725 — 0.0731) 11.03 [0.070) GENERAL INFORMATION _ HIONTWHEELISUSPENSIONISTEEHIMG ‘ ”"m ’""‘ “"’ m sum sum: um Minimum m "and mm — :5 (one) Cold «in manure Up In so kg (200 an Im 20:: u:- (2.00 magma. 29 psi! — :wg‘mm" mm zoo m (2.00 Inllcm’. 29 us“ — Ma mnuul — Mn mfg?) wnm rim rum-n mam — 1mm) Axial 2.41 (am) wmn mum". dhm 30.75 x 1 (1.21 2 tum — Forkwdngfrnlmmh smmusm mm mm: Fun «uh. mnom rm moo) amma mm mm Pm Hundl sum-i... Fluid 554a — Fortnuldlwd 1mm» — Folk fluid run-dry 234 cm’ (7,9 us oz. 31 lmn or) — sawing nun mung mum ‘ 1.04 - L53 an (2.29- 3211b.) -— — ma mumsusrsusm ”"ic "‘"‘ ""' rrm mm mm Mlnhvmm mu and doom 2.0 tom Continuum: unmmmmmum zoo in (zoom-.239“) — ngmmum "’9'“ zoo kr- (2,00 WI, 29 pl) — Am mnom — m 10.000: w m mmm \ mm — 1010.09! L AIM — 2» ma: wm humdm 6mm 21.5: 110510.04. — ant-mummy 2o-3om- mm -— arm drum up. no.0 mu m (51: Ban Ilnlm minim-u ts mm Lo (cum _ H uuc um: mm um nan swam sum: wan 5;)qu um «um 001 a w l am disc mum. u (0.15) as (mu) Bah dlll runoul — EN (0‘01!) Mum cyllnflnr swim: LD‘ 117w - um (0.5000 -o.w1 n 111» (c.6022) Pinon on. 12.37: » may (one: wast) 12,95 «mm m “up" I (Minder LD‘ 25.100- 25.“ [LN - 1.“) 25450 (LMZO) | Hmn on. 25363 » 2530: (um 42mm 25.3w mm) BEER“. INFORMATION — BATTERY/CHARGING sva "E” mum may Capaclly 12v — 5 Ah Curr-M mm. 1 mA mun vow i Fully ammo 13.0 — 12.2 v mm' m aiming “0012.: v Chiming ciu- Noun-l M NIO h ’°'“ mm 3.0 N”) in Aimnuur Cap-paw m W/smo rpm Dinning can ruimnu o: — 0.0 n Noaulnomicflflu mum-mi vom- ‘98— 2000 ms , no wsmo rpm AM 1000 “3‘ 15.! VIEW rpm — IGNmON SYSTEM nail mam Snlrk piuq wax ususo snnami cam umrw For cold cum-m (Mow s‘cm‘F) 01W Uiepsa-u For mama high spud mm I m uzxsn-u 5pm pluu pup } in- in mm mm - 0.0: in) ignition puii pun wing. I 100 v mlnlmum Ali-mum mix-{mil pm vuluuc I m v minimum Ignition pain p-nmxpr punk wimp. 7 in v minimum igniiipn dminu -r~ mm I w Brae/mo rpm Full new-m \ E' ITDC F ELECTRIC suntan u“ "‘"' "m l'l'all «mm mm" sum mm mm wing mansion m- moo g 450 a 5mm motor mm length 12.5 — 13.0 um —o.sii 3.5 ".133! 1-10 GENERAL INFORMATION — UGH’I’SIMETEH/SWITCHES rrm "summon 3qu \ “"5“,” i 99— mo 12 v — auras w ‘ (Man/low bowl Alt-r1000 ”woo/sew ' mumm- um I: v - 2/31 on mm W) Lincnu um 12 v » . up «a w: Frummrn Ilgnl! Hum 12 v—ach (22M leum .ignuugm 12v-azon123vm Immm ngm u v- 3.4 w High boom indium! l2 V — 3.‘ W Tum mm hub-luv 12 v- 3.: w Noml mummy 11 v—aw sa . and indlcnnr m7 zoom 12 v —2 w Fun mm 20A Sub m. w A x z 1-11 GENERAL INFORMATION TORQUE VALUES W Fm TYPE Fm TYPE NM “ ' W 6 mm Mx hon um ml 5 mm W “01.2.91 I mm Ml boll Ind nu! 5 mm W 9 (0.3. 5!!) 8 mm hex boll Ind "MI 6 mm llnw bolt (8 mm hurl) 3 (0,9. 6.5) m mmhlxbflland nul 31(15, 25) fimmwbofllwmm Mimnm "(1.1. Q) 11 mm hu boll Ind mu 6‘ (5.5. w) 3 mm Hanan boll and nut 26 (2.7, 20) “1 mm "Inga ball Ind ml! 39 [4,0, 2') - mun upucIflmIoru mm um m in: impomm m... - unm- lhould bu mm m undid lnrqul um. lirud mm, NOTES: I, Apply a lacking mm In the “woods. 2. Lafi hind thrlldl :. sun. k U-llIfl. a ALOC hon: uphoa wm- - m om. _ BM mm In I W "EM 0'" mm, M m W W mud-I - on pump Humming w :I a In tho. 7) Mud-I- 01-.de sum plug 2 In I: In. I) van uazummm 4 s Iou.o.7I eyum nude-munch honor nm a s 2312:, I7) Cyunau huu ban a 3 I2 (m. In em unlock-i ball 2 1 20 (2.0, 14) Nm I (Mind-r new umr ban 2 a In (1.0, 7) Gunman-ml: um”: elm Inmm I a 12(11,s) mum mm Ind: m I In 7105,55) Mon 1 sum dmm mpg-y Inn ball I a 12 (1.2, w) Gum-In mum «ulna Bill I B 2511.5. 19) «mi Pdmaly am: can lock um I Is 51 (54, :9) W Drm Ipmclm ball 2 y 6 I2 111. 9) an driln non I 12 25 (2.5. ‘8) rim-W moumlno ball 6 I a 23 [2.3. 17) Cnnknufi mounting ”In I s 12 0.2. s) on puuqo III-u mourning mu 3 s In (1.0, 7) Not- I Mun-UM um: Flywhlol holl I It) so (3.0. a) sumruumn mounflng umw :I s s (0.9. 5.5) Now I. 1 sum: "wanting but! I 5 a (0.3. M) Mr win clump um I 5 a ma, 4:) lanhion 9qu my mounung non 2 a In (117. 1) Sunor mmomvan-I um I a a (0.6, u) 1-12 GENERAL INFORMATION — FRAME 111m BIA. mu: m 0111 lm) N111 «@111. um ‘1 new rum-M rm Sm: Shaving lad: moumlwscmw 2 a 910.9,”) ‘ Mann 6 mm pod-l pivot up 11m 1 a 22 (2,2. 1:) Guam pml link mimr lock Inn (Imm) 1 a 1011.0. 71 I More 2 Summer pm-I 1m mum lock rm! 1 5 1011.0, 7) Side stand plvm bolt 1 10 11) 11.0, 7) 1 5m mm viva! nm 1 10 2913.11.22) ‘ More A Fun! um lock 11m 1 I8 2612.7, 20) Englnc W: Engm 1mm mourning mu 1 1a a: 153. A61 Engine mr mourning run 1 10 so 19.11, 66I 7mm mmmm; Stood-In m run 1 22 71 17,5, 541 snoring m bearing Idlunina run I 1 22 :1 10.3, 22) Forkhwplnchbon 2 7 "(1.1.31 Fm homu- pinch ban 2 a 1.135, 231 From 1. bolt 1 12 «213.1. «I am- am mmmling ban a a as (1.0, 211) Mm 5 What mu :6 ac 2.2 410.4, 231 Tim "In mu 1 1m 310.122) an up 2 23 22 122, 1a) Fortmbon 2 1; 20110.11) ‘ Note 1 hymn-mam . Ruuxll run 1 1: as 19.0, “I 1 mm 4 WM Ipoh u no 2.2 ¢ (0.1, 2.91 Tin um mu 1 m 310:, 2.21 Drrm mock-1 mourning mu 4 10 u (as. ‘8] N91. 2 Shock mam mourning mu 11mm) 2 a 26 (2,7. 201 (low-r) 2 111 A2 «.3. :11) Swing-rm pm nul 1 H 3319.11.35) Now A Dtlv- chain nlidor mounfinn ulf upping Icrlw 3 5 310.1221 Dm- ehlln Idluml Ina nm 2 a 1011.0.71 Wu: 1mm CIIIW Mn ban 1 a 22 (22. 191 CallprnbmA 1 3 13111.13) Callur bind my. 1 7 e (as. 4.3) Plfl flln ‘ 2 1° ‘9 (L5. 13) PM nln plug 2 10 210.2, 1.4) tulip-r bucket mmmfing bolt 2 a an m. 22) Non: 5 Huh hon ball 2 10 3013.5, 25) Mmrwllndly hula-rho“ 2 a 12 (1.2. 91 Mnmr :ynm-r rmrvorr up mm 2 2 1 (11.1. 0.7) 1 Brlh lmr p'mn hall 1 s 3 tore. my arm 1w pivot Inn 1 . a a (0.5. 431 ‘ arm mm munllnn mew 1 I 1 19.1, 0.7) um um clump new 2 ‘ 3 11112.91 1 mar/Wm Huangm met-1 mundng rmr 1 10 «115.251 More I Tall 119m rum mun-11mg mu 2 ‘ a J 1 40.7. 5.11 1-13 GEIERAL INFORMAflON TOOLS NOTES: 1. Enulv n1 oammlrcilfly Ivllllbl. 1n U.S.A 2. Noll libllln USA. 3. Allemlliv. tool. usual-non Tool. "WEI W" DEF. IEO lehlfl“°7 “out lav-I now. 0740‘ ~ 0010000 5 Whul won munch 07701 - 01120300 NOTE 2 12, 13 Vllvl ldiumr much B 077* - 0033100 NOTE 3: 3 am ~ xisozoo 11mm: DID ernch onus , 00111001 :1 mnmwmnch. 10x24 111111 11171540211100 9 Emmion bl! 077|0v00205M NOTE | 9 Gel! hold" 0772‘A DOIOZW 0 Fmal bold“ 07725 - W 10 FNwMol pull-r 07733 - W2000‘ I0 VIM uuldl adv-1,55 mm mu: - oomoo 7 Amokm-anszSn-‘m onto—001mm 11, 1:1 Winn-"L 37 x to mm o7n§< 00111200 12 Annual-m. uxn mm onu-ooloaoo 1 11,12 Amclmlont, 52 x 65 mm 07740 — 00|0400 1| Almehmenhuxflmm WAG—WING I1 P1101. 15mm OWN—0040300 11.12.13 P1112120 mm 0774: - oodosoo 11 Pllm,2§mm onu-oodoooo 11 ”101.2me (INK-WING 11 Bunng rumom mod, 15 mm mm — 0050400 12, 13 Boning vlmwm Mm 077“ » M011” 12, ‘3 Oil ml driver 07747 » 0010100 12 Oil Deal driver amt-mam 07707 — W‘W‘ 12 move: ova—ammo 11112.1: Vllva spring mom 07151 - ooloooo 1 Vqu an cum NOW 1 Seal cutlm, 2015 mm (45" IN) 077” - 0010100 7 5081 cm", 22 mm (‘5‘ EX) anon - 0010701 7 Flu elm". 25 mm (31' IN) 077.) - 00121170 7 Flu um. 21.6 mm 132' EX) 017m - noun» 7 Imflor omn 30 mm (00' INIEX) ohm-comm 7 Elm-r hold-v. 0,5 mm 0770‘ ~ 0010101 NOTE 1 1 Pllm lonw month 01m » M0201 5 Snip ring plhll 0781‘ - mom: 1‘ 51min; mm m 0151a - 37111101 1: Burma r-movu II! 07930 - a71noo1 I: — Ramon: hlmfl- n79ao»371n1oo — swing romantic m cm: 47mm — Rama"! migm 077" ~001020| NOTE 3: 07030 - 3710200 Billing mm m, 16 mm 079311— Kcmooo 11 — Rummy llllfl. I5 111111 07030 - KC10100 H — Rammrhnd,15mm 07930AXCI0200 11 — Nlmmv wllgm 071" >001020I NOTE 3: I! 07030 - 3710M 1-14 GEIERAI. INFORMATION nsswnou TOOL NUMBER T M REE sec. Ball mudrivlr 070444150001 ' :2 sum baring drivar 07940 - scum ‘ Iz Naodlu belting tummy 01846 » um I3 Pinnn hm 07955- 3000000 1 a Valvo guide rumor, m5 mm 07954 - mom ‘ NOTE 3: 7 07934 — osaooon (USA. nnlv) Clutch unnr holder MGMB — «noun a Puk volhoo ldomo- 0mm - 0020100 NOTE a: lo lmria dimnouic "my (mud-I 026; Diivo nhnin tool at WNMH - Mmmoa ‘ NOTE 3: 3 «mm»: - MRIOWA {USA mm Analog Inn-rtSANWA) sp—Isoj—‘rnorsu 13. 17.19 Analog run-r 0(0wa TH — 5H 10, 11, IB 1-15 GENERAL INFORMATION “IRRIGATION & SEAL POINTS - ENGINE lmTION MATERIAL Hock- rm ma nun xiiainq lume- Engim on Cam chlin Tammi-don 50.1mm ma naming: Pinon pin halt Pinon pin lume- Conn-suing rod wall and Euh beating Pisum rIng llldlnu lurfm mien ring and ring gnaw- Cr-nmuk big and shin lurk m Ind aIVoI mm when Sam drum groom elm db: » Vain nun mm quid. mining same-i Molybdmum dlluIfldl Vain nuidl (um [um llIdinu mm; on (a mlxmn all/1 Cmm bushlna inner mm maln- all Ind 172 Elm loboa mam-mm dkulfidl M3. 4 gnr who: gnu-I cu gm. Ci hulking illdlnq nun-c. Ml. a, cs mm lurk grown on m plm Icnw inma- Locking mm sun-r am on!" Man mm cumin loan-r letI non mm 1-16 GENERAL INFORMATION — FRAME Locum MATERIAL REMARKS Steering mm bearing urn Mulli purpose gmn me wn-u dual .ul no. Ran: whocl huh dun soul lip: Smdometo! our insida Wiml .qu oumr nun-u Rnr unml Mug Dflvefl Hung: dun seal up. Roll brake anchor man ank- um um hm nod-I viva! nun Swing-rm plvm sum oum sumo- Swlna-rm pm mm ml "at Swing-rm pm humlng ‘ 1 17mm. plpl |nnII turf]:- Side and pivot \ (in-mm podnl awn Clutch lml um: hon ‘ 5mm»; lack mourning mmm Locking mm Drive an». clue mounting mum-mo Hulmac noun mounting bull mad! Fork all «.1 up. Pro-Home «noon-bu Fork up but: mm M ssa or .qulv-In Inks m 1 wllndur Dino nd cup: DOT : or DDT 4 bunk; Coup-r n Inn and mum Iull mm: c-nw pmon duo: nub smoom on». me om. lmr 9M)! boll Hmdlcmr grip nnnmum Honda Band A or Ham. and Grip emu-m (UuSAnnly) 1-17 GENERAL INFORMATION CABLE & HARNESS ROUTING (3) RIGHT TURN SIGNAL WIRE (I) BRAKE HOSE (1) MAIN WIRE HARNESS 1-18 GENERAL INFORMATION (3) IGNIYION SWITCH WIRE (A) SPEEDOMETER WIRE (Z) INDICATOR PANEL WIRE (I) RIGHT NANDLEBAR SWITCH WIRE (5) LEFT HANDLEBAR SWITCH WIRE ILEFI' TURN SIGNAL WIRE m RIGHTTURN SIGNAL M‘IIRE V“ m HEADLIGHT was man my grammar: into M mnnmor box, '”V r UNIV! i x ‘\ Q 1-19 GENERAL INFORMATION 131REGULA1oR/RECHHER (2) IGNITION CONTROL MODULE [ICMJ r, (E! CLUTCH CAIE 1-20 GENERAL INFORMATION (2) REGULATOR/RECTIFIER 4P CONNEC‘YOR (1) MAIN WIRE HARNESS If” REGUUITORMECT'IFIEH 2P CONNECTOR II) IGNITION COIL PNIMARV WIRE CONNECTORS IS] IGNITION CONTROL MODULE (ICM) [8) SPEEDDMETER CABLE 1-21 GENERAL INFORMAflON 43) REGULATORIRECYIHER CONNECFORS (It CLUTCH CABLE m CNOKE CABLE (1) ALYERNATOMGNITVDN PULSE GENERATOR/NEUTRAL SWITCH WIRE (IUDIODE 1 ~22 GENERAL INFORMATION (4) HESLILAYORIHECTIFIER l3) CARBURETOR AIR VENY ma: (U BATTERY NEGATIVE CABLE (1 [10) AIR CLEANEfi TUBE nu CRANKCASE BRE/Al'HER was ' ‘ ' / (5) CARHURETOR OVERFLOW ”BE 17) AIR CLEANER HOUSING DRA‘N TUBE (a) CHANKCASE BREATHER SEPAMTOR - - A IN TURE 1-23 GENERAL INFORMATION I2) RIGHT TURN SIGNAL WIRE 1-24 GENERAL INFORMATION EMISSION CONTROL SYSTEM ROUTING (California Twl Only) III EVAPORATIVE EMISSION (EVA?) CANISTER ,/ m EVAPORATIVE EMISSION ’ was: comm VALVE ’0‘ 15) EVAP CANISTER DRAIN TUBE (No. a) [4) Alli VENT TUBE (1| AIR TUBE (No. 2) l5) VACUUM TUBE [No‘ II) (I) AIR TUBE (No, 5) © (151MB TUBE (No. 5} (H) CARBURETDR DRAIN TUBE (93 VACUUM TUBE (No, I" IlalFUELTANK BHEATHEB TUBE (WINE TUBEWu. A) [12) AIR VENT TUBE UU FUEL TANK BREATHER TUBE (NB, ‘) 1 -25 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The us Environmenm Proumun Agency and CIMomia Au Resourm Boom (mm mmm mlnulmumr: m codify mar men mmorcycles wrnw with ewicabze exhaua emissions standards during men useful Wu. when unarmed .m m numea according (a (M Instruction: provldodl and mu malorcyclu hum aha! January I. 198:: mmva mm applicable nniu mission lam-m In! one my at 6,000 km (3,730 miles) am: In mm a! mu nu ma ummm porch-w, Mun mama and mainr Iain-d according no me innmnioas promo. CompIi-nca wilh me mm- or m Dinribmor'e Limrnau Warmmy luv Honda Mmmrynle Emlsmn Connor Syn-ms is mmrv in order m me me numb": symm warranty In sum SOURCE OF EMISSIONS The common process prodwes carbon mamxkie and hvdmrbuns Central aI hydrocarbons is very Impala!“ mun. undev cert-in oondilmn new read In Tum! phomchumbll smug when subieued m sunNgM. Carbon monalndv dun nm run In me some my, hm 'n is mxic Hum‘II Mom- Car. Lme ulilins Jean nrhuramv unina: us well u ulhar ”sum; to reduce urban monoxlde and hydror urban EXHAUST EMISSION CONTROL SVSTEM The exhausl omisamn conlml system Is mmpoud ul a lean carburelor 301mm and no amusrmems shuulu no mam excepl ma Ipeed Idlmlmenl mm m Ihrnflli nap sci-w. The exhaust emiubon annual mum is unnmlo lmm mo cvnnkcm muss-on conlml svfilm. DHANKCASE EMISSION CONTROL SYSTEM Tm .ngma s unmoved will! a cloud crlnkcasa lynnm Mich routes manic-so smiesiam Illmugh the air clelnel into the communion number. m CARBURETDR (2) AIR CLEANER a CF: N W / / <3 : FRESH Am . : mow-av GAS l3) CRANK CASE BREATNER SEPARATOR 1-26 GENERAL INFORMAYION EVAPORATIVE EMISSION CONTROL SYSTEM (Cnll'umia typo only) m: vehicle mmpnas w-Ih Cahlorma Arr Resources 30am evapcuanve enussm regululcns Fuel vane! {mm The fuel Tank and camuremr .s cinema mu m evapomwe eMIss'on (EVAP) can-sun where u IS absemed and flared while we 509m: ‘5 slowed Whpn m: engme I: runmng nu ma mpomwe asts-on IEVAPI Bulge comm! mm :5 open. 9qu vnpnr .n we EVAF camster Ts drawn mm ma angma xnrcugn me carburelur (UFUELTANK It) CAHEURETDR (1] EVAPORATIVE EMISSION PURGE CONTROL VALVE (EVAP PURGE CONTROL VALVEI l3) EVAPORAYIVE EMISSION (EVAF) CANISTER <21 : FRESN Am « : FUEL VAPOR NOISE EMISSION CONTROL SVSTEM TAMPERING WITH THE NOISE CONYROL svsTEM Is FROHIBITED- maul law nvnhibllo [he IoIlowmg an: or m can; my they-cl: (I) Yha mmoval or rendering .nopemiv- by any pman. om: man to: purpom ol mointonancn, ropair cl renlncemam, a! any devme or element ol desuqn lmwrmrltad inm any n-w vehicla var ma purpose of noin canlml mu m as sale uv deIivzrv m The ultimate purchase! or while u is m um: (2» ma us: at m. vahicll mu such own 0! m- maul nl duinn has been removed 0v vendamd inapemiy. by lny person. AMONG THOSE ACTS PRESUMED TO CDNSTITIJ'IE TAMPERING ARE THE ACTS LISTED BELOW: I. Ramoval at, or punclunng ol mo mufflol. mm“, header pan: or any nlhnv compunenl which conduch axh-un ems. 2. namow at, m punuunng ov any pm 09 [he make synam, :. Lack of manor malntenanoo. 4. Raplacina any moving part: (II me vehicle, 4» van; M «n. exhaust or inlake syn-n. mm pan: umar man mm Ipaclfiaa by m. manmmum. 1-27 MEAL [FORMATION EMISSION CONTROL INFORMATION LABELS (II.S.A. ONLY) An Emh‘bn CDMNI lfllormnlorl leII II but-d an III! lit mnwmmum mlwsidemwmbamnmmmdh. nmmmm VEHICLE EMISSION OONTI'IOL INFORMATIM UPDATE LABEL Mm maxim - high I'm-m clrhuratuv Idiuslmum. mm mumuulmmvmmdmmmum lunrucllenl Inf ob'llinina ml undan lllul In gIvIn In Squ Lllllr 132. Whln madluning m- umm-uu but u; my low unima- m-cifiuzions. b. lurI lo mmcvl min undu- I-bul. VACUUM HOSE ROUTING DIAGRAM LABEL ('96 - '0! Wu“ lypn onlvl nu Vlmum Hoc- Routing mum label h onlhl .0er housing cow-r :- mm, m lck am» mu! mm b. mum-d In and iv. I‘) EMISSION CONTROL INFORMATION LABEL VEEOEHOSE WWW Ow EIEIIE FMILV -!m.x “IF“ A NICE 1-28 MEMO FRAME/300V PANELS/EXHAUSY SYSTEM BODY PANEL LOCATIONS (6| SIDE COVER (3) FRONT SEAT (4) REAR SEAT <5) REAR FENDER 2-0 2. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS 2-0 FUEL TANK 2—3 SERVICE INFORMAHON 2-1 FRONT FENDER 24 TROUBLESHOOTING 24 REAR FENDER 1-4 SIDE COVER 2-2 EXHAUST SYSTEM 2-5 - SEAT 2-2 SERVICE INFORMATION GENERAL - G-uuu heMuly/h-n-Newix (xplmm n4” pen-i- mm". KEEP OUT OF REACH OF CHILDREN Sula-x bum my and: mm mm mm u not unwed m ml him (mount: an 11le or um'nd Work in a wall vamilma am, Smoking or Illnwing films or ialrts m m- work um or when gasoline ls stoma can own a fire or lxalotlorl. TM: union cover: vomovll and Muslim»: o! m- lmly annals, lual IIIII ma urn-um swam Always replace me axhlufl pip. yum nlm rnmnvlna mo uthlI plp- lmm m. anglnn. when inmlllng mu nxhnun amum, loosely inmll all nl mu exhaust ulna lanmma. Always uthan me oxhousl clump: fim, than IFQMIII mu mnuming fun-non. N van “ng me mounting mun-r: fim, ma Ixhnusl Dion my nnl m: pramrlv. . Alwnvl lmnon me axmlm mum lor Ian mar inmlmlon. TORQUE VALUES Fuel VlIVIl Dock nul 25 N-m (2.7 kgflm, 20 IBM” Exmusl alps iolm nun M Ma (I .t kwh'rl. ID IEMJ TROUBLESHOOTING Exam- nail-nu nolll ~ amnn uxmumymm - Exhaun 9. uk 9w mum-nu « Dal-"mad axhault iynom - Exhluu w Isak - Clean-d mumar 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER REMOVAL] INSTALLATION Remove lhu smla covm maummg scmw Raxaasa ma gmmmnls [mm M .w ammu- housing xaua than mmuve \ha sin. cave: mm" the s‘de covar rn me revme army 0! ramova} SEAT REMOVAL Remove the tea! seal mounlmg balls. Shoe me real tam backward, men remcwa u ugward‘ Ramuveme from sea! mnummg nous. (Z) FRONT SEAT Slxdevhevrum :em buckwavd‘ man “may. :1 upward FRAME/EODV PANELS/EXHAUST SYSTEM - ~ . INSTALLATION (2| mom SEAT \ mm" m. mm m: wgmng ms hook wnn me llama "man and nghlun ma (mm sum mommng bans Inilall ma rear seat augnmg ixs hack mu me 55:! ban '2' BRACKEY bracket groove, Inn." and lvghlen (ha rear sea! mounlmg bulls CAUTION - Damldunwgr w um human um.- mun": m. Nun/u: FUEL TANK REMOVALIINSTALLAHON L—— - Guab'nl LI emu-u, flan-uh and "plum "In unu- mafia-'1‘ KEEP our or guru or CHILDRFN Remove the seat [pine z-zp. Yum me fuel Volvo OFF and dilconnecl me We! lubn Rumovs ma Iual (Ink maunling malt: and cal|lr:. than ‘ mmovl mu fuol nnk. Disconnect ma In-I nnk mama: lube -. 1 BREATHE“ TUBE Inmnnian u in me raven: order at removal. NOTE « After install-lion, turn me me» valve 0N main». sure mum no lucl Illk FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL Remnva me screw and fllscnnnac! me speedometer cable lrom me gearbox Ramova ma ipeednmumr :5th «mm m mud: on me from land-r Ramave ms lrunl Vermer muummg hulls, hunt lender and mm hue qulde. lnslsflluon ls m lhe Ievaru oldu a! removal REAR FENDER REMOVAL Remove um seal (9-9. 2-2) Remove me bolt and connmm covu. Dlsnol’mecl [he rsarlum Signal we connecmrs Relanie m min slgnal wuss "am the clamps Remave me ml and um. elgnal unit .mmbly FRAME/BODV PANELS/EXHAUST SVSTEM Ducnnnecl me my lender suh-hlrneis oonnccmrs t3) REAR “N99: Remuve me mm, ham and 7931 lands! assemb‘y I W CONNECTORS A :2) sons INSTALLATION m REAR FENDER Inimfl-Iinn I: in me reverse order at removal. EXHAUST SYSTEM REMOVAL m vi - m .9: mm. m. 11M”! lymm vhf/I i. m NOTE ‘ rh- Inn at rigm muMIm can be mmuvad innivmuauy. Remm/u me axhlull pvpa 1mm "um and imm mum. FRAME/300V PANELS/EXHAUST SYSTEM Lumen ma amw we mm mm mm (1) Bow :2) JOWT BAND fiamuve ma 'ullowrng 7 Passengervoomeg momma new , FOOYDBQ and collav 7 Mufflev bYaCle! muurmng Dans arm callers # imam [upr- 4 Exhaust pine gum 7 Ethm Ville 1mm naskm — —. PAsssrgsea FDOTPEG INSTALLATION u N-m (u kgl~m, m mun FRAME/BODY PANELS/EXHAUST SYSTEM msmu the exhaust We w mp 'evn'sn o'mv M 'emom! NDYE - Aiways rem: :ne Exhaust Lupe gum; in mm rune Easkei W‘U" nuw ones ‘ When ms‘m‘hng Ihe exnfium We mu meta“ at (he Vasmnr evs mam Nun, hqhmn me nxhaus’ ma ,mm mm Yhun hghwr (he uxhaus‘l We mm! um: um mnummg vasxenws ~ A\ passgnger «a 9g msquuun mm: m buss walk mu m "m brackalgvouv as shIwn Yonouev Emu-m pip- iolm In“ H N-m n I igtvm. H) mm 2-7 3. MAINTENANCE SERVICE INFORMATION 3-! DRIVE CHAIN 3-12 MAINTENANCE SCHEDULE 3-3 BRAKE FLUID 3-15 FUEL LINE 34 BRAKE SHOE/PAD WEAR 3-18 THROTTLE OPERATION 3-4 BRAKE SYSTEM 3-16 CARBURETOR ONOKE 3-5 BRAKE LIGHT SWITCH 3-11 AIR CLEANER 3-5 HEADLIGHT AIM 3-17 CRANKCASE HEATHER 3-6 CLUTCH SYSTEM 3-13 SPARK PLUG 3-8 SIDE STAND 3-!8 VALVE CLEARANCE 3-7 SUSPENSION 3-15 ENGINE OIL 3-9 NUTS BOLTS, FASTENEIS 3-19 ENGIIE OIL STRAINER SCREEN 3-10 WHEELS/TIRES 3-20 ENGINE IDLE SPEED 3-11 STEERING HEAD BEARINGS 3-20 EVAPORATNE EMSSION CONTROL SVSTEM ICALIFORNIA TYPE ONLVI 3-11 SERVICE INFORMATION GENERAL _ . Whammlen-{ilu’hflw undvlrvmin rm. mm" mnwndl-trluu. Smuuormwm/Imx mum-meme-unnvmunmmmuufwmm - ”mam-lmkmduhhlw m.uurmmmu lullvnlihrd. Nmrn-m-wu-nmbutm Th "WWW.”MunnnwWMmmemalnnmnw-aywmmm - I’ll“ mo molorcwla an level mound heIore 5"an any work. SPECIFICATIONS ITEM spec-MAM ThrmlIl pdp'mpllv I 7>GIVIWIIUIZ~IIAIM Splrk plug ch NIPPONDENSO | ink}? 7 ’7 7 menu uwsn-u i Farmld dim-u (bolaw B’UH'F) CREHSA umsnvu #_ cum“ uzzsswu 5pm plug gun E 0.9 - 0: mm (0.02 — 0.03 m VIIVI ale-Inna I IN UVM - 0.” mm 10.002 — 0,00‘ In) ”ii 7’ V 7 mos A mm mm (0.002 - 0.004 In) ITEM mam Engmn on Al drlinlnn L5 um 11,: us at. 1.3 Imp nu unanirv Ax mutumbw 1.5 um (13 us :11, u Imp m) Rummemkd Inninu oil HONDA Gm wrote on 01 «mm»: rumor all API newton :uumwlon s; or 56 Vmsw SAE 10w » to EnnlnIKJ-spud 1,100:le mama-m ‘5—25mm(5]a»1lnl ammo-ma hnkn fluid can or 4 V 777777 arm pea-Ihunm 2n-nmmta/I< Hum) cum. MuhIIplly m—mmmtlll»3l¢int 11mm [From 100-1811? ‘ Eur mm - aswc 66? Cold m- Up In so kg (m nu) ma Front 200 :9. (2m lu/um’. 3 psi) mm". Roar zoo :9. (Lou wcmz. :- In!) Up an mad-mm mm mm mm m u». 12.00 knicml, 29 pi) Ru! zoo kP: (2.00 want. 2: sun Mlnlmum «u find am PM“ 1-5 mm “-05 i"! ‘ fiw u mm mm": TORQUE VALUES sum plug 12 N-m A12 I'm. a Mm vw- mun-r lock mu 10 N1" 11.0 um, 7 M40 cwm had now! boll an N-m 11.0 mm, 7 mm wnu Ipoh T1"! VIIVI! nut TOOLS vm. some"; wunfl‘ a fimlng up much am cluln am — Llni mm hold-r Whoa wan wnnch 25 N-m 12.5 MM, ‘6 Mm an N-m (9.0 inf-m, is IM) 4 Mm (OJ Mm, 2.! [Mm 3 Mm [03 Infill, 2.2 MM 077M — m or time ~ KEW 077“ ~ WIND! 07HMH — MRIOIOG WHMH - MF‘ID‘30 07701 - mm Max milubh In USA. 3-2 MAINTENANCE SCHEDULE Morin nu num- Imp-mien In In. mun Mum-I n Inch Mud mum-Mina who, I: 4mm and Dan. Mm. mun-kal- or mm H mm e um, n.- n-puu A: Am L: manna-I m knowing nuns mum mu- modllnlcll knowlongl. cm-In Ium (panicuuny mm mmd - um "I mlv mm:- mm maul Imam-um Ind m comm rhoIr Iufllodud mum Mu. mm Mom mom READING (NOTE II XI,” ml 0.5 I 3 I2 I6 20 1‘ ITEMS xmum In a m m m m an FUEL uus I I I u mom OPERATION I I I u unauanoa max: I I I NRCIEANER 3-5 mum mam-Ian u SPANK mm H :57 H mm "0' VALVE CLEAN} ENG"! OIL ENGIIE OIL 8mm SCREEN ENGINE IDLE SPEED EVAPOMTNE EMISSKIN BOWL SYSTEM DRIVE OWN MAKE FLUID BRAKE SHOE/FAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE SYAND S-II SUSPENSION NUTS, UOLTBI FASTENERS 3-19 WIELSII'IHES 110 STEERING HEAD WES 5-20 E 5 g Inn-EMISSION RELATED ITEMS ‘ ShouldbourvleldbymlunmdzldMONDAmhnuM-Il’umrhllpmlaoulndflfvleldulnflll mmwmm -- Inmmduhly, wo mmm Whammmwl‘wm Imam HONDAd-lor. NOTES: 1. At Hahn odmm mdlnq, Input adv-imam Irmnl Infill-hid hum. 2. Slrvlnl mm (mummy thn mung In Mum-IN um or any mu. 3. 5mm mun Inqume when rldlng In "in or m In» III-mu. a, 1:."an wu- only. 5. Nlpllu mp, 2 yum 01 n Imam cum-m [MIN-l, whlchlvur com. flm. Ruplmm nquIm Mum-I IIIIII. MAINTENANCE FUEL LINE ‘ m FUEL TUBE ' Chuck mu my hues (01 delarmvahcn, damage ur leakage Replace mu 'usl [me u nacessdrv THROTTLE OPERATION Check in! smooxh (News gvip mu Opening and amnmann mu cmsmg m answering posilions Chuck ma mrmxln names and 1691326 mam "may m daluri ammo. klnked m damagnd Lubricale the memo cabins, il mvoma operation it mu smoom Musum me lies play al ma Lhrunla grip flange. FREE PLAV:2-§mm (1/12— I/unl Thronle grip nae play can he odlunad m eflhar and ov me lhmulo Bahia Mmur ud|ullmum are mean Mm m: now “may, Removame Gus: cnvlr 1mm me adlunorv Amusl (he (m pm by saommg the lock nut and Imning the adlusler l3! ADJUSTER L2} LOCK NUT Mme: augustmenm are made wuh me lower odiumrs. Aamsr me owe may by Ioosanmg m. lock m and mmsng [he Bdiuflur Aha: admmmam, lighten um um nuts securely. Rachael ma lhmule aparanon Ruplam any dam-gen pans. iv necassnrv 3-4 MAINTENANCE CARBURETOR CHOKE The choke svszem uses a me» ennchmenl mun Conlvollec m a slamng enncnmem {SE} valve The SE vsIve apens [he enrichmsm mm we a came when me make levev cm mp handIehHr Is nullen hack mcroxf‘wzn Check for smomn choke lever operanon and Iunnnzle we choke cable II .equuaa. Impact my cable 1m cucks wmm coma allow moinure u: my. Rapraca me name I1 necesw'v AIR CLEANER Remove me Isl: sum LDVf‘f {stage 272\ Remove m saw; and an cleaner hausmg cover DISCDNVDCI Ihe brealher mne "am we aw cleaner PuII um me an cleaner saumg plaxa, lhel» ramuva (he an cIaaneI 1mm me Imusmg Dvswm me uw :Iuannr m accovdanco wfih mu mamtunanco unedule InsxaII me Dreamy mm :o me new an cIeaner Irma“ me new av cIeanEr and secure a by commessmg [he mung plate as shown a I NEW AIR CLEANER (3y siflme PLATE InslalI me ramDvEd pans m the vevevse omev af remnvaI .2 EREArHER TUBEA MAINTENANCE CRANKCASE HEATHER Remove me drain plug from m breath-1 lube in empty any oaposiu. Hoinpull "19 main plug and clip. NOTE - Servlce mun liegunnlly when riding H1 um or n lull mien! SPARK PLUG Ditcwlntct ma npark plug up! and remove me splrk plugs NOTE n around I. spark plug ham wnn comp and hflom mmovlnu. Ind be Iulo um no more I allawod lo .nm IM combunlon chamber. Hemnve the spark ohm and lnspefl 01 replace n lesclibed in me maintenance schedule. INSPECTION Check In. lollowing ond mplooo ii masonry lmommendnd fiplll plug: pm 34) - lnlumor lor damage ~ Elaouoaos farm]! - Burning condition. colon: in — dark to ligm Drown innicam good condition. — noun-vs Iighmm mole-m malfuncuoning igniliun "mm or loan rnmure. — won or black wow deposit indlcates ovanich minum REUSING A SPARK PLUG Clun me spark plug declrodes w'nn a wlm brush or woclol plug clumv. cum m: gun belwecu me mm and sl‘da ale-modes wllh . wire»pr lulu pluqc. u mum, nulun ms gnp by bending (h! m- alumnae uMulN. "ARK PLUG GAP: DJ - 0.7 mm [0.02 4).” In) ll) DRAIN PLUG ‘ U) SPARK, PLULj cu (I) CENTER ELECTRDDE . la] INSULATOR [— u.eA 0.7 mm (0,02 ~ 0.03 In) 3-6 CAUTION - 7,, "mm mm, m w ”mm, (mm )mml new," In mm "mm. Mummnmmnghm llllrr/myflrlllulqur Human-H the sum plug m the cvllndsv man and hand llgmen. man lumua m specxlicanun manna; 12 Mm [1.2 lgN-n, 9 IbMtl REPLACING A SPARK PLUG Sat lhe plug gap In suecilicaunn wuh a wlrwvne (solar \ gauge (see snows). CAUTION [)0 ml 41‘ (mg/ll ( 1pm pm lnsull and hand xlgman ma new mm plug. man lighlan u maul I/Z cl 5 mm film {he mung washnr comm me see! alme plug hole. VALVE CLEARANCE NOTE lnspecl .Ta Edlun ma valve clearance w l: [he angin- is cold (below arcms‘n. fiamnva Iheiual unk lgaqu 1-3). Ramon um um plug up um lgnlllan colll. filmove mo buns arm cylmder hand covu. Ramon me spam cllug (page are) Remove me crankshak and nmlng hole cap uslrlu ma spar mnl malv TOOL: Timing up munch 07709 - 001000] (I) cmuxénfrr HOLE CAP MAINTENANCE I2) SPARK PLUG CAP MAINTENANCE Tum ma cyanman clockwln, and allgn m T mark an [ha Hywhnnl wlth [he ”max mark nu me ’5“ wank-ms: cuvm Mukn sun! me No 1 or No 2 won [5 3! me on me mm presslon slvoku mom m. minke and exnnusl vulva clearance: ol me :ylln- day a! me nv imamna e halal gauge belwoen m. adlusl- mg scmw and valve sum. VALVE W: INIEX: 0.05- WIII mm “LINK - 01304 in] mm If nueiury by [conning Ina lock m and "mung me emu-"nu umw unlil mm 1: a sligm an; on me ml»: gauge, Hnld the adlunlng screw Ind (lghton [ha IDCK fluL YDDL; Vern aiming wm-en a mm mm a om- Kssom Tonqu: lo Min ".0 inf-m, 7 DH" Rechack lhe valve clearance, Tum the crankshafl cuumulclcckwhe ana lull mm [360 denvees) end ullgn me ‘T” mall on me flywhaal wllh the Index mark on me In crankclu cover. Check «us vulva claaunu m mm mm" cylmaor. VALVE CLEARANCE: INIEX: a,“ ~ 0.10 mm (0.002 - 0.004 Inl 3-8 MAINTENANCE Check IhaI the cvlmder heed covev packmg Is in gum: condl Imn‘ replace II necessary menu Ihl cvlindar head cave: Insxau ma maunImg rubbers and hoks, lth human the boIIs lo we spawned (Mane TORQUE In Nrm (1.0 “Mn. 1 IM-RI Check IMI D-rings me in good condemn, and mm” Ihe lIming how can and crankshafl hole can Inmu (he removed pm: In me runs: only nr rumuvar, ENGINE OIL OIL LEVEL INSPECTION Place the mammym on level ground Check Ihe nil level uiing me on mlu cap/dlpthck by plasma q mm m We! hols wIIhcuI :crewmg u III II mo on InveI Is balaw or naaI ma Iowar lavnl Iina on Iho mpmck, add m- rocammandad on up to ma upper Ienl RECOMMENDED ENGINE OIL: Nondl 6N4 Lmoln all or Nuinlm API "Nice We”: 5F 0' SG Vinooskv: Iaw ~ In NOTE other vwcosmsa snuwn m the chem may he used when m avevage lempevalure m wow "6an area Is wumn ma mmcaxed rungs. ReIan [he mpsncn, MAINTENANCE ENGINE OIL CHANGE M - I] ma mm. mm bf mum; Ia do mm mm, mm mm m: Ina u vellum-ma NM rim IM- tlglrn In an mrhud um]. 11" rxlunul («mm palm-flan: urban may. ”a. ll... any mm In.“ n/mluflmunflr and land In mm. w-vm up ma engme NOTE ~ Change 1M engine ail mm m. mgm warm and ms mmolrvclu on leval mum: m mule complels dralnmg _ ,. "F ‘ [H D AIN BOLT/SEALI Remove lha 0H flllur cap/dmsllck and drum boll MUTIDN - L‘lrn‘mulm mllllm mun ll." lunlr'lfn‘pvulzvllw :4. m nwm will my um mmmllmmlmmw llumwh m; u unhkh unlrn Mu handle mm’ ml rm 1‘ mm bum u n ,mll mlvlmblr m mm 044th ml. my mm. mm ma/l mm hurl/1H mm: m [’01qu u/n'r muullmg um] all Drain mg on complslaly. Check max m. sailing washer on me dram nan ls In “and canaiunn. mt walla! ll moo-saw Install and Human ms dram ball TORQUE: 25 M [1.5 iii-Ill. It IbHfl FIN lhe cmnkuu wlm lecommnndod englne all OIL “PAW: ml L5 In- (La us at. 1,3 Imp all m.- nrulnln. _ 4 Inn-II me all filler Clp/dlpfllck. Sun me enplna and Isl u «1|- fm 2m 3 mlnulus, Swn lha engln: and check mu ma oil level is al m- upper level line an ma dimlck. Make sure Xhala are no ml lean l llllolLFlL AP IF TIA ENGINE OIL STIAINER SCREEN m smxmzn SCREEN lzl on. PUMP Dlmnlho "gin. ml, Remava ma nil pump [page #2). Romania ma angina nil flrIIn-r Ina!!! Iran! “I! oil pump. Clun [ha mains! Iowan by w hing I! In clean inlv'nl Ind blowing :1 dry with compmm . . Helmtall the all film scrum anlo ma nil Dumpl Inmll ma oil pump (pug. #5). Fl" lhs cmnkcaaa up (a m. plnpfir level with raccmmanflad OII 3-10 ENGINE IDLE SPEED m— I/rm "I‘m mull b< mm, m (In um wad. rub m. m: and a nu mm‘latrd. Nov rurr m mgl'u r. .r 01de mu. m: unrrrur mmr'ru pubmuuu mom. llama“: rm that my mm In: u/mrsrbmm and Int to drum. NOTE ~ Inapaa and adiusl ma mm speed mrr an omer anulna malnlanance xleml um bun mflarmsfl and are wnhm spocmcmronu m. angma mun be warm var accurate rm speed mango non and adjuslmanl. Warm up we engInn 1m lbaul xen mInulee Tum mu lhmnla mp suaw u manila-1m mm ma speci- find idle speed IDLESPEEDHAM: loom!" EVAPORATIVE EMISSION CONTROL SYS- TEM (CALIFORNIA TVPE ONLVI amok m. lube: Demos" ma duel mnk. EVA? owner, EVAP purge conlwl vulva and carom-rm fol uuanurmon, dam In! or loose! connecflun: chuck the EVAF‘ camstar 1m clack: oruthax damlua nmr to ma Vacuum mm Houung Dlamam Label and Cabla A Hams“ Ruunng rug: Lzsr Iunuha cannacuann MAINTENANCE E I» , AMHEDWLE 510? SCREW (ll EVAP FUEGE CONTROL VALVE MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION L - szu mpm nu wan :10: um: rim-:1.» Eu engine .3 mp ”I'll. Turn ma lgniu‘un swllcn OFF. place ms mulorcycle on us :ide stand and mm ma mnunismn imo nalmnl. Check me slack ln the mm mm lawn run mldway between me spluckau. CHAIN SW1“ - 25 mm (sit - I in) CAUTION - melc llmm .Ylm‘k 51‘ mm 4: MI Hr man may 1141me m 1mm: Lubricare ma nrlvn mm with Pu: Honda Cluln Lune or equivalem chain Iunrlum dulgnau spacific-lly Ia! uie wlm o—rlng chains, Wine of! ma “can chain Iuh ADJUSTMENT Loonnlhc rear lea mu. Loos-n ham lock nun um [um boll‘l Idlusflnu nuls unlll ma nan-n arm ch. slack ‘ls ommofl Mnkn mu m- lndol man: on In: bom ndluslar: an llignod with m. rear adgu ann- um :lols in ma swing-rm. Human bum lock runs. quhtan lha may .xle nul n7 me spoclflcd mrqua. TONGUE: H N-m mo Ilyhn, 5 WI) Ruchodl the firiva chIIn llqu and (me wheel 10min“ Lubvicml the driva chlirl wilh Flo Hand. Chain Lube or aquivnIml mm lubrium fissiamd specific-Irv 1m use wlln O-n'ng chains. Wlp. 0" ma sxclu ch-In lube. Chock the drivl chain WIIV indium! Ilbll. II the lrmw mark 0' In: chain ldiullul ranch-3 (he Ind 1009 on the label, replace the drwu chlln with I nlw BM (alga 3- III. CLEANING AND LUBRICATION Clan m- cnaln wlln nan-n-mmnhla or nlun (lath palm sol- venl and MD. ll dry. an m. m. chain has a: a mmplmely beIma luhncafing Imam me arm chlln lav pustlhle damana or wear. Rnnlacs my chin mu hai a-mapad mum, lame f‘ming links. or unarwln Ipnnm unurvicaabln. lnmlllng n nuw :hnin an badly wom sorocllus will cauu me new chum lo waav quickly Impact and mpInm sum-l u newts-w (3) NON-FLAMMABLE on HIGH FLASH POINT SOLVENT Ill CLEAN (zl WIPE AND ORV 3-12 Lubrim- mu mm chlln wilh Pm Honda chum Lulu m Iqulv m chain Iubdanl enigma spoclrlally Var m on Owing chlInI. Wipe om!" ewe-u ch-In Ium SPI'IOCKEI'S INSPECTION {film IVII drle and drivlo mocha sum for Wu! of dam- IM: I'IDIM If "com-w. Nweluul nmdmminonwmnlvrockm M mm M Inmckm mIIII b! In good Oofldhlan. nr m- ncw real-cumin! aIIIIn WIII wur rapidly‘ Check In. lI’lchIIlIu bolu Ind mm In III. drM Ind drivsn nurockm n my m loan. mm... mm. REPLACEMENT This mmwcvelo um! I dvlvu chlln WI". l ll'k-d mumr Ilnk. Loot-n [M MINI ehlln (Illn- 1‘2)‘ Ammu- m. will ml .- shawn. 7001.: Drhldllhlhdl-l MIN-"RIM“!!! WHMH — "RIM“ (US-A. 1|!le NOTE - wm mm. m mam lonl, follaw m. mlnulwlur-r‘l Inmalnn. MAINTENANCE 1 n LUBRICATE I3} PRO NDNDA CHAIN LUBE on EQUIVALENT WWEAR. I?) NORMAL II) DRIVE CD‘IAIN TOOL SET 3-13 MAINTENANCE 1.qu Iha cvlmpod Din until :1 [M "will! link From "In our skin 0' IN WIN, Ind (Imam 1M link with (III drIvI chlin um TOOL: DIN- Mn Incl In OTNMH - ”In!“ ur (mum - MIDI“ tun. sully) Rumuvl mp drivn chain. annvo "VI Bxuxl driv. chlin llnkl from "In fllw driv: mm mm. m mun: ml, NOTE - Indudl me all“! I k WM" you mum lb. drlvo chnin linlu. “U110" - Nmr mat the nil drive chain. mum! I/nlr. mamr link plan and Oman. Inmll Ilia now drivn Hula. Ammbll me an mum link. D-dngl Ind pimv cannon . mm w my [ml [run an m .10. MV: duh. andmlmll m. m. mm m ukulifimnan null/ad" I). am“: A‘s-mm. and m the will tool. You.- Dlivl flfln Incl Ill mm— MMMM at MM — MMMM IDEA. MI Mm mm nu ma mum ||nl plm m Inn-m prepnrw. Mulun m mum link pm My“. nmloclld from m. plum arm mm: W us-mss Imll nus-mu I'll IK: 12 - 1.4 mm It”: - Ilol In! Surh m. mum link plus. m MASTER LINK (2] DNIVE CHAIN TOOL SET (3) MASTER LINK I1) LINK ¢—Iz) 10a LINK —o l4) DRIVE CHAIN TOOL SET [1) STANDARD LENGTH r TEL—“:65 3-14 Main suru ma: mu pms am fiukud properly by muuurlng [ha ammom a! me naked uaa Milng a man :nllpu, DIAMETER OF THE STAKE!) um um: 5.5 mm In}: in) me 5.85 mm [0.222 in mm sukmg. mm ma mm area 01 m mask-r lrnl (or cram. H mm .s any arm-mm realm: m. rnnsxal llnk, Owing: and plan. mu'ncm - A (17hr ”mm mm a (II/Hm! mm 1an Hum rm! 5» med. BRAKE FLUID CAUTION 04- run mu 4.11am: mm «111m. av Mn an! mu rmMIb/r mm nun other Du um um... mm," "mm: m mm m, n'urm whm Mm, m: (run-(u! Armd )plllmg [11ml my pumlnl [11min at mmnmm Hm u mg.- m "mm [mm hum" nu mm u u NOTE When We nuia Intel is low. chick me make pads to: wear Inn nm paga), A law «we luvel may m an: in wear M lhl bllkl Dldfi. N In. hrak. pads are worn, I»: comm niuon is nushofl am, can an: mounu for a law rmrvmr lanl n m. mm and: am no: worn mu nu «ma mm in law, check «mile tystem rm mm use nm paw Check lhe make men/DIV level lhmunh the sigh! glut I! ma Iovll us nu: ma low-r llvul m-vl, check "up br-k- pad wuv (an nsxl panel MAINTENANG u) SUDE CALIPER 3-15 MAINTENANCE BRAKE SHOE/PAD WEAR FRONT BRAKE PADS cnm me mu pad in: was! seams ma brake finds a 21mm pad 1: wum nu ma Donor“ 0! Wear hmll gmove Ruler m 0.191! wt rm mm pnfl mnucamum REAR BRAKE SHOE Ramses [he make shoes {r we aunw on me make um ahgns wuh me reieunca mark '11” when me real bun Dedll ls walled Run" to was 13.9 for Duke shun llplucnmam FRONT BRAKE Flrmly ”my m brake 99v“. and chuck mm no mr has anlavad me Imam n ma mm leals sun 01 spongy wnan opemm breed ma air nom ma system. Inspecl ma brake no" and lining: (a! oexeviombon, crack: and signs 51 lepkans Yiumen any mos. hmngs Replace nan; and fining- u vaqulled Relay la page H»: [or brake meaamg pmcmuras, BRAKE PEDAL FREE PLAY cnemne mm poo-A rm pm FREE PIAV. 20 -30 mm 43/0- 1-!“ hi) 3-16 H Idlunmant 1: "Henry, um {ha rear brake nmumng nut NOTE - Arm adlusbnq um um. pad-V has pm, check me me! man- ngm swath operafiun mu mm H necalsary BRAKE UGHT SWITCH NOTE ~ Perform m u ( mk- switch ld|uilmunl aflar admsfing ma braku poem no. play, - Tho hum bnk- “gm [witch dou nm require ldwnmum. Adiun mo mm huh! swilch in mm [he brake huh! wdl com: on whan m. mks paw a scanned 20 mm (3/: m), and mm anaeucmsm beams Hold mo Iwikh body and mm ma adjulling nul. Do um (um ma swilch body. HEADLIGHT AIM _ - An mu, aqua Mam: n; ma mount... them w any/Imam"... mad/ulna]. Mn NOTE - Adjust me handily?“ beam as specified by Hum law: an} kulnnans Pm. me mmamycle an a level surface. '11! -2M Adina mg hndhqm beam veulcally by lonwnma m. mm Iighl lam-mg ban Alt-vim Ad'un vmicany Dy mining m. vertical adjulnng sum Adjust hnrizomzlly by tumlng m. harmmml adjuninn wruw MAINTENANCE ’7 Horizon-ML“ ADJUSTMENT VERWCAL ADJUSTMENT 3-17 MAINTENANCE CLUTCH SYSTEM mam. me clulch free play u the and of ma clutch rum FREE Puv: In - zn mm 1319 - 3/4 In! Mlfinf amuumam no nude wuh me upper nflluuar in ma clulch lam, Loalan um um run and mm m admin! cMmoN - nu "dun!" nun m dtlnmfird 4/" n ”(inflow nm N, m. 1mm mmmm mum memwm If [he adjuster Is lhwlded out nur VI! limil and m: carted 9m p|av cannot be Dblalned. turn the winner all [he way in and back on! on: Ium. Yigman lhe lock nu! ma mlke a mile: amuumam a: nuanced mow, Mniot adiunmunx i: per'mmad 5| (he clulch um Loon" ma Incl nu! ma mm m; amumng mu m unjusl m. plnv Hold ma amumnq mu securely whlla lighmmnp ma lack mu, Iv propar me play animal In ntmmm or the dumb Nip: dunno me last n’du, diummhre ann mwm ma clutch [m min 9) SIDE STAND Supnon ma mmorwcln on a nun: mnm cum me sing mm: spring (or damngn or ions at tension. Chock m. am. lunfl auamnly lo! lI-anom of muvomanl ma lubricate (he ulna mun plum If nacemry. cum the Side nan-1 ignition cubafl mum. ~ 5i! amide ma motorcycie and rake me side and — Srsn the annine mm the lranlmiaslun .n neuh’al‘ (hen shlh m. lvansmlsalon mm gen, mm the clutch lavev squeezed. 7 Mwu ma Md: um: um dawn 7 Tue angina should may as ma slda sland is inwaven H m I! a pram-m with the sysmm, chuck ma Sid: “and sw-Ich {union 13) (1) LOCK NUT l2) ADJUSTER \ 1‘! SIDE SYAND 3-18 MAINTENANCE SUSPENSION _— ‘ mu. m er any: (Hartman pan: [mil pawn—yd: nu:- ma, Ind tomL new or rem arr, a...“ err-puma 01/0" 7 kidinr n .rrrarqdr um [null] amp-mm run-am yall rm e].- mum udpaulblt Irv-q FRONT Check me action 0! m. (art: by operating ma lmnl hiatus and wmpreulw the hem tutpsnsiun several eres Check me smile ammexy fur slgns er lasts. uamaee er louse manners Realm damaged compounnn which annual ea vepaired. flahltn an mm and balm never tn sun-on :2 for lam service REAR Support (he mmorcycll warm and rma m. rear wheel on me around. Check {or worn ewrng-rm hummus by grabbing the mar wheel and mamminn la mow the wheel sifla 10 5mg Replace me taming. iv any leeseneu I: "area. Check ma mien er me shock absavbavi by complasmng Ihem n ml times. Check the swim sneak absorber assembly rer srgni n! leaks. dlmaw er loose ramneu. Raplm damaged eomponenu which urinal be repaired, Tighten an nun and balls. Refer (0 union 1: Mr mock abwrhlr service. NUTS. BOLTS, FASTENERS Chick mar an ennui: "ms and bolts are owned re «heir comet xerque valuu (page I-Iz). Chick mu an cunev gins. :n'aw clips. mm clamps and ubll my: are «1 man and prnpuriy moved MAINTENANCE WHEELS/1' IRES NOTE {ainresnve :hnuld m chucked wmn m- COLD. Ems un REDOMMENDED TIE PRESSURE AND THE SllE: Unit: uh 1kg!/cm’,psll "\ \ mom nun Cold Uplosflku ’ m: Izoalnsnam 1°°‘T‘°°r?i>2m(z.oo,29) 9"” uvuamnximum suve Mighmmw momma) 1001100291 V ISO/BO- I5 Tm: sm- 3.00 -15 HP MIC as? Chock Hm xim var cm, cmboddcd mm, or nth-v damlgv. Check the "on! and rear maul: In! Imanun (Inf-v m up “on 12 end13). Mnsum the "and daulh a: mo comer a! mu um Ropllco nu ma Mun me "and damn menu lha {allow me "mm. mum TIEAD Din“: moan: 1.5 mm (0.0! In) REM: 2.0 mm (0." ill Tighten lny mow wok-a TOOL Wilt-l look- wunsh 0710‘ - 00203011 No! "Ill-III. In USA. Maui; A N-m lino huh-1,23 mo STEERING HEAD BEARINGS LA m sTEEmNG HEAD SEAPINGS “ 1, NOTE - Chock mm nu mug! cabin do not iumflum mm mm dlabar rmuon, Support m. mmorcvcla ucumlv Ind rllu the from wheel on ma gmund cm: mu m. rundlobar moves mm "um um. lo use. n ma hlnfllahar mnvn unavamy, binds, m nu varlicul mavemenl. impocnhe naming head bearing: (mum. m 3-20 LUBRICATION SYSTEM lUBHICATION SYSTEM DIAGRAM (I) CAMSHAFT m OIL PUMP (GI CDUNTERSHAFT l5) OIL WINER SCREEN 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DlAGRAM 4-0 moualssuoonue 4-1 same: INFORMATION u on. PUMP 4.2 SERVICE INFORMA‘HON GENERAL - runny—"umym‘uamuvmayu/nmmtwww.mmmmpm.mmmnuum,m youM-xtdollonndaflyklfi. Bknmdvbukaolhomuhl’ MW“ withmq-dmrnmumlifllnlkr hmflhuudnlt SPECIFICATIONS um: mm (in) «an arm sewn: uuln' EnuIna my capacity 1 A: drlIninu 1.5 may ([6 us m. 1.3 Imp nu — - A: dismamhly La lilu (LB us cl. 1.: Imp ml _ Rmmmnndad nngim oil Hana. Gm um. ail nr Iquiv-Ienl mmnr nil Aw Iarviu mum-um so: a! se — vmmv. SAE 10w ~ «2 on pump mmr Yip ale-rum 0.15m)“; 0.20 (0,003) Body mum. ms— am 10.00! — mow 0.25 mum Side durum mos » 0.13 (0.002 - mas) o." (0.006) TORQUE VALUES on drum ball 25 Nm (2.5 mm, 19 mm on Damn mnunu'ng Icrow m N-m (1.0 kgI-m, 7 IBM!) EmeMImm-Wdlwnwm mason-m ~ Emmi! on ma. - on nm ohlngod an." annual! ~ Warn vinon ling: - nun gum funky ~ on no! changnd an." mug): - Worn piston rlnnl - may nun gum 4—1 LUBRICATION SVSTEM REMOVAL Dam ma annlno oil man 340), Remove um um crankcase saver mags s-ar and crankshsh hole can. flame me nvwwael counterclockwnse unm [he mm m me an pump pm .ugns mm mg ml pump onlchlng screws Remove Iha “use umws and on pump unmbly Romow ma 04mg. (1| OIL 9.qu DISASSEMBLV Ramava mo on Il¢a1nar semen mo clean IL (n STRAWER SCREEN Remave me mew Ind on pump cnvu, new.) pin um an» RBI Ramave ma mnar and nulu mum. (z) PUMF COVER ‘" SCREW Ramuvu ma boll: mu golrcnva: m BOLTS (2) GEAR COVER LUEHICATION SVSTEM Remove me pump gear Ind pull the pump shah am of me at WW 5mm pump may a Thoroughly clean all ma componlmi mPuMPGEAR INSPECTION Tumpornruv lnslall me ad pump shunr Irma" the outer Ind {nnar mum Inln ma cu! pump «may Mas-um the up alumna- SERVKI uMIT: 030 mm mm! In) Mmura ma pump bow clnnunm SERVICE LIMIT: 0.2: mm (0.010 In} Magnum [M side durum: mm; a snughr edge and fun" gluon, SERVICE LIMIT; a.“ mm (0.006 In) LUBR‘CATION SYSTEM ASSEMBLY (l! OIL PUMP COVER (3) 0H. PUMP BODY m DRIVEN GEAR t5) OUTER ROTOR (a: |NNER ROTOR (1! SYRAINER SCREEN (3) GEAR COVER (2) PUMP GEAR Inn-all me all pump 3mm and pump gen: mm the an puma body, ulI man In. pump shah and near Inn-1| ma non cavar and human mu nous, LUBRICATION SYSTEM Install the Inan ma oumr rotors. n m cubnuu. between me pump mm and ions! Inmll m dowel pan. Inmll me all nump cnvlr and Iighmn ma Icvuw, Inmn mg ml Itmlnnr mean In ma ml pump body. H) STRAINER SCREEN LNSTALLA'HON Apply oil to me new 041"} Inst-ll - now O-flna into (M crankcase. Inuall m. an yump ma lighten m- mm mews m the swarm mmua, menus: w M-m u.o kflhn. 7 m1 Inna” m dam mum-n com (plus N2) and mam-4| hall: can. Fm lhl Mankcnu with rmmmcndnd angina all (909! 3'9]. FUEL SVSTEM t. , 4. L, , v‘gfid‘fl A 5-0 5. FUEL SYSTEM SERVICE INFORMATION 5-1 GAHBURETOI'I INSTALLA‘HON 54 1 TROUBLESHOOTING 5-3 PILOT SCREW ADJUSTMENT 5-12 CARBUIIETOR REMOVAL 54 HIGH ALTITUDE ADJUSTMENT 5-13 CARIUIIE‘IOH DISASSEMBLV 54 AIR CLEANER HOUSING 5-14 CARBUI'IEI‘OII ASSEMBLV 6~7 same: INFORMATION GEKML - - Gaul-1 1; .mm mm «my. mm mm, [rumor amen or CHILDREN. ~ Ummumkwln‘mhmrod.mrmmwbnflmflmrnnlkmhuuclaudm.TM .mmmrmmwrwummmwmmmwmwuw,nun-"mutua- mumwvflhlnulnllmmnmhumm - nmummmmwhfim.m“Mmmaugmuuonumuummd «mm Work In I WI“ VlntIIIIId um, Smnklrm or IIIWIW film" a! lplrh In rho WWII Iran or whir- anon». in flared an (Jule I ”re M unlulon. CAUTION - B: W: w rem rnv #1095”!!me helm dearth-5 nu Wind [ll-1:659: with tvnlpflywdm‘l Tn. my” nu‘hl be m‘d NOTE - n m- mmolcydo I; to be cured for man than one month. drum In. no“ autumn ruol Inn in m. "on ehlmblr my cause don-d lam making In hard surfing or pool dnvublllw. ~ Wan ammo m umummv, plies m Iwmvad quollm oonuimr under ma clvbumnr mm mm. Iooun m nor-w ma drlin m- carbur'mr. - When din-nmblinn 01- fuel uymm mm, null (In Ian-non: of Rh. o-lIllfll. Raglan. Ihlm wilh naw an“ on mmmbly, um "moving I». albumen wrap m. m- pon M m nulno Mm - Ihon mm: or war n . pitta nlupo In prov-m my Mien mum-I Iran dropplnfi mm m. onglnl. a. m. w mmm m. cam Mun mun-Inna m. urbu- man 5-1 FUEL SVSTEM SPECIFICATIONS ITEM mm CIrbur-Inr ldsnliflmkm numb-c l 49 mm wpe VEJSC ’ Califolni- mu vans I Clnldn type vzaso Mam ill ”I 10 Slow m as PHD! wmw Inllill npaning 7-3/1 mm out mm mm: mm 2-1;: lum: am Mon Iml ms mm «m m) we spend moo: m mm ‘I'Immll grip m. pllv z — 9 mm (m: — m In) TORQUE VALUES Fuel VINE Ind nut 26 N‘m11‘7 mm. In IbMKI TOOL Camumov Ila-I level can»! 07401 — oamooo TROUBLESHOOTING Emil- mm but won’! all - N0 lull lo urbumm‘ ' E091" MOM wllh lull ~ No mm a: ping (anmnn warm hurry) > Clogged llv mum ~ Inm III Ink - Improper shah Mazatlan - Impmnar mum. mmn‘un Englm MIMI nun-womanl- lmpmuv chub DDOVIIIOII lawman manunann 50d com-minim! Inuk- Iir Ink Income: Edit and Imam pilm sen-w alum-mm Law mm compnuitm surfing nnrichm-m (SE) my. [luck won Dlmlpd nlrdnq lurkrhmlnl (SE) VIM llll Rich mlxluni Lian mlxtun clung-d ammo! Mung mm W - militia" mm (-qu - Laan mimm Mum filth. led-don - Ignhlun mum flukv - Lun minar- rm p-lwmln- Ian—um um poo! an my - Full .ymm cum-d - lgnin‘nn mum mm - Alr ulnnnr emu FUEL SYSTEM um ‘ human mum malfunction - Clrbumormlflumlon - Lu" mlmm ~ Rich mhaur. L.- Inlnun Clean-d MI in mm mm "In mm luvel m low Clogged Ilr want In». Inun loot Vlcuum piston stuck alum mm mu- - Chow lir charm - Wom In who: nnodll In: - may Ion vllva ~ no.1 law Ice Man - Sunlnn lnflehmwl (SE) v-Iv- nm opln ~ Dim-god «mum mIcnmm IsEI vllvv an - cum“ an 3.: mm m u. m - Imam com. um. opurminn - sum»: mnmmm (SE) vllv- [met or Human“ 5-3 FUEL SYSTEM CARBURETOB REMOVAL Loosen me slamng ennchmem (SE1 vnlva rm: and vsmuve me SE valve ham me camumm nemme me mrume cable mum-r screws and macannm me "Home cables lrum the "muffin drum CAUTION - Dumuhuk /..m/».rmmm. mink Iv n'leHu/nrurr Jmnn'lrll run/mm 1m 4! u u mmm mm: Looun me commuting lube band screw fiamnva m: urhuvemr muunung mus Ind carburewl. Diuunnm the my van! lube and ovarflow rubs CARBURETUR DISASSEMBLV STARTING ENRICHMENT (SE) VALVE ‘ Dwscnnnecl [he choke cable and ham me SE valv: and ’ remove me valve wrmg Check me vawa rm n1:ks.umnve§ m olhev damage Choc! m- vatve seax 7m waar FUEL SYSTEM DIAPHRAGM/VACUUM PISTON > V m CHAMBER COVER note " Thu duphmgmlvacuum prawn can he lumaved wilhnm remuvmg ma float chamber. Rumovnhe vucuum ahlmbovcavav and air vw lube guvda by ramming me (our screwia 1- H) SCREWS Rumnvn mo camplol an Spring and dupmanm/vuuum n) SPRING pimm \ Imam ma vacuum pmon w wear, mm. m umav aamaga. Make sum ma pmon mnvu up And down may m ma chamber (2) DIAPHRAGM Put» mu m naanla homer down Ind turn it counterclockr win so angles: with - lcmwdrivar Than mmove ma nae ma holdav, spring, .ax nondla and mam: hum ma diar phlegm/vacuum pzatun lnspacl Iha wt Mama [at Ixcmlve wall n ma up or 0mm namaaa Check luv u mm mapmqm or other detavloruhon FLOAT AND JEI’S Remove ma mm scrsws ma mam-m: pump mapmgm mm l1) SCREWS (2) DIAPHRAGM COVER 5-5 FUE L SVSYEM Ramnw "m sunng dsaphragm and [mm 1378001 [2) mAPHRAGM (I) SPRING Remove ma accoxeramv hnk bum calls! and washm m UNK BOU’ (z) SCREWS Remove me low screws arm m- "Dal chamber, Remove the mllnwmg. m FLOAI CHAMBER _ Final pm _ Float * float vulva l1? FLOAT (Z) FLOAT VALVE Imp-u ma "out vulva 901 gram/Di and men. and raplacl u nacmary, mam ma agammn m mu um Remava the knowing: — Mam 1m _ Needle ‘9! mm. — Neodln m _ Slaw Jul Tum the min: screw m and record nu.- numba: 0' mm: balm: u sum hgmly use [his n n rafarunoe (m mmsulla Hun CAUTION - Bumpy In my ,mm Inrn mu u 1!! m w mm mun \‘(nm u m: a 4.. mul‘ wuz Remove me one: screw Inspacl ma gum screw and each la! and veplaca mm. IH'nay are Warn 0: dammed. 510w opan all carbumo: body opening! wxm mmpvassed ml. 5-6 FUEL SYSTEM CABBUIIETOR ASSEMBLY (at VACUUM CHAMBER COVER IE} JET NEEDlE HOLDER “NET NEEDLE (1) AMELERATOR PUMP LINK (I3? FLOAT CHAMBER 5-7 FUEL SYSTEM FLOAT AND JETS L I3I NEEDLE JET HOLDER Insun me IuIInwing — SlowiaI IAI MAIN JET r Needlo isI 7 Noedltum holder , Msmm CAUTION — * unmm Am mm u/vn'dwunmhrd a n9 ~ Hand]! “1: mt (1ISLDW JE1 Irma” me pun: aurcw mu qum I! m n: angInol panifian I15 noIed fluvlnq "mum Parlmm nIloI scvsw amusxmem II a new 0H0! straw Is Insnllau (gage 511’ (5) PILOT SCREW (2) MAIN JET (:I) SLOW JEr / III PILOT SCREW In-xaII Iha neat and Iluu valva nu ma carburetor body, man inmaII "I! “an am am mlauah ms body and "an. FLOAT LEVEL INSPECTION Max In: aw valve sealed and me "as! arm “m muchmg me vawe. measure the "oil Ievel wem me snacml mar as shown Flo-t Iml. 105 mm 10.7: InI rooL- cmnm mm Ilul niunu 07m » 0010000 Thu .‘Iaal unnol m nuluslad Ramam [he mm assembly .I ma mm IavaI IS mu 0! soamfi- canon (In) FJ.OAT LEVEL GAUGE 5-8 FUEL SVSTEM z) FLOAT CHAMBER Ian a new O-rmq \n ma mm chnmhur Inst-H me "can chamber, Imam M: (cur Hum chamher screws 1:!) LINK BOLT (z) SCREWS Inmu the localelalnt um; wallwv calm and mm bah. H) FLOAT CHAMBER 5.. ma ham and mm” m. acculnrnmr pump shah/aw pmgm, NOTE - Align the diaphmgm {aha mm theiymovn a! ms "nu . chamber. (11 BOOT (1) D|APMRAGM [1) SPRING mm” me alum-gm some and own. CAUT‘DN ~ Dz) nmpmrh m «(mph/aw um" m an?! nghmn [he uiaphmam cover mews. m DIAPHRAGM COVER 5-9 FUEL SVSTEM DMPHMGMIVACUUM PISTON m DIAPHRAGM/VACUUM PISTON Insull mu In Media spring and in nasal: holds! m mo vuuum vision Push m ‘3! "mm: hnldav m and mm H 90 dagraas clack MSE‘ yPRING / “ (2) JET NEEDLE (I) HOLDER mm“ m: mapnuqnwacuum pimn In m: clnmmmr body, m CHAMBER covsa an‘pmng me diaphragm up Mr» me weave of me cubuve In! 9ch Hold me vacuum pmon up m almost In“ open 50 me am- ‘3?5PR|NG\ nhraqm u no! menu»: by lhe chamber cover Inn-ll mp crumbs! mm wxm me sunna nhgnma I“ uh wilh ma hale in m- carbur-mv. and mm. mm It Isa-l Mo urlwl mm lalunmng m. muum prawn. (I) DIAPHRAGM - ‘ Inmn me remaining muum chamber cover sctews. (21 TUBE GUIDE I CHAMBER COVER uunou ' » Du rm! p. n up mnmm and" m. dumbrr turn STARTING ENRICHMENT (SE) VALVE ‘ Install [he apnng aver ma choke came and cannacl ma cable and to the SE vulva .12; CABLE END Maya m. chnke lever all lb: way up and down and make sum mu [he s: vulva overlie: Waverly 5-10 FUEL SVSTEM CABBUBETOB INSTALLATION Comm "1: wvemnw lube and lvr venl tube mun the new glskal amo me insumov Chock met me 0an I: m 90nd conduion‘ mulls: II news my mm” the camunlor mm me fume man and “amen ma :Irbumlo! muummn nuxs. fight-n um lnIulamr harm mow Can/19:1 ma Ihmllla clhln w mu mrmu. drum. man inmn um Ughlan ma 01mm. cam. gum- mm. Inn-II lhe mninu mmhmm 15a valve In mu camumor may. and fighmn ma mu Incumly Rnula ma overflow rum and lirvam lube canary (ma 1. 13% Adjusx m: mmme nriv her play [page any him" {he mmuvfld parts "1 the "worm Univ 01 mmaval. FUEL SVSTEM PILOT SCIIEW ADJUSTMENT IDLE DROF PROCEDURE "-— - um tum: um: be mm. m I!» mm: m, mm at»: m m u «"me A‘rwr m an an... in .- "(mam The (mm mm... prim-nu may. mmw p. mu my mm 1m D/rmurlnuun and India dam. NOTE - I'he pIIm screw Is Emory preset. Adjustmem Is not nec- essary unIess lhs umuretov Is avarhaulad or a new pilot «new I: Installed. Use a whomever wilh modultions of 50 rpm change. . Tum me nilnl scvaw cIuckwila unlil ix um liamlv‘ and man back it our m m. spacifiulmn uiwn. nm I: .n 1m- (in! umna [mm m m Iinnl pilot Icvaw unjunmem, CAUTION - Duncan: 1» the DH»! Jun‘ mu .111 m u» rjlha p110! mm 1; mm rlml mm: m mu "TIM. WING: 2-3]! um am 1. Wclm We angina up to npamtinn mmparfluu Slop Ind nu riding In! ‘0 mmulss vs wfficmm, 14 sum me engine and connem a "charmer lccordmu to me techunmev menuvmurers mnmcxions, u . Sun the shame Ind adjust [he Idle speed with [he rhmr He slop mew, ID|.E SEED: 1,400 : 100 rpm 9' Tum mo pnm mew in or aux Ilowly m obtain m- manm nngme splat]. mmmu m. idle spend with me Ihmtfla mp screw :4 Turn me pilal saw an nnuI ma enuma spaed drops 50 mm. Radius! xhe Idle weed Mm me mmnle stop screw. 9 Apply Locme 601 Dr aquIvalenl ID me inside Mme Ilmiun cap. Plac. me up ova! Ina aiIDl screw so (I!!! II can be turned clukwlee any This w-II pmenl )dwslmcnl m III: noun xamlockwm dlmflon which lichen] me lual minute, NOTE - Be :araIuI not w lum lha pIIm lcraw whnn inn-Inna m I‘mllar cape ._ I II) THROTTLE STOP SCREWJ (a! LIMITER CAP (I! FILOY SCREW ' m srowzas 5-12 HIGH ALTITUDE ADJUSTMENT wnan m vohiclo n m m apmma :onlinunullv Abov- 2,ooo m (e500 um um clrhumor mun be mum-ad u follows In Improw drivnbnlrv and doom” mum mlx» llofli. erm no mo mm. m calming mummy, Slog m an r‘dtnfl '0: TD mlnmu [I WIN". Tum thn Wot 1cm dockwbo m tum Adjun ma idl- sound to Moo 3 mo rum wim my mum mp “m4 mumsmmulzmlnmmdm NOTE - TM! Idluflmum mull be made It high llthude lo ensure props! llluh lltkuda uplrilioll. Am . mm. Emlninn Cumml Worm-flan Updm max on m «.11 um 04 m. llr ell-Mr musing n shown In um mm mm lllullrlflun. NOTE - no no: mm» m. Tubal m my pm mm on ho mny runond "am m. was. CAUTION - Sun-lined antral-Tm N an «my: 7m! m sma/m 415w nu wua m 1mm: «yawn» Mk1! alarm man" my mm mm m nu: may and mm In mfir. I: may at" mm mm. m m m nvcrhmnng Whun m mm. u to ho unwind cominuoufly wow 5,000 In: (Lsoo ml, mm m pilot new to m. Law Allhuda Sailing lpocmld mow, LawAu'rfunE m: 112mm Adhm m. ldk Duo-d 1.400 t 190 rpm whh m- mmmo non W. 8. mm no mm mm wlmnom: u low «hum nan-av. on Vlhlcln Emission Conual Imam-mun Updllo lenl mu I. mm on m- m m. m m u: mum mu;- Inn. I" PILOT SCREW (I) PVLOT SCREW 5-13 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL Ramava mo iuunwmg 7 Rue! under (page 2 (‘r a Sme covers {page 272) 7 Raw whea‘ «page x30: 7 BEHGW (page ‘54) D‘scunnmme veal make ham nwuch canneclol. Remove the menu: rehv much lrom ma humry my Remove the bolts and hanarv may Discunnecx me crankc-su bra-mm lube how the manner sapmmv Loasan ma nonnmmg mho harm sum. (3} BATTERV TRAY u) BREATHER TUBE Remove [M an :Iaannr hnuimg mounnng Imus Hr BOLTS mm and remavs me an cleanev hmmng backward, ‘ H, A,“ CLEANER HOUSING 5-14 FUEL SVS‘I'EM INSTALLATBON Inuilluiofl II in m mt!- otdu ul rlmuvll. ( l2) umnv mv 5-15 ENGINE REMOVALIINSTALLATDN as Mm (9.0 kW, as Ier) 1: MM (1,2 mm. 9 mm 6-0 6. ENGINE REMOVAL/INSTALLATION SERVIcE INFORMATION 3-1 ENGINE INSYALLATION u ENGInE REMOVAL m SERVICE INFORMATION GENERAL - Thu InIlowing compamnu mquim Inglno mmovll rm urvua. — CVIindnv hum-m: ISllflinn 7) 7 oylmum/piuou (Sumiun I) —- Crinkshlfl ISucu'on 11» —— Tnnsmiuion (5mm m - 1M VuIlawInn oumpumnu can be gamma wIth .nqlne Inn-Had ln mo Inmo. — Cumm-h (Scalar: 1) — Clutch ls'cuun s) — Gumhilt “Mm (Section 9] — Commor (Soalou 5) — Oil Pump (Semen O) SPECIFICATIONS "EM 5mm»: Engine uIlZpIny m drIIrlInu 1.5 nm (1.: Us m.1.3lmp :11) Al giiusamhly 7 1.87““! (1.9 US In. 1.6lmp qu Engin- w-Igl'u 33.5 kg (34.9 lbs) TORQUE VALUES Exhlull pip. lnIm mu Enninl ml mourning nul Gamma pedal plvm nut Drive wrudwx bolt 14 N-m (1.5 km. 10 lel) 83 Mm (3.5 Wm. 61 mm) 12 N-m (1.2 “:1szle l2 N-m (I1 Wml 9 Ibl-fll ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL m CARBURETOR Suppon ma molurwclo usmq a sum mud or a mug Tum ma lunman mm. OFF mm disconnect the mmerv mum/914 wirairomlhalurminal. Dram (he engine 0“ [pegs 340)‘ Remove the folbowing. — cmummr wage 54y — SaMual rm {gags 2.2. 3» —- Exhaun symm mm- 2-4: Dlscannact nu.- snark plug cam m SPARK Drsconnacl me much cable from me nmckm and mulch 2 CmeH mm; mm Rsmnve m- n." and 5mm momr uhl- lrom the sum: mom: finmuvama bah Ind nngme glound wzra. stconnou ma crankcase hummer separawr tube from me crankcase Dllconnncl ms muomng connacwrs _ Almmmnv connenar . (z) NEUTMUEXCITER CO‘L — Namul swash connaaov - CONNEcmn - Emmcml cunnacxor , — Ignmon pulse genemnr cannectov ; . . /. ,(ar IGNmoN PULSE GENERA TOR cwscron ._nd Remove me gurlhlh pan-I link pinch mm Hemovl Ihe Ieh mama mourning bull: and VuumeQ/Bisr snm linkage Assembly 6-2 ENGINE REMOVALIWSTALLATION Remuvu ma ban and we stand swnch “ ' 43) LEFT CRANKCASE REAR COVER anuvo ms hens and sxmer molar came cAamn anuve the balls and {24! cvankcusu mar cam Remove me mung pma mm. mung ulna and awe spluckel Ramon me upper any-no hangev nul and ban ,1 Remove the mm, helm and unpar ennlne hangar mam Remove me 7mm angme hunger nuu and nuns Remove [ha mu, can and 1mm angina hanger Imam Remove [he rur annxnc mounnnu nuns and [NHL men rumava m. angina lmm m. m: We of me frame 7 Note m: duractmn a.‘ me engme hanger mm, mum and nangev mm ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION InauII Ina unglno inla ma Irma Tempolanly InslaII me real enema hangal Don: and mm. In an ma Imm angina rung-I macm, man Iampamin inn-11ml nangm hell: am: mackax ban. Inn-II Inc unpol angIn. nangm pIm, man Iampamin mm" ma nangu mm ham and hangar :2on Fun fighlan [he mn nnglna hangar nun; m ma apocmaa Iomua TORQUE: ll N-m [9.0 lawn. 5 M4“ figman Ina ham angina hunger buckel ban [0 ma apocmaa lnmul Maui: 62 Min (63 hut-m, u but) Tighten [he upper angina nangav pIaIa nuts and hunger nul Iecure'v. Inn-II Ina drivn auvackaI and fixing ulna In In. :nunllr , ' 2 FIXIG PLATE shah, InsI-II Ind tight-n ma IIxIng pllu bum Io 1M weaned town: Yonnue: 12 MM I11 “In. 3 mm Insull Iha Ian crankcase rear cover anfl human ma bans. Rum: ma Inna: molar aama Ind aamva n M": m- uhlu clamp: um norm Roulo ma mun mud switch wire uropefly (nag: I Is), InmII ma Iida mud much nIinnIng mo switch pin wilh mu bids mnd hula and the witch amuvn wim we Iatum spring huldinq pm Secure ma aide alarm swimh mm a naw buIl. mucus.- Io Mm (LII lawn, 7 lad-h) , V ‘3) SIDE STAND-[VITO (I I DRIVE SPROCKET 12) CABLE CLAMP 6-4 ENGINE REMOVAL/INSTALLATION mm» m. um foolpeglguuhm mug: mamw and mmll and ughum me mauming bans. \nslaH ma gurshiu mm m we spindle ananmg we punch mans. Install and lighlen m. pinch mm m me apecmaa lemma. TOfiDUE: I0 Mm (1‘0 kglvm, 7 leI) connect "I: lolluwmg conneclml: A Ignilian mm quanta! mummy — Exc .vconwnnmor ~ Nnmral xwilch connocmr 7 Mammrconneam , . . I,A I. m xenmon PULSEENERAYOR CONN ' -' _-r Comm m. unmas- hie-(ha! who u: m- unq‘na (5» SPARK PLUG CA? 1 mm" the angina gmund win and upmn the hall comm me clulch cum. to ma cxmcn arm ma mam Inmll ma :pm plug cups, 1 ‘ r v m GRDUND wmzx . A3)§TARTEE MOTOR'CABLE mun [he (allowing: (2) CARBURETOR — Exhaust imam (plus 2-4) — Camumm (page 5711) — snvmx mm mag. 24. a» Pm me crankcm mm m racommtmdad angina an rpm 3-9: Aunm ma clulch mm mm my {page 3-IE\. 6-5 CVLIIIDER HEAD/VALVES 23 N~m>23 huh». ‘7 mm wan-munkafmnwu % \. 59 a 20 N4“ [2,0 “I‘m, 1‘ IM‘M 12 N~m [1.2 IlM-mJ WHO 7. CYLINDER HEADNALVES sEIMDE INFORMATION 1-1 VALVE GUDE IIEPLABEMENT 7-10 TROUBLESHOOTING 1.2 VALVE SEAT INSPECTION/REFAOWG 1.11 CVLIIIDEH OOWRESSION TEST m cvuuDEn HEAD ASSEMBLY 7-14 nochn AflM/CAMSHAFT REMOVAL 7-3 cvuunEH HEAD msnwmou 7-15 cvuuDEn HEAD REMOVAL 1-7 CAMSHAFr/aochn ARM cvuuDEH HEAD DISASSEMBLV u 'W‘mnw 7'" cvuunEn HEAD INSPECflON 7.0 SERVICE INFORMATION GEEK“. - This union aw." “MD. 0' lhl cvllnd-r hurl. vulva, loam Inn: Ind cam-M. ~ Roch! I'm: Ind umuhm Dun bl urviud wim m. lflDIM Inflalhd In MI (nmo. Tn. origin. mun b. mm M "wining nu Evilnd-r mud Ind um - WhIn alummming. mu ma non m mun-mum pm. in Imuu um um um ram-Ind In m-iv min-1 Iomkwi. ' Gun III diulumbhd Dam wlm clunlng IDIVMI! and my mom by blowIng mom a" wilh “marl-Cd III Mon imp-sign. - anew lrm “Mm-n. an 1. ml Ihmugh an Mu in m cyunw bun. mun m an pun-9o: Mov- mmhllna wllndw Mud End mam arm hold-r. - a. umfi-I nut to dlmlu. nu naming when m." rlmnving m. cylindnr mad cow m1 cylinder nun. SPECIWTIONS um: mm (In) nan STANDMD names Lum- Cylindu wmpm‘siuu IJW RF. {"1 IWDM’. I“ “II It _ 600 mm (Ml-mot hna mrpap. — «1010.004; Vam ma Valv- channe- IN/EX 0.00 - 0.10 (0.002 — mow —— "‘V' “I“ V“. mm on. m “50 — “as mun 0.2151) “2 (0313. Ex 5.430 — Due (0213: - 0.21m no (01m Valve guldo LD. m 5.1754435 (011504.219) 5.50umn I EX 5.17575!“ (0.1156~0.1‘W) 5.50 (0.217) Snm—lo—guldo dun-Ice | IN MI» - 0.056 (0.0004 - 0.00“) 0.0: (0.0031 EX 1m - 0.055(04M12 - 0.0022) 0.“) (mm!) Vam 5m widm lN/EX IJ7— H (0039 - 0.0a) u; 1007) VIN. wing Inner I [W 293 (1.18) 3‘0 ".14! ’V" ""W‘I‘ 0m : IN/EX 33211.50) 7 '— i ‘ 7370(qu Ruck-7 I'm . ROM! arm LD. ‘ IN/EX 10.000— ”.015 (0.3931 r 0.3913! 10.1!)(03981 I Rock-v In“ In!“ 0.0. I INIEX 8.972 -9.8l7 ((1323— 1312) '3‘ (0‘3”) [ Roam "In—mm channel INIEX 0.0!! - 0.043 (0.0005 — 0.0017) 0.05 (0,002) urn-nan c-m lab- hligllt ‘ m 27.383—21.543u.a78I . 1.08“) 273 (um I ‘ EX 21309-27.” (1.01‘1- H7775} Z7.0(1.00I Runoul — 0.05 (0.002) Joumul 0.0. 19.967 — 19.931 (0.7WI - 0.7800) 19.“ (0.750 Bushing Lo, 2006: - 10.05: 70.7300 — 0.7007) 20.20 (0.705» 7-1 CVUNDER HEAD/VALUES 20 M110 man, 14 mm Amy - mung um 10 m mum TORQUE VALVES wm udlustur luck nm 10 Nm ".0 mm. 7 mm mums, hum-mm" hum: nul 23 Nm «2.: mm. 17 mm Cynnun mm ban ‘2 M1102 mm, 0 Mm Cum Iwodlu boll cum" hud cover you 10 N4“ (1.0 mm 7 [mu TOOLS Timing my wnmch 01700 — 0010001 Vllvl guide driven 5.5 mm D7762 — 00101“ v: - yulda mm .5100 mm 0779p 0010000 Sill nun-v. 2‘3 mm (45“ INIEX) 077.34 OOIOIDO Flll um", 25 mm (32" IN) 07731 - 0013000 Fln um, 25 mm (32“ Ex) 01730 - 0012001 lnllrior away. 25 mm (00' MEX) 07130 - 0014500 Cmr holder. 5.5 mm 07781 - WIMOI TROUBLESHOOTING «man 0000000 ur 07884 >DQWD (LLSA. only) ~ thou Ira mmhllv lull-bl. in USA. - Engine napalm pranmm ululllv um mnlm gamma. Thou pmbhm an no alumna by - common an: or by [riding mglno nom- m m lop-um wnn - sounding mu mm. - mm parlmmlm i0 900: n m w. chuck for whit: much in m- mnlcm Mar mm. n I». who I- tmoky, chldK lurr l loin-1 plmn ring1SonInn 8). law MM - vuIv-x — Imam um «mum — Bumod or Mn! valv- — [Mamet um timing — Wonk um wrung Cvllndor hind: — taking 0! aimed mm m — wan-a brunet-d cvlllm-r nun - Worn m/IImI-r, plmn or pinto" minim-111m a) man pony-um - Exconivo carbon build-up on plfilon mm or on communion chlmbu man man ~ Worn mu m 0! van:- mud: - Dam-cad mm ml - Worn cylindev. plmn 0r pmnn ringl (mlon s) Emu-m nun - Imam-x vllvo Mluamm « Slhklnq mm a, mm 0.». wring - Worn roam um mum mu mu. - Lawcvllndlroomnu-lon - Inuh Iirluk o. . Emu-Iv- cmmn bulld-uy on m- glllon and ur mmlon mm Insulting 07 ml nob- - Excluiv- urban build-up - Wum pimn ma zyunuu mam a) CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST _— - ”Maw-mknuflqubmummrmuu m. u wn-nndllot NM m u» "(I'M ion In “mam n. l—K‘nfl (Malphomclflan mum [I‘M-a; mulauulmubumnulllz-lmm Warm up m. mginn. Stap m- anqin. I a mmovu me spark plum, Inn-II . mmpmuian gauge. Open me mom all the way ma crank (ha angin- wlm m mnar motor um“ me nauq- mldlnq amp. dung WESSON PRESSURE: moo WI (“2 Iglun‘, 15! pi} n no rpm Law comvrmmn nan b. caused by: — Blown cvllndar hm gum — Imympcv vulva afliustmem — v-Iv- Innu- — Wum pimn ring nrcvllndu mgr. comma-non can b- emu-o by: —Cubon deWIILI In cambulllnn dumber or on pinon hand ROCKER AllM/CAMSHAFI' REMOVAL fiamovo the We! link (9095 2-3). name" the Inuk plug ulna. Ramon ma tqnmon calls. Elmo" m bolt: and cylindgl bald naval. Ramon m. cvllnflo! hold covey packing. Remove the Usnhahafl Ind liming hole cup: ufilna mu spa- :iaI Iool. TD“; Tlmlnc up wr‘och 07709 - 0010001 CYLINDER HEAD/VALVES Tum ma :r-nluhm conmuclackwlll nun Illun lhc 'T‘ mlri an the “Mail wlth the mm mm on ma Ian crank- case cow. Looun ma umnmh hold-r mm Ind wand-r hum bum In wanna hm In 2 - a mpu. Ramuw ma mn- Ind ummufi norm-n um aml plus. Tums - 5 mm W Imam rock-r Irm nun Ind pull my Imfilv lrm mm out 51ml “MM hnldw. \ (1)5mmSCREW\ Ramon (hi rock-l Inn nd rod“! Irm wring; (Ill SPRINS‘ (2D ROCKER ARM NOTE % 0 erk Ind non m- 6} lmhlod n! m Insur- "Ill [buy no mlmlI-fl In their nriqlnl maxim. (I) ROCKER ARM SHAFT Pu” the wedge A oi me cam chum lensmnet smigm up Whlle hnldmn ma wedge E down to relzes: m: cam chum tension Saturn wedga A wnh a 2 mm am as shown. fiamava ma um wmckel mm. Turn ma cmnkahak counlarclockwisa um; mm, mm lemon! ma mhar um sprocket mk. NQTE ' as careful nmto ("Dome mm Baroda! bum mm ma Crank- me SIM: (ha mm smack”! of! mo umxhlfi flung! Ind "mow the cam chain from me lurocknl. Homcva m. mum-n lrom the rig?“ llde mu remova ma urn sprockn Hang m. cum chnin mm a piles 01 wire m pmam n 1mm llllinv inm me crankulu‘ Rumcvu the sum ung‘ 5pm! ma husmng imm m. mm mm. NOTE ~ The snap {mg and spacer am Inmnad on ma Ian glee omy. CYLINDER HEAD/VALVES (3t 2 mm PIN (17 SNAP RING \ , , go \A I» * U (37 EUSHINGS / l2! SPACER 7-5 CVUNDER HEAD] VALVES INSPECTION mum me make! arms lav was! ur damage (a me camshaft conmn sum“ and [m n plugged all me. NOTE - If mo umshan camm SHHIDG 0' m rockar arm is dam- aged or abnormally wum, check m can! lobes Var dam age Measure ma ID. 0' ”Ch locker arm SERVICE ”MIT. "Ho mm (0.990 In) lnspm m mam Irm shah: in: will or nun-9a. Mluumml 0.0 Much rum um mm. same: um: :31 mm (0.390 in) c-Iculm the mckor mmdolhun clwunca, / / same: man: mos In!!! Iowa In» Imam ma ”mum bushing: m wuv m fllmlgu. Manuv: m: m aVauch bnlhlng, SERV‘OE MIT: 2120 mm (0.75 in) Support bum and: at m camnhak w-m \Hflocks and maa~ sum 1h: camsmn Iunuul mm i am gauge same: LMIT: ME mm [0.002 In! CYL|NDER HEAD/VALVES Messura the camshnfl you"!!! on SERVICE LMIT: 19.32 mm (0.7” in] Measuru ma hmghl at each cum lube sewn: um. IN: 172 mm (1.07 Inl EX: 21.0 mm [Lou In] CYLINDER HEAD REMOVAL Remove the angina from me lame (union 5). Remove mo comm: (page 7-:9. Remove me nuts and inuke manifold. Ramon the cam chain lensitmer upper bull and loosen the lawn? boll. . P354 *- . (2LT§N§IONER LOWER 39m" 7-7 CVUNDER HEAD/VALVES Funnuvu ma cylindar hud balu. nu! and me cylfinde: Mad, NOTE - B- car-ml no! to Ian ma "om mind." has eon ml inn: 1:.- cyllnnu, cau'nou - Do my "71).: m thdrr Wm M um I My mm” mm Ramm- ma dowIl pm: mu cylludu new gum. CYLINDER HEAD DISASSEMBLY ngmma me mark plug: lmm m- cyllndlr head. Ramovo um um spring mum, rminovs. lprinnl um value using the lunch! mu as Ihawu. TOOL- vm who comm-u «7157 » mom um - Ta prnwu 1m 4:01:11».an m mam: m We mum mm mm. mum m "Maw u» roan: NOTE - erk an pun: dunng aismmmy so Ihw can be pal-cad back in lhlir uriqinll Incubus. lem In: vulva “cm tall. Ind valve spring ”on, (2) OUTER SPRING 1|) RETAINER - O (5) STEM SEAL {/0 0) SPRING SEAT f 13) INNER spams 7-8 CYLINDER HEAD/VALVES CYLINDER HEAD INSPECTION (U COMBUSTION CHAMBERS cvuuosn HEAD ‘ I // R-mu carbon dunnl'm hum m- mmbunlon numb-m Chock In. wart ulna hole nnd vulva nun (u: cum. NOTE . Avold dlmlfilnu m. m surfac- - 6mm wm com on sum! it mm In iolvam. Chndx m. cvlindu hurt my wlrpm wnh - «mm min. and ham mum. m uvm’: (LID mm [0.004 In) VALVE SPRING M-uun mu his lung": M the Innnr .nu mmr vllvl lpn'ngl. SEW um: Inna: an m [Lu In) DIM 37,0 "III II,“ In] noplm mo spring. u (May an menu than n.- "Mu lim- _ m VALVE/VALVE GUIDE mined Olch VIM lo! bending burning a! Abnormal mm van, Chock VIIVI mawmonl m lhe guide, manure Ind "no"! aAch vulva mm CLO. 35mm: LM‘rs: IN: 5A2 mm 102‘: In) Ex: in mm luv: In) "LINDEN HEAD/VALVES Ream lhe nuldu m mum my cum" devout! helm m VALVE GUIDE “AME" woman ole-amt. lnulrl m rumu 9mm the combustion chumbev m. a! m. bud mm mm mu- m rumor clockwi-e. 700.: Vlh-mlldnnulnnslfimm ”HI-Mu m - m (USA. on") Msnur' m1 mcord each um gula. LD. names LMT: wax: 5.50 m Iozfl ill Sum-ex nah VIM m D.D. [mm m conesponding uuidl LD‘ In nbuin m- nlm-lo-guldl durum». M Lin“: IN: lfl mm «Lou ill EX: 0.10 mm (0.”. h) ll nu mm-ln-guldl :Iur-nu Ixccodt m. llrvien limin, mm». H a m guifll wkh "mam lflmnmlonl would bdrm m. dmlnfl mmn Ioluanet. ll w, mun my gum: - uncanny Ind rum In EL u an «um-twain. elm-nu axcuds nu uwla Ilmlu mm m gulch! lhn. rupllcs the vulva Ind gulau. NOTE ~ Rifle- Ihl VII" In“ whlnovo thl vulva fluid“ In riflmadlfifigi? U VALVE GUIDE REPLACEMENT Chill mo renal-cement vulva yuiau 4n m. 0mm union of - rallipamlorfov Iboul In ham. Heal me :yllnuev head W van » 15m: (211 A mail will I hot vim or am. _—__ - 1. my hmu. «.1 am, glam when nun" m kulcl - - ('l VALVE GUIDE DRIVER gm laud. um - 00 ml at a um h In hem rhz ryIi-uer haul: u mm mm umpin. Support the cylindu head and drive nu! ma "In guidu [mm m. nombunion Eli-Mb" skin 01 m cyllnam head. TOOL' Vivi m HM, 5.5 mm 077‘! - WWI” 7-10 ”LINDEN HEAD/VALVES Inmll I an O Worn cyllmhr of plum ring: Eur-In unci- . Worn cylindln 91mm or pmon rum - Imprumr ("mu-lion of plmn ring! ~ Scared or mod amen or chlndor wall OHM"; - Emu tumor! bulld-up on the Dillon hud w oom- huller chlmbu Mug a. mould nah- ~ Worn vim" and cvumm - 5mm urban buildrup “UNDER/PISTON lEMOVAl CYLINDER REMOVAL Ramon m. (mmmw _ (Minder head (page 74> — um ch unslcnsr \mr bot! (pm 7-7) — Cum mm unmm ama- — (Mina-r Ramon m. dowll pm: and cylindll gaskn. HSTON REMOVAL Romuvo n omen Bin cup with Wen. NOTE - Do "m M me am In" Into the cvlnkcue. Pvm m: pimn pin am 0! 2m pinun um! mm: m- pit tun. CAUTION ~ Alwy-x "41de um pulp» when prnmnx out the pun». [ml to [arr ”mm” m m. mgqndbmrm. CYLINDER/PISTON INSPECTION cvuuosn INSPECTION Inspect m- mp of ma cvlindcr cm urn-ya, SERVE M: 0‘06 mm [0.002 lull (NUMBER/PISTON m CAM CHAIN TENSID‘NER LOWER sou CYLINDER] PISTON mm m. cvllnd-r ham 10“ mm ur dam-nu. MoalurI m- oyflndev LD. In x Ind Y axis It mm lwfll Yuk! ma maximum rucdlnn m domrm‘na mo cvlindu wun SERVICE LMT: 53.10"“! [2.0” h) Coleman the "DIV Ind out 0' round It Ihmo lmls in X Ind Y uh. Take I’M maximum rewing lo Malmlu mom. IERVIGE LIMY: "9': a.” Inn [0.00: h) on cl rm 0.“ lllll [0.001 in Th. cyllndor mm be rem-ma and an avnmu pitta" Mod If mu unma Hmlu nu nun-m nu mum». mm which: no mmm oz mm [mm In) an mm mm In) nu plnon m cyunanr cl. .nc- lay an avmu- pimm mun b0: am 4.04 mm (0mm 7 name my PISTON INSPEC'HON R-mnvn m. plnun mm. NOTE Do not divulge the pinion ring: dullnn rumor“ Ramon Iny carbon mun-m «m m. pimn ring umavnn. using .n old pinnn ring I: lhawn. 8-4 CYLINDER/PISTON Tumour-my mm" the pinnn mg: m mar prupev posilion with ma mm lacing up. Muasuro tho pmpn rmwwing groan almanac wlm ma Hugs pushed inn: me urwvn SEN/K! UMIT: Tau: mm mm (0.0“ In) Sow-at Mo mm (0.004 In) Inspm mu pmpn for mm or dlmaga man we pinnn ring squlrlly inm m. hollom a! m. cylin~ um and manuvl ma ring and glp NOTE - Push the ring: mu: ma cylinder wnn ma mp nl mu pimn u: be sun Ihoy m Iquavnly in m. cynndu. SM LIMIT: Tag: 045 mm (0,01. In) Socond: 0.” mm [032‘ In) Oll (ltd. I'd): 0.90 mm (1&5 In] Mauura the dlnmelev of m. pinnn en lo mm (01 in) mm lhe hoflcm Ind 30 rhymes lo mo pinion pin hole. m mar: anon-m (1min) Ca|cullla ma pmpn-xocynnuar alumna T-ka . maximum funding In dualmino mo dunne- same: mm: 0.10 mm mm In) Manure ma vision pin hora. SEW qur: ISM mm (0.59: Inl 8-5 CVIJNDERIPISTON Mums ma 0.0. oi u». piaun pin saw: uurr: u.u m [use In) CalculaIa the nimnAm-pimon nln claarinca. WE mar: 0.07 mm (0.00: In) Manure ma cumming rod mail me LD, sewn: mm: 15.0! mm (0.501 ml CYLINDER/PISTON INSTALLATION PISTON RING INSTALU‘HON Clo-n m. pinion ring mauve: mumugm mu aim-II m. pi.- mn rings, NOTE Apply all m m. pimn rlng‘. Avoid pillnn um pinnn ring d-mm during insullullnn. Inn-II on pinan ring: with m. mulling mi using up [)0 nm mix m ion mi mam! ringl.‘ m. [up ring in nu rower mun ma mend ring In wldm. Do nu! align (ht flops In mu oll ring: (side rail!) Space ma pinon ring and gap: 110 degrees mam Aha: Inn-llilion. me rings would mm- mm In an ring gmnvu (I) TOP RING 2) SECOND ‘20' RING ilk (3) SIDE - RAILS [4) SPACER 8-6 PISTON INSTALLATION Cllln a" luv alike! mlmlill {mm the cvlindll hue Ind umma upper mm. NOTE - a. curatu not to a mm m. gukn Apply 3 mm can at dawn ennln: on m the wnnecflng (od um." um. um: pman plm. Cw" 2M owning in“: th. cunmu with a an. mm" m. yimm nd pimn pim, using nlw pimn pin clips. Kimmie ma mg. NOTE Inn-II m plug" with n. -m- mm (ulna the mm side. Do m Illgn m. won an: c|ip'l and gap mm m plnou CIRCUI- Do nm m m. clip I'll Inlo I'm mam-so. Install an dml pins ma . new gankat Can [he :ylmdu ham and piston; wlm main. on. Plane m. pinon bum undcr m. plnonl, mmpmn m: ph- ion vino. and Ilia: m wllndar zwu ma pilmnl‘ TOOL: numbn- nun—moo Runny/a ma nimn hues. CVLINDERIHST ON Inmu the cam chlin luniinnlr 1m: th Insxan ma cam emin unnniunev was. ("mu ma cyllnfllv hand man 7715). 12) CM CHAIN TENSIONER LOWER BOLT/ SEALING WASHER \ 8-8 9-0 9. CLUTCH/GEABSHIFT LINKAGE same: INFORMATION 9-1 mm AM) on. PUMP DRIVE TROUBLESHOOTING 9-2 GM M mam 0““me covsn smmrr LINKAGE 9-10 REMOVAL 9-3 mam mmxcas: covzn mum-c N INSTALLATION s12 SERVICE INFORMATION GENERAL - This mien cov-rl rlmnvnl and Inn-Italian M m. mun, prIm-ry um. gut. ail pump am. your m: 9.111an unk- .ga. Thus some“ an In port-mum mm m. tnninl inn-Ilsa in m. rum. SPEGFICATIONS um: mm (no ITEM 31mm sewn um I Chnch lava! em may w - 2n (3/! - am ‘Ifl Clulch lpnnfl Irlo llngfll 313(13) 3&0 [1.12, cm» an: thickness 2.92 » us an 15 — mm) 1.3mm) Chnch pm warm. — 0.20 (omen Clullh out" Ll 28-000 - 1601' (Lam ~ LUZMI 20.05 "4025) Cllflch out" auIdI I'D, 20.000 > 11021 (0,7874 ~ 01582} 1035 (DJ-I 0.0. 25.9597 25980110220 - ”1228) 25.99 (L020) TORQUE VALUES clmun rm: mm 12 MM (1.2 kyl-m,97|1M(I Clutch mm rock mu sum mum uoppu um boll Gunnin mum tprlng pin Pvimnrv arm our lock mu TOOLS CIutch some! holder Gur huIdor Loch um wvunch,10 x u mm Emu-ion rm 7: N-m (7.5 MM. 50 Mm ‘2 NM [L2 W. 5 IBM!) 15 N4"! [2V5 Iqhn. 18 lefl ”fly I lacking agar". to the threads 5: MM (5.: kghu. 39 Ian WGMB — Kfimol 0772‘- oomzoo 0771643020100 077?! — 0020600 or equivalent commarcmllv :inIBbIl in USA, CLUTCH/GEARSHIFI’ UNKAGE TROUBLESHOOTING FIu'lv dutch (mention an uni-W be counted by ldiuulinl lhl hal UM. Mlmmmwnh Tmmhbnh-nmmdu- Damaged, Idaho at dlnv :Imwh uhlo . Worn mm drum W arm Impflwovlv routed dutch ablu . w.» 9: broken wnhm spindle mum luring ammo :vah mm mauhlnllm - mm mm «m m Flullv clutch IIII-r plI mung Dummd Ihm drum cam wow-s Worn nu! down! lion lam MI m m at W m Mm em W w pad-I wl m m..- . You much elm lovnr mac may - wm or mm «mm mum- mum noting - Chum pm wlrpod - am gum-m wind). - Oll lav-I um high, Impropu all mommy, or mum" and - cm m on .ddnlva (II-nil uln- cum mm "Juana an am can: Won elm :pdnfi: No elm lam hu- phy Chndx hr an mm" Hun in mm Misadjun-d dumb um Dim-god m mm mm lurk am min rm mm [mm 0mm. oil vim'flv Imam-c1 nunhlfi Iplndle umbw Dlmwld mm «um um 9mm CLUTCH/GEARSHIFT UNKAGE RIGHT CMNKCASE COVER REMOVAL ‘ (2: seems ERAchr a Drain ma angina on (m. a-m. Human m. mu and mm Ioomeg bucket Dimunnun mu :Iutch cable «um ma clmh mu leave mu huh! and fig?“ crankcase cover, Remove me glskn ma aml pink CLUTCH UFTEH HEMOVALIINSTALLA‘HON Remuvema clutch Mm rod. CLUTCH/GEARSMIFT LINKAGE Remav: um um: sprung hum ms and 0! the clam arm ‘3’ (“L SEN- Check me clulch arm, mm rod and spllng 1m we!" or dlm :92 cm): the ml am my damage. my LIFTER ARM Apply aruummo 0» ml hp and mm m nlulch arm inn: m. vigm cunkuu cover. mm" m Hhev mung, m LIFTER SPRING Shgmlv mm mu clulch lrm clockwisa And Install ma Mm 7 UFTER HOD rod 1mm viuhl mnmse cavav , ' CLUTCH REMOVAL Remove lhu clulch Mm pma bum. plus and claw" swings. NOTE ~ Looun [he clumh )ihel pllla Don-1n I criuuoll plllem In 2 > 3 slow. Unslakslha cxmcn lock nul with a an“ m winflar. cAunoN . a: :anqu rm] 1:: dun...“ m, mmfi mm; 9-4 CLUTCH/GEARSHIFT LINKAGE amm- m. clulnh cam: lock mu UIinq m. Iplcinl mnls, (I) ‘3me ‘55 7E“ Home" ‘ 2) ' NU E H FPS TOOLS: elm not. hold" MGM! - “70101 www.mxztm IITII641 Posmon me nvanx balance! wmghv as show" em mmn mu cam chain m we remss under 01 Igmnvsl mm" xha cam chum mums: and mm washav, and ”cure 11) CAM CHAIN TENSIONER— mam war: a aim-p m WASHER Inn-u the crankah-fl mm me ma mum” I" CRANKSHN’T ‘ ‘ m NUT when lhe crankahuh mvummu bola and run \a me specir find torque Yams.- Ban: 1: Mm (2,! hut-m. 11 IM—m Nut: I2 N-m (12 um. s INN lnmll m lummiuion (pug: um. Assemble me crankcase tpaqe Wm. CRANK CASE BEARING REPLACEMENT Sanctum ms crankcasn nerves (gage new Ramuvama usmmh wage ”£1 Hamnve me lvansmiislun mega v.41 Yum the inner race 01 such bailing wnh yuur fingel 1m hairlngs shoum lurn smuulhly and quinfly Ana chuck mm ma oum rum 0! each beating in; lvgmly m [he crankcase 11-10 caANKSMAFT/TRANSMISSION mum minim-u: ‘ ' {va MAINSNF BEAmrvc Drive am [he mainlhnfl and mam-n bearings Drive new bearinp inlu nu ngm cnnmlo using me saws! mols TOOLS: mum-h halving: Drlvut O77“ —- W100“) Animatfll “mm 01746—001050“ Pllfl. 15 mm 01740 - 0040800 W hiding: Dm- 07709 - 00I0000 Alt-durum. 51 1 so mm 07706 - 0010600 man 2|? mm 077“ » 0000600 U" mull: Remove nu cununah ma :nunmuhnk all sum Ramnva me an passage plam sum m1 plm. CMNKSNAFI’ITRANSMISSION Drive nut the mummhm and manna: mar-n95. 4 “ EEAR'NG REMOVE“ Hnmave Iha main-hm bunng uling mo mum look mom: Ina-In. turnout, 16 mm 079:: - chsoo mm mum 97m - moan a: 97036 — mm mum only] Driw n-w bearings Inln m- ». crlnhcua, TOOLS: hum W Dflvl 071‘. — mm Amflxumm WITH-MI“ M 35 mm 0771‘ -m mum m4 m mun-mm Mmmfllfim mid-W101” cum-n bud... Dr"! 071‘! - mom Ammln. ‘2 x ‘7 mm OT". < W10“ nun. 22 mm mm - «moon [null . um Grins. Apply n inching agem m m nil pamg. mam mnunlina scrlw threads. Ian the oil plunge mm and Iighxen m lcmws m mu :pocifiod lovqun. WE: In M!" (1,0 I'M". 7 M) 11-12 CRANKSHAFFITHANSMISSION mm" mu new cmnhhlh me counlouhnh all "Ell BAUWN ~ ()0 a." am: pm» mmmlmfi MI wt Man A», (Mam: $an ruxl m M mu Had 11.1 ml 711mg: m 1).. mark mm" m: mnumk lam 11.10). Inmfl lhalranimiminn lplge u-n CRANKCASE BEARING LOCAHONS m GEARSHIFY SPINDLE DUST SEAL (5» CRANKSHAFT DUST SEAL (a) CRANKSNAFT /'\\ (SicOUNTERSHAFr (”MAINSNAFY \ DUSTSEAL aEAaINszoz) mm 19) ccumznsmxrr «a. MAINSHAFT NEEDLE BEARING BEARING (am) (sacs: CMNKCASE ASSEMBLY mun m. downl pm: m: nuw gum CRANKSHAFI'ITRANSMISSION Assomhla me cranium: mum xogflhlrr Inmu Ind mam." rm: mm mm ulnknaso mm; NOTE - “amen [he Ilghl crankcne bolrs in a macros: p-nem In 2 - snap; Install and nghmn ma rwn left crankcase halts. mm” m. neutral swatch and new-4 Mitch m plum, and name" rm. ball mun the removed mm m me mam moor a! rumovll. 11-14 FRONT WHEEL/SUSPENSIONISTEERING 30 Na! (11 ROM", 22 IM) 1 2-0 12. FRONT WHEEL/SUSPENSION/STEEIIING SERVICE INFORMATION 12-1 FRONT WHEEL Iz-a TROUBLESHOOTING Iz-z FORK 124: HANDLEIAR 12—3 STEERING STEM 12.22 SERVICE INFORMATION GENERAL ~ Amy-Wm:did:uplnlhuxuopflumnMcfltmh‘ltdpdlmthlnam‘mfllheruM'k In“: but: lanolin: 'l'lL - When uwlninq m. mm mm, fork or sharing mm, supper! Ihe motorcycle sucumy wnh . [Ink or am" lupporl. - Me: to (Milan u 107 brake mum Infnrmln'on SPECIFICATIONS um: mm a.» ITEM 3 Imuwu 85mm: umrr Minimum me mad cow. — 1.5 «mm Cnld Xim prelim! Up In 50 kg (200 lb) Iold m k?! (1.00 kuflcm‘. 23 nli) 7 70p m mafimum warn tap-div m up. (no kmml. 29 an — Ann mnnul — 0.20 mom Wm! rim runom Raainl —- 2.0 (one) Axial 2.0 (0.09) Wheal hub-Io-Iim dimnco 30.75: I {m x mm Fork up mg 'm Imam 545.9 [21.50) 535.1 [11.07) Fork lube runaul 0.2010309) flocnmmondld fork fluid Pm Hand: Suspaniim Fluid SS-l Fork fluid llvll I29 (5." Fork 1mm upaciry 13‘ cm‘ (7.): us 01,8.ZINID oz) SIeerIng mad blaring pinion! In: - L55 kg (2.29 — 317 lb!) YDHOUE VALUES Smring mm nuI smnng mm Marina “Imam-g mu Fnrk my plnch >on Park mum pinch boll me IXID ball Brake :llipor mom mounlmg ban Brake aIsc mourning boll wm-I spoke Tir- vum nul Fm up Fm mm mm Hoadllgm mum moundng bah 14 MM (7.5 kgI-m. 5‘ mm 3 N-m (0.3 IgI-m. 2.2 mm) :1 N-m (1.1 kgf-m. a lM-ll) 34 N>m [15 mm. 25 mm) 52 Mr?“ [63 knlrrn. I! "If!“ an N-m m kgl-m. 22 mm) ALDC ban 39 Nm an kgI-m, 29 mm) ALOC bolt 4 NM (0.4 mm, 2.9 mm a N-m can mm. 2.2 mm 12 MM In mm, Ia lam :0 him In Wm, 14 Ibm Amy 5 Iockmo mm m m. mind: 34 N-m 13.5 mm, 25 mm 12-1 FRONT WKELISUSPENSIONISTEEHING TOOLS Whul wok. munch Bearing nmuvlv nun. 15 mm 07701 - 0020300 nm lvdlnblo |n U.S.A 07740 - 0050100 Burma nmuvu nun 07740 ~ 0050700 Drlvlv 07140 ~ 0010000 Amhmuannxwmm 0170641010200 Autumn, u x 41 mm 077w — 0010300 Film.1§mm m7ts~0040300 Du lul drivu body 07717 - 0010100 on I am" midlmlnl 07707 ~ 0010501 sen-mm mm sock-x 079104710001 Ban run nmam 019“» 1700000 Stem hearing driver 07040 — Gcwooo TROUBLESHOD'HNG Hun mains Wind an Inn: - SID-ring hud bunting winning run mo mm . Funny whoa! Ian-ring! ~ Funny nuring hud baring . F-uny Minot-r you ~ mmclem fire Planar! - Hem haul am - Faulty lln uh mien MNIMWCMMMW . Wnksprlnnt . Bord «m - am from m. - wnm mun-d Incumy . Flully m-ring hm baring ~ m hm: - Worn when! harms ' W0"! Mlnwrfll 91M oompon-nn ~ wm mm Mock mmr mmwmu - Bnmn’m ~ Wnrmlmulwhoclburingl - Faultnire - Unbalmsdflveandwhool ~ LWMHUIHIMI ' Llell'Ipr-lurl mm min - 1mm m «use: viscoskv - Bunk lurk when - Cloanod fluid put-w W flaky - Law m lluld Irv-I ' Lon- fink {III-III" - Lack at am In gamma-r gm 1 2-2 FRONT WHEEL/SUSPENSIONISTEERING HANDLEBAH (21 HEARVEW MIRRORS , REMOVAL anove mu wu. nun-1:. Rumnve ms rcnrvxcw mxrmrs m WIRE BANDS Remove ma grip and by nolamg m grip and ma vanlovmg we mm. m scnzw / meREND D‘scunnlu me much lw'nch wires 4mm ma swilch, W CLUYQH SWFTCH WIRES , Remnve [ha Llulch lnvar Roma: buns. haldnr and mum lever mum usemhrv t2) BOLTS m CLUTCN LEVER BRACKET 12p LEFT HANDLEEAR SWITCH Ramon me can nmanmv swilch mm: m SCREWS 12-3 FRONT WHEEL] SUSPENSION] STEERING stcrmnac! me chm cable (mm ma choke lever m: remove ‘7’ CHOKE LEV” "V2 lah hand‘nbav SWRC" \ m EHGKE CABLE D\sconnec1malmm mm swmth mm: from me switch K3? HOLDER Ramuve me masxev cwmder may buns, holds! and meme m MASTER CVLmoen cylinder asscmbw \ , Ramuva m. "gm handlebar swxmhlxmunla houama mm: ‘2’ “‘5’” ”ANDLEBA“ SW’TCWWROWLE "WSW“ Dmconnec‘ nu.- mvonlu :anlas horn ma mmmu Dips and mmuvu [he ngm hnndiuhuv much/«Mom: huuaing. 2} THROWLE PIPE 1 2-4 FRONT WHEEL/SUSPENSIONISTEERING CAPS GLUE Hemuva ma handlcber upper huldav caps nemavn me upuer holds: halls, hulaau and handlebar (Z) SPEEDOMETER V U! EOLYS Ramnvl ma halls and smlaumemrflndlcmov pmal Imm- blyl Remove ma nun. lawar hnlfllrl. cushion wuhln and cum» ion ruhhuu. u) BOLTS / INSTALLATION (3| SPEEDOMEYER Infiill ma tushlon mhhers, washers mm lawn huldon ' h I h In ls. Tamvomllly mu ten [he umr o a! nu m LOWER MOLDEHS mm" “In :peedameummimor panel asssmaly and (iqmnn m: bolls FRONT WHEEL/SUSPENSION/STEERING le ma handlobar on ma Iawm hnlunrs. 2’ 2!?“ ”OWE“ W HANDLER” Install the upw humor: and tampomvily ugnun the upper " ' holder Donn mum ma lower may nul. Ahgn ma punch mark an ma hundlabm wim me [on a! ma Inwav human Install the upper ”alarm on ma hanmabur mm mm punch mm: Vulwaru Yigmen the iron: hows um. than ngmen me rear no“: (I) PUNCH MARKS Iv me handlabm gnu: wars removed, apuly Hondl Band A 0! Honda Hand Grin Comm (usA only) m m: msraa 0' ma grip and :0 ma clean surfacn 0! m. Hth m: M: Mn dram: Wan a — 5 mmulas and mm: Iha gap, Home [he gnp lar even apmiwmn o1 (ha adhnwe NOTE - Allowma adha a to amour. how below using Comma ma mvoulu cams m m. lhrunla an» "Inga Inst-U lha riuhl handlebar swhchlthmnla Mushy aKamng n5 lumnng pin mm me halo .n flux hundlabu a) LOCATING PIN ' m THROY‘I'LE PIPE 1 2-6 FRONT WHEELlSUSPENSION/STEER|NG mm m «mm mw m m m Sm mmw HANDLE“; swwcwaow HOUSING mm" me mane: cylinder augning ma am: my me mum ”WASTE “UNDER “’PUNC” M‘F“ cvhnderwim the punch mark an ma hnnmabal. \ (21HOLDEH Inslall ma mmar cvhndav home: with (he 'UF" mark Vaclav / ,, up. Tighten ma unper mu fim, man the lower non Venous: 12 "rm (1: kgl-m. a leII Connect the bum: switch wire: (SVBOLTS (SIBRAKE SWIYCH WlHES ‘(SD‘UP' MARK (AH-IDLE ’(ZICHOKE LEVER v / Cormocl "12 chain cable nu ma choke lave: Inmn the left nandtabar switch housmq unanmq in locatlny pin whh the hula m m: handieoar human m fnrwam screw (HSL we" we 19a: screw IZASCREWS 12-7 FRONT WHEEL/SUSPENS|DNISTEERING mull the clutch levev bracket assembly anumng we end oi “'CLWCH LEVER BMW” lha mam W"! m punch mark on m. handlehu, (UPUNCH MARK ”man me much um: mum name: mm m 'UP’ mark ,- ming up Tigmn ma uanar mm fim, man m lawnr ban. TORQUE: 12 Nm (t2 hut-m. 9 my Comm ma clmch lelch wuss, {4 // «sxsons (3v 'uw MARK mm" mm gnp and and name" the scmw (nscflsw Inslarl [he wvre ban-15V (2) HEARViEW MIRRORS lnsla” me rearvmw mirrors FRONT WHEEL REMOVAL Sunpnn ma momrcvcla securaly usmg a ham or “laws- 15M Rumova m. tpeudamalm came solnng scrnw and mscmr not! me cams 12-8 Lemon the hum uln pmch NFL Forum: um um and m (mm whnol. Remava me sma cull-r from the dam whoa! hubv Ramcve the speedometer gear box h'am mo .11 wnnl huhr INSPECTION Sat me me In V-hloch Ind manuro mo runom. Maul mnuul I; 1/2 Ihatoul Indiwurnading, 85m “511’:an mm «1.000 In) Tum m» inn-v mm of "ch marina wilh your flnanr. The homing: monk! mm smunlhlv and qulmly. Alw chock mu am buying null! race nu ugnuy In [M mm, anove and dllcurfl {ha hlailngs if lhly do no! Hun mommy. qulnly. m n may in lnasaly In m- huh NOTE Ramona me ngs In mlrl Pack nlw tuning; wim qmu Ind Install mam imu the huh wing m- will mm: (Ma 1271 II. FRONT wNEEL/SUSPENSIONISTEERING IIIWHEEL BEARING 12—9 FRONT WHEEL/SUSPENSIONISTEERING Check the rim “maul by gluing ma wheel m a lurnmg mm Spln mu mm by mum. and mm on mnom mung a dill inni~ calm. Mull runoul ll IR In. Kolll lndlutov liming. m UM": RIG-I: 1.0 M10." h!) Add: H mm [10' In? DISASSEMBLV Ramavu the bum Ind buk- disc, Ream: 1h: dun Iea‘ and madamemv an! mainutfrum m- lm whaal hub. Remove the dust seal hum mu rinm wheel huh. Inn." m. Marina rumour hand mm m. mung. From the cumin m. Inmn m. buying lemma! mm ma arm the bearing am at 01. wk... huh. Ramon me nimnca collar and dvrvu am the may marina, mots: Magma-nun.» mun-mm Mug mm- M mu » mm . A l (H BEARING REMOVER HEAD 12-10 FRONT WMEEL/SUSPENSIDNISTEERING ASSEMBLY (1) RIGH'T DUST SEAL Pack Ill bearing cavities with nmuv CAU'DDN - an rillmullan old Mama. am a Imam; hm hm mmwd, ”no harm; man be rrplaanl mm a now an, DvM in l n-w Ian balling mainly Mm in mud lidl hn‘w auL Insull an aim coll-1.11100 mm in x». mm gia- buring whh ils uni-d aid mug om. TOOLS: Dvlw 07143-00!” Ammflxflmm WHO-WIN Pilot. Ii mm 077“ — mm _—__ - mmwmmnwmfiuunmmpwvmu rut-cu. Inn-ll ma mm a»: on me whael mm. lnmll m. mum mm mm mounting mu m the tpocifled IONUB. TORQUE: 39 N4" [4‘0 kfl-m. 3 “DH“ (2) DISTANCE COLLAR 43) LEFI‘ WHEEL BEARING M) LEFT DUST SEAL (5b BRAKE DISC 17) RIGHT WHEfl BEARING mom WHEEL/SUSPENSIDNISTEEHING Plano m- rlm on m. won: men. Pllu mo huh win «In M: no. down and begin llcing with now mun. Aalumm hub palifiun In "Ill mu airline! from [M hub lfll and surf-c- m m. lid. of rim in 30.75 2 1 mm ".21 t 0‘04 (n) u lhawn. TO“.- qum mm dunno mn-Hhhufi‘. WdN-mNJWZJIM Check me rim nmmn (pig: 1340). Install ma wudnmnur gm m-incr mm me Im when huh. n anina in mm mm m. flats in the hull Apply areal. to ma mm lull lips und inmll il lnm "In In" wheel hub‘ FHI m. ludammr Bur box with arm. Inmll mo modem gear box In the wnul mm. nllunlnq its mm with m. rut-liner rungs. Auw mm m me mm m. lip- .m lnmll n in!!! nu uum wmn nub, mun m. dam um. cull-r. INSYALLAHON lmull m honl Mm: mm m but IaoI w um me am: disc is pcaiu'omd him-an um am, being ureful not w film-w m. pom Inn-II m. lrum mu. Fmiflun nu lug on ma mandamallr on! box mm m m Mmompwonme llfifmllsg. ‘3015: ‘| mm(‘,21:0,0un) A—,/‘ 12-12 FRONT WNEELISUSPENSION/STEERING InnuH and xighlun (hrs ”(In to (he Ipscifiad Iorque menu? 62 Mm (6.3 Int-m, 46 mm) ‘ngmn 0»: HI: nlnch mm Conner! the speedumerev came and secure I: wim a saw FORK REMOVAL Ramuva ma inlluwmu - From mm: maps 12 s; — fink. Elfin“ (page Vlv ID) III: A»: allmv an Inn mum": nun. Im- an bran m Ramova my balls and from imam Loosen m From [um signal hrankm bun/ML m Tof HNCH a,” ' Lonsan ma mm (on pinch hnlL "k ‘ I . / / ' , / N me 1cm x: muuammed. loosen (he lovk can but do not ramav: n m. Luosen ma ’ovk whom much In)“ and lemuvt (he Povk lube harm the 'mfi lap vagz and staring 5mm 1 TURN S‘GNAL "‘ . BOLV “m BOTTOM FINCH Eon 12-13 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLV Ramova me lurk cap - In. 1m 1m u and" gum pnulu. 1 u can mm. "mm nu 1th up. (2) FORK YUBE anm/l m (ark wing. Pour mu m. fork fluid by pumping m cm mp. mull u'mu. Hum m can slide! m a vice with somaws or a map :9ch ‘1’ “0"“ SW“ Remove the lurk mu no“ wlm a hax wrench NOTE ~ If [he furl: piston mms with ma socks! boll. lempmirily mm“ (he fork spnnq nno fork cap. Remove me dun seal (I) DUST SEAL 1|) Fonx CAP m FORK SPRING 12-14 FRONT WHEEL/SUSPENSIONISTEERING aamuve m: all sunl nnppar flnw. "i SKIPPER R|NG Pull me lurk mm mu umu reslmm mm m. Midu bum ing in nu Then move it m und out, tipping m. bulhlnn ngnny mm! m. fork mm sugar-lat «am me (ark .nugr, Th- slid-v bushing wm be loved am by m mi mu: hulhlng. ' Romovl nu an lock piece from ma «ark llidcv. H) OIL LOCK PIECE Q fiamnve (ha flog Hug 1mm lht Dark Milan. I? (2) FORK PISTON ( I] SYOP RING 12-15 FRONT WHEEL/SUSPENSION/STEERING leuve me Iart piston um Inbound spring Imm me am "1 FORK HSTON tuba. (z) REBOUND spawn III 0“. SEAL (3) SLIDER BUSNING (A) FORK TUBE /3U5HING R-mnm In. nil "II. buck—up ring Ind indor mulling Imm ma Iurk tum. NOTE - Do not nmove me lurk tube bushing unlm it Is uncou- urv 1o mollw it will I new unuv (Z) BACK-UP RING INSPECTION M uh. MI-url m. fork wing rm mm SEIVIfi LIMIT: 538.! mm ‘21.!" In] M mlfldwlm Chink [he fort (ube‘ lurk l or nil beck pim Ind Ian! pimn Io! 0am. milks. Ind "an! or Abnormal wall, chuck mu hm piltan ring In! wnr or dlmlm. chuck m: mbouna wnnn Iar hligw or dlml . final-m me wmpununu iI uncanny. 12-16 FRONT WHEEL/SUSPENSIONISTEERING Flue ma lurk tube in V-hluu lflfl musurl ml mnouL Actual runom 1- v2 «1- total Indiana: rndlnq. BEIMCE Llllrr: on mu «moi In) m roux was Full an- m Vim-fly mm m. llldm and lurk who hulkingl Rial-m [he bushings If man Is mm moring or Icrmn- , Ina. ori ma Mon is worn so um um oopw sum Ipooar; ‘2’ “a“? ””6 an man man WI 01 (no 0mm “Mm, cu.“ m. buck-up ring: mm: 21 n m i. any uimniun n m- poinn mm". 11) 305mm: (9) FORK BOLT (7) REBOUND SPRING 22 NM (21 mm. 161%) l8) FORK TUBE (1n) FORK SPRING ASSEMBLY mausrseu (system: me\®7 u) OILS AI. / ! (JIBACK-UP amt: \.Q / l2) SLIDE! BUSHING ll) FORK SLIDER uzyronx TUBE ] BUSHING // 2n NM (2.0 mm, 14 mm V m) OIL LOCK PIECE 1 2—1 7 FRONT WHEEL/SUSPENSIONISTEERING Mm Mummy, wash .u pens wnh 5 mph flash or nomflam- W OIL SEN- (Zl SLIDE“ BUSHING mam: sow-In Ind wipe mum dry. (I) FORKYUBE Install 1 mm: lork mb- bushing 1! ma hulhlng has been BUSHWG "may-d Inn-ll m lllding hulhing. back-up um; m: . n-w nil su} NOTE - Inmu ma on IBM wilh m llp "my now" 4:) BACKUP RING mm" m- rubaund Spring and fork oiuon mm mu «m lube. 0’ FORK PISTON m REBOUND 5mm: /// (1] FORK PISTON Inmn mu slap nus emu m: lurk vision (2) STOP RING Inn-l} the oil tank pisca arm: mo lurk pisxan em! (1! FORK TUBE (I) OIL LOCK PIECE than" me lurk tube mm ma fork slldev, (3) FORK SLIDER 12-18 FRONT WHEEL/SUSPENSIONISTEEHING Ham mu «m usaar in a vine m we law: or a snap wwel. ”i FORK SLIDE“ Apply a lockmg agent in the fork mm bolt mud: and mm" Ind light." me mm mm mu 3 mm sealing wash-r imo m folk puma, NOTE :1 me am pinun mm- mam" mm m mm mm, Iem purlrflv mmll m. «m spring we lork can YWIHMM [2.9% 11 MR) Drive m. all sun m using mu spacial mm (N OIL SEAL DRIVER BDDV mom: chantry-body «mu-mom on II‘ Mm mm «17.1 - 00mm 121 OIL SEAL DRIVER ATTACHMENT " Insull m- :10me ring in“: me 1m Ilidll gvaow ucmly. "’ 579"“ “'"G Inn-ll ma dun Iaul m DUST SEAL 12-19 HIONT WHEEL/SUSPENSIONISTEEIUNG Paur {ha Imiflsd Imoum a! rlcammnflnd fork «ma inlo lhI fork lub‘. REMEMBEDFOIIKHUID: ’70“me mawmvm: Illun‘nluluhlzlfl‘flx) Pump (he lork IUD. lave"! “mm In romova lapped 317 {mm the law portion of mo loft tuba. Compass me lork I“ fully .na m'uun m. oil [mi from [ha lop D! m. 1m um. FORK OILLEVEk ‘3 mm [5,! In) (I) DIL LEVEL Pull m. um um. up .na mnlll m. huh Ipliug with m. xignuy wanna call Ind (Icing dawn Inn-II - cw Damn nmn lhe fork no. {2) FORK CAP Inn-1| m- lurk up can [he lurk Iuba. 12-20 FRONY WHEEL/SUSPENSOONISTEERING INSTALLAHON m FORK rune END InslaH nu. lurk mm mm [he smnnng slam. mam mm snvnal brackm m1 fork my wings Angn me mp and a! me hm tuba wim ma unner amuse n! ma mp bridge as shnwn Tighten [he banam Image D'nfl" nun YOROUE' 34 Nm 1: s Irma", 25 Ium Tighlln m. fmk cap in ma spamhed (cirque n .I was mmavm venous: 22 um (2.2 mm, In Iwu Tighxen the my mm mm boil m the spocmeazurqua rescue: In Mm ".1 mm. 3 mm Insnll and ugmn xha (mm mm ugnnl uracm ban/mu (a) TURN SKENAL UNIV BOLT/WT mun m: ham innuev with me brake huse uav VH1 WON“ FENDER Inna” and "mum ma hnntfandav mnunlmg hmxs. Inna” (he "on! whee! (page \2-111 Irma“ mo brake calmnr (page 14 ‘2: (3‘. BOLTS 12 BRAKE HOSE STAV 12-21 FRONT WNEEL/SUSPENSION/STEEHING STEERING STEM m sous REMOVAL Romova mo lulluwmg' Handlebar (page l2-3) — From wheel 19.99 In; — Headlight case —— Speaoomatal (page may — Ign‘mon smch (page \H) Ramove me ban: and connocxor box Remove me From brake has: cllmn bohs, mass Mama and tram cox/err Ramnva the run and headth blackul Laosan me steering mm mu. Ramnve mu 1an 1.9: (page 1271:) Rumove me mm nut and washer and the mp bndge Ramon (ha flecnng mm bearing amustmg nm usmg ma , special locl TOOL 3mm nun sock-t 07936 ~ 37mm 12-22 Ramnva Ina unplr hearing inner ma. neel ball: ml and mavmu mm. NOTE ~ Be urflul no! lo Ioou mu M934 hall-I BEARING RACE REPLACEMENT NOTE - Amv- mum m. bolvlnne we no" u a m. Ramwa m upper um Iowa! balling 0mm um um“ ma will mm. TOOL‘ III not «mm 01“. - mom Inmu the marina um um onto the mm In prmm my mum: from being damaged when lemovlnn "In Iowa! During 1mm m. ”cm m. mm. Ramon mu law-v During inn-v me. with - cm“! In omniv- alum ml, being umml nmlo Minna! me mm. Remowm dun leal and washer, Inmu m. wuhar nnlo me merino mm. Apply gmu m um dun ml up. and inn." it ova! In: moving mm, Inst-ll - flaw Iamr be-rlnq Inna: rm uliuu u Inoclal tool and a hydnulic man. Tom.- Stlullll film MW 0M - Gm FRONT WNEELISUSPENSION/STEERING HI UPPER INNER fiACi 12) STEEL BALLS (3) DU?! fiALM/ASHER l2) LOWER \NNER RACE I1ISTEMNu'r 13) SEEKING STEM DRIVER [2) LOWER INNER RACE (1) DUST SEAL/WASHER 12-23 FRONT WHEEL/SUSPENSIONIHEERING Drivo nuw budnq ulnar rum lmu m. nailing Mud plan. m3: (2) ATTACHMENT Mu. mu—moooo Ammflxumm onto-mm (1) DRIVER INSTALLATION GI BEARING ADJUSTING NUT 3 Min (03 bah“, 1.2 "1"" (2) UPPER BEARING STEEL BALL 1le ll) UPPER INNER RACE (I) STEERING STEM (10) LOWER BEARING STEEL BALL l2" (3) WASHER (E) DUST SEAL App‘v mm In up”! Ina lower WINK: "cu. lnfllll IM 71 ll“! ball! onto uch Boning rm. Insert an nau‘mg mm mm m. nanny and am, being cur-ml not to map nu ml mm Inna" ma “ppm buying mm mm ma mm Ian-ring new.» inn um. 1 2-24 Tignun ma mm boning lap-Inna nu! m m. imml mum TOOL: Stillman-MIMI! mil-1mm" Imus: 25 MI! (2.5 lull". It m: Mwa mo naming mm 69M and M. lock-[Winch rm umu Ia um ma hasnngm Mm sum mu m nil-ring sum mam Imanmly, wimnm pm or blndino: mun loom me During Idiuning nm. Rofignnn me baring “misting nut no mo spocifiod lorqua, MI! W [0.8 kW. 11 M) Roebuck (Ml me nnorvnn film moves Imnumly wlvhaul Pluvnr binding, mun m. lop bridge. mun me folk mu (Dane 12-21). Install the washer and 3mm nul 1197’"an steering flem mil Yo [he speciflod Inmuo. TORQUE: 7‘ NM (75 Him. 54 m) STEERING HEAD BEARING PHELOAD swam um mmmcvcla unng n wnrk mm: 0! box undnr m- angina and mu m. from whnl (”1 (ha mound. Pmlon xha staring mm to m. straight than! pctmnn. Hook n spring 5:: I. nu m to». um um: muiuvl m- u. ‘ ing head baring pvu‘oldv NOTE ' Make sure ml! (hers is no cable or wrn turn I unedu- ance. Th- mm llluuld be wkhin I.“ A 1.5: kg (129 - 3.37 lb). u m mama dun not lull wilhln mo Iim'm, mm ma from whnl mm: flu ground and Mini! 9.. marina bnvlng Idlulflnfi nm. FRONT WHEELISUSPENSION/STEERNG (I) STEERING STEM SOCKET 12-25 FRONT wHEEL/SUSPENSION/S’TEERING msxa» the haadhghx mom and ugmar Ms M lnslaH we mm hose clamp and mum Ihe boil: (3) BRAKE HOSE CLAMP Inmu me cannecmv box and lighten lha bans ‘2’ “”5 Inmll m. munwmg: A «gnniun swam (page we; — Spsodnmaler {me 13-!) — Haadllghl use a Front wheel mags 11 m 7 Hundlubav (my: may 12-26 HEAR WHEEUWKEISUSPENSON 88 Mm (Min, 55 IBM“ 29 -m (L7 Ital-m. 10 IN“) as N-m (9.4! mm, 5 mm I! Mr» “.3 - In. 3' lbf-M 1 3-0 13. REAR WHEEUBRAKE/SUSPENSION SERVICE INFORMATION 13-1 suocx ABSORBER 13-12 TROUBLESHOOTING 13—2 smeARM 13-13 REAR WHEEL 13-3 MAKE PEDAL 13—16 REAR BRAKE 13-9 SERVICE INFORMATION GENERAL Ill - Ammh-wfi-M-mmmmbhmdmmum-dm-Wh-Mauxh yin-B1 um tag-min. mu - A jack n1 mm: mppon i- mqulmd Io mopnn the maturwfll. spearmnous Unit: mm II") m ITAMMD sewn: um Minimum me new depth — 2.0 (one) Cnld [In mum Up In so kg 1200 lb) ion: m m (2.00 kqf/cm', 29 pli) — imammm “‘9'“ mu m (2.00 inf/W, a uni) — Me runnut — 0.10 (nous) Whul nm mom R-d-al — 2‘» (am Axi-l —— 2,0 (0,08) WHIGI "Ulric-(IVY! dinnnce I"! t I (0435 t 0,0” — “Viki pedal I!“ DIIY 10 - 30 (3M -‘-1/‘) — aim drum n). ma (5,12) 131 my arm mung midi-ms 4.6 (0.15) 2.0 (one) TONGUE VALUES REM BIG! MAX Rut who-I wan Rm lira valvn um Dl’IVIlI spvockal moumlng nul Rm mock nbsonm immr moi-mine non R. [hock Ibserbov law-r muumlnc boll Swing-ml pivot mu Drive ch-in lIIdll mourning wow Driv- chuin mm: Inck nut as Mm (9.9 mm, as Ith l Mm (0.. infirm 2.3 "1"“ : Nm (0.: mm, 2.1mm 64 NM (6.5 Raf-m. 37 IbH'O 25 Nm (2.7 mm, 20 mm :2 N10 “.3 not-rm 31 mm as N-m (9.0 mm. as mm 3 NM (0.3 hut-m. 22 mm ID N-m ".0 kgl-m, 1 mm 13-1 REAR WHEEL/BRAKE/SUSPENSION TOOLS wm-I Ipok- much soaring mmmr ms. 15 mm Buflng «new: man Dvlvnr Minimum 31 x :5 mm Ammm. u x 17 mm Pilul. 15 mm swing nmuvlr m — Ram-r um». — Blln'nu mmnver m — Rumour migm N-dll tan-ring mum-r TROUBLESHOOTING anus-um nub- - Wank thocl .monm ipvlng . on lung. 1mm amp" unn ' "mm Ill-won ldlflflmlm - Law [in prom" and mum . Income! IWIM Idiumom : Bun swimnn Divot - Dam-95d Iwinoum pivot Inching: - 30m MW Imh - mun Ilu Dru-um 0770‘ - 0020330 no! lvll|lhla In U.S.A 07745 - 0050400 07746 < W100 07749 - ooloooo 07716 - ammo!) 01746 - 0010300 07746 - com 07836 - :1 1000! 01536 A 3110100 07936 - :11 mm 07741 ‘ 0010201 or 07936 - 371nm mm ~ mm Suw- tn an. id- or do- not Ind: mm ' Blnl m! Ildl . Axl- anynmonucmln gain-9mm nu oqunl on mm mu Inn Man wow-lg Eon! llm Worn mfwhfll bearings Fanny «a Low m mum Faulty will-norm plvm bushinol 13-2 REAR WNEELIBRAKE/SUSPENSION REAR WHEEL (a) AmusTiN'G'NUT REMOVAL ‘ Suppon m. momrcycla seculnly mung a hniil m aqmm lam. Remove tun following: — Cam: pin — Nut. washer. rubbuv washer — Pivot Don — Bnkv panel moppur arm — Anlualinu nu! — Erika md, spring a-mave m. m. nul ma Wuhan . _ _ (3» REAR AXLE Luann m: um. chum Idiunars. ’ ' Push [he ran! wheel hrwlrd Damn the drivu chain. Ramova m we lmm me Ian Hide and vamove um um wmat. Ramon ms adv. chIIn adjumnrs. INSPECHON Auk Place me we in V-blocks and Manama me mnnm. Amml runnul is 1/2 the total Infllcalnr Isadmg. SERVIQ UM": 0.20 mm (0.008 in! (ImEARAij Whld chuck ma nm runoul By placing mu whlal in a mmmg slam: Spm m» whanl finwly mm mm me when! mmg 5 mm mm calm. Amm mnum u 1,12 mm mm mdxcalm veadmg SEW/l“ LM'TS: M 2.0 mm (0.0! In! V 2.0 mm (omlnl 13-3 REAR WHEEL/BRAKEISUSPENSION wnul Durinn Yum we may rage at each heanng With your linger. Beafinas shauld mm smnolMy mu qumly. N50 mm mm ma hesnng aux-r mm fin llghliv m We mm Ramona and mum ma bearing: w ma Inca; do my mm smoolhly and uulolly,au1lhny m Inauw m ma hub NOTE ~ Rapllce me whoa! ounngs .n guns, mm“ quack-t cry.“ m. condition 0! ma final amen somckal mm. Raul-cl ma :piocksl .( worn or mam-and. NOTE v u my rm a m upmcm mun-m raplmmsnn mm m any. chum and arm sprucm - NOVBV Install a new drive chlm on 3 W0"! wrecks! or E warn chain an new unlocks“, Bum chain find lplocke‘ mull n. in good condmen or we vaulacaman! chain or samcm will wanv rapidly. DISASSEMBLV leova um um. nlnul numbw hum ma ngm whm huh, Remove ma flrwan ”any: tram me Ie't wheel hub NOYE - N you wm b- A‘sammma ma drmn "Inga. Iooun mu flnven :pmckel nous Mme remnving Ih: driven Vllng: hum the mm mm, m WHEEL BEARING m GOOD (1) REPLACE //\ //\\ (I) DRIVEN FLANGE 13-4 REAR WNEEL/BRAKE/SUSPENSION / m NUTS our-m fling. thq mnmll Loosen lha drivun sprodml mm Remove [he dlmn fllnue lmm lhn whaal huh, man mmava ma dflven uprmkex nuts and spmckal Rama»: xha mm mm Remove the flr‘wen fling! collar. Drivl out me driven rungs beenng Whnl mung man! Inst!“ [he balling mmovm haad mm (he balling Frum lhe opposite m1: Inlull (he balling ramnval lhlfl and drive "I! bearing cm a! Ihe who-1mm Remove "ll dimnce collar and driva out (ha olhef bailing. TOOLS: lulllIamnav-M. 15mm OHIO—0050400 Inlilu mm I'll" 0T!“ - 0050100 13-5 REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY In New WHEEL BEARING (B) DRIVEN FLANGE 6‘ Mm l5 5 kgl»m. 48 mm) WM“ inmn (I) DRIVER Pack Ill bearing uv|lias with grease. CAUTION - Nat! mural/an urd Mung. "Mr 11 anx Im hm Imwlwl, m, [mm/u: mum ”plural w"): u um um- Drivl In a new It!!! hearing lauumly with in Ilalod lids luv ".9 am. Irma“ lha Mil-“:3 60“”. [hurl drws ln Ihl "gm Sid: bilrr inc mm. In sealed side suing om. room: on»: «no: - mm W doc: Ammnxnmm onu-ooim “’ ”WE" uh nun: Athena-m. :2 x as mm mm — nomoo m I5 mm mm - mom Mm «ung- hiring im-fl'b‘on pm: me new drive» Flange bearing mm m drivzn flange . why me spacu! m4. tools; mm mm — oomooa awn-m. 42 1 A7 mm mm - mam , n "M ‘5 M “77“ ' m 1"gmA‘l’TACHMENY/PILOT 13-6 REAR WHEEL/BRAKEISUSPENSION Pun m. rim on me work bunch. me- m. mm wlm m In sit" down and begin tuning wmu nlw lpoku‘ Minn uh. huh position so that the d‘nuuca hum ma huh mm ma wrhel In tho llfll al rlm it 21.5 :1 mm mm : MA In] a mm. 1001: Wind ”dun MM 011" - moo nut-Mm USA " 2|.6x I mm TONI“: A Man [0.4 ”In. 1| “it! (0.06 : 004 in) Chuck m rim runoln (our 1341 AppN gram n: ma cum ml xlpu, m... Instill it {me me ad» m E nus1 SEAL m Hung. “ lnmll the dvivm flange wllur. Inn-II nu ma“ dumps: rubben lnle ul- whul mm REAR WHEEL/BRAKE/SUSPENSION - be m p: null In! In: brute drum or «upping pawr will A: "and. mulaH me deen flange assemwv mm m. Ian wheel huh u the drwen spinckel m. unmoved. maul! ma ouvan aproclm and ugman ma nun, YoaouE: 64 Nm (s5 kyhn, 47 Mm mmH ma um nus anar (nnamm brake dmm ammblv mm the ngm whesi mm, INSTALLATION mm“ mm dnvs chum adjulurs inlo mo Iwmgan’n Prue ma mu whul mm rho Mama and mint me all: mruugh the fish dnve chum adjunct. reur wheel, "uh! 3102 mm and Wm mam adyunar Inn-ll ma orwa chaln unlo me drivan spruckar Hy DRIV N FLANGE ASsEMELV (H SIDE COLLAR u: DRNE ciAiu ADJUSTER) 13-8 REAR WHEEL] BRAKE] SUSPENSION h) SYOPPER Am Inn-II ma wuherana looselv insxall Ihe we run InslaII ms Duke and “owe: arm emu me br-ke panal InsuII ma nan, mbhev cushlun, washev and nun [hen uuhtan mg nuL Secure me nu! wuh 3 MW canar am In!!!” [ha [DIM Diet: Io Um make arm and connecl {he mm mm wnh ms spun} Inmu me .munmg mu. Minn m. driv: nhnin :Imk (page my. Tum." ma axle nul In m- rammed Inrqua. move: In Mm no kahm as Hm MIMI the In! but! (959! 3-16). REAR BRAKE REMOVAL Ramcva the mm wheel (page 13-3) Remove me bake panel lrom m mar whueI (Dene 134;. INSPECTION Mouun m. vur braka drum LD. SERVICE um: 1:1 mm (5.2 in) REAR WHEEL/BRAKEISUSPENSION Measure me brake “rung xmcknnss SEW UM" 1 0 mm (on: In] DtsAssEMBLV Remove we [make shoes and spring- (1) BRAKE SHOES Remove ma nut, ball and links arm. Rumnvs ma momma: plum, 1m seal and brake cam. m INDICATOR PLATE 1:) SPRINGS 13-10 REAR WHEEL/BRAKE/SUSPENSiON ASSEMBLY (J) BRAKE CAM 4n BRAKE SHOES I I Am (1) BRAKE ARM (2) NBC R PLATE (7) FELY SEAL (a) BRAKE PANEL Apply am” m the nuchov pm and bukl um‘ lnmll mo bmko cam mm m. mm panel. :1) ANCHOR PIN ' (I) BRAKE CAM Apply on to the Ian ml ma Inn-ll i: am the bran pancL (3) Wm: TOOTH/GROOVE mm" m wall Indium plln on ma brake cam aligning km on ”ME wlda mum will! Ihe with 9mm on me tum cam FELY SEAL 13-11 REAR WHEELIBRAKE/SUSPENSION Inmll mu brake arm Illunlnu mu punch mlrks n! the arm arm m: Drake cam. Inn-II the brake arm pinch ban and n‘qman the run securely, Inn-ll m. mm mm and sprlnai. mm" m: brlko panal inla [he whn‘ huh Inns- 1: a), mun the nu whool (mg- um m BRAKE SHOES SHOCK ABSORBER REMOVAL suppon m. mommy/cu mumly Ming . hnin or squwm llnlv Ramove the upper mu Iawev mounnng ham and :hnck nmamr, INSPECTION Vim-Hy imm [he mock nblorbar In: damage. emu m — Dnmpev rod in! band or damage — Dunno! mm Invdulcrmllinn ar on link! — Uppel mu lowuiulm bushingmvww 0v Gamay: Chock smoum dlmver DDOMUOI’I CAUTION . [)0 nm dnam'mhk m, (MIL mm” Rqalacihrz mm ubmmv mm rmlmm u «mud (2: BUSHINGS \ (3] BOLT (z) SPRINGS 13-12 REAR WHEEL/BRAKEISUSPENSION INSTALLATION msIaH me shock absumm mm me name mm” and “gm" 1hr,- uppnr and ‘owL-r muu'umg mus to me spewed (mung YOROUE‘ Uppcr mourning how 2: Nrm (2 1 kg! m. 20 Mm Low" mounting ban. :2 N-m u 3 kglm‘ 31 Mm SWINGABM REMOVAL Remove me rear wheel [page 113» chonnen me rear bvale Dnda‘ rotuvn aprmg Remave the hens and mm mam cover Remove me rem shack absumer nger mounlmg nous. Remuve ma swmgavm pwul nun huh and swmgmm D|SASSEMBLV <31 STOPPEFV ARM Remove the loHowmg . Drwa thmn sham , Flam brake Dane! smupar arm r (2) DRIVE CHAIN sunen REAR WHEEL/BRAKE/SUSPENSION Remove ma dusx seal caps and war :oHMs INSPECTION cum the vam busmngs and mummr won av dlmage Check me swmgurm lot cracks or damage PNOT BUSHING REPLACEMENT Ramave me nulsifle pivol bulhinnl using ma spachl mm: TOOLS: Boning nmovov ul «7330 - 7310001 —n.u1ngmvnrhmau ome-nioloo —lladni "mowm 07936-371000!) — Runny-r w-Inm 0T1" - 001020! at 071m » 37‘0200 Drive om me msme vlvol bushmus Apoly amass 19 me msme cl me plvol bun-mm Drive naw bulhlnga mm m awlnglrm. TOOL Nud- Inlring mow-r 0753! - Km (Ir DUSY SEAL CAPS %0 m PIVOT mum's / m BUSHINGS (2) PIVOT COLLAR m BEARING REMOVER (n NEEDLE BEARING REMOVER 13-14 ASSEMBLV 15) STOPPER ARM m SWINGARM flea ‘ (3| PIVOT ausmNG ®@ _7 l2) DUST SEAL CAP 2 ' m PIVOT COLLAR Gvuau the pivot collars and inmn mam mlo ma nwingavm plum Aoply grease m the mm seal rigs and mm" me dust seal caps onlu ma swmg-rm pwal. mm" ma vslv brake "Donor arm, nun, wring washer. mam wuhsvnnu nm 129an ma nu! murely kmall . nnw mm" mm secure ma mu Irma" me chain snug: and ngmen me screws. REAR WNEEL/BMKE/SUSPENSIDN kew DRIVE CNAIN ADJusTER m DRIVE CHAIN SUDER (2) ”‘1 Dusr SEAL CAPS of m"! Pwo’téaufis g o m STOPPER ARM m snans 43) DRIVE CHAIN SLIUER Qg cow-ran Pwl 13—15 REAR WHEEL] BRAKE] SUSPENSION INSTALLATION \nsxaH me swmgar‘m mm ma 4mm and mm pm pm Dull from [he 18?! Srde mm“ and lighten ms pwul mu n: ma spL-cwfzsd mmuu 70!qu 88 Nm Is.» Inn", 56 Ihmr lns‘aH ma shock abswhev \uwov mounxmg hens and bgmen mam m rho spem'wed lmqua warms» L2 Mm (l 3 mm, as Imm ms‘aH me «we (mam cover znn ngmon me now; mun me mar male pedal mxurn sprmg I Mum mo mm mm (page ‘3 m BRAKE PEDAL REMOVAL Remove Ihe adjuslmg nun make Ind and sunng Vvom the rear brake um, Dlsmnmyc: ma make Dada! mum. spnng me Ihs sw‘ng arm Drsconncct me man swuch sunny H?) SWITCH SPRING 13-16 REAR WHEEL/BRAKE/SUSPENSION Remove the brake pada‘ mm meM huh and brake pedal (1) HNCH BOLYNI, y Remove me man» pen»: pwcx s’mfi um umxu mm as an assnmbw Remove Me com um and mm: um and sepllrate me make m JOINY Pm ma horn me pwal suau 13) SHAKE ROD / H) COTTER PIN (A) BRAKE PEDAL Pon INSTALLATION InslaHauon rs m we vuvsrsa order av removal NOTE AI mmllsxion. nhgn the uunch marks a! mu padal gum and pedal (HBRAEFEIEL‘ 13-17 HYDRAULIC BRAKE 1 N11! (0,1 Raf-M; 0,7 WM!) ‘2 N-m (1,1 Hahn. 9 “3M” :4 Nvm (3,5 knfvm,251bf~fl) 8 MM (0.! Hal-m. ‘3 Hi“) 3A N-m 13.5 inf-m4 25 IN!!! 9 "1010.0 kW", 1.3mm 2 N-m [0.2 “Hm Ll [bf-m 22 Mr: (2.1 hat-m, I5 Mk) II! Mm 11.5 kqv-m, 1:! Ian 14-0 14. HYDRAULIC BRAKE same: (mama-non 1M BRAKE PAD/DISC m TROUBLESHOOHNG 1L2 mas-r511 cvuunen 1“ aux: nun: REPLACEMENT/AIR BRAKE cmzn 14.10 mums 1&3 SERVICE INFORMATION GENERAL - Auu—tmmaxupdmzmwppm.mm.m,mmm.mmrim-ugh mummy-mug... uunon ~ mu mum; 1m.» M m. painted. phullr or rubhflparu ram 11 m. ar my law-11w" um paru whlmw w ”Jim I: uwlrzd. - This uciion Wm mllnl'mnco mm (mm hydlauliv huh. - Once an war-uric mm m: mm mm, 0' im- bnkl Mk Iponny, m. mum mun be bled. - D1: nm wimipn mmrinl m ant-r1110 mum wim- Illllnu 1M man/11h: - Anny; nu (mm 001' a or 4 balm mm (mm - mica 0011mm" when servicing the 5mm. D0 11111 mlx durum 1w- oi fluid mm mly nm be mpmma. - Amy. a.“ brak- npnllu‘nn bathr- Vining ma mmmc, SPEUFICATIONS Unit mm rm) HEM "mm m Lll'l' Spacifiud huh fluid DOT :1 or 4 _ Enl- dis: micknm (.0 (0.10) 3.5 (0.14) am dice vunouk — 0.30 (0,012) Mum WIIMM Cylinder”). 12.700 - 10740105000 - 05017) 12.755 (0.5022) Pinon 0.0. 12.661 - 12.004 (0.5000 — 0.101») 12.35 (0.00781 Huh uiipcr Cvllmhr 1.1). 25.000 45.005 (1.0000 - 1.00011 15.0501100201 Man on. 15353 - 25.350 (0.9991 - 0.9531) | 25.300 (0.9901) TMOUE VALUES c-Iipor bacm mounllng bolt :0 NM (:1 kgV-m. zz IM-h) ALoc hull BM. how on 0011 :u M1110!) um, 25 (W1) Caliw bleed-1 VII" 5 Min (0.5 kafm, 4.3 mm CIIIpOV pin boll 22 MM (2.: mm, (SM-m Aunlvl lacking 099011001901de Culenl all! ball A 111 Mm (1.3 km? , 1:111:00) Apply a lacking mm to 1m (mm: "a pin 111 N-m (1.11 tum. (310m he pin ping 2 win (01 1mm, 1.4 mm mm mm in». damp boil 1: N-m (1.2 km, 0 mm mm cyfindu holder Doll 12 N-m (1.2 km, 11 Mm Mum :yiimur memoir up wow 1 Mn (0.1 kph», 07 Mm arm kw" aim boll (1 Mai (0.0 qu-m. 4: 10m ami- Imnr pivot 11111 0 N-m (0.0 Icahn. 42 mm Brlkt mm (11011me ban 1 Mn (0.1 mm, 0.7 Ibm) 14-1 HYDMUUC “AK! TOOLS Snap ring psi-n 0791‘ — 3230001 murmur-9mm inhuman-munda- A11 in hydr-ulic mum - Cumin-tad hnh nod/dine Lacking hydraulic lymm - Miulignod whul Com-mm hub pad/disc - Chanda/under“ huh/hm [oim Wom mllper mm" on! - Warpodlddurmnd huh due Worn MW Mllldor Wan cups Caliper not llldlng prupodv Worn brlkn we!“ Cont-mum ullw luh an. Cfllpur m llldlnn prop-fly - Contaminated hl'lh Did/CID: Law but. we Iml - Mhdinnod wh-ol Clogged nun mum - an bun nan-wan WuDId/daformtd bun an: - w-np-aoetonma mm mu mummy" unw plum Stww mm cvlinfllr pinon Corn-minmd mm: cvilndlv am mk- lam Caxipu nm Ilium may M .I- M mum/mama but. lymm Suckinwvnm uuw amen Calla-r not unanw pmplm de-d nuld plunge worn unpe- plnon ml Sh’dinulwnm mum cylindnr pium Bill! bri- er 14-2 BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING CAUTION - U" mu "ll". [717?];le mum: in mm m: mum who: llllm. llu Murmur ~ Awnrf «rd/mp fluid a» minim. plmflr m Mlvbrr ,umi Plun- a my um mm pan! x‘hrnnn mi» , n w “A wnli ma lluid voiorvou pmllal in ma gmund, ramuve Ihu mwairmuai Ind dluuhraum Carma a bleed mun to ma caliper bleed valvev Loosen mu bland vulva and Dump the brake lever Slop pumping m- 1mm! who" no mare fluid Ilowl oui DI 1h! hlaau valva. BRAKE FLUID FILUNG Fill the moi: wrm DDT 3 ur A brake lluld lmm a mind can- llinarv CAUTION - Do not mix damn: npu ujflmi 17m m not cumpdllblr Connm - commercially avnllahle huka bleudar to me blood vllw, Pump ma blaku hlaader and lawn m. mud vnlw, adding fluid Mm! in. fluid level in ma manor cyllnlinr mum" il low, NOTE - Cluck in: MM Isvel on." whila hlaodinn ma mm in pmunl lll’ lum- Damn pumped mm in. 1mm. - who" ulmg a mu ale-ding ml, lullaw me manuIacA man aplralInq Imrumons. Hope-i m- innow proczdure! umil Ii! bubeo: do nm .ppui in m. pianic ho” NOTE - um I: dnming (ha bloeddr lmm mound ma mud vulva than”. ml the mud- wilh T-flon mm H a brake Nude: :5 max av-ilabla, fill mo mnmr :ylmdur and operate [he brlk! lava! ID fill me Miam (page u-l), cum in: blood Valvuv Nan, parIbrm mo BLEEDING placa- dun (ulna 1‘ ‘I HVDRAUUC BRAKE 1 4-3 HYDRAULIC BRAKE BRAKE BLEEDING Cormack a dour blend hos: m ma blend unm- Pump up ma sysmm pvassum With the levar unm mere are no a" Duhhlna m ma flmd fluwmg on: at me masts: cvhndar nnd lava! musunca 15 «an ‘ Squaoze ma brake lever. open m: bleed vabve H2 [um and than close we valve NDYE f 00 nu! mean (he brake \ever umvl the bleed "Ive has been closed 2. Relaua the brake Isvm my me mum) vmv- ha: neen closed m UPPER LEVEL Repeal sum 1 and 2 Mn“! bubble: :easa xu appear m m: num comma am of m bbaed ”we mm." the weed valve venue a N-m nu kgl-m. 4.3 Mm Fill ma Rum reserve-r mma uapu luveL Rmnslall lhe dlanmagm and :owvon cover. and rigm-n mu m RESERVOIR COVER (2: SCRE Icmwt minus: I Mm nu kgt-m‘ 0.7 Mm BRAKE PAD/DISC BRAKE PAD REPLACEMENT NOTE - Always mplnca ma nmkéEas in pan to assum mm disc plenum Rumove \hn pm pm plugs and launch mu pad pm: Ramon the calar mnunnng mm: and minute! 14-4 HYDRAULIC BRAKE Remove me pad mm and brake Dada Make lull mm mu pad spring is m plan- a: nrmwn. Inllall the bake pads, Pth m- Duke pads agaum ma pad spring, man install m: pad . Push the caliper plflens all the way In In lllow lnflallnlmn ai new bake Dad. NOTE - chuck ma nun fluid luv. 7! me bvake mum cvlmdm rmwniv mil opamnnn «:3an the ‘eval to nu. HYDRAULIC BRAKE (“Tamera MOUNTING abTTs 1w Install the bvnke wiper m m: In“ fwk Ice :0 ma dlic is man tinned between me pads. Insllll nnd nghnn ma new arm calmer moummg ban: YOMMJE: 3D Mm 111 kgI-m. R Ibfl'l) rignnm ma um pins, TORQUE: 1! Man (1.8 kgl-m, 13 “71-10 mm“ mm lighten me um um pIugs YOROUE: 1 M [0.2 ham. 1.. Mn) BRAKE DISC INSPECTION Manure ma nun my: lhlcknan mm . mlcromemr. sewn: LIMIT: 3.5 mm (M4 in) Momma ma brake ms: warpnga mm a max mmcamr SERVICE mm 0.10 mm (0.011an MASTER CYLINDER m nwvnsw an‘dn my PIVOT BOLT/NUT REMOVAL Dilwnnecl ma lmsk- swarm wim‘ fialmwa the vuwiew miv‘rDL Romave the p'rvot nln, bol! and make (ever. , ‘ "in aux; LEVER m BRAKE swrrcnyflag. 14-6 HYDRAUUC BRAKE Dram ma brake mlam (psge W3} m MASTER CYLINDER Remove the Duke hum oil born malmq washan and brake hon. cAunoN - AvnId mum. fund I». puInIeIL Mu: m rubber plnx. PM"! a m, mvr mm mm whnm‘rr the mm H "mm: Remove me bqu ham mu mum :yllnder holder and ramavu lha mull! :vlinder DISASSEMBLV [3) SNAP RING was (2) 5m RING Ramnvu the Dual. Romavc m. snap nnu hum m mam: cyi‘mflnv body mm: M: lucial [MI I! Ihwn. TOOL Smp rIng pun 0m. « 1220001 , (I) BOOT RImuvI “I! mlmr mac" Ind spying. Cl-an [ha lniide 01th: cyHndor and marvel! with hrlka "Him /(2) spam Q.) (1) MASTER PISTON INSPECTION cam mo pinnn bum, wimlry cup and iacondlrv cup Im luigun m dun-go. Chock the mam cvflnder and mum to: abnonml sum. Manure Ihe mm-r wflndlr LD, SERVICE um: us: mm (om in) 1 4-7 HYDRAULIC BRAKE Mluule the mailer cylinder pillon O D. SERVICE Lian: Ilufi mm (0.191: In] K ! N-m (0.! kqfim. 0.7 IbHu ASSEMBLY 12 N17! (L1 kqtm, 9 “7“!) :u N-m (3.5 mm 0° 25 lhl-m (8) RESERVOIR CAP (5) PRIMARV CUP m MASTER PlSTON a (3) SECONDARY CUP MEAGM PLATE (2) SNAP RING \u (H BOOT (DI DMRAGM (9] SPRING I NM (0.1 kgfim. 0.7 Int-m CAUTION n) SPfllNG - m» w mm», (um um”, mu» mug and m «u a m m, mu m PRIMARY cup tumult"! mdlvulm/lmru ll) SECONDMV —— cup Coat all parts wilh cleIn hmk: fluid below lmmbiy‘ Din the pimn In brllte fluld. Imu the wing to the 9mm Inn-II the pinion lmmbly mums" - Wm Aurlulla‘ng m. mp1. do not nllmlhe hp: :9 mm mm. mu 7 Q 7 if ’m“ (2; MASTER nsrou 14-8 MVDRAULIC BRAKE lnsull ma map r‘mg (2) SNAP RING leEFS 4H SNAP RING CAUTION - a. my... [he "mp mm an mm m My 1mm r Insuu m. mm f] 500, Place [ha mamm cvhndav on the handlnbw. (ll PUNCH MARK Inna" ma mafiarcyhndar haldev mm m: ‘UP' mark faclna up Augn me and ov me masts: cwnaav with ma punch mm on ml handlehil Human me upper mu am, men m. mm. non 105011511 N1“ "2 lid-m. ! but) (3) 'UP' MARK m wufl mm" the mm no“ wok“ with ma on Doll and am so» inn mm", Push me mu. m- galnn m. nopplr, mm mm." an all bun IO "IO lpflfl 0 107mm. 12) eSEALING WASHERS Tommi: 34 "m (3.5 kfim. 15 M411 1“ BRAKE HOSE EVELE_T Inmu ma brlka lavar. ‘ First inn-u and Iinhlen me pwm non n: ma spacifiad (3, ngAnwgw MIRh'on mama. mucus: a Man In km. u but) \ Hora m: wvol ban and Human ma mu m "In npaciliw lemua. (2) PIVOT BOLT/NUY TORQUE: 9 him I“ kyhn, 4‘: mu Comma m- mu switch mm. mun m. roarvinw mirror. rm use "Ismail m m. "[790! map and bleed my man Iv!‘ um (plan 143) r ‘1 m BRAKE LEVER <4) BRAKE swwcrj “fig. 14-9 HVDRAUUC BRAKE BRAKE CALIPEH REMOVAL Drain m. m uvmm «pupa um leavn lhl oil ham sullnq waihlls and brake hose lyelol jainL annva the runner mauming hull: um um mm pads Hugo 1w). - Aumd mum fluid 1». panned ”hunt. at th7 mm an‘ a rug um Mm path whlnnrr 11.1 mm. 1: ummi DISASSEMBLV (3) BRACKET PIN BOOT Ramovn ma calmer buck" lmm m. ulipov body. (A: PAD spams m “up“ ”RACK“ flamovo m. “up" pm been from m- huclm Ramon ma pad spring and mum pa» boot from the u»- w my. (2? CAMPER PIN BODY Hut! a snap towal Dvov ms piston, Fashion the wipe: body mm the pmom down and apply lml“ minim 01 air Brown to ma flu'vd inlll‘ Io mmaw the unions. - Dowutnlfllmm ovMuglhnaqumodmrlalhe am 14-10 HYDRAULIC BRAKE INSPECTION Chuck me =ng" :vtmder for Jeanna or other dam-an Mums the cum" cvlindar LD‘ semmx qur; 5.460 mm (1.00m In) chock mo cahpcv pmon- for Krnchau, Icallnu a! my dam an: Manure me calipsv pixlon DID. SERVES Lllln’: 25.30!» mm (mash inI ASSEMBLV m PIN EOLTA 22 N-m (2.1 kqhn, Is IbMfl I2) PAD SPRING (BI CAMPER BRACKET .& (a) PIN BOLT I3) PAD PINS 18 N-m (La hut-m, I3 mm In N-m (La qu-m‘ I3 Mm m (m DUST SEAL (8 PISTON SEAL . 15! CALIPER PlsmN [II PAD PIN PLUGS 2 N-m (0,1 kgI-m. Ll lbI-m 14-11 HYDRAULIC BRAKE Com me new amen mus wlm mun huke llulfl Coal the new dull um wlth aillconn gmn. m ”570,4 35an Inn-u me mm and I1qu um mm m. groove: or me cm 1w bodv. Can we cal-par pinam win. clean mm mm: and mm" mm mm m. anger cylinder with may open and: lownvd the pan 0 (2) m DUST SEALS {3! CAMPER PISTONS Inn-ll ma and spring in (he calipov body m PAD SPRING /(1)BRACKEY PIN 3001 ‘ I u a cl|ipar ma broom pin haul! m mm m amyiaum ( "33:37 mun-u mm mm new ones. mun m. huckm pin boot into me cellpav hndv. Install the colipu pin mm imo [he braclwt. App|v sillcnnu are“. to ma uhper Ind bucket um: um inmll [he calipIr bucks] mm m- culmer body, (3) CALIPEH PIN BOOT lNSfALLATOON Inn)“ I!!! link: pad- Ind uliwr MW (he M lurk I09 (DID! Ib-5L lnmll m. ban has: mm In me auger body with two new Malina wllhln Ind oil bah. Pm «nu hm: hm mm m we flapper on [he ediwv. man damn m. nil mm m ma mama lorquo. mmmms'wmznwu nu ma blood mo bnkl hydmunc 1mm (mu: 1M), u :‘L' I . ' (I! gm; CALIPER m 9 SEALING vygnsas 14-12 BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM (I) REGULATORIRECFIFIER ,1 FUSE wags“A v 41 Y Y Y 1 l | l I m REGULATOR/RECTIFIER (I) ALTERNATOR (3) BATTERY 1 5-0 15. BAfiEBY/CHARGING SYSTEM SYSTEM DIAGRAM 15-0 CHARGING SYSTEM INSPECTION 15-1 SERVICE “FORMATION 15-1 ALTERNATOR CHARGING WIL 15—8 TROUBLESHOO'HNG 15~3 REGULATOR/RECHFIER 1 56 BATTERY 154 SERVICE INFORMA'HON BMML - mmmwwpmmqmm-numun1rmmmummm. n.mamauxmw(mmLcm~nnnummmummuw~mumuam M ”Wmuwymmmm —UWminwvmnuh-amfammn-m1wuuunm - Mum. —[India-d.mkpMmeflflfiM-fl-fljmfiumfl-lflaflm - mmarmcuuycnnam - Atwly: mm name name" "but. Mum discunmlrw luv «mm eomponam, CAUTIW - Wzmrl‘rnlmlmmrw mykdnnmgtdulrnmmkolmwmn mmckdnrdhmmud wwuhe wwwmuow mammmum ~ For nan-mild nor-go. mmtm m. mm, yin n . mu cmm. ma mm 2: in a cool. dry up.“ For mmmum "win. ,mm. m. mud hm-ly nvnrv ma non. ‘ Fm u bannry mminmu In a mud motorcycle, dlwnnnoa m. "univ- bmry uh'lu from the bunny mmiml, "M - - TM mlinlenam Ina hmry mum b0 molmd when 9! MM! [he Ind III‘ in Ian/ho lifn‘ 1 5 um ~ m bunny mummm be mmi Amway In new m mun tum-[mu w «u: mm" m. bunny. rm omen, can be dam-95a .¢ ovarcrumed m Munich-road, or w «en lo alumnus for - tong perm, The“ :Ime mn‘ amen: cunmbma m shun-mug m "m. sun“ of ma b-narv Em um: norm-I nu. ma paflormancn of m. binary dmrimm undo! 2 — 3 my: nanny mug. mly mam mar mm clinging. mu and-r h-lvy mu. m mitig- wm amp quickly mu m lullly an. out. Far (bi. mu, m. churning um I: can named Io be m mourn, Battery Wham m mum tram uranium in In: wary Imu, which muv was: In be an Watch-ma wmptom, If m of m humrv um: I: Ih ma and binary vonm don no! menus, on mulatuv/maillar wwllc new volt-u: m t - mun. Um I'll cvndlfionu. [he clocvolm lml no" down muddy. um lmubluhnoling m. charging mum. chuck In: prop-n nu and mlinunlm of m mmy. Chock KIM w- my n «mu-any under heavy um, m n hlvlnq m hudllghl m: uxmgm ON m long unoa. alum wnmm my mg m. mammal- rm man, will arms-mug- whnn n.- mmmyclu i: not in an For this mun. can m. bunny awry m wnkl no pun": lulflliun from tanning. Filling . mw :2er wim .xmma will produc- mm mm, but uni-1 m Ichi'vl in mlximum urban-m, 1mm chug- m. binary. Am. m. bllllrv m. i: lungmmd um. lt‘ I—chugnm when checking me churning mum, ulwlyl follow mu nsp- in m. [MN-shooting mm mm (pop- 153; 15-1 BATTERY/CHARGING SVSTEM “my all-I'll: m- moau uomn Mm A mnlmmnco-frn (Mn binary, nmomw ma «allowing about MF ball-VI“. — my only lh |Icqul that com- WM vh- bonny — Uu nu mm mumm- — Soul mo bmorv properly — Nmr upon m sI-ll og-in CAUTION - Far Many may... do an extend [it (mm mm" and u... 11mm an m: mm, u“ p/mm anal: or (hang link my m. (It: [may Ind mllmnmwmn bmrlu mm! m almond u on appmprin "upon-hour m- mg mm moon Iongm at lull Sit m bunny Amp. H1. Salaam- Switch on m. Emitti- Mow chug" (IMCflHm) (01 me ill. M [h- ban-IV being churned. SI! III. “ml! to “II NEW “11’ polifiun Ind norm-a ml bun-w clamp: Whln Eh. llml mu ml “with!" when" I on MIN flaw blnw mi»: ml "and. W701"! (WGMJ—OO‘MW)—Murlo m- Oust-lion Mum-1 op: mmplllo an Inn." mum/m.- W leu In "In 1mm In m. Column! Mlnull for m Hand] Imry le Ind Chfifill lamry Chlrglf h! dull“ hmrv chiming mp1. 11-- Chrimn B-aurv chug-r macunzm a a mum rum-m [Imp-rug.) ryp- susgn-d m prouuu cum n - Dun- mm m- lorllw duration 0! m. cn-rgc, Ivan i0 mu vnlug- Vll'ill. Th- Hond- Blmrv Tutu (07GMJ ‘m‘ooom um: I 'h-d‘ an m: bunny In am the Jam! bmwy mmfillan ll lb. lim- of an Inn an In manurld. TM: providn .n mum- mmnrmipn nl m. bull-w mmpn — gum (9111:". hi: my law). Dr Don! lrIdL - Slow-chum ma bun-Iv whlnmv pouihllr qulck chiming would In an mummy pronoun" anly‘ - Rmm rm balmy lvnm ma mmonym var charging. - m bun-w on mu mmorcycl- I: - malnuum-lm mar 00 nor rry m mm rm mm mm up- mn dunng «urging Do mu m p aonvammnpl bunny an a roplmmmn SFECIHCJITIONS ITEM mutton w homily I2 V — 8 Ah ‘ Curr-m Isak-g: I MA was Vprrpg. Fully nhltgod 110—13.” ‘ (W9 mm cMrIIna Bolow 12.:v Chiming uurnm Normal 0.: mo n \ arm 10 All .9 r. Alt-tulle" Clpoclly m wanna rpm Charglng coll mum. oz— 0.3 a mam/mum: ngulmd yam. 'se - 2m 13.5 — m: ws.ooo rpm MI! mo up - m V/smo rpm TOOLS Analog rum mum) msu pquivmm mmmiully minus in USA Anlkw um: (SANWA) SP-150 :— 1 5-2 TROUBLESHOOTING Inn-y W ’ Flully regulator/reams: am and-who'd Imam-.1 Mann- mu bunny cumm Ink-n- (link In: ‘5-7). \_—__,— Coma lawn» mum-d volunolplgl 1w), mmmm" an volugn ("me u lull-w value.) m naulllur/mcxifiur nd gmunu um (pawl Is-a)‘ Nmmal cm m. lhmlor (ch-lying mil) mm.“ ' l! (M ”finial/mam Gunman! (plu- 15-8)‘ Normal Mulmd Ahlwmul BATTERY/CHARGING SVS'I'EM 5mm win tumu- may human Iw'nch hum rogulmr/rlnifior Funny bun-w Opon circuit in who ham-n Luau conmcllonz Own lune Flulw «mm: mm, nwullmrlmliflnr 1 5-3 HATTERYICHARGING SVSTEIA REMOVAL Remov- tha mm Sid. savor (MI 2-2). leavl m bllIIrv holds! band. minimum V‘- mllm CON. and men m0 Nihiva “N04 Ind roman lhe binary. INHALLATION lmll m. bum-y in m. mm. mm o! rlmovnl with m m wiring In new". NOTE # Cannon m- poxh'nn hirm'rnII Vim Ind “In tho nognivl nun. Arm inlulliny ma blurry, ml! rho Xannlnlll WI"! dun 9mm. mam-n m. mmavnd pm: VOLTAGE INSPECM Mum. m. bm-y valua- unmg I High-I multimullr‘ vouuas: m w: nu» “.2 v mwmuuv 1001; mm canny-runny "duh MTI'ERVTESTING NOTE ~ AW fluv "II mrl I!" of flummlbll mud-h Ouch I amlim. Duke fluid, nhflmlv‘l‘ a! cloth [wall whln cunning me mm, the belt unnamed by me mm my em. a «a. mm m mm. TOG; Int-y all-um on BI—flfl (USA MN) Sammy noun-n m. min“ punitive (~) ublc Vim. than our-nu: me nwnivn H mm. NOTE - Far mum: In mulls. In sum en: mm. mm- and mum- m In gone mm; condition mu "m . ucurl mum" m b. mull n nu nun-w J M) BLACK (2) BATTERY 15-4 Same tamper-tum «(Itch la 'HIGH' 0' 'LOW' dwdlno an (be amblem xampumum, Pulh in [M lppfup'iutl In! button '0! hrs: secondt Ind and [hi common of BI. bill-n] an [he moist NOTE BATTERY/CHARGING SVSI'EM Q°°°°°©©° 1s=claoflarluwu HlGH: 15%: (NF) m niqhar L . (1) TEST BUTTONS - Fm (h. mu chm, DO NOT ch l m- hmfly bulb" tuning; I“! n In In ‘1: il" condition. um romummmumr, My”!ban(rlawbfimmv¢mge ruling on“: man in 1'..er mu mun/m mm»; um 7 mzubmnbpmmjbrmnmduxumm. — munoianmlwllhmlbeinauflowdnmllmalkulw prim m~m~,~wma.mmry. — um um m- mama-m 2mm "damn! mm. allow-u "Manama-m mmwm NOTE ~ T11- muh of I mm an IM mm! lull: il MIIIVI lo In. Imp. hour rlflng ol m. blmrv. Ally BATTERY READING IN THE GREEN ZONE IS 0K. Bun-rial mould only he ell-mod I! may mm nu YELLOW nr RED mn- BATI'ERV CHAHGNG - mmm-wmmmuummm :u—nm‘mmWMcm. - mmmmwlmicmmm arm-gammmw‘rmum—l. [mum —vwmumfll~,~bwifim —Ud-fllb~llillwqu,fluhvflmlnlhflfl magnum - mum-u. -ymmmrm.jm~mum hmnflqlmqu‘dh-lmdmllfiyxb til. ~ MWDNMPFIAIW.MIWMUM. fi E 00600©©0 \_I GREEN (>L ‘2‘ +3) 15-5 BATI'EIWICNAHGING SYSTEM hummuy, wmr Ind dull. Clun ma bunny turminlll and palixinn m. halt-w n In my mm m. chomuru ma Iuds will p-rmit, Du m plm humus bulaw me churn an”: Iron: m mm "WV 00m lfld “MID. "I! charm”. no not when bmeriu on (w of the euro». Bo um um llr mm m not mound. You: W hilt-r1 chm MGIDIZII . Yum m Power Swnuh no me OFF mam». . 5-: ma bmry Amp. HI. Selena! 5mm:- fur ma :Iu at m. bouncy bung chug-d S» m- Ylmu lo m pol an India-M by mo Hand. Tm y, RED- 3 RE 2 a! VELan I u you ur- churning . now bun-Iv. m m. mm. m m. NEW BATI’ n. l. Art-uh flu! clump: m m- binary Karminlll: RED Ia Positive, aucxm Magma. u- Comm me burn"; able! oniv WM» m. Pawn! Switch I: OF L‘ . Cummmmmmrmsummvmm- wnknmmwummm Yum «In my Swllcn In «no ON man. When on :Imv nun-s m "mm" volition, mo mm- im cycle I: eon-94m. Tum m Pom: Swim OFF ma dilemma! ms dumpl. NOTE Tn- cn-mu wln lumm Ic-IIy switch to m. 'Trlekl mod! lfill '31. u! ell-twin: Kim! Ills I‘Ipud. .4 . Lu m. humy coal Ior u lam Ian mm a. mu gau- Ina mm mm mm‘ a. an»: m. m try um; um Mandi Bunny Tum ma won-mo it mommy um]: i - above my» BATTERY AMP NR. SELECTION SWITCH u-n nun name an“ an» 3-1 m. Ippruprilll lmrL houv (will TIMER TIMI. NEW BATT o a 7 RED 4 VELLW ———— 1 5-6 “WV/CHANGING SYSTEM CHARGING SYSTEM INSPECTION NOTE I“ NEGATIVE TERMINAL wm mum»: m churning mum, mock m. mum wmponlms me “an «my: morning ‘9 mo mu- bI-duooung on me :53. Mmurmq dreuiu mm- was «why mu moods nu olpoc‘fly M m- x-uv mly anu— amm- (a an un Infar- Inning man no. u! mum at m. high cup-my ring. (In. mm gnaw-y m 10 law upuilv ungu unlII you Mn «N comm rlnqc m ynu do nut cum-g. I”. KW. - Whun mlwrlnn mm" «mm ell-cum. mu m gm— Iian mm. on, u m. "than i: suddenly lumld an win; I I“ m. mm M MOW. l2) NEGATIVE CABLE LEAKAGE INSPECHON Chock m bum mm mm. mum m-kina . mum-a vuluua mum's", Yum ma innlu'on mm W and dilcnnnm :5. many mg- III'VB “bk from "In MIN, Connect m. mm awn-n mo "mm um. mu mg mg» «in manual. The vnllluu Mum indie-x- In: nun 1 mA wllh nu Ignlxion "(M a", WE AME: I M Inn. EGULATED VOLTAGE INSPECI'ION g - ummnmhmuamm—hmu mkufl-n-fll‘tflnnmflaufi-h-lmhd-n rummmmuummm-y mmqmmnmwum NOTE ~ a. um um mm in In good sandman Marv pnrvarm- inq mi: m. Warm up w. mum. Io norm-I awning [mum-nun, Stop the luginl, and eon-m mu Manny In um". Chancel I mm Ind Ila-n (M unglnl. Allow m- mm- m mu, mm mm." m. mam. spud pmduany. 7h. voluul lhould a. nomrvll-d n mm. W 'II-m:IS.§-I avnsmmm mmnu-Iuvnlmmm UU’TION - a. ram/u up! wall-m me bunny pannw tabl! :9 mm lhtfnlm! .th mung, 15-7 BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL NOTE lx ls no: llecsssary to remove lhe stamr call In make nus lasl INSPECTION Remove me 1021 mm mnge 27:) D:scnrlnecl me mgulaluv’recllllsl lallemawr) 3P connector ‘ , V . k H V l ' I ‘ cm {he mslumnce between a three el uw lnrmxnals m ALERNATOR 3P CONNECTOR STANDARD: 0 2 - 0.6 ll (-1 arc/so Fl Chsck lo: canllllully bolween all was Yellow (armmals and Ground, Them should bu no conllnullv Raplue me almmmol sum l' voadmgs am far hevnnn me smnanm, or ll any wlm ma conlmullv m ground Ruler m mnon lo lm sum removal flEGULATOR/REC'I'IFIER anlEcoNNEcroRs svsrsul msvec‘non .‘7 Ramuve Illa fuel mull Wane 23> Mullen me renulamr/mcflfier wuneclors, and check [hem luv loose coma“ or summed Iermmals I! the tequllled valloae reading lsee page I57I Is om ol me speclficallon. measure the valley: helween connector (err minals lwlve harness slda) as anlow: ITEM YEW]. ‘ SPECIFICATION Elnavv chuglng Rad/WM: (4 ma 3;:er vaTuue ‘ n: , 959mm H Ihaulfl raging! cmging call Yellow and Yellow 0.2 ~ as n [mu m was“) Gmund llrla Gram and ground Conlinuily should ans! u all components 51 me chargmu :yslam m normal .nd "law are nu loose cannecllons u m. rogulamr/racliliev con honors, ropllm m. regulmuv/rmifiel unll 15-8 BATTERY/CHARGING SVSTEM REPLACEMENT D'sconrzeu we vegmatavrrenmer mmnacmrs Rumav: mu [mks and regmmomalmrm 15-9 IGNITDN SYSTEM SYSTEM DIAGRAM / (2) IGNITION SWITCH ISY ENGINE STD? SWITCH u) CLUTCH swrrcn =. i g l}\ \/” (5) )GNITIDN CONTROL MODULE HEM! n\' “ “fix $91, -; 16-0 16. IGNITION SYSTEM SYSTEM DIAGRAM 1H IGNITION SYSTEM INSPECTION IN SERVICE INFORMATION 16-1 IGNITION COIL 16-7 TROUBLESHOO‘HNG 16-3 IGNITION TIMING 1&7 SERVICE INFORMATION GENERAL ”hmunknnmhdamwwi.udlmvlhe-uh-MWNmmflumgl-ahuududmm Thwmmm-mfllmm-qmuhnnfmmuunflmwmm CAM - 5am than“! lea-mm” m.- be damaged i/ummli or (murder: in: ”man: m minim-mm whil: Ml uni-m mm n ow and mu u pmum. wn-n flrvicinn ma lunilinll mum. nlmvnullaw my new in the uoubluhoollng aqua-lee on page I53. Tm ignlu‘on liming unnot b0 Mfume mm m- lunltion Control Muauln IICM) in f-mry pmot The Innltlou Control Module IICM) may In umaood II dropped. Alla II "I. Dunn-lam ia dImm-d when Gun!!! II flowing. mo Imam llamas may damage Iho modqui Almy! cum on ma IgnIIIurl lwhch Mull BINICIW. A hullv Ionnion mam II often rel-led m poor ammonium. Chuck mull ammonium Moll arm-fling. Muka Inn (he bmury in “newly churned. Using the mum mom Mm a mall bonny mulh In I Maw-r mam: crlnking wen! u will u no work It In lurk plum . Uu Ipllk plug M m. mm mm rlngl. Using . wart plug with an Inwrm hon mm can dam-n. me win SPECIFICATIONS "BA 8mm snark ohm NGK NIPPONDENSO Sum-m CRGHSA uzossn-u For cold cum-u (wow 5"CIH°F) CREHSA Ulanl-U Fm «mud-a mun lplld vidlnn CR7NSA uzstn-u 5pm alug up 0.5 ~ 0.7 mm mm — om in) lgnfllnn coil wk votin- m V minimum All-mule! mile: on" pm volt-fie ma v minimum lgnlnnn n gmarllm mlk wall-g. 0.1 v minimum lgnluan lImInq 'F' mm 1m amt/mo rpm Full lav-mm ' 2&- arm: 16-1 IGNITION SYSTEM TORQUE VALUES spun mun Ignillon mm. gun-um! mm mm TOOLS lmvia ulna-Tonic I”!!! (mount 825) nr Punk vnllm may“: 12 Nrm (1.2 lghn. 9 Mk) ID N-m (Lo kgfwn. 7 MR) DTHGJ - 002mm with Commarcillly Inn-ul- nigh-I munlmot-r [lrllnndlncl m MnIDcv minimum) 1 6-2 IGM'I'ION SYSTEM TROUBLESHOOTING Imam ma Iouawinn below dilemma I"! swam — r-urtv wart 9M: — Loon uwk plua up or mm plug Mr- cnnnlcllon — mm W mm nu ma: plug up uuung mo Ignmnn coll manflarv venue) Y'mporlflly smug. m Ignition eon wfm un om: good on ma yum-n m. npm m H mm )- apart, I» mung-d ignmon call I: flullv‘ m-putnfia. Dunn—dim M—u—nm—Hm luniliun call u- 9... van... 1. n» mum-mu Imp-amu- In law. an. m mu: m.“ Imu- mm), W Cmidnl Inn-1 a no law. - um um mumullnc any". arm‘s—r mam-d um. um nfl mmw (Sm-n .- «arm-I u m up we: Mmmflmmnmmmmmw mu. Hanuwmnmuwnm-mwlum umuammnmh. hmlcllflnm-mnhw-NoJ-lmmmlh, -r‘!r r- ran-hum Imw‘wllflldlvlvmnn-fluumuu mum-nu. mummwumm mwmmummw. mummmmmm. unawarmwmmuhwwmwiunlmw, Fuly-Htmmelm Mwflmmmrlmfllm. mmmuanuv-u—Im). levmmb-W .mnymunaummnu- Inflow" V Funky-untMuI-dhumwlmm . Fn-YWIOHMI.‘ .mmuumIWI-uum. (Datum-Mu mum-n . Cumulus-durum. -IlI-vlmfllt mm. 3. mumm' wmwmumww-m 1. I. L L O. 1. & humuumhnmmahwmulm gum, ”u UM an won-p. r-mmwmhmmmmi— Inn-mm.» rum pull van-g. mu- m hum-m l-W cum mm Innkim a... meuvnn-p. mmmmmbmm.mmmm I...” 1;“me Cr-lflnan-dhmlow. -lmvundv Wu! 0: No Spark 4». Fanny lplrk nlug Foulod spark ping Funky lwflmou contrvl module Blob" a! [hon-d tplflt plug Mr. Sink-n or 3?!on i iriom mull FIIIWY Ignition Mitch hairy ignition pulu wmr Fluny unfit-r coll FIUN’Y Mlno no» lwilch Lao-e vr dkoonnemd Ignition IVIWHI wins Good 59-111 Law Cumnrnni'on fin vmn may {win - Worn eyiirmr Ind pinon ring Corr-amulet! Normal - Luklnnldsmogad cyllnder new ‘ gum Seized vulva Impmpu ulv- flmlng 1 m cylimrmmman L sun by Mowing norm-i pfmrl —. Engim Sun: am S‘upl —-- Impmn-l anon opuuion . Camumur imnmly ldjulud Int-kl pipl inking |mpmcv ignman liming 1mm 20 lgnkion call or ign'nson puiu penny-tor) Fuei oonwminulad Erwin. pm Not Fin Flaudad carbur-lm Chnh cloud - Thrml- um up." - Ail dun-r dirty 5. Rimmll um nun-n 1pm ping —~ Wat Plug 20-1 mumsnoonne ENGINE MCKS POWEII PwflNICu-l x. lulu mul- w m. urounfl .nn —‘ wrmlu Do No! Spin 4». win by hand Fruly wnonl 5pm ley z. Chuckllu pmluu ——0 Prawn Law ——-- Fflfiurl Non-all 3. Amllm fluidly from lawn: loam! —’ Elvin. Spud Not Chang” —‘~ Whln crumb I; lulu-ed - Engine Spud Law-nu wm cum. I. Mum n. Aecullm-llphfly —- Enqlnl Spud uuu Nm H- menu. ' Enan. Spud Inez-m s, CMcqunllionllmlr-u —— Income! —-- Comm 5. mellndnroommun —* Imam-.1 —>- Normll . 7‘ Chock summer for clogging Elm“! Nq donning I a. mmov- mm plug — Foul-d O'Dhcoloud —-- Nm fouM Or Dilculann! s CuckolmvuI-nd waldo" —. Income: ——‘—.- Carm - l V Roman wllndn hm mum —- v.1" nun Nm Lummn 4-- impulubflc on Properly - v-m Trlln Lubflmd Properly arm dragging Wom ov mm whul During Faulty lire "Iva Punctur- cmmn Iliwlng Warn dulth aha/plan wmua um aim/vim Wuk cum. wring swung lnrlchmnnt um ON Clan-d Air cit-M! Rama-d lul flow Clonnofl muffin Pinuhcd MOI uni but!!!" Flully ignition normal madm- mey lunilian puhl gun-mm Vllva stuck oven Wom cvllndav Ind pinon rings Llaklnddlmmd hold Wm Impmnlr VIM llmlng tub-mm no! "Mun lmmmly .nougn Hun not urviofid lroqu-mlv Enough sum plug in Inccunn nm range on |m| too high an Intel «on low Cnnnminltud an clawed all pm: Clogged all normal orifice 20-2 TROUBLESHOOHNG m. Cal-I n. cram»: InulmwM-ung —- Dwmuflnq —-- Nm MARINE ‘2, WM!“ of run at high ID.” —‘ Enainl Knm Englm Do- Nm Kn” - Exennlvo arbor: bulmn m oombunlon numb“ u» at poor quum (ml am illwlnu Lun 'ull mhmav- Wmnn typo 01 m» Worn pIIIOn m: cylindlr Wrong m» a! nu: mum um band-III In comnm'on mum-r lunflion liming loo name (mm mm control madam - Lun iuu mmm POOR PERFORMANCE AT LOW AND IDLE SPEED m c.— 1. Chock mum timing 1m lmprow sqnnum liming Comm 2. Chickurhumof DIM new —‘ Imam —" Mluumm Cam 3. 12mm lulunn mm. nip. 4» baking —>- Nomi: 4. am lama-n —— wmorlnnrm'mum —~- sum Good 5pm (Fanny human ml moduk) 5.. mm: Lon-c cumum mounting nm Bum-god lmlalov Flukv clrbon atwfl hulod IDIrk plus Funny anman comm moan!- Flu'fv lqnfllen coll Brut-n or would Inn-k plug wir- Flukv anal»- flop Iwilch Fanny lgniflnn who non-mar huny each-r coil Funny ignition mm Lama 07 damn-cm: Won 1mm wil- 20-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 'o-Ihl- Gin-n 1, Chuck Innklun nminn Inwm "W Con-ct z Dimnnm ml lubul carburetor % Full Flaw Restricted 4% Fuel Flam ley l nemvelne cumulnnvlnfl chick —- Claw-d for clawed in: Nol Clouand A. check valvaliming ——> Imam —- Faunv ignilion :annol modulu F-ulty lunifion nulu Ilmmv (:1qu Incl “no cloggod lull tank braalhol Gaga-d lu-I Imam mm Cllln Cam aploellol rm lnmuofl prop-7hr nan-u 5. Chuck vain swim wm ——~ mm lprinu Nat Wllk POOH HANDLING Penu- cum L Nit-cling a MW 2. N ailhar wheel ls wobbllng —__,. :I. ll mu motomycla pull: tn one side —’ SIerinu stain Idluslinn run we llgnl Dammod Inning hnd mrlng. Emmi“ who-l buying plly Bum vim lmpropcrly lnmlled wnael hub Swlngmn phlfll mm mos-MW wum am Imm- Faulty shock mam From mm m: who-l not nllgn-a Bank fork Ban! l'wlnglrm Bern IXIH Barn lame 20-4 21. INDEX AIR CLEANER AIR CLEANER HOUSING ALTERNATOR CHARGING COIL ALTERNATOR INSTALLATION ALTERNATOR REMOVAL BATTERY BODY PANEL LOCATIONS BRAKE CAUPER BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH (MAINTENANCEI 347 BRAKE LIGHT SWITCH (LIGHTS/METERISWI’TCHESI IB-B BRAKE PAD/DISC BRAKE PEDAL BRAKE SHOE/FAD WEAR BRAKE SYSTEM BULB REPLACEMENT CABLE B HARNESS ROUTING WSHAFTIROCKER ARM INSTALLATION CARBURETOR ASSEMBLY CARBURETOR CHOKE CARBURETOFI DISASSEMBLV CARBURETOR INSTALLATION CARBURETOR REMOVAL CHARGING SYSTEM INSPECTION CLUTCH CLUTCH SWTTCH CLUTCH SYSTEM CRANKCASE ASSEMBLY CRANKMSE BEARING REPLACEMENT CRANKCASE BREATHER CRANKCASE SEPARATION CRANKSHAFT CYLINDER/PISTON INSPECTION CYLINDERIPISTON INSTALLATION CYLINDER/PISTON REMOVAL CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY CYLINDER HEAD DISASSEMBLV CYIJNDER HEAD INSPECTION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL DIODE DRIVE CHAIN EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLVI EMISSION CONTROL SYSTEMS ENGINE IDIE SPEED ENGINE INSTALLATION ENGINE OIL ENGINE OIL STRAINER SCREEN ENGINE REMOVAL EVAPORATIVE EMISSION CONTROL SYSTEM (ULIFORNIA TYPE ONLY) EXHAUST SYSTEM FORK FRONT FENDER FRONT WHEEL FUEL LINE FUEL TANK GEARSHIF‘I’ UNKAEE 14.1 13—1! :Hc J-IG 184 ME 7-Il 57 1-5 5-1 5‘" 5-: I57 5»: 1H 31! I1-13 11-10 3-6 11-3 11-8 8-3 H 3‘3 7‘3 7-" 7-3 7‘! 7.“ 7-7 17-11 3-12 1-28 I725 341 3-5 3-I D 52 3-11 1-5 In: 2-4 12-8 273 9-10 GENERAL SAFETY HANDLEBAR HANDLEBAR SWITCHES HEADLle AIM HIGH ALTITUDE ADJUSTMENT HORN IGNITION CDIL IGNITION SWITCH IGNITION SYSTEM INSPECTION IGNITION TIMING LUBRICATION 51 SEAL POINTS LUBRICATION SYSTEM DIAGRAM MAINTENANCE SCHEDULE MASTER CVUNDER MODEL IDENTIFICATION NEUTRAL SWITCH NUTS, BOLTS, FASTENERS OIL PUMP PILOT SCREW ADJUSTMENT PRIMARY AND OIL PUMP DRIVE GEARS REAR BRAKE REAR FENDER REAR WHEEL REGUMTDBIRECTIFIER RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKDSE COVER REMOVAL ROCKER ARMICAMSNAFT REMOVAL SEAT SERVICE INFORMATION (ALTERNATORISTARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFI' LINKAGE) (CRANKSHAFI’IT'RANSMISSIONI (CYLINDER HEADNALVES) (CVLINDERMSTONI (ELECTRIC STATEN) (ENGINE REMOVAIJINSTALLATIONI (FRAME/BOON PANELS/EXHAUST SYSTEM) (FRONT WHEEUSUSPENSION/STEERINGI (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (UGH'I'SMETER/SWITCHESI (LUBRICATION SYSTEM) (MAINTENANCE) (REAR WHEEL’BRAKE/SUSPENSIONI SERVICE RULES SHOCK ABSORBER SIDE COVER SIDE STAND SIDE STAND SWITCH SPARK PLUG SPECIFICATIONS SPEEDOMETER STARTER CLUTCH STARTER MOTOR STARTER RELAY SWITCH STEERING HEAD BEARING STEERING STEM SUSPENSION 1-1 12-3 15-7 3-” 5-13 mm I57 we IS-l IE7 Ms INDEX SWINGARM SYSTEM DIAGRAM [HAVEN/CHARGING SVSI'EM) (ELECTRIC SYAflTERI IIGNITION SYSTEM) WRO'ITLE OPERATION YooLs TONGUE VALUES TRANSMISSION TROUBLESHOOVING (ALTERNATOWSYARTER CLUTCH) (BATTERY/CHARGING SYSTEM) ICLUYCI VGEARSHIIT LINKAGE! (CHANKCASE’IMNSMISSION) (CYLINDER HEAD/VALVES) ICVUNMR/PISYONI [ELECTRIC STARTERI (ENGINE DOES NOT STARY 0H IS HARD TO STAR” IENGINE LACKS POWER) {FRAME/500V PANEIS/EXHAUST SYSTEM) IFRON'I’WNEELISUSPENSIONISI’EERING) (FUEL SVSYEM) I HYDRAULIC BRAKE) (IGNITION SYSTEM) ILUIRICATION SVSTEMI (POOR HANDLING) POOH PERFORMANCE AT LOW AND IDLE SPEED) (POOR PERFORMANCE A7 HIGH SPEEDI {REAR WHEELIIRAKE/SUSPENSIM) TURN SIGNAL HELAV VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAY INSPECnoN/REFALING WHEELS/TIRES WIRING DIAGRAM 111a 1543 174) 3,; MA Hz 1H NH 153 ”-2 7-1 "-1 20“ 24 12-1 w: 19-: H 20—3 134 18-10 Mn 7-11 Is-I 21-2 IZ1III