QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION

Manual organization/Warnings, cautions and notes/Safety/Serial numbers/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage
CHAPTER TWO/TROUBLESHOOTING

Starting the engine/Engine performance/Electrical component replacement/Starting system/Charging system/Ignition system (1986-1997 models)/Ignition system (1998-2003 models, except 1200S models)/Ignition system (1998-2003 1200S models)/Fuel system/Engine noises/Engine smoke/Leakdown test/Engine lubrication/Clutch/Transmission/Electrical testing/Electronic speedometer/tachometer/Turn signal module (1991-1996 models)/Turn signal module (1997-2003 models)/Excessive vibration/Front suspension and steering/Brake problems
CHAPTER THREE/LUBRICATION, MAINTENANCE AND TUNE-UP

Fuel type/Maintenance schedule/Routine safety checks/Tires and wheels/Periodic lubrication/Periodic maintenance/Tune-up/Air filter/Compression test/Spark plugs/Ignition timing adjustment
CHAPTER FOUR/ENGINE TOP END

Tools/Rocker cover assembly/Cylinder head/Valves and valve components/Pushrods and covers/Cylinder Pistons and piston rings/Oil tank and oil lines
CHAPTER FIVE/ENGINE LOWER END
Tools/Engine service/Engine stand/Engine/Valve tappets and guides (1986-1990 models)/Valve tappets (1991-2003 models)/Gearcase cover and timing gears/Oil pump (1986-1990 models)/Oil pump (1991-2003 models)/Oil filter mount (1986-1990 models)/Oil filter mount (1991-2003 models)/Crankcase and crankshaft/Cylinder studs/Engine break-in
CHAPTER SIX/PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)
Primary drive cover/Clutch release mechanism/Primary chain adjuster/Primary drive/clutch/Clutch cable
CHAPTER SEVEN/PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)
Primary drive cover (1991-1993 models)/Primary drive cover (1994-2003 models)/Clutch release mechanism (1991-1993 models)/Clutch release mechanism (1994-2003 models)/Primary chain adjuster/Primary drive/clutch/Clutch cable
CHAPTER EIGHT/FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission/Shifter mechanism/
CHAPTER NINE/FIVE-SPEED TRANSMISSION (1991-2003 MODELS)
Transmission/Shift forks and shift drum/Mainshaft and countershaft/Main drive gear/Access door bearings/Right transmission case bearings/Shift mechanism
CHAPTER TEN/FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)
Air filter backplate/Carburetor/Intake manifold/Fuel hose and clamps/Throttle and idle cables/Choke cable/Fuel tank/Fuel shutoff valve/Exhaust system/Evaporative emission control system (California models) CHAPTER ELEVEN/FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS) Air filter backplate/Carburetor/Intake manifold/Fuel hose and clamps/Throttle and idle cables/Starting enrichment valve (choke) cable/Fuel tank/Fuel shutoff valve (1988-1994 models)/Fuel shutoff valve (1995-2003 models)/Exhaust system (all models except 883R models)/Exhaust system (883R models)/Evaporative emission control system (California models) CHAPTER TWELVE/ELECTRICAL SYSTEM Electrical component replacement/Electrical connectors/Battery (1986-1996 models)/Battery (1997-2003 models)/Charging system/Alternator (1986-1990 models)/Alternator (1991-2003 models)/Ignition system (1986-1997 models)/Ignition system (1998-2003, all models except 1200S models)/Ignition system (1998-2003 1200S models)/Ignition coil/Bank angle sensor (1998-2003 models)/Manifold absolute pressure (MAP) sensor (1998-2003 1200S models)/Starter/Starter solenoid/Lighting system/Electronic speedometer/tachometer/Switches/Horn/Electrical bracket/Turn signal flasher (1986-1990 models)/Turn signal module (1991-2003 models)/Circuit breakers (1986-1997 models)/Fuses (1998-2003 models)/Electrical connectors/Wiring diagrams
CHAPTER THIRTEEN/WHEELS, TIRES AND SECONDARY DRIVE
Motorcycle stands/Front wheel/Front hub (1986-1999 models)/Front hub (2000-2003 models)/Rear wheel Rear hub (1986-1999 models)/Rear hub (2000-2003 models)/Drive chain and sprockets/Drive belt and sprockets/Wheel runout/Laced wheels/Disc and cast wheels/Wheel balance/Tires
CHAPTER FOURTEEN/FRONT SUSPENSION AND STEERING
Handlebar/Front fork (all models except 1200S models)/Front fork (1200S models)/Steering head and stem/Steering head bearing/Steering play adjustment
CHAPTER FIFTEEN/REAR SUSPENSION
Shock absorbers/Swing arm
CHAPTER SIXTEEN/BRAKES
Brake fluid selection/Brake service/Front brake pads (1986-1999 models)/Front brake pads (2000-2003 models)/Front brake caliper (1986-1999 models)/Front brake caliper (2000-2003 models)/Front master cylinder (1986-1995 models)/Front master cylinder (1996-2003 models)/Rear brake pads (1986-early 1987 models)/Rear brake pads (late 1987-1999 models)/Rear brake pads (2000-2003 models)/Rear brake caliper (1986-early 1987 models)/Rear brake caliper (late 1987-1999 models)/Rear brake caliper (2000-2003 models)/Rear master cylinder (1986-early 1987 models)/Rear master cylinder (late 1987-2003 models)/Brake hose and line replacement/Brake disc/Bleeding the system/Brake fluid draining/Flushing the brake system
CHAPTER SEVENTEEN/BODY
Seat/Front fender/Rear fender/Footrests/Forward foot controls (1999-2003 883C and 1200C models)/Sidestand/Fork lock
INDEX
WIRING DIAGRAMS