Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Special tools / Basic service methods / Storage

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Engine performance / Starting system / Charging system / Ignition system / Fuel system / Engine noises / Engine lubrication / Clutch / Transmission / Lighting system / Excessive vibration / Front suspension and steering / Brake system

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Tires and wheels / Battery / Engine lubrication / Fork oil / Control cables / Periodic lubrication / Air filter / Brakes / Drive chain and sprockets / Cooling system / Rear suspension / Fasteners / Tune-up

CHAPTER FOUR / ENGINE TOP END
Service precautions / Cylinder head covers / Camshafts / Camshaft chain tension and guide rails / Camshaft drive chain / Cylinder head / Valve lifters and shims / Valves and valve components / Cylinder / Pistons and piston rings

CHAPTER FIVE / ENGINE LOWER END
Servicing engine in frame / Engine / Crankcase right side cover / Crankcase left side cover / Tachometer drive mechanism / Oil pumps / Primary drive gear and camshaft drive chain / Starter clutch and gears / Crankcase, crankshaft and balancer shaft / Engine oil circuit bleeding / Engine break-in

CHAPTER SIX / CLUTCH
Clutch release lever and bearings / Clutch / Clutch service / Clutch cable replacement

CHAPTER SEVEN / TRANSMISSION AND GEARSHIFT MECHANISM
Transmission operation / Transmission / Transmission overhaul / Transmission inspection / Internal shift mechanism

CHAPTER EIGHT / FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Carburetor operation / Carburetor / Throttle cable / Starting enrichment valve (choke) cable replacement / Fuel tank / Fuel shutoff valve / Air filter air box / Exhaust system / Crankcase breather system / Evaporative emission control system (California models) / Evaporative emission control system service / Secondary air system (U.S. and Switzerland models)

CHAPTER NINE / ELECTRICAL SYSTEM
Preliminary inspections / Battery box / Charging system / Alternator / Voltage regulator / Capacitor discharge ignition / Starting system / Starter relay replacement / Lighting system / Switches / Horn / Instruments / Fuses / Wiring diagram

CHAPTER TEN / COOLING SYSTEM
Safety precautions / Hoses and hose clamps / Cooling system inspection / Radiator and cooling fan / Cooling fan / Thermostat / Water pump

CHAPTER ELEVEN / WHEELS, HUBS, TIRES AND DRIVE CHAIN
Bike stands / Front wheel / Rear wheel / Driven sprocket and driven flange / Front and rear hubs / Wheel runout / Wheel service / Wheel balance / Tires / Tire changing / Drive sprocket and chain

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Steering head / Front fork

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / Rear swing arm / Swing arm service / Shock linkage / Bearing replacement

CHAPTER FOURTEEN / BRAKES
Brake fluid selection / Brake service / Front brake pad replacement / Front brake caliper / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake hose replacement / Brake disc / Bleeding the system

CHAPTER FIFTEEN / BODY
Seat / Front fender / Rear mudguard / Cylinder head side cover / Side cover / Engine lower cover / Windshield and front fairing / Fuel tankcover / Saddlebags / Footpegs

INDEX