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 | Basic service methods | Storage

CHAPTER TWO | TROUBLESHOOTING

Operating requirements | Starting the engine (carbureted models) | Starting the engine (fuel injected models) | Starting difficulties | Engine performance | Engine noises | Engine lubrication | Cylinder leakdown test | Clutch | Gearshift linkage | Transmission | Fuel system (carbureted models) | Fuel system (fuel injection models) | Electrical system | Lighting system | Charging system | Ignition system | Starting system | Front suspension and steering | Brake system

CHAPTER THREE | LUBRICATION, MAINTENANCE AND TUNE-UP

Fuel type | Tune-up procedures | Air filter | Engine compression test | Spark plugs | Ignition timing inspection | Valve clearance | Carburetor synchronization (1998-2001 models) | Fuel injection starter valve synchronization (2002-2003 models) | Idle speed adjustment (all models) | Fuel hose inspection | Control cable lubrication (non-nylon lined cables only) | Throttle cables | Starter enrichment (choke) cable | Clutch cable adjustment | Gearshift pedal adjustment | EXUP system | Engine oil and filter | Cooling system | Emission control systems | Battery | Tires and wheels | Drive chain | Brake system | Headlight aim inspection | Sidestand and ignition cut-off switch inspection | Steering bearing inspection | Front suspension inspection | Rear suspension inspection | Fastener inspection | Wheel bearing inspection | Lights and horn inspection

CHAPTER FOUR | ENGINE TOP END

Engine service notes | Cylinder head cover | Camshafts | Camshaft chain tensioner | Camshaft chain, timing sprocket and chain guide | Cylinder head | Valve lifters and shims | Valves and valve components

CHAPTER FIVE | ENGINE LOWER END

Servicing engine in frame | Engine service notes | Engine | Oil pan, oil strainer and pressure relief valve | Oil pump/water pump | Crankcase | Piston and connecting rod assembly | Crankshaft | Break-in procedure

CHAPTER SIX | CLUTCH AND EXTERNAL SHIFT MECHANISM

Clutch cover | Clutch | Starter clutch and starter reduction gears | External gearshift mechanism

CHAPTER SEVEN | TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission and internal shift mechanism | Transmission inspection | Internal shift mechanism inspection

CHAPTER EIGHT | FUEL, CARBURETORS, EMISSION CONTROL AND EXHAUST SYSTEMS Fuel tank | Fuel shutoff valve | Fuel level sender | Air filter housing | Carburetor | Carburetor overhaul | Carburetor adjustments | Throttle cable replacement | Starter (choke) cable replacement | Fuel pump | Fuel filter | Emission control system labels | Crankcase breather system | Evaporative emission control system (California models only) | Air induction system (AIS) | Exhaust system | EXUP system (1998-2001 models)

CHAPTER NINE | FUEL, ELECTRONIC FUEL INJECTION AND EXHAUST SYSTEMS Fuel injection system precautions | Hose and wiring harness identification | Depressurizing the fuel system | Fuel tank | Air filter housing | Throttle body | Fuel injectors | Vacuum slide | Pressure regulator | Fuel pressure check | Fuel pump | Cylinder identification sensor | Intake air pressure sensor | Intake air temperature sensor | Atmospheric pressure sensor | Crankshaft position sensor | Lean angle cut-off switch | Throttle cable replacement | Exhaust system | EXUP system (2002-2003 models) | Diagnostic system (2000-2001 models) | Diagnostic system (2002-2003 models) |

CHAPTER TEN | ELECTRICAL SYSTEM

Electrical component replacement | Electrical connectors | Battery | Charging system | Alternator rotor and stator | Ignition system | Relay unit ignition circuit (1998-2001 models) | Starting circuit cut-off relay ignition circuit (2002-2003 models) | Starter | Starter relay switch | Relay unit (1998-2001 models) or starting circuit cut-off relay unit (2002-2003 models) starting circuit | Lighting system | Combination meter | Speed sensor | Cooling system switches and sensors | Turn signal relay | Fuel level warning light sender (2000-2001 models) | Fuel pump relay | Throttle position sensor | Oil level sensor and relay | Horn | Switches | Fuses | Wiring diagrams

CHAPTER ELEVEN | COOLING SYSTEM

Cooling system inspection | Hoses and hose clamps | Coolant reserve tank | Radiator | Cooling fan | Thermostat | Thermostat housing and inlet pipes | Water pump | Oil cooler and crankcase water jacket fitting

CHAPTER TWELVE | WHEELS, TIRES AND DRIVE CHAIN

Motorcycle stands | Front wheel | Rear wheel | Rear coupling and rear sprocket | Front and rear hubs | Wheel runout and balance | Tire changing | Tire repairs | Drive chain

CHAPTER THIRTEEN | FRONT SUSPENSION AND STEERING

Handlebar assemblies | Front fork | Steering head and stem | Steering head bearing races | Steering stem bearing replacement

CHAPTER FOURTEEN | REAR SUSPENSION

Shock linkage | Shock absorber | Swing arm bearing replacement

CHAPTER FIFTEEN | BRAKES

Brake fluid selection | Preventing brake fluid damage | Brake service | Front brake pads | Front brake caliper | Front master cylinder | Rear brake pads | Rear brake caliper (1998-2001 models) | Rear brake caliper (2002-2003 models) | Rear master cylinder | Brake hose replacement | Brake disc | Rear brake pedal | Brake bleeding

CHAPTER SIXTEEN | BODY PANELS

Body panel fasteners | Rider's seat | Passenger seat | Rear cowl (1998-2001 models) | Rear cowl (2002-2003 models) | Bottom cowl | Side fairing (1998-2001 models) | Side fairing (2002-2003 models) | Mirrors | Windshield | Front fairing (1998-2001 models) | Front fairing (2002-2003 models) | Front fender

INDEX

WIRING DIAGRAMS