TABLE OF CONTENTS

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION (VEHICLE IDENTIFICATION NUMBER, MODEL CODE), FEATURES, IMPORTANT INFORMATION (PREPARATION FOR REMOVAL AND DISASSEMBLY, REPLACEMENT PARTS, GASKETS, OIL SEALS AND O-RINGS, LOCK WASHERS/PLATES AND COTTER PINS, BEARINGS AND OIL SEALS, CIRCLIPS), CHECKING THE CONNECTIONS, SPECIAL TOOLS.

SPECIFICATIONS
GENERAL SPECIFICATIONS, ENGINE SPECIFICATIONS, CHASSIS SPECIFICATIONS, ELECTRICAL SPECIFICATIONS, TIGHTENING TORQUES (GENERAL TIGHTENING TORQUES, ENGINE TIGHTENING TORQUES, CHASSIS TIGHTENING TORQUES), LUBRICATION POINTS AND LUBRICANT TYPES (ENGINE LUBRICATION POINTS AND LUBRICANT TYPES, CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES), ENGINE OIL LUBRICATION CHART, ENGINE OIL FLOW DIAGRAMS, TRANSFER GEAR OIL FLOW DIAGRAMS, CABLE ROUTING.

PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION, PERIODIC MAINTENANCE/LUBRICATION INTERVALS, GENERAL MAINTENANCE AND LUBRICATION CHART, SEATS AND SIDE COVERS, XV16AT ACCESSORY PARTS, FUEL TANK, AIR FILTER CASE, ENGINE (ADJUSTING THE VALVE CLEARANCE, ADJUSTING THE ENGINE IDLING SPEED, ADJUSTING THE THROTTLE CABLE FREE PLAY, CHECKING THE SPARK PLUGS, CHECKING THE IGNITION TIMING, MEASURING THE COMPRESSION PRESSURE, CHECKING THE ENGINE OIL LEVEL, CHANGING THE ENGINE OIL, MEASURING THE ENGINE OIL PRESSURE, CHECKING THE TRANSFER GEAR OIL LEVEL, CHANGING THE TRANSFER GEAR OIL, ADJUSTING THE CLUTCH CABLE FREE PLAY, CLEANING THE AIR FILTER ELEMENT, CHECKING THE CARBURETOR JOINT, CHECKING THE FUEL HOSES AND FUEL FILTER, CHECKING THE CYLINDER HEAD BREATHER HOSE AND, TRANSFER GEAR CASE BREATHER HOSE, CHECKING THE EXHAUST SYSTEM), CHASSIS (ADJUSTING THE FRONT BRAKE, ADJUSTING THE REAR BRAKE, CHECKING THE BRAKE FLUID LEVEL, CHECKING THE FRONT BRAKE PADS, CHECKING THE REAR BRAKE PADS, ADJUSTING THE REAR BRAKE LIGHT SWITCH, CHECKING THE BRAKE HOSE, BLEEDING THE HYDRAULIC BRAKE SYSTEM, ADJUSTING THE SHIFT PEDAL, ADJUSTING THE DRIVE BELT SLACK, CHECKING AND ADJUSTING THE STEERING HEAD, CHECKING THE FRONT FORK, ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY, CHECKING THE TIRES, CHECKING AND TIGHTENING THE SPOKES, CHECKING AND LUBRICATING THE CABLES, LUBRICATING THE LEVERS AND PEDALS, LUBRICATING THE SIDESTAND, LUBRICATING THE REAR SUSPENSION), ELECTRICAL SYSTEM (CHECKING AND CHARGING THE BATTERY, CHECKING THE FUSES, REPLACING THE HEADLIGHT BULB, ADJUSTING THE HEADLIGHT BEAM), INSTRUMENT FUNCTIONS (INDICATOR LIGHTS, COMBINATION METER).

CHASSIS
FRONT WHEEL AND BRAKE DISCS (REMOVING THE FRONT WHEEL, DISASSEMBLING THE FRONT WHEEL, CHECKING THE FRONT WHEEL, CHECKING THE BRAKE DISCS, ASSEMBLING THE FRONT WHEEL, INSTALLING THE FRONT WHEEL, ADJUSTING THE FRONT WHEEL STATIC BALANCE), REAR WHEEL - BRAKE DISC AND REAR WHEEL PULLEY (REMOVING THE REAR WHEEL, CHECKING THE REAR WHEEL, CHECKING THE REAR WHEEL DRIVE HUB, CHECKING AND REPLACING THE REAR WHEEL PULLEY, ASSEMBLING THE REAR WHEEL, INSTALLING THE REAR WHEEL, ADJUSTING THE REAR WHEEL STATIC BALANCE), FRONT AND REAR BRAKES (REPLACING THE FRONT BRAKE PADS, REPLACING THE REAR BRAKE PADS, DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER, DISASSEMBLING THE REAR BRAKE MASTER CYLINDER, CHECKING THE FRONT AND REAR BRAKE MASTER, CYLINDERS, ASSEMBLING AND INSTALLING THE FRONT BRAKE, MASTER CYLINDER, ASSEMBLING AND INSTALLING THE REAR BRAKE, MASTER CYLINDER, DISASSEMBLING THE FRONT BRAKE CALIPERS, DISASSEMBLING THE REAR BRAKE CALIPER, CHECKING THE FRONT AND REAR BRAKE CALIPERS, ASSEMBLING AND INSTALLING THE FRONT, BRAKE CALIPERS, ASSEMBLING AND INSTALLING THE REAR, BRAKE CALIPER), FRONT FORK (REMOVING THE FRONT FORK LEGS, DISASSEMBLING THE FRONT FORK LEGS, CHECKING THE FRONT FORK LEGS, ASSEMBLING THE FRONT FORK LEGS, INSTALLING THE FRONT FORK LEGS), HANDLEBAR (REMOVING THE HANDLEBAR, CHECKING THE HANDLEBAR,, INSTALLING THE HANDLEBAR), STEERING HEAD (REMOVING THE LOWER BRACKET, CHECKING THE STEERING HEAD, INSTALLING THE STEERING HEAD), REAR SHOCK ABSORBER AND SWINGARM (HANDLING THE REAR SHOCK ABSORBER, DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER, REMOVING THE REAR SHOCK ABSORBER AND SWINGARM, CHECKING THE REAR SHOCK ABSORBER, CHECKING THE REPLAY ARM AND CONNECTING ARM, CHECKING THE SWINGARM, INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM), DRIVE BELT AND DRIVE PULLEY (REMOVING THE DRIVE BELT AND DRIVE PULLEY, CHECKING THE DRIVE BELT, INSTALLING THE DRIVE BELT AND DRIVE PULLEY).

ENGINE
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS (REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS, CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS, CHECKING THE ROCKER ARM BASES, CHECKING THE PUSH RODS, CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES, BLEEDING THE VALVE LIFTER, CHECKING THE PUSH ROD COVERS, INSTALLING THE VALVE LIFTERS AND PUSH ROD COVERS, INSTALLING THE ROCKER ARMS AND PUSH RODS, INSTALLING THE CYLINDER HEAD COVERS, INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER), CAMSHAFTS (REMOVING THE CAMSHAFTS, CHECKING THE CAMSHAFTS, CHECKING THE DECOMPRESSION SYSTEM, CHECKING THE OIL DELIVERY PIPE, INSTALLING THE CAMSHAFTS), CYLINDER HEADS (REMOVING THE CYLINDER HEADS, CHECKING THE CYLINDER HEADS, CHECKING THE OIL DELIVERY PIPE, INSTALLING THE CYLINDER HEADS), VALVES AND VALVE SPRINGS (REMOVING THE VALVES, CHECKING THE VALVES AND VALVE GUIDES, CHECKING THE VALVE SEATS, CHECKING THE VALVE SPRINGS, INSTALLING THE VALVES), CYLINDERS AND PISTONS (REMOVING THE CYLINDERS AND PISTONS, CHECKING THE CYLINDERS AND PISTONS, CHECKING THE PISTON RINGS, CHECKING THE PISTON PINS, INSTALLING THE PISTONS AND CYLINDERS), CLUTCH (REMOVING THE CLUTCH, REMOVING THE PRIMARY DRIVE GEAR, CHECKING THE FRICTION PLATES, CHECKING THE CLUTCH PLATES, CHECKING THE CLUTCH SPRING PLATE, CHECKING THE CLUTCH HOUSING, CHECKING THE CLUTCH BOSS, CHECKING THE PRESSURE PLATE, CHECKING THE PULL LEVER SHAFT AND PULL ROD, CHECKING THE PRIMARY DRIVE, INSTALLING THE PICKUP COIL AND PULL LEVER SHAFT, INSTALLING THE PRIMARY DRIVE GEAR, INSTALLING THE CLUTCH), SHIFT SHAFT (CHECKING THE SHIFT SHAFT, CHECKING THE STOPPER LEVER, INSTALLING THE STOPPER LEVER AND SHIFT SHAFT), GENERATOR AND STARTER CLUTCH (REMOVING THE GENERATOR, CHECKING THE STARTER CLUTCH, INSTALLING THE GENERATOR), TRANSFER GEAR CASE (REMOVING THE BATTERY, REMOVING THE MIDDLE DRIVEN SHAFT, CHECKING THE MIDDLE DRIVE, CHECKING THE OIL STRAINER, CHECKING THE OIL PUMP, CHECKING THE OIL PIPE, ASSEMBLING THE OIL PUMP, INSTALLING THE TRANSFER GEAR CASE, INSTALLING THE OIL TANK COVER, INSTALLING THE BATTERY), CRANKCASE (DISASSEMBLING THE CRANKCASE, CHECKING THE CRANKCASE, CHECKING THE BEARINGS AND OIL SEAL, CHECKING THE OIL DELIVERY PIPE, CHECKING THE ENGINE OIL PUMP DRIVE, ASSEMBLING THE CRANKCASE), ENGINE OIL PUMP (CHECKING THE OIL PUMP, CHECKING THE RELIEF VALVE, CHECKING THE OIL STRAINER, ASSEMBLING THE OIL PUMP, INSTALLING THE OIL PUMP, INSTALLING THE OIL STRAINER), CRANKSHAFT AND CONNECTING RODS (REMOVING THE CRANKSHAFT, REMOVING THE CONNECTING RODS, CHECKING THE CRANKSHAFT AND CONNECTING RODS, INSTALLING THE CONNECTING RODS, INSTALLING THE CRANKSHAFT), TRANSMISSION (CHECKING THE SHIFT FORKS, CHECKING THE SHIFT DRUM ASSEMBLY, CHECKING THE TRANSMISSION, INSTALLING THE TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS).

CARBURETOR
CARBURETOR (CHECKING THE CARBURETOR, CHECKING THE CARBURETOR JOINT, ASSEMBLING THE CARBURETOR, INSTALLING THE CARBURETOR JOINT, INSTALLING THE CARBURETOR, MEASURING AND ADJUSTING THE FUEL LEVEL, CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR, CHECKING THE FUEL PUMP, CHECKING THE FUEL COCK, CHECKING THE FUEL COCK OPERATION), AIR INDUCTION SYSTEM (AIR INJECTION, AIR CUTOFF VALVE, CHECKING THE AIR INDUCTION SYSTEM, INSTALLING THE AIR INDUCTION SYSTEM).

ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS, ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS, SWITCHES (CHECKING SWITCH CONTINUITY), CHECKING THE SWITCHES, CHECKING THE BULBS AND BULB SOCKETS (TYPES OF BULBS, CHECKING THE CONDITION OF THE BULBS, CHECKING THE CONDITION OF THE BULB SOCKETS, CHECKING THE LEDs), IGNITION SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), ELECTRIC STARTING SYSTEM (CIRCUIT DIAGRAM, STARTING CIRCUIT CUTOFF SYSTEM OPERATION, TROUBLESHOOTING), STARTER MOTOR (CHECKING THE STARTER MOTOR, ASSEMBLING THE STARTER MOTOR, INSTALLING THE STARTER MOTOR), CHARGING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), LIGHTING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING, CHECKING THE LIGHTING SYSTEM), SIGNALING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING, CHECKING THE SIGNALING SYSTEM), FUEL PUMP SYSTEM (CIRCUIT DIAGRAM, FUEL PUMP CIRCUIT OPERATION, TROUBLESHOOTING, CHECKING THE FUEL PUMP), CARBURETOR HEATING SYSTEM (CIRCUIT DIAGRAM, TROUBLESHOOTING), SELF-DIAGNOSIS (TROUBLESHOOTING).

TROUBLESHOOTING
STARTING PROBLEMS (ENGINE, FUEL SYSTEM, ELECTRICAL SYSTEMS), INCORRECT ENGINE IDLING SPEED (ENGINE, FUEL SYSTEM, ELECTRICAL SYSTEMS), POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE (ENGINE, FUEL SYSTEM), FAULTY GEAR SHIFTING (SHIFTING IS DIFFICULT, SHIFT PEDAL DOES NOT MOVE, JUMPS OUT OF GEAR), FAULTY CLUTCH (CLUTCH SLIPS, CLUTCH DRAGS), OVERHEATING (ENGINE, FUEL SYSTEM, CHASSIS, ELECTRICAL SYSTEMS), POOR BRAKING PERFORMANCE, FAULTY FRONT FORK LEGS (LEAKING OIL, MALFUNCTION), UNSTABLE HANDLING, FAULTY LIGHTING OR SIGNALING SYSTEM (HEADLIGHT DOES NOT LIGHT, HEADLIGHT BULB BURNT OUT, TAIL/BRAKE LIGHT DOES NOT LIGHT, TAIL/BRAKE LIGHT BULB BURNT OUT, TURN SIGNAL DOES NOT LIGHT, TURN SIGNAL BLINKS SLOWLY, TURN SIGNAL REMAINS LIT, TURN SIGNAL BLINKS QUICKLY, HORN DOES NOT SOUND).