QUICK REFERENCE DATA

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

CHAPTER TWO/ TROUBLESHOOTING
Water damage
Engine operating requirements
Engine will not start
Poor idle speed performance
Poor medium and high speed performance
Electrical testing
Starting system
Charging system
Ignition system
Lighting system
Fuel system
Engine overheating
Engine
Engine noises
Cylinder leakdown test
Clutch
Transmission
Final drive
Handling
Frame noise
Brakes

CHAPTER THREE/ LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride check list
Maintenance schedule
Tires and wheels
Battery
Engine oil and filter
Final drive gearcase oil
Control cable lubrication
General lubrication
Air and fuel system
Brake system
Spark arrestor
Suspension
Fasteners
Valve clearance
Engine compression test
Spark plug
Ignition timing
Idle speed adjustment
Specifications

CHAPTER FOUR/ ENGINE TOP END
Cylinder head cover
Rocker arms, pushrods and cylinder head
Valves and valve components
Cylinder
Piston and piston rings
Camshaft
Specifications

CHAPTER FIVE/ ENGINE LOWER END
Engine removal/installation
Oil cooler
Alternator cover
Flywheel and starter gears
Gearshift linkage
Oil pump
Oil screen and strainer
Crankcase and crankshaft
Engine break-in
Specifications

CHAPTER SIX/ CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover
Clutch release mechanism
Centrifugal clutch and primary drive gear
Change clutch
Specifications

CHAPTER SEVEN/ TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission overhaul
Reverse idle gear assembly
Transmission inspection
Internal shift mechanism
Reverse selector cable replacement
Specifications

CHAPTER EIGHT / FUEL, AIR AND EXHAUST SYSTEMS
Carburetor
Carburetor adjustments
Throttle housing
Throttle cable replacement
Choke cable replacement
Fuel tank
Fuel valve
Air box
Exhaust system
Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Electrical component replacement
Electrical connectors
Battery negative terminal
Charging system
Alternator
Ignition system
Starter
Starter relay
Starter relay
Diode
Lighting system
Switches
Fuse
Specifications

CHAPTER TEN / WHEELS, HUBS AND TIRES
Front wheel
Front hub
Rear wheel
Rear hub
Tires
Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Handlebar
Steering shaft
Tie rods
Steering knuckle
Control arms
Ball joint replacement
Shock absorbers
Specifications

CHAPTER TWELVE / REAR AXLE, SUSPENSION AND FINAL DRIVE
Shock absorber
Rear axle
Final drive
Driveshaft
Swing arm
Specifications

CHAPTER THIRTEEN / BRAKES
Brake service
Front brake pads
Front brake caliper
Front master cylinder
Brake hose replacement
Brake fluid draining
Brake bleeding
Rear brake drum
Rear brake pedal and cable
Rear brake lever/parking brake cable
Specifications

CHAPTER FOURTEEN / BODY
Retaining clips
Retaining tabs
Seat
Side covers
Fuel tank cover
Front fender
Front and rear guards
Rear fender
Footpegs and mud guards
Handlebar cover

INDEX

WIRING DIAGRAMS