QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Transmission linkage / Transmission / Electrical testing / Final drive / Front suspension and steering / Brake system

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Cylinder identification / Pre-ride inspection / MoDiTeC diagnosis and integral ABS bleed test / Throttle cable operation and adjustment / Engine oil and filter / Transmission / Final drive / Clutch / Brake system / Cooling system / Battery service / Front suspension inspection / Sidestand / Centerstand (manual) / Rear wheel mounting bolts inspection / Swing arm bearing inspection / Speedometer sensor cleaning (ABS II) / Tune-up / Compression test / Air filter replacement / Fuel filter replacement / Valve clearance / Slide rail, tensioner rail lining and thrust piece replacement / Spark plugs / Tires and wheels / Lights and horn inspection / Non-scheduled inspection and maintenance / Rear shock adjustment / Specifications

CHAPTER FOUR / ENGINE
Engine service / Engine / Engine block / Crankshaft cover / Cylinder head cover / Timing cover, cam chain tensioner and crankshaft oil seal / Timing chain, chain guides and camshaft sprockets / Crankshaft rotor flange and sprocket / Camshafts / Cylinder head / Valves and valve components / Intermediate housing and driver / Auxiliary shaft, starter clutch and starter idler gear / Auxiliary shaft and starter clutch overhaul / Auxiliary shaft front bearing and oil seal replacement / Main oil seal replacement / Pistons and connecting rods / Crankshaft / Oil pan, lower crankcase half and output shaft / Output shaft overhaul / Break-in procedure / Specifications

CHAPTER FIVE / CLUTCH
Clutch / Clutch master cylinder / Clutch slave cylinder / Clutch system draining / Clutch system bleeding / Specifications

CHAPTER SIX / TRANSMISSION AND SHIFT MECHANISM
Transmission / Transmission rubber bushings / Transmission seal replacement (assembled transmission) / Transmission disassembly / Transmission housing and front cover inspection, bushing and seal replacement / Shift mechanism / Transmission shaft overhaul / Transmission reassembly / Reverse system (LT models) / Specifications

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Fuel injection system / Fuel tank / Fuel filter replacement / Fuel pump replacement / Fuel tank vent and float (RS and GT models) / Fuel level sensor / Roll-over valve (LT models) / Air box / Air intake guide / Fuel pressure check / Fuel rail, fuel injectors and pressure regulator / Throttle body / Fuel hose replacement / Motronic control unit / Air temperature sensor / Coolant temperature sensor / Oxygen sensor / Exhaust system / Carbon canister / Throttle and cruise control cables / Cruise control unit / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
(ENGINE) Battery / Charging system / Alternator / Starting system / Starter / Starter relay / Ignition coil / Hall-effect sensors / Ignition timing / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
(BODY) Bulbs / Headlight housing / Headlight adjuster cable replacement (LT models) / Turn signal bulb holder / Instrument panel / Electronic equipment box / Relays / Flasher unit / Fuses / Switches / Electrical components / On-board computer (LT models) / Power socket / Horn / Audio assembly / Wiring diagrams / Specifications

CHAPTER TEN / COOLING AND LUBRICATION SYSTEMS
Temperature warning system / Cooling system inspection / Hoses / Coolant reserve tank / Radiators / Cooling fans / Thermostat / Coolant pipe / Water/oil pump / Oil cooler housing and thermostat (RS and GT models) / Oil cooler (RS and GT models) / Specifications

CHAPTER ELEVEN / WHEELS AND TIRES
Motorcycle workstands / Front wheel / Front wheel bearings / Rear wheel / Wheels / Tires / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebars, grips and controls / Upper fork bridge / Lower fork bridge and ball joint / Front fork / Front strut / Steering damper / Suspension A-arm / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Final drive unit / Final drive unit overhaul / Ring and pinion gear adjustments / Swing arm and front drive shaft / Specifications

CHAPTER FOURTEEN / BRAKE SYSTEM
(ABS II) Brake service / ABS II / Brake pads / Brake calipers / Brake fluid filler adapter / Front master cylinder / Rear master cylinder / Brake disc and sensor wheel / ABS sensor / ABS control unit / ABS relay / Rear brake pedal / Brake bleeding / Specifications

CHAPTER FIFTEEN / BRAKE SYSTEM
(INTEGRAL ABS) Brake service / Integral ABS / Brake pads / Brake calipers / Front master cylinder / Rear master cylinder / Brake disc and sensor wheel / ABS sensors / ABS control unit / Rear brake pedal / Specifications

CHAPTER SIXTEEN / BODY AND FRAME
(RS AND GT MODELS) Saddlebags and holder / Seat / Front fender / Windshield and holder assembly / Hand guard/front turn signal housing (- RS models) / Upper fairing / Instrument panel trim (-on RS and GT models) / Fairing side panels / Engine spoiler / Side covers / Grab handle and luggage rack / Lock carrier / Rear section / Rear fender assembly / Left front footpeg and holder / Left rear footpeg and holder / Right front footpeg and holder / Right rear footpeg and holder / Sidestand / Centerstand / Cross-tube / Raising the frame / Specifications

CHAPTER SEVENTEEN / BODY AND FRAME
(LT MODELS) Windshield / Front fender / Mirrors / Wind deflector / Front turn signal indicator / Bottom fuel tank cover / Bumper strip / Fairing side panels / Radio compartment cover / Fuel tank cover / Engine spoiler assembly / Handlebar covers / Upper fork bridge cover / Outer instrument cover / Upper fairing / Inner instrument cover / Footrest assemblies / Crash bar assembly / Sidestand / Engine guard and manual centerstand / Engine guard and electro-hydraulic centerstand (EHCS) / Seats / Battery covers / License plate holder / Trunk / Rear trunk trim / Saddlebags / Cross-tube / Raising the frame / Specifications

INDEX

WIRING DIAGRAMS