ADOInONAL
ITEMS REQUIRING FREQUENT
REPLACEMENT······························································3-7
AlA
CLEANER·······························································3-10
AlA CLEANER HOUSING ·······························
··
·············5-7
ALTERNATOR CHARGING CQll·········
..
······
..
····
··
·
..
····l&
8
BALANCER
GEAR/BALANCER ··································· 12·6
BA
TTEAY
...................................................... ················
16
·6
BATTERY/CHARGING SYSTEM SPECIFICATIONS ··· , -, 1
BRAKE
FLUiD·········
······················································3
-26
BRAKE FLUID REPLACEMENT/AIR BLEEDING ......... 15-6
BRAKE
PAD WEAR ...................................................... 3-27
BRAKE
PADIDISC ...................................................... , 5-10
BRAKE PEDAL····························································15-24
BRAKE SYSTEM ...................................................... ····3-27
CABLE
& HARNESS ROUTING···································1-23
CAM CHAIN TENSIONER
/C
AM
CHAIN GUIDE ·········8-14
CAMSHAFT/ROCKER
ARM
INSTALLATION··············8-27
CAMSHAFT/ROCKER
ARM
REMOVAL ························8-7
CARBURETOR
ADJUSTMENT
·····································5·6
CARBURETOR ASSEMBLY ·································
.... ····5-18
CARBURETOR DISASSEMBLY···································5-13
CARBURETOR INSTALLATION
,·
.... ···
..
···
..
······
..
··········5-24
CARBURETOR REMOVAL·············
..
··
..
··
···
······
..
···
..
·
..
···5·1 1
CHARGING SYSTEM INSPECTION
··
..
····
..
·
..
··
.... ·····
..
··16·6
CLUTCH
......
..
.................................................. ····
..
··
··
..
··
1 0-7
CLUTCH SWiTCH······
..
······•
..
··········· .... ·
..
············
..
········ 19-7
CLUTCH
SySTEM
····
..
··
..
· .... ···
..
····································3-28
CLUTCH/STARTER CLUTCH/KICKSTARTEA/
GEARSHIFT
LINKAGE SPECIFICATIONS
..
·········
..
········1-9
COMPETITlON MAINTENANCE SCHEDULE
..
···
..
·
..
··
..
·3·
6
COMPONENT LOCATION
ALTERNATOR ···················
..
···
..
·
..
··
..
···· .... ················11-2
BATIERY
/CHARGING SYSTEM····
..
···· .. ·····
..
··········16-2
CLUTCH/STARTER CLUTCHI
KICKSTARTERIGEARSHIFT
LINKAGE ··················· 10-2
CRANKCASE/CRANKSHAFTfTRANSMISSIONI
BALANCER ···········
..
···
..
··
..
··
..
···
..
·
..
··
..
···· .... ················ 12-2
CYLINDER
HEADNALVES
··
..
····
..
···
..
···
..
··
..
··
········
..
····8-2
CYlINDERlPISTON ······•
..
····
..
·····
..
···
.... ··········
..
·
..
·······9·2
ELECTRIC STARTER ···························
.... ·
..
··· ......
··
..
18-2
ENGINE
REMOVAUlNSTALLATION
..
··········
..
··
..
······7-2
FRONT WHEEUSUSPENSION
/S
TEERING
····
..
·
..
··· 13-2
FUEL SySTEM····
..
·····
..
·•·
·
..
·······
..
·······························5-2
HYDRAULIC BRAKE ········
..
···
..
··
..
··
..
··
.... ················
..
·15-2
IGNITION SYSTEM ·····················
··
..
···
..
·
..
················
17
-2
LIGHTS/METER/SWITCHES ·····
..
········ .... ···
..
·
··
..
······19-2
REAR
WHEEUSUSPENSION··································14-2
CONTROL CABLES
..
····················································3-29
COOLANT REPLACEMENT
···
..
····
.... ····
..
··
..
·
..
··
..
·············6-6
COOLING SYSTEM ·················
..
·····
..
··
..
···
..
· .... · .... · .. ·
..
···3·13
COOLING SYSTEM SPECIFICATIONS
..
······
..
···
..
·
..
·······1-7
CRANKCASE ASSEMBLY ···········
..
·
..
··
..
··· ......
··
..........
12
-2 1
CRANKCASE BEARING REPLACEMENT ·················
12
-13
CRANKCASE BREATHER ·····················
..
·····················3-'1
CRANKCASE SEPARATION
..
··
.... ·····
..
··
..
···········
..
·
..
·····12·7
CRANKCASElCRANKSHAFTfTRANSMISSION/
BALANCER SPECIFICATIONS
..
·····
..
····
..
······
..
···
····
·
··
····· 1-9
CRANKSHAFT INSTALLATION ····
..
···
..
······
..
···
··········12-18
CRANKSHAFT REMOVAL ······
..
·····
..
···
..
···
..
··
··
··
..
··
····
··
'2
·12
CYLINDER COMPRESSION TEST·
....
··
..
··
..
·
..
···
..
······
..
····8-6
CYLINDER
HEAD
ASSEMBLY
····· ....
····
..
······················8-23
CYLINDER
HEAD COVER INSTALLATION ····· .... ········8-30
CYLINDER
HEAD COVER REMOVAL ·
..
·········· .... ····
..
····8-6
CYLINDER
HEAD DISASSEMBLY··
..
··· .... ·······
..
·
..
·
..
·····8-15
CYLINDER
HEAD INSPECTION·········
..
························8-17
CYLINDER
HEAD INSTALLATION ······
..
···············
..
·····8-25
CYLINDER
HEAD REMOVAL·····················
..
········
..
··
..
··8-
'2
CYLINDER HEADNALVES SPECIFICATIONS·····
..
·······'-8
CYLINDER INSTALLATION ··,··
..
··········
..
························ 9-8
22. INDEX
CYLINDER REMOVAL ·
..
···
..
··
..
·
..
···
..
····
..
···
..
··
..
··
..
····
..
··
..
··
9-4
CYLINDERIPISTON INSPECTION ......
··
..
······
..
········
..
··
..
· 9-5
CYLINDER/PISTON SPECIFICATIONS · .... ··········
..
···
..
··· 1-8
DRIVE CHAIN········································
..
················
..
···3·21
DRIVE CHAIN
ROLLER ................................................ 3-25
DRIVE CHAIN SLIDER ................................................. 3-24
DRIVE SPROCKET ................
..
....................................... 7-4
DRIVE/DRIVEN SPROCKET·······
..
································ 3·25
ELECTRIC STARTER SPECIFICATIONS···
..
··
············" 1-12
EMISSION CONTROL SYSTEMS ····
..
···
..
···
·····
··
··········
'-33
ENGINE & FRAME TORQUE VALUES··
..
······
..
···
..
···
..
· ' ·13
ENGINE GUARD·
..
··
..
·
..
··
..
····• .... ·
..
···
.... ···
..
···
..
·
..
····
..
········ 2-4
ENGINE IDLE SPEED···
..
··
..
·····
..
· .... ······
..
··········
..
·········· 3-19
ENGINE
INSTALLAT
ION···············································7-7
ENGINE
OIUOIL
FILTER
··
..
·····
..
···
..
······························ 3-
17
ENGINE REMOVAL ....................................................... 7·5
ENGINE STOP
BUTION
·····················
..
···
..
··
..
··
..
···
..
··
..
19-6
EXHAUST
PIPE
/MUFFLER .......................................... 3-29
EXHAUST
SYSTEM ...................................................... 2-8
FLYWHEEL·······················
···
············
··
..
·························'1-5
FORK···
..
················
..
················································
..
·13-12
FRONT BRAKE CALIPER··········································· 15-18
FRONT
MASTER CyLINDER···············
..
···················· 15-12
FRONT
VISOR ............................................................... 2·5
FRONT WHEEL·
..
· .... ·
..
·······
..
·
..
··
..
··
..
····· .... ·
..
··
..
···
..
···
..
··· 13-7
FRONT
WHEEUSUSPENSIONI
STEERING SPECIFICATIONS
..................................... 1-10
FUEL LINE···
..
·································································3-8
FUEL STRAINER SCREEN ............................................ 3-8
FUEL
SYSTEM SPECIFICATIONS ·
..
····· .... ·········
..
········· 1
·7
FUEL
TANK
·····
..
··
..
······
..
··············
..
···
....
··
..
···
..
·················2-7
GEARSHIFT LINKAGE··············································· 10
-25
GENERAL
SPECIFICATIONS ........................................ 1-5
HANDLEBAR···
..
···············
..
·····································
..
·
13
·3
1
HEADLIGHT ............ , ............................
....
................ ·
..
·19·4
HEADLIGHT
AIM
......................................................... 3-28
HIGH
AL
nTUDE
ADJUSTMENT
(California
type
onIV)···············
..
···········
..
··············· .... · 5-29
HOT START ......................................................... ··········3-9
HYDRAULIC
BRAKE SPECIFICAnONS·············
..
······· 1
-1
1
IGNITION CONTROL MODULE (ICM) ....
··
..
·
..
··
..
·········
17
-8
IGNITION SYSTEM INSPECTION··
··
..
··
·
..
··
.... ·········
..
·
..
17
-5
IGNITION SYSTEM SPECiFiCATIONS······················· 1-
11
IGNITION
TIMING
....................................................... 17-8
KICKSTARTER
..
··········
..
·····················
..
······················10-15
LEFT CRANKCASE COVER INSTALLATION·····
..
·······
11
-7
LEFT
CRANKCASE COVER REMOVAL ......................
11
-4
lIGHTS/METEA/SWITCHES SPECIFICATIONS ········· 1-12
LUBRICATION & SEAL POINTS·
..
·····
..
···
..
···········
..
··
..
· 1-20
LUBRICATION SYSTEM
DIAGRAM
··
..
·
..
···
..
··
..
············· 4-2
LUBRICATION SYSTEM SPECIFICATIONS··
..
············· 1-6
~
MAIN
RELAY (,
04
,
'0
5) ················
..
························· .... · 19-9
~
MAINTENANCE
SCHEDULE
'04 - '06 ..................................................................... 3-4
After
'06· ....
···
..
··
..
·
..
·,·
..
·····
..
··
..
···
..
·····
..
···
..
·
..
··
..
···
..
··
..
···3-5
MODEL IDENTIFICATION
..
··········································· 1-2
NUTS, BOLTS, FASTENERS
..
··································
..
· 3·33
OIL
JET ..........
...
........................................
..
. ····
..
············ 4-6
OIL PUMP
...................................................................... 4-7
OIL STRAINER····································
..
···
..
·····
..
··,·
..
·
..
····4-4
OPTIONAL PARTS
..
·····
..
··
..
·········
..
······
..
······················· 1-30
PILOT SCREW
ADJUSTMENT
................................... 5-27
PISTON
INSTAllAT
ION ·····················
..
···
..
·
..
··
.... · .... ····· 9-8
PISTON REMOVAL······
..
··
..
·····
..
··
.... ····
..
··
..
····················· 9-4
PRESSURE RELIEF VALVE ·····
..
···························
..
··
..
··· 4-5
RADIATOR
.........................................
..
.......................... 6-8
RADIATOR COOLANT·
..
··•······
..
··
..
···························•··· 3-13
RADIATOR RESERVE
TANK·
·································
..
· .... 6·9
RADIATOR SHROUD····················
..
··········
..
·
..
················ 2-4
22
-1