ADDITIONAL ITEMS REQUIRING FREOUENT
REPLACEMENT
···················
···
··
······························
··
··
···
·4·7
AIR
CLEANER··········
··
··
··
····
··
············
··
··············
··
··
··
·······4·10
AIR
CLEANER
HO
USING ···············
··
·
··
····
··
···
··
··········
··
··· 6·7
ALTERNATOR CHARGING
CQll
·
··
..
··
..
··
..
··
··
..
···
···
..
·
..
..
17·8
AUTO-DECOMPRESSION SYSTEM (
After
'07)
··
···
··
····2·2
BALANCER
GEAR/BALANCER ···································
13
·8
BATTERy
·····
·
······················
·
······
···
··········
·
···········
·
·········
17
-6
BATTERY/CHARGING SYSTEM SPEC1FICATIONS ·
..
1·
12
BRAKE FLUiD·······················
··
······································ 4-29
BRAKE FLUID REPLACEMENT/AIR BLEEDING ····
··
··· 16-6
BRAKE PAD WEAR ··· .... ·
..
···
·
···
..
·
..
··
.... ··
..
·
..
·
···
..
·····
..
···
..
·4-30
BRAKE PAD/DISC ·
..
··
.... ···
···
..
···
..
··
··
·
..
·
··
·
..
·
..
···
..
····· .... ··16-10
BRAKE PEDAL·
..
·····
..
······
..
··
··
..
··
..
·
..
···
..
··· ...... ···
..
···
··
..
·
··
16-24
BRAKE
SYSTEM ·
..
··
....
··
..
·
..
····
..
·
..
·
..
···
..
··
..
··
..
··· .... ·
..
···
..
··4-30
CABLE
& HARNESS ROUTING ('05 - '07) ·
..
·
..
· .... ···
..
··
1-25
CABLE
& HARNESS ROUTING (
After
·07}··· .... ·····
..
·
..
1-32
CAM CHAIN TENSIONERICAM CHAIN GUIDE ·
..
......
9-25
CAMSHAFT INSTALLATION
..
··
..
·
..
· ....
··
..
·
..
··
··
..
·
··
····
..
·
··
9-39
CAMSHAFT INSTALLATION ('05
- ·07)·
..
..
· ....
..
...... ·
..
·9
-37
CAMSHAFT REMOVAL ('05
- '07)· .... ·
..
......
..
..
....
·
....
·
....
·9-S
CAMSHAFT REMOVAL
(
After
'07) ···· ...... ···
..
··
..
·· .... ·
..
·9
-
'6
CARSURETOR
ADJUSTMENT
·····
..
··· ......
···
..
····· ....
··
..
···6-6
CARBURETOR
ASSEMBLY
····
..
·····
..
··· ......
···
..
··
..
··
..
··
..
··
6-1S
CARBURETOR DISASSEMBLY
.... · .... ···
..
· .... ·
..
·
..
·· .... ·
..
·6-13
CARBURETOR INSTALLATION
...... · ...... ·
..
· .......... · ...... 6-24
CARBURETOR REMOVAL
..
··
··
..
··
·· ....
··
..
···
····
..
··
..
·
..
..
··
..
·6
-
11
CHARGING SYSTEM INSPECTION ·
··
..
·····
··
..
··
..
· ....
··
..
·17-7
CLUTCH
..
·
..
·
··
....
··
·
··
..
··
..
·······
..
···
..
·
··
··
·
..
·· ...... ·
··
········
..
···
..
·1
1-7
CLUTCH
LEVER
··· ....
··
.... ··
..
·
··
···
..
··
··
·
..
··· .... ·
..
··
····
··
.... ····14-52
CLUTCH SWITCH
......................................................... 20-S
CLUTCH SYSTEM ·
..
··
.... ····· ....
··
..
·
..
··
..
··
.... ·
..
··
..
····
..
·
..
··
..
·4-
31
CLUTCHISTARTER CLUTCH/KICKSTARTER/
GEARSHIFT
LINKAGE SPECIFICATIONS ·
..
·· ....
··
···
..
··
..
· ' ·9
COMPETlnON
MAINTENANCE SCHEDULE
..
······
..
··
..
·4·6
COMPONENT LOCATION
ALTERNATOR ....
..
....
·
....
..
..
....
·
..
·
.. ..
·
.. ..
.... ·
..
·
....
· .... ·
..
·12·2
BAnERY
/CHARGING SYSTEM · .... · .... ·
..
· ............ ·
..
17·2
CLUTCH/STARTER CLUTCH/KICKSTARTER/
GEARSHIFT LINKAGE·
..
··
..
··· .... ···
..
···
..
· ....
··
.... ··· .... ·
..
1 1·2
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER ·
..
······
..
···· .... ···
..
···
..
·
..
· .... ··· ......
··
..
·······
..
···13·2
CYLINDER HEADN ALVES··
...... · ....
···
..
·
..
··· .... ·
··
....
··
..
·9-2
CYLINDERIPISTON ·
..
....
··
·
..
···
.... ····
..
···
··
..
···
..
····
···
..
·
..
10-2
ELECTRIC
STARTER ·
..
··
..
··········
..
···
..
······
..
···
..
······
..
··
19-2
ENGINE REMOVAUINSTALLATION
..
..
..
·
..
..
· ...... ·
..
·
..
8-2
FRONT WHEEUSUSPENS
ION
/STEERING
..
........
..
14-2
FUEL SYSTEM
··
..
· ....
··
..
··
..
·
··
..
··
..
· .... · .... ·
..
· .... · ......
··
..
·
··
·6-2
HYDRAULIC BRAKE
··
..
·
..
···
..
·······
..
· .... ·····
..
··
....
··
..
·
..
··
16-2
IGNITION SYSTEM ···
..
·
..
·
..
·
..
···· ....
··
..
····· ....
··
..
······
..
··
18-2
LlGHTSIMETERISWITCHES
..
····
..
···
..
···
···
..
···· .... ···
..
·20-2
REAR
WHEEUSUSPENSION .... · ....
..
..
.... · ....
..
..
· .... ·
..
1 5-2
CONTROL CAB
LE
S
··
.... ··
..
·
..
·
··
..
····· .... ··
..
·
··
···
..
··
·
..
······
..
··4-32
COOLANT REPLACEMENT
...
..
.....
..
................
..
......
..
..
...
7-6
COOLING SYSTEM··· .... ·····
..
··
..
··
····
..
···
..
····· ....
··
..
··· .... ···4-14
COOLING SYSTEM SPECIFICATIONS
..
·
..
···
..
···
...... ·
..
··· ' -7
CRANKCASE
ASSEMBLY
.... · ...... ·
..
..
· ........ ·
..
· ........ ·
..
·13-25
CRANKCASE
BEARING REPLACEMENT ····
..
···
......
··
'3
·16
CRANKCASE
BREATHER
··
....
··
..
··
··
.... ·· .... ····
..
·· ......
··
..
·
·4
-
11
CRANKCASE SEPARATION
..
···
..
·
..
·
..
··
··
..
· .... ·
..
··· ...... ··13-
'O
CRANKCASE/CRANKSHAFTfTRANSMISSIONI
BALANCER SPECIFICATIONS ('05
. ·07) ...... · ...... ·
..
....
..
1·9
CRANKCASEICRANKSHAFTfTRANSMISSIONI
BALANCER SPECIFICATIONS
(
After
'07}
..
·
..
..
·
..
·
..
...... 1· 10
CRANKSHAFT INSTALLATION
.... · .... · ...... ···
..
···
..
·
..
·
..
13-
21
CRANKSHAFT
REMOVAL·
··
..
··
..
·····
..
····
..
··
..
· ........ ·
..
·
··
13-14
CYLINDER COMPRESSION TEST··
..
····
..
········· .... ·
..
··
..
···9-7
CYLINDER
HEAD ASSEMBLY··
..
···· ....
··
..
··
..
··
..
···
..
·
..
··
..
·9-33
CYLINDER
HEAD COVER
INSTALLATlON··
..
···
..
·
..
··
..
·9
-42
23. INDEX
CY
LI
NDER HEAD COVER REMOVAL ......
....
..
..
·
..
...... ·
..
· 9-7
CYLIN
DER
HEAD
DiSASSEMBLy
..
·
..
··
..
····
..
·· .... ··
..
··
..
· 9·27
CYLINDER
HEAD INSPECTION ....
..
.
..
......................
..
. 9-2S
CYLIN
DER
HEAD INSTALLATION·
..
··
..
·
..
··
··
..
··· ....
..
····· 9-36
CYLINDER HEAD REMOVAL .
..
....................
..
..........
..
. 9-24
CYLINDER HEADN ALVES SPECIFICATIONS· .......... ·
..
1-S
CYLINDER
INSTALLATION
········ ....
··
..
·
..
···
..
· .... · ........ · 10-10
CYLINDER
REMOVAL··
..
· ....
··
.... · .... ·
..
··
..
····
..
···
..
······
..
··· 10-5
CYUNDERIPISTON SPECIFICATIONS
........ · .... ·
....
· ...... 1-8
DRIVE CHAIN
··
.... ·····
..
··
..
··
....
···
..
··
..
···
..
··
..
··
..
·
···
..
·
..
·
..
· .... · 4·24
DRIVE CHAIN
ROL
LER
..
.....
..
..
...................
....
.............. 4-28
DRIVE CHAIN SLIDER ........
..
...
..
.......
..
....................
....
. 4-27
DRIVE SPROCKET ·
..
···
..
··
....
··
..
············
..
··
....
······ ......
···
..
··
8-4
DRIVE/DRIVEN SPROCKET
...... · ..........
..
·
....
· .... · ....
..
.... · 4·28
ELECTRIC STARTER SPECIFICATION·
.... · ...... · ...... · .... 1-13
EMISSION CONTROL SYSTEMS
··
..
··
..
·
..
·
..
·
..
··· ......
··
..
· 1-40
ENGINE & FRAME TORQUE VALUES ...... · ....
..
...... ·
..
· 1-14
ENGINE
GUARD·
..
·
..
···
..
··
..
···
..
····
..
···
..
··
..
··
.... ······ .... ·
..
··
..
··
3-5
ENGINE
IDLE SPEED···
..
··
..
·
··
·
..
···
..
····
..
·····
....
··
..
··
·· ......
··
4-22
ENGINE
INSTALLA
TION·
..
·····
··
··
..
····
..
·
··
··
....
···
..
···
..
·
..
··
..
·
S-S
ENGINE
OIUOIL
FILTER·· ....
··
..
··
·
..
··
·
..
··
..
··
....
··
..
···· ...... ·· 4-19
ENGINE REMOVAL·
..
··
..
·· .... ·· .... ·
..
····
..
··
..
· ....
··
..
·
···
...... ··
..
8-5
ENGINE
STOP
BUnON
· .... ·
..
· ...... ·
..
· ............
..
............ 20-7
EXHAUST
PIPEIMUFFLER .......................................... 4-33
EXHAUST
SYSTEM ............................................
..
........ 3·9
FLYWHEEL ....
"""""
"
",
,,
,,
,,,,,,,,,,,,,,,,,,,,
,,
,,
,,,,
,,,,
,,,,
,,
,,,,,, 12-5
FORK
..
..
....
..
...
..
..
..
.
..
.......
..
..
..
..
...
..
.........
..
.........
..
.... ······ 14-13
FRONT BRAKE CALIPER······
..
··
..
··
··
····
..
··
..
··
··
..
··
..
·
··
··
··
16-18
FRONT
MASTER CyLINDER
..
....
..
·
..
· ...................... ·
..
16-12
FRONT
VISOR ..............
...
...........................
...
..
...
........... 3-5
FRONT
WHEEL···
..
·
..
· .... · ...... ·
..
··
..
····
..
··
..
·
..
····
..
··
.... ······
..
14-S
FRONT WHEEUSUSPENSION/STEERING
SPECIFICATIONS
................................
..
...................... 1-11
FUEL
LINE···
..
· ....
··
..
•
..
·
..
·· ....
..
·
..
··
..
···
·
..
··
··
···
..
·
···
..
· .... ·
..
·
··
..
· 4-8
FUEL
STRAINER SCREEN ...
..
..................
..
........
..
......... 4-8
FUEL
SYSTEM SPECIFICATIONS
..
.........................
..
... 1-7
FUEL
TANK
..
··
..
··
·
..
·
..
·············
..
··
··
··
·····
··
·
··
..
········ .... ··
..
·
..
··
3-8
GEARSHIFT LINKAGE·····
..
·
··
..
····
..
····
..
·
..
··
....
··
..
···· ......
11
·24
GENERAL SPECIFICATIONS ·
..
··
..
····
..
·
..
····
..
·
··
..
···
..
·
..
···
..
1-5
HANDLEBAR
··
.... ··· .... ···
..
··
..
•···
..
···
..
····
..
·
..
··
....
··
·
..
···
..
·
..
· 14-33
HEADLIGHT
..
...........................
..
..............
..
....
..
............ 20·4
HEADLIGHT
AIM
......
...
..
..
....
...
..
...........
..
..
..
.......
..
......... 4-
31
HOT
START
..
· ....
··
..
·
..
···
..
··
..
··
···
···
..
··
··
..
··
..
··
··
..
···
·
····
..
·
..
··· 4-10
HPSD
(Honda P
ro
gressive
Steering
Damper)
:
After
'07
FRONT WHEEUSUSPENSION/STEERING
....
······ 14-38
TECHNICAL FEATURE·····
..
·
..
··
······
..
··
..
····
..
··
..
·······
..
··· 2-3
HYDRAULIC BRAKE
SPEC
IFICATIONS·
..
····
..
·· .... ·····
..
1·12
IGNITION COIL
...... ·· .... ·
..
····
..
···
..
··
..
····
..
··
..
·
..
·
..
· .... ·· ...... · 18·7
IGNITION CONTROL
MODULE (ICM)
..
·
.... ....
·
..
· ...... ·
..
18-7
IGNITION SYSTEM INSPECTION····
..
··
........
··
....
··
...... · 18-5
IGNITION SYSTEM SPECIFICATIONS
..
· .... · ....
..
·
..
·
..
..
· 1-12
IGNITION
TIMING
.......
..
.
.. ..
.........................
....
.....
..
...
..
18-8
KICKSTARTER
..
..
..
...... · ...... · ....
..
...... ·
..
..
....
..
·
....
..
·
..
..
·
..
·
11
·15
lEFT
CRANKCASE COVER
INSTALLAT
ION·
..
· .......... 12·6
LEFT CRANKCASE COVER REMOVAL
..
·
..
·
..
·
..
·
..
· ...... · 12·4
LIGHTS/METER/SWITCHES SPECiFiCATIONS ·······
..
'-13
LUBRICATION & SEAL POINTS ·
..
· ........................ · .... 1-
21
LUBRICATION SYSTEM
DIAGRAM
..............
..
............. 5-2
LUBRICATION SYSTEM SPECiFiCATIONS· ........ · ...... · 1-7
MAINTENANCE SCHEDULE ('05. '06 ) ......
..
..
....
........... 4-4
MAINTENANCE SCHEDULE
(Aft
er ·06)
..
........
..
·
..
··
..
·
..
· 4-5
MODEL IDENTIFICATION
.............. · .... · ..........
..
..
·
..
· ...... · 1-2
NUTS
. BOLTS. FASTENERS
..
· ...... · ........
..
..
..
............ ·
..
4-36
Oil
JET
.......................................................................... 5·6
OIL
PUMp
···
..
· .... · ...... ··
..
·
··
..
···
..
···
..
····
..
··
.... ·
..
· .... ·
..
·
..
· .... ·
..
5-7
Oil STRAINER
..
··
..
·
··
··
.... ··
..
···
..
···
..
····
..
··
..
··
·
..
·
..
·
..
···
..
·
..
···
..
5·4
OPTIONAL PARTS··
..
·
..
·
···
..
···
..
··
·
..
····
..
··
..
··
..
···
··
.... ·
..
·
..
··· 1-37
PilOT
SCREW
ADJUSTMENT
..
..
.....
..
............
....
........ 6-27
PISTON INSTALLATION·
..
····
..
···
..
····
..
··
..
··
..
·
····
··
·
··
····
..
· 10-9
23-1
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