Product Information
Table of Contents
1. General Information
- General Safety (Page 1-1)
- Service Rules (Page 1-2)
- Model Identification (Page 1-3)
- Specifications (Page 1-4)
- Torque Values (Page 1-12)
- Tools (Page 1-15)
- Lubrication & Seal Points (Page 1-17)
- Cable & Harness Routing (Page 1-19)
- Optional Parts (Page 1-24)
2. Frame/Body Panels/Exhaust System
- Frame Inspection (Page 2-1)
- Body Panels Removal/Installation (Page 2-5)
- Exhaust System Removal/Installation (Page 2-8)
3. Maintenance
- Maintenance Schedule (Page 3-1)
- Lubrication Points (Page 3-4)
- Checking & Replacing (Page 3-7)
- Adjustment Procedures (Page 3-10)
4. Fuel System
- Fuel Tank Removal/Installation (Page 4-1)
- Carburetor Removal/Disassembly (Page 4-4)
- Carburetor Inspection/Assembly (Page 4-8)
- Fuel System Troubleshooting (Page 4-12)
5. Cooling System
- Radiator Removal/Installation (Page 5-1)
- Coolant Replacement (Page 5-4)
- Water Pump Inspection/Repair (Page 5-7)
- Cooling System Troubleshooting (Page 5-10)
6. Engine Removal/Installation
- Engine Removal Procedure (Page 6-1)
- Engine Installation Procedure (Page 6-7)
7. Cylinder Head/Cylinder/Piston
- Cylinder Head Removal/Inspection (Page 7-1)
- Cylinder Removal/Inspection (Page 7-5)
- Piston Removal/Inspection (Page 7-9)
- Reassembly Procedures (Page 7-13)
8. Composite Racing Valve (CRV)
- CRV Removal/Inspection (Page 8-1)
- CRV Cleaning/Adjustment (Page 8-5)
- CRV Reassembly Procedures (Page 8-9)
9. Clutch/Kickstarter
- Clutch Removal/Inspection (Page 9-1)
- Clutch Assembly Procedures (Page 9-5)
- Kickstarter Removal/Inspection (Page 9-9)
- Kickstarter Assembly Procedures (Page 9-13)
10. Transmission/Crankshaft/Balancer
- Transmission Removal/Inspection (Page 10-1)
- Transmission Assembly Procedures (Page 10-5)
- Crankshaft Removal/Inspection (Page 10-9)
- Crankshaft Assembly Procedures (Page 10-13)
- Balancer Removal/Inspection (Page 10-17)
- Balancer Assembly Procedures (Page 10-21)
11. Front Wheel/Suspension/Steering
- Front Wheel Removal/Inspection (Page 11-1)
- Front Suspension Removal/Inspection (Page 11-5)
- Front Suspension Assembly Procedures (Page 11-9)
- Steering Removal/Inspection (Page 11-13)
- Steering Assembly Procedures (Page 11-17)
12. Rear Wheel/Suspension
- Rear Wheel Removal/Inspection (Page 12-1)
- Rear Suspension Removal/Inspection (Page 12-5)
- Rear Suspension Assembly Procedures (Page 12-9)
13. Hydraulic Brake
- Brake System Overview (Page 13-1)
- Front Brake Removal/Inspection (Page 13-5)
- Front Brake Assembly Procedures (Page 13-9)
- Rear Brake Removal/Inspection (Page 13-13)
- Rear Brake Assembly Procedures (Page 13-17)
- Brake System Troubleshooting (Page 13-21)
14. Ignition System/Alternator
- Ignition System Overview (Page 14-1)
- Ignition Coil Removal/Inspection (Page 14-5)
- Ignition Coil Assembly Procedures (Page 14-9)
- Alternator Removal/Inspection (Page 14-13)
- Alternator Assembly Procedures (Page 14-17)
- Ignition System Troubleshooting (Page 14-21)
15. Wiring Diagram
- Wiring Diagram Overview (Page 15-1)
- Detailed Wiring Diagrams (Page 15-5)
16. Technical Features
- Technical Innovations (Page 16-1)
- Performance Characteristics (Page 16-5)
17. Troubleshooting
- Engine Troubleshooting (Page 17-1)
- Electrical System Troubleshooting (Page 17-5)
- Mechanical System Troubleshooting (Page 17-9)
18. Index
- Index of Topics (Page 18-1)
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