Product Information
Table of Contents
1. GENERAL INFORMATION
- General Safety 1-1
- Service Rules 1-2
- Model Identification 1-3
- Specifications 1-3
- Torque Values 1-5
- Tools 1-6
- Cable & Harness Routing 1-8
2. LUBRICATION
- Lubrication Points 2-1
- Lubrication Schedule 2-2
- Recommended Lubricants 2-3
3. MAINTENANCE
- Maintenance Schedule 3-1
- Pre-ride Inspection 3-2
- Engine Oil Change 3-3
- Air Filter Service 3-4
- Spark Plug Maintenance 3-5
4. FUEL SYSTEM
- Fuel Tank Removal/Installation 4-1
- Carburetor Adjustment 4-2
- Fuel Line Inspection 4-3
- Fuel Filter Replacement 4-4
5. ENGINE REMOVAL/INSTALLATION
- Engine Removal 5-1
- Engine Installation 5-5
- Engine Mount Inspection 5-9
6. ENGINE
- Cylinder Head/Cylinder/Piston 6-1
- Recoil Starter/Alternator 6-7
- Starter Motor 6-13
- Balancer Gear/Crankshaft 6-18
7. TRANSMISSION/BELT CONVERTER
- Transmission Removal 7-1
- Belt Converter Inspection 7-5
- Transmission Installation 7-9
8. FRONT WHEEL/SUSPENSION
- Front Wheel Removal 8-1
- Front Suspension Inspection 8-5
- Front Suspension Installation 8-9
9. REAR WHEEL/SUSPENSION
- Rear Wheel Removal 9-1
- Rear Suspension Inspection 9-5
- Rear Suspension Installation 9-9
10. BRAKE SYSTEM
- Brake Pad Replacement 10-1
- Brake Fluid Change 10-5
- Brake Line Inspection 10-9
11. FRAME PARTS/EXHAUST MUFFLER
- Frame Inspection 11-1
- Exhaust Muffler Removal 11-5
- Exhaust Muffler Installation 11-9
12. IGNITION SYSTEM
- Ignition Coil Testing 12-1
- CDI Unit Testing 12-5
- Spark Plug Cap Inspection 12-9
13. BATTERY/CHARGING SYSTEM
- Battery Inspection 13-1
- Charging System Testing 13-5
- Battery Replacement 13-9
14. STARTER SYSTEM
- Starter Relay Inspection 14-1
- Starter Motor Testing 14-5
- Starter Switch Inspection 14-9
15. LIGHTS/SWITCHES
- Headlight Bulb Replacement 15-1
- Taillight Bulb Replacement 15-5
- Switch Operation Check 15-9
16. TROUBLESHOOTING
- Engine Troubleshooting 16-1
- Electrical Troubleshooting 16-5
- Transmission Troubleshooting 16-9
17. INDEX
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