Front CoverCommon Service ManualPictureSafety NoticeContentsSymbolsAbbreviations

1 General Information1-1 General Safety1-21-3 Service Rules1-41-5

1-6 Fastners1-71-81-91-101-111-121-13

1-14 Ball Bearing Replacement1-151-16

1-17 Tool Compatability Chart

2 Maintenance2-2 Fuel Line2-3 Throttle2-4 Oil Pump and Line2-5 Carburetor Choke2-6 Air Cleaner2-7 Crankcase Breather2-8 Spark Plug2-9 Valve Clearance2-10

2-11 Engine Oil2-122-132-14

2-15 Decarbonizing2-16 Carburetor Synchronization2-17 Radiator Coolant2-18 Cooling System2-19 Secondary Air Supply2-20 Transmission Oil2-21 Drive Chain2-222-232-24

2-25 Final Drive Oil2-26 Battery2-27 Brake Fluid2-28 Brake Shoe Wear2-29 Brake System2-30 Brake Light Switch2-31 Headlight Aim2-32 Clutch System2-33 Side Stand2-34 Suspension2-35 Spark Arrester2-36 Wheels/Tires2-37

2-38 Steering Head Bearings2-39 Wheel Alignment

3 Engine Testing3-1 Trouble Shooting3-2 Compression Testing3-3 Leak-Down Testing3-4

4 Lubrication4-1 Service Data4-2 Troubleshooting4-3 System Descriptions4-4 Wet/Dry Sump4-5 Two Stroke Systems4-6 Premix4-7 Oil Pump Descriptions4-8 Plunger Type4-9 Oil Pressure Check4-10 Pressure Relief Valve4-11 Oil Pump/Line Bleeding4-12 Oil Cooler Inspection

5 Cooling System5-1 Service Information5-2 System Descriptions5-3 Radiator5-4 Radiator Cap5-5 Thermostat5-6 Coolant5-7 System Testing5-85-9

6 Exhaust System6-1 Service Information6-2 System Description6-3

7 Emission Control Systems7-1 Service Information7-2 System Descriptions7-3

7-4 Noise Emission Control System7-5 System Inspections7-6 AVCV7-7

7-8 Secondary Air Supply System7-9 Emission Control Information Labels

8 Fuel System8-1 Service Information8-2 Troubleshooting8-3 System Description8-48-58-6

8-7 Accelerator Pump8-8 Fuel Line8-9 Carburetor Disassembly8-108-118-128-138-148-158-168-17

8-18 Pilot Screw Adjustment8-198-208-218-22

8-23 Limit Cap Installation8-24 Accelerator Pump Adjustment

9 Cylinder Head9-1 Service Information9-2 System Description9-3 Valve Train9-4 Valve Lifter Mechanism9-5 Camshaft9-6 Rocker Arm9-7 Cylinder Head Inspection9-8 Cylinder Head Disassembly9-9 Valve Guides9-10

9-11 Valve Seats9-129-13

9-14 Cylinder Head Assembly9-15 Initial Camshaft Lubrication

10 Cylinder/Piston10-1 Service Information10-2 System Description10-3 Piston10-4 2-Stroke10-5 Cylinder10-6 Piston/Piston Ring10-7

10-8 Piston Pin Inspection10-9 Piston Installation10-10 Cylinder Installation

11 Clutch11-1 Service Information11-2 System Descriptions11-3 Judder Spring Purpose11-4 One Way Clutch System11-5 Power Flow Diagram11-6

11-7 Wet Multiplate Centrifugal Clutch11-8 Gear Shift Lifter11-9 Separated Shift Clutch11-10 Clutch Inspection11-11 Clutch Removal11-1211-1311-1411-1511-1611-1711-18

11-19 Clutch Reassembly11-2011-2111-2211-2311-2411-25

11-26 Clutch Lifter Reassembly11-27 Hydraulic Clutch System Service11-28 Air Bleeding11-2911-30

11-31 Clutch Slave Cylinder11-32

12 V-Matic Belt Drive System12-1 Service Information12-2 System Description12-3 Drive Pully Operation12-4 Driven Pulley/Centrifugal Dry Clutch12-5 Drive Belt12-6 Drive Pulley12-7 Disassembly12-8 Assembly12-9 Drive Pulley Face Installation12-10 Clutch/Driven Pulley12-11 Inspection12-12 Clutch Shoe Replacement12-13 Driven Face Bearing Replacement12-14 Clutch/Driven Pulley Assembly12-15

13 Transmission13-1 Service Information13-2 System Description13-3 Planetary Gear Type13-4 Shift Start13-5 Constant Mesh Transmission13-6 Transmission Disassembly13-713-8

14 Crankcase/Crankshaft14-1 Service Information14-2 System Descriptions14-3 Crankshaft Inspection14-4

14-5 Main Bearing Selection14-6

14-7 Main Bearing Selection14-8 Connecting Rod Bearings14-9

14-10 Connecting Rod14-11

15 Final Drive/Output Shaft15-1 Service Information15-2 Output Shaft15-315-4

15-5 Final Drive Removal15-615-715-8

15-9 Universal Joint Inspection

16 Wheels/Tires16-1 Service Information16-2 Wheel Removal/Installation16-316-4

16-5 Rear Wheel16-616-7

16-8 Wheel Bearing Replacement16-9 Basic Tire Information16-10

16-11 Tire Removal16-1216-13

16-14 Tire Installation16-1516-16

16-17 Wheel Balancing16-1816-1916-2016-2116-22

17 Brakes17-1 Troubleshooting17-2 Brake System Descriptions17-3 Hydraulic Brakes17-417-517-617-7

17-8 Hydraulic Disc Brakes17-917-10 Brake Pad Replacement17-11

17-12 Brake Caliper17-13

17-14 Brake Disc Inspection17-15 Master Piston Inspection17-16 Mechanical Drum Brakes17-1717-1817-19

18 Front Suspension18-1 Service Information18-2 System Descriptions18-3 Oil Damper Principles18-4 Telescopic Fork18-5 Fork Removal18-618-718-818-918-10

18-11 Handlebars18-1218-1318-14

18-15 Steering Stem18-16

18-17 Race Replacement18-1818-1918-2018-21

18-22 Steering Head Preload18-23

19 Rear Suspension19-1 Service Information19-2 System Descriptions19-319-4

19-5 Rear Damper Springs19-6

19-7 Shock Absorber19-819-919-10

19-11 Swingarm19-12

20 Frame/Body Panel20-1 Service Information20-2 Description20-3

20-4 Inspection

21 Electrical Fundamentals21-1 Service Information21-221-321-421-5

21-6 Basic Electronic Knowledge21-721-821-921-1021-1121-1221-13

21-14 Basic Electrical Diagnostic Methods21-1521-1621-1721-18

22 Battery/Charging/Lighting System22-1 Service Information22-2 Troubleshooting22-3 Charging System22-4 Battery Descriptions22-522-6

22-7 Motorcycles Without Batteries22-8 Battery Removal/installation22-9 Battery Testing/Charging22-1022-11

22-12 Charging System Descriptions22-1322-1422-1522-1622-1722-18

22-19 Charging System Inspection22-2022-2122-2222-2322-2422-25

22-26 Alternator22-2722-2822-29

23 Ignition Systems23-1 Service Information23-223-3

23-4 Systems Descriptions23-523-623-723-8

23-9 Spark Plug23-10 Spark Test23-11 Ignition Timing23-12 Ignition Coil23-1323-1423-15

23-16 Transistorized Ignition System23-17

24 Electric Starter/Starter Clutch24-1 Service Information24-2 Troubleshooting24-3 Disassembly24-424-524-7

24-8 Clutch Switch Diode Inspection24-9 Starter Pinion Inspection

25 Lights/Meters/Switches25-1 Service Information25-2 Oil Pressure Warning Light25-3

25-4 Fan Motor Switch25-5 Coolant Temperature Guage25-6

25-7 Fuel Gauge25-8 Low Fuel Indicator25-9 Fuel Pump25-10

25-11 Headlight Bulb25-12 Switches25-1325-1425-15

25-16 Turn Signal Lights25-17 Horn