Quick Reference Data ix General Information 1(31) Manual organization Warnings, cautions and notes Safety Serial numbers Fasteners Shop supplies Tools Measuring tools Electrical system fundamentals Service methods Storage Troubleshooting 32(81) Starting the engine Engine performance Electrical component replacement Starting system Charging system Ignition system (1986-1997 models) Ignition system (1998-2003 models, except 1200S models) Ignition system (1998-2003 1200S models) Fuel system Engine noises Engine smoke Leakdown test Engine lubrication Clutch Transmission Electrical testing Electronic speedometer/tachometer Turn signal module (1991-1996 models) Turn signal module (1997-2003 models) Excessive vibration Front suspension and steering Brake problems Lubrication, Maintenance and Tune-Up 113(38) Fuel type Maintenance schedule Routine safety checks Tires and wheels Periodic lubrication Periodic maintenance Tune-up Air filter Compression test Spark plugs Ignition timing adjustment Engine Top End 151(46) Tools Rocker cover assembly Cylinder head Valves and valve components Pushrods and covers Cylinder Pistons and piston rings Oil tank and oil lines Engine Lower End 197(54) Tools Engine service Engine stand Engine Valve tappets and guides (1986-1990 models) Valve tappets (1991-2003 models) Gearcase cover and timing gears Oil pump (1986-1990 models) Oil pump (1991-2003 models) Oil filter mount (1986-1990 models) Oil filter mount (1991-2003 models) Crankcase and crankshaft Cylinder studs Engine break-in Primary Drive and Clutch (1986-1990 Models) 251(13) Primary drive cover Clutch release mechanism Primary chain adjuster Primary drive/clutch Clutch cable Primary Drive And Clutch (1991-2003 Models) 264(20) Primary drive cover (1991-1993 models) Primary drive cover (1994-2003 models) Clutch release mechanism (1991-1993 models) Clutch release mechanism (1994-2003 models) Primary chain adjuster Primary drive/clutch Clutch cable Four-Speed Transmission (1986-1990 Models) 284(20) Transmission Shifter mechanism Five-Speed Transmission (1991-2003 Models) 304(29) Transmission Shift forks and shift drum Mainshaft and countershaft Main drive gear Access door bearings Right transmission case bearings Shift mechanism Fuel, Emission Control And Exhaust Systems (1986-1987 Models) 333(17) Air filter backplate Carburetor Intake manifold Fuel hose and clamps Throttle and idle cables Choke cable Fuel tank Fuel shutoff valve Exhaust system Evaporative emission control system (California models) Fuel, Emission Control and Exhaust Systems (1988-2003 Models) 350(42) Air filter backplate Carburetor Intake manifold Fuel hose and clamps Throttle and idle cables Starting enrichment valve (choke) cable Fuel tank Fuel shutoff valve (1988-1994 models) Fuel shutoff valve (1995-2003 models) Exhaust system (all models except 883R models) Exhaust system (883R models) Evaporative emission control system (California models) Electrical System 392(74) Electrical component replacement Electrical connectors Battery (1986-1996 models) Battery (1997-2003 models) Charging system Alternator (1986-1990 models) Alternator (1991-2003 models) Ignition system (1986-1997 models) Ignition system (1998-2003, all models except 1200S models) Ignition system (1998-2003 1200S models) Ignition coil Bank angle sensor (1998-2003 models) Manifold absolute pressure (MAP) sensor (1998-2003 1200S models) Starter Starter solenoid Lighting system Electronic speedometer/tachometer Switches Horn Electrical bracket Turn signal flasher (1986-1990 models) Turn signal module (1991-2003 models) Circuit breakers (1986-1997 models) Fuses (1998-2003 models) Electrical connectors Wiring diagrams Wheels, Tires And Secondary Drive 466(34) Motorcycle stands Front wheel Front hub (1986-1999 models) Front hub (2000-2003 models) Rear wheel Rear hub (1986-1999 models) Rear hub (2000-2003 models) Drive chain and sprockets Drive belt and sprockets Wheel runout Laced wheels Disc and cast wheels Wheel balance Tires Front Suspension and Steering 500(26) Handlebar Front fork (all models except 1200S models) Front fork (1200S models) Steering head and stem Steering head bearing Steering play adjustment Rear Suspension 526(7) Shock absorbers Swing arm Brakes 533(57) Brake fluid selection Brake service Front brake pads (1986-1999 models) Front brake pads (2000-2003 models) Front brake caliper (1986-1999 models) Front brake caliper (2000-2003 models) Front master cylinder (1986-1995 models) Front master cylinder (1996-2003 models) Rear brake pads (1986-early 1987 models) Rear brake pads (late 1987-1999 models) Rear brake pads (2000-2003 models) Rear brake caliper (1986-early 1987 models) Rear brake caliper (late 1987-1999 models) Rear brake caliper (2000-2003 models) Rear master cylinder (1986-early 1987 models) Rear master cylinder (late 1987-2003 models) Brake hose and line replacement Brake disc Bleeding the system Brake fluid draining Flushing the brake system Body 590(11) Seat Front fender Rear fender Footrests Forward foot controls (1999-2003 883C and 1200C models) Sidestand Fork lock Index 601(5) Wiring Diagrams 606