Quick Reference Data ix General Information 1(35) Manual organization Notes, cautions and warnings Safety first Service hints Parts replacement Torque specifications Fasteners Lubricants RTV gasket sealant Threadlock Gasket remover Expendable supplies Parts replacement Basic hand tools Test equipment Precision measuring tools Special tools Cleaning solvent Mechanic's tips Ball bearing replacement Oil seals Riding safety Troubleshooting 36(24) Operating requirements Troubleshooting instruments Starting the engine Emergency troubleshooting Engine starting troubleshooting Engine performance Engine noises Engine lubrication Clutch Gearshift linkage Transmission Electrical troubleshooting Test equipment Basic test procedures Electrical problems Charging system troubleshooting Ignition system troubleshooting Starter system troubleshooting Carburetor troubleshooting Excessive vibration Front suspension and steering Brake problems Lubrication, Maintenance and Tune-Up 60(47) Routine checks Pre-checks Service intervals Tires and wheels Battery New battery installation Battery electrical cable connectors Periodic lubrication Periodic maintenance Tune-up Engine 107(113) Engine principles Servicing engine in frame Engine External oil line Crankcase right-hand side cover Cylinder head and camshafts Cylinder head and cover inspection Camshaft inspection Rocker arm and hydraulic lash adjuster assemblies Valves and valve components Cylinder block Camshaft, drive chains, guides and tensioner assemblies Pistons and piston rings Oil pump Primary drive gear Balancer assembly and starter gears Front bevel gear assembly Crankcase Crankshaft and connecting rods Break-in Clutch 220(14) Clutch Clutch release mechanism Transmission and Geareshift Mechanisms 234(18) External gearshift mechanism Transmission and internal shift mechanism Fuel, Emission Control and Exhaust Systems 252(37) Carburetor operation Carburetor service Carburetor assembly Carburetor service Carburetor adjustments Fuel system cleanliness inspection Throttle cable replacement Choke cable replacement Air filter Fuel tank Fuel shutoff valve and filter Fuel level sensor Crankcase breather system (U.S. only) Evaporative emission control system (California models only) Clean air system (California and Switzerland models) Exhaust system Electrical System 289(56) Electrical connectors Battery negative terminal Charging system Voltage regulator/rectifier Alternator Transistorized ignition system Starter system Electric starter Starter relay Lighting system Switches Electrical components Junction box and fuse panel Wiring diagrams Liquid Cooling System 345(9) Hoses and hose clamps Cooling system check Pressure check Radiator Cooling fan and shroud Thermostat and housing Water pump Hoses Front Suspension and Steering 354(35) Front wheel Front hub Wheels Tires Tire changing Tire repairs Handlebar Steering head and stem Steering head bearing races Front forks Rear Suspension and Final Drive 389(24) Rear wheel Rear hub Final drive unit Drive shaft Swing arm Shock absorbers Brakes 413(29) Front disc brakes Front brake pad replacement Front brake caliper Front master cylinder Front brake hose replacement Front brake disc Bleeding the system Rear drum brake Rear brake pedal and cable/rod assembly Frame 442(7) Seat Frame side covers Frame head side covers Footpegs Sidestand Centerstand Front fender Rear fender Rear hand grip Frame Index 449(4) Wiring Diagrams 453