I13'LiIII:KII ~:teM:!;, ,eofi\f,orrn '10 ail @1:'t:"I~b'le U.S:.A .. FE!dBnrl M:Obu \l'e'hl~le SafBly Stali1Cli!

mls ;afi'iidl U.S.A, E:miIKlf1lI1l1:e:nta'11 ProteeliDiiI A'Qancy raglllla.'liiIillM Cf'I:eetive: 'O'!'II"the' (I!!rte ot 11il8nufa£itur;e,_

To lI1i1.airdaili'il .Iti!rt!, :$<!II'C'L'y. 'l2~nJlil;PJ)!lnY.. ~n.d ernllilshm a 001 no:i:se ooilItool parl"oomanCBI, it i5 95:sMtia~ ·1hi:U tli1e procedjnaB, spe;ciifiGB.1ii!lmi6. and 5E!rviCO·lln$lJllleUOI!!~; 11T1111ll1~ rn~F11.l1al 8~ ·foIJawed ..

. Any BUD.liI1itl!Jii:eI!lJ sl1alfSticn ifJI' .In:lj~s'bfiBm 0.,' tmls:i;llOn S!ll~''te!'!1! ;!i!i!lldl no-ISle QI;II1Ibl;III'E:i!II_01Ipo:n_iI!'.fIm !IlIu1!aidIB of

ji"l!I!i:oo..,· ~!;p;9Cilii~iOfiI:!i, may be I~O:hlD:Ite.{l1 by law.. - ...

2003

'-'SUIELL ® .XB!9R F~REBOIlT~M1

MOIDEl!

SERVlllrC·E MANUA.L,

'''Iil!IB iffiiJrn1Jlrt:i'o.n lin tn.s, Senrlee PWaoosl 8~18S {Ii) 2OIlI;3, S'l.!l~p Fireboil:TI1i meR modB'llm01Dli'CY'Oles.

~"

COPVIiiI!IGHli' 200~ B1.!I~l.1...IIL:ilS,iRrBUTiIO 1'1.1 ,COMPANY NIl.L ItiIiIGHiIi·S· ,if{~S.ru:NED PART NO.1. '991W3-m'Y

'~MJ - 3.m-OB.l'02

MAINmENA1NCE

·1

2

ENGINE,

...

3

IflUEL SYS,TEM

EllECllRIC STARTrEIR

-5

I DRPlEJT1RAJNS'MI~SSION ,6

7'

APPENIDICES

FORIEWOR'ID

IGENERAL

TIlls.; ,S~ Manual has !b!3an ~are(iI '!.&11th N,"IJ plJrpo:e.eS in ntfnC_ Fir~. it W,'II acQlJ:=.iIn..l: tha 1I5.E!f' wRh ths Q)fl$1nitdlloo of 1ha BUB!] produot ana a~ In Ih.e perrormBIlO!3' uf ~ Maintoenanve am repair. 8eoom:ly; iL will in 1IQd'uce D the professional BuU2l "R:t':flIil'Id;a'n ~he lsrast fi'e4d-R'LM ,[jfl(l1a.!!:lDI'l(alJ~d map rapair rm!ill'lOO:s.. We sl~tv beiava, 1:h<i.t 'IJi"iis, .saMes M8Ji1UClIJ Yrill Imke YOI.II ;eI:!IBOCialion with BU' v.rQdr U r:;1.S II1\lilI ro IP! e a sa n1' and! p lDiIitab I !3'_

HOWTOUS,E

YOUR SERVICE, MAJN,UAL

• $~Ion ,~-ChasaiB

• :SeetIoo 7-ElectricaJl

'.' AppEilildi;l; D-ttooe' and 'lNif,e 'Rommgs

IJ.S(J; 1M 'TASLE m: CONTENTS fOIiQINif"lgJ 'this IFtJlREWORD Otf 'lh!3' INDEX ~L Inc- ~ of Ihe beok to lind [he (I'e$lred aubJect.

Note mat eadTI m:=.i1!U!!i1 s8ction opeC is ~!.len'lfalJlf IliilJm'b8R In the upper 1!3;j't CHi riglilt tlanCi oomer of !he PB@EI. "iIbo !'W1iilbering ~-y5tt::1M llifl!)W'$ Ihe ussr to qureldy ma CFO$S refer.enceC - o~~ by fl- , 'in91 tmr,cugl1 ~~ pages..

RJr' C)l:®1~, the n2irth topic (CLUTCH) ih s.ec.1100 iJI1oE! (MAIN. ffioJANCE) is fiSlsd as:

11.'5IICWi!iCIHI,

The 11_91 ",ill appear in [he, upper left or righm ha'nd eemer (Ii: 1tie pi:L{I e.

IPREIPARATI'ON fOR SIER,ViICE

A,WARNING

Ga8QIJne ~a: a:dJ1IUIiISI, flliil'lilrm~b e trnrl IhJgh1", e:xp'losiva'. AlWtlyt.; $~P ~he i!!lIiIi!J.E:rne wfiI!3I1I 1'1Jf1J81iIiW er sem~mgl1hB iuB'1 ,Ei~:5;'teIJj). Do not ~mo'k>e 6:1" al]ow' OJiII3n f,!alll1lEl' Qt ,:!;[j:P:iUiliii rlear 1l!!ie wgd: aim. losi!laqlJaia 5afC'1y p'~I!J1:I.gn8, ma", lre8ufl: li'n [persona~ irqmy.

Good [prBpa:mtioo is 'IIt1fI/ 11mp;!lW.il1t '0Cw IBf:Ii!::i8n~ ssNica I/Io'OFK. Ii; cie'(7ln 'WOrk aJB9 al:!he:e.1Brl of ,aaeh joD wfIll.";.tllolN ~u ID parfumll '~ II"EIpilll" as easIY .and! ql-liCidy .as po5Sible, ~ will l"iedtu;:e the ililcidence o~ mi:!i,plaood toots and parts. II; motmcyde tlil;rt i::; 'EI.!ol.CQSSi;!:ely dlll1J' s'houfd bEl' c1!3anE1d ool'(IFe work starts. Cle:;ln!nY .. oc:ca.'5iiJlliilly unx:owr ~g of trouble. lrooIs, iRsl!rum!3ms ill"i(j any parts ~d fur the j)Jt; shou 00 'gal"MFOO Mi'ore 'WI!l!rk B 13ta.rt&d_ lrnte;nruptif'tg a)lJtt to Ii;:J.i::;s!te tools or parts is a Oi";$tradlOf1l and ca.U3ea, n_eemls:» d'ati)\- S(''e AF,PEJIlDIX A.-liOOILS ifcr ~L reQuired klr!!p9Cia.1 servic>3 WIJ rk.

NOTE

.. To a~ ,LiflfleCessary d':.al3aggmbJ;:. carsfuJiy rem:f &; ret-, glrvs ~ in;fi;l,rmaifoo DC'lOre fep@r IWt1I!t is aiBItsd ..

• In tigtN6llr;!:(lb~ fhe fflJmaer which ~ t.hs ti'ol1Jite of ,(!< part ~tt;\5 rhs qU-dJtruy iIt.et'e$Sl3.ry' ;fur Dne ~ ~!1'1Ji):

In. oaddloo to the infDlima'lioo pMr;. .... 1~ In thb :SeiNio8 Mil.nual. B.uell !lJs;lrlh!U1ioo Crnp.cr81iofll will ptlr'iOOiei.WV Is~ue SaMD8 IBUllatins to BYcG de;:il'P..r:!L $ervioa ~ ~F interim etJglneering changes BDd :;uWleFf!en~a~ Irrlh.rmation_

USE ,GENUENE REPLACEMENT IPARTS

AWAIRNING J

When replacemBfilt [p;ill1iU itl1li reqUJli'edl, use ,only.' ge:nu lne BllI'JIIll pt.U'ts Of p~ with ,equ'iw1!3f11 dh~IiiI~~s ~wtllf:h [lm::tuDe '1:yp!9., :EilirElntgffi mllllm~te:rt5il)_ Failure ito do su' may l1esulit In [I:J4IOOUi!:t I1i1B.lfum:IKItiJ ,anel IPO:$$Ib.'i~ "perSQo81 imjufJ.

'\

TiJ '8n:SUD9 :sa!is'[ilICtol)' and 1:=.is1ing rapairs, m~B"filllll\i' 10 II ow '!:he SocNire ;.ianuaH Mmc:t'iom; and uGJIII Oflly .genJJf.ne Buell re;plsoem8rTI parts, llhis is your assurance ~ha1: h!3' p3ri1E 'you i3..~EI u-.g Will rtt rtghrt, opara1e' PliOfI'Elrf:t and tast longer.

i.

-SAFETY DEFI'Nllli110NlS

$t::.!le>merrts, Inl itnU., $e!"lt.IJte IrrtiI~rHIJl!3J11 plleeetlet! ~ '!~e' 'i'o'i~ Ilowrng wnrdl!i iilll'8 af :1!ip;liE!CiII~ 'significafilill3i;

AWAFtNdNG

V/AIIUi[N,G lim:liOilfss 81 IPiIlIIBI"dill[ly iii SZSro1l!U IS, ,~llIiI1ioo iW\l1lf:h" Ilf I!IiI;it ,BwJded, 'eJ!l!l!ld 1IE!~I1!: lill di!!.sth 'D:r '5ieflcus, iIi'lJi.lfiit·

I

t.AUTiIONI [n(:llle:il:e-:s iI!i pOlteMI;(lty iIlIu"U',dlous, ,s~uJit!\On whicJil', if 'l!I)[]llllVOide.d, may rBBu'lt in mir;J;{I(' !Ili~ mOOBl'Rie tI'!JIU:!'Y.

CAUTIONI

(iAllfTlON wi'lihout!' iII1iIl9 :lSafety a'19rt :1Sym'ool iliKlill:ales 131 ipol1!irillllall¥ hB~sKI'ci~51, '5iltuatl'cin wJil'too, H' lnot ,Bwlded, lrilili1)l' iI'9:!i!!lll inl J!iatlOO5 pi"Of!JS1fIi¥ ;d~riBagJil.

• P'm,per I!Ie:rvilCl!i and r.e~I'r' i!B iimpCi!1!Sn1I: tn:r 'Ihs' :SSM" lIellCle' (lr;te~3!mon 01' ;(11 rne-cI'Ul,nleli I'IlICIdl,l'et'$. Thesan.rii iI:e III ro !l:ilJidlil (lE!S Il'eC D:lililm;an d ad iilliI.<d1 'daIS !i:t"i'1Jed in 'Ih~ S!e1l"ll'1'ce Msnue! i;lJ'E!' effECt'I~ me1!liKKiIs tDor I~r'[Ormllil; S>ef"i,(I~ opcf:'MICnl. :So.me, O.f 'tr"etel Itervlee' o;penatioos, rjsqujl\Ei 1he, 9S9 01: teDls &JlI'I!iCi1l11!t' dQ:!iig.n9d 'fO~ iIlhi:ll ilulliPOSa, Tlh.95e ,SpGlliiiatJ 'tQiOls ~hou~d 1t;J.e Il!~ed whe~ ,!;!Indi ;P.5i ree@mQ1e!'l'(i!~" II: I~ i_mp:!Jrl:ant '00' nillle 'UiJat SlIlmilil WilrnlnSi5 ~a:inl!illM' !!lEiS, ~' apBf:Hr.e ;EBl'1i!kiE!l' methiflds. w:rn1iZ:1i1 oO'uld dsm'~!1Ie '!:I!Ie' mo~e¥SJe' iAAI~ l!"el.n(!l~r' It IlIn~e', "me :JIJ~III!l tlilis S:E!r!i'[OB lIanu:a'l~ IHI'ow9Y9.F" plbalS!3< remsmber tlii~' tl!w!!5Ie W;!Jmllilg5l, ,el!!e i1i~: all"II!I.e'lu!3I'1;1E!'"

'.' :Si'rie6 Owl] iIXM.J![J1 lifll: 1p;D~ibJy Kli'iD'rf" ,e'i'aIlJ'3fe, er ;(!idlrlse '!:hE!' :!;I:eflllicie' ~~iI;Ie. '00 :;In Ji)fIo$~lble ~SI: ~Q iW\l'IliZ:h 5Brlti:&lB' llilili'QtiJl be P!iltCiilrmilJi:R, or of flili6! PJill:5:!!iiD:IJtIi fiiap. ando.u_8 !!:CnsaqUBOOS8. ,D'il !§iC:'h metlhcilIl" w.a hBliTe nDt lunde~t:lkfm ,:i~ sueh Ibfi'lO~.dI e.:wlu~Uon'. .AoC:O!;'(f!tn~l!J, IBn]/UI!IE!' w'JiJo. UIS!3i6! ,S :sE!l!1I'iCB Pll'm::edUIl'e D"F tool 'lfffii~1i1 I~, not re(lOmmenCiedi 1:1).1' Buei! IMU;s:1 1Ir:JI; 1~I.!~h!:V s;at~' hi.linl;leJJf 'diJst In'e'i Ih Sf' hi's nCf 'Ihs, iniF,!iEii!trlo:r:s. 5at'~ty Wii] lliJ;9 jillopalftlimdi H aJ Ii'Osliilt

iii 'IUs"" 8:lJII6I' tPl\!iJibii!~lj!Jllil 'whBn lIJI~n!jjl hillitllfiSlfS, "Jtll,jl~ C~ h;'iIlrau111c: pr'E!l!Ii!J:!1!'.~, '§lBs~ pl!JllE!IiEi, :l;ifilril!tgl 'i!:!l!il1r!pIf{!'S8EiI';ljj~ saiiCI'8 Ml'li'lmsrs ;mi!l simili!ln' tOOI1;, 1EI~ Ie:!iP!E!JtiiiaiIY ,e.a1.!l'do:u~ wli1enl 1I,!I~ln!;l pu[lll!Ii,g~ PIIE!!3$ln!l ifIt" ,f:i!l!mpIl"eI;lI;lII!lJgI aqui'pmBnt. iliha IDfC9.8 inwl:1lE!dI,~sn mu~ pcIirlis ibo 'Ily' IOUI1H.a1'dI 'Min c::onSIli::lt;fUtle 'ktli'Oe" pO$$iI!Jly II"9U"", i':n,iQ in 1p;9:l'S(Insl i~ullY-

PROIDUCT RIEFE:RIENCES,

-----

AWAFtNINGi

IF@[I@l!!j' line dlr.eeltl;l\l'l!i; 111~le(l on ~III J!):lIOcl'ui~. Ci;llIel'ul!y rB3d EtIIII8b!34IS. wa~iIiIiIili8~ and !I:R'UtiD:nl6! lbefuf'S' uss. IlnsdEr' (!108m !!iIS_~' 1~e£:8l!jjl@1!IL!!i M8l' lre.,$ull: ll'n l~r'I!ICnei~ II!IJJmy"

Wh8'1l re!Sranc:e is: macla in 'Ihia Se'.f'!I..ic:e l~nuBli ito :3i :epacjfi~c, twflfld fl«1tI/e IP~', tool {Ir ~M'!i1ern, an equl~lenl' product, tool OT rms.ilDlleM I1iIB1f be ,subshlulsd

JI!.II tools ~tlCtnC:d in mflS, 111I~1 wirl"l an utiD", '~J"' {I~ "(It' prefEmB 1IiIllilI: be ordered ~hrougl1:

II{ enl:.li1@O're

• SP:X, 'GmPOl'8i:iiD:nJ 266.l3~ Ui!kl!I1iJ!lIFlh!;!t8i!;B

WEilr,nm. Mi~ll'i!ill"n 4BilIM--:1i499 '1ie:1e<phD_ne: ~ ~.~4'5-:;;!!:2:M

Dtr~et all !'lrodU!:::l' retu..rris, oor·mFlIiy {If;" ,otl"ieffWlse, to Ihe tcOim~ng ,ad)jfesa:

tGe 1\\1", !\IO(I';e'

Afln; RilIliLlIrlililildi Goods c&'i! Eili!j,e'nhawsf I[i!rl:ve

iCI'l'MtQ!nJil~ M[nlilISlOm 5i5lll6ilJi.OO9!ji,

J

Same. r;!!rCioedureg; in, this Servioe, ~nuaJ cain 'IDr ~he 1!lSe< oj:

ILocI! i te&i IP 1"IJdudIs.. IF 'you imrB ,~n:P' qu E!:;ti';ons ~ rtl iF~ !...;;::idi fa PrOOuct usa-ge er relajle.i/INh~ler iC£atloos. p!etIiSe e.a'!! Lootite GDIJL at ~,,,8f}!)...Zl23-51 06..

OONllENTS

All flIhotogr:aplM. iilluBtratti'GIilS and procB!iIurea, mB1l oot rilEiC&E1- JSr.)Jil~ d8PL'c~ ~ moo. currMI, ifI"tl)dc~ ~ cOI'FIponen!, tuL are Ibasadl on the Islasl: produo1ion 'inj'cfrTils~ion ,a,\i'aiil'able at the time 'oi' IP u bilta lion..

Sincs prodoo1: irrn;prn'o'e.lM:nt is our txmlinual 91031. Busll DfJS.lrih:llian GOrpofoi:diim res-ef\leS i1hijjl l'iigh~ 11.0 eh~ ~eomcaiIi~ ,egl!J~p-rnilem OF de-:::ign.'l; :;It. i;lfll/tif1'!iB 1NithoU~ notice ;f.!mll '1'1.11hout inc:urmg dbligalioo.

BI!Il8I] Ip;rnl!l~:l!Icts are mam:'l!lhJic1jl!(rlJid IIJnil!3t'" IDililIiJi iIiI~ mlllrs, ,1M i1:Ji19 'fOlJOWlng UJ~S. paliEliill.$ - ,5.2957a2, :54355M" !5a~224S~ ,49'396i116, 4B61714., oiIi~i9:44B4~ 52!J9G19, 5'3DiiI:iffi5, ,4,17M;ii!::l\, !6.il~ ~e~ itiI111J~;nn, ~.~ ~" D4l401~, ~13~'4Q"

n,

." '

TAB,lE OF CONTENTS

If!'a;gc No,

SECTION 1 • IMA~Nl1ENANCE

. "-'

ill ~ 1 . GEI!I'iell'a~ •• ,".,"., •••• .._ .. - •• · •• ~.~.~.~i~ u.~., •• ,.

SerWtfig ~ NQw' IM/l:;ilo-~le _._. __ ._ .. _._ .. _. __ ._._ _. __

$Rfe Q!p.EiI'Blin~ Mail'llBlila1iCC _. __ ._. __ ._ .. _._. __ . ._.

~~::C~:I_~~~:~: .. :~:~::::::::::::::~~:~:::::~~:::~:::~~:~:~~:~:~:

Leal1 []y"e _._u_ , •. __ ._. __ ._. __ ._ _. __ ._._ _ .••.•..•. - .. -

1,.2 PI u~~d RBq ui re:me;nt5i .•....... , .. , .. ~.~''I!,., •

Geru:!'liF.1l .. _._ .. _. __ ._. __ ._ .. _._ .. _. __ ._ .., ..... _._. __ . . __ ._. __ ._. __ ._

IJJnifedl Sfal~ SYS1:emI. __ ._ _._. __ ._ .. _._ .. _. __ ._w _.-

Mg~rlc Sys:te_m ._._ .. _. __ ._ .. _ .•. ~ •. ~ •.••.•. _ .... ,_ .. _ .. _._. __ . __ ._._

Prim tI.IJ lJii\r(l;/ThmS!il1 $:;iD_n arieL. _. __ . _. __ -.-

Fi 'OFfI Fori; Oil._. __ ._. __ ._ .. _. __ ._. __ ._ .. _._._ -ro-'--'-'--'-'--'-'_

Brake IRluidl . __ ._. __ ._ .. _ ,._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._ .

Hilel .,. ._.,_._ .. _. __ ._._ _. __ ._. __ ._ _._ .. _._ _ .. _._ .. _. __ .

En,gina' Oil ._. __ " .•.•• __ ._. __ ._ _._ .. _. __ ._. __ ._. __ ._ .

lRec~mendad Oil G~ qli1l.I::I£c} . ..,,,- .. _._. __ . __ ._. __ .

1.3, Carle oil IMolded-:in-Colo:r B,dy'

PB~nel:Sl .1 •• 1 •••••••••••••••• rii 1i!!!~!0II.1I1 •• l •••••• - •••• _ •••• ~.fII.III.!IJ

G.erJer<lJ_ ,_. __ ._ _._ .. _._._._. __ ._. __ ._ .. _ .••. _ - .. -._.

Aeoomrmand'!l!IIiIlProd'!OCt'S ,_._. __ . __ ._. __ ._. __ ._. __ ._ _._.

c~ ruw M;iI...In1:eJiJancB' _. __ ._ .• _._. __ ._._._ _._. __ ._. __ ._.

Wami.ng ._ .••.• .,. .•..•. _.-._. __ . __ ._. __ ._. __ ._. __ ._. __ ._._._ .•..•.•.. _ .....

Cleaning E!letweE;n W:"~Qs .. " ,_. __ ._. __ ._ .. _. . __ ._._.

pooShilg _._ .. _._ _. __ ._ _. __ ._. __ ._ .. _m -.,-,_ •• _ •

',finor Scralm lRi3Iili1oval _. ,_._ .. _._ _. __ ._. __ ._ .••

~jD-li Scra!-clilcs , ,-._ .. _. __ ._. __ ._ .. _._ _. __ .•.••.•..•.•.. -

" ,.,4 [Battery Mabnenance _ .. , .. , .. ~.~.~ .• ,.

General .. _._ .. _._ ... _. __ ._ .••.•..•.•.. _. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._ ..•.•

6atl:ffi'Y l'estim.g _. __ ._. __ ._ _. __ ._ _ .. _._.,_._. __ ._. __ ._ .. _._

VcrII.rila.er'"fesit _ .. _. __ ._ _._.-._._ _. __ ._ _._._ .•.•..•.••. -._

Vl!lll1lme~a~ ired (ta'ble) _ .. ,. __ ._. __ ._. __ . __ ._. __ ._._

IBafte:ry DiSotOnnection andl Removal __ ._ .. _._ - .

(::h)an!~ ;aM h1l8pedioFli .. _._ ... _ .. _._._ ••••••••• m.--._. __ ._. __ . __ .

Storage _._ .. _._ ..•.•...• m •••• _. __ ._. __ ._. __ ._. __ • __ ._. __ ._. __ ._. __ .

Battery Instda1ion and] Oomiilittioo.-.-._-,_. __ ._. __ . __ ._. __ .

1.5, EliiIlg'ine lubrita~iGn System., .. , .... ,'*

Gcne!'"8J _. __ .- .. _._ .. _. __ .-. __ ._ .. _. __ ._. __ ._._ ••••••••• ,-m .-. __ ._ .. _._ .. -.

'Ciheclrirlg Engjne Oillb<evel ._, __ ._. __ ._ .. _. __ ._. __ ._. __ ._ ..•.•..•.

Ohan.ging en' e Oil ElJ1d1lPitte.r.. __ ._ .. _ m ,._._-.-.

Draining 00 __ ._ .. _._ - __ ._. __ ._. __ ._ .. _. __ ._. __ ._._;: •.

CMf!~rn§! F-Itte~ _._ _. __ ._. __ . __ ._. __ ._ ..•••..•.•..•. _ .. _. __ ._. __ ._.

IREJlla~in~1 Oi~ m-·-· .-._ .. _. __ ._. __ ._._._. __ ._._ .

IRocommeMed Oill GrcOOles (latte): "._-,_._-._. __ . __ ._.- ..

1-1 1-1 1-1 1·1 1-"1 1-1

1~2 1-~ "-·2 1~ 1-2 1-2 1-2 1-2 1-2 '1-2

1-4 1-41· 1-.4).

1~ "'-4 :I-~ 14 1-4 ~-4.

1[ .. 5 1-5 1-5 1-6 1-$. '1-$ 1-6 1..:6 1~7

'14

'11 .. 6 ~-:8 1-'9 1-'9 1··9 1-g

NQ

1 J5 BIi'Qke Sy.stem Maint8nance' _.n.. 1-11

G:a:narel._. __ ._. __ .• u _ •• _. __ ._. __ ._. __ • __ ._. __ ._. __ 1--11

It!a9el;]l~ IBr-aj{~!ii _._ .. _. __ ._ .. _._ ... _. __ ._. __ ._ _ .•..•.••.•. __ ._. __ ._.~_ 1--11

Bra1e "fll"Ou~otif1gl tlJable} __ ._ _._ .. _. __ ._. __ ._. __ ..... 1--12

81C:edlngl Fr.anl IBr.ake _._. __ ._ .. _._ .. _._ _. __ ._. __ ._ 1·13

Bleedingl Rear 81'a.Mr. .. m _, __ ._. __ ._. __ ._ ••• _. __ ._..... 1·-14

Brak>s IRM'aJ MjuSlment ._ _._ .. _. __ ._. __ ._ _._ .. _ _" 1-'1 §

~ P'ad Thibkna55 _._ _, on- _._. __ ._ ••• -._ •• _. __ •

BraiKe Rotor' TITIlct:ness .. _._ .. _._ .. _._ _. __ ._ .. _._ .. _._ .• _ •••••••••••

l3.taKJe Pad FI~18IJBm8nl __ ._. __ ._ •.•.•..•. m •••• -'.· __ ·_, __ ._. __ ._.

Front P:"dd iR.OO1ovai -._. __ ._. __ ._. __ ._. __ . __ ._._ .. _. __ ._ .... m •••• Rront Pad IlnatellBfion •.•••• ,. .•••••••• _ .. _._._ .. _. __ ._. __ ._ .. _._ ..

Rc.ilIr PilI:1I Ren;lI:[lI.eL. ._. __ . __ ._. __ ._._._ .•..•.•..•. ..,_._ ... _. __

Reaf Pad En.s~i"I_ .. _._ .. _. __ ._. __ ._ .. _._. __ . ._ .. _._ ..•.•.

1,.'7 l'i_n!.s, ,and WhreEds .•... , .. , .. ~.~ .. , .•.....•.. .,.

TII"Ei InElat10n _ .• -._. __ .- _._ .. _._ .. _. __ ._. __ ._ -._ -

Tire' Pressures {tatlle) roo _,_,_._ •• _._. __ • __ ._. __ ._. __ ._

~al BcaJilI'lQs •.. -._ _. __ ._ .. _._. __ ._ .. _._ _._ .. _ -.,-,-

1.8, IClutch .. ' .. ·.r .. _ •••••• u, •• ~ •• '.~n •• i. , ••• , •• r •• ".~.~.

TrBn8miisl:iioo FluiCi"",,, _ .. _. __ ._. __ . __ ._._ _. __ ._. __ ._. __ .•.•

AdjuSlrnena •. -_._ .. _. __ ._._-.-. __ ._. __ ._ _._ .. _ -._. __ ._.-

1.91 Drive Bet~ :Sy5tem ., .. , .. , ..•.. , .. , ",'.'

G.~eraJl __ ._. __ ._ .. _._ _._._._ _.-._._. __ ._ .. _._ .. _. __ ._. __ ._. __ .

tn~e1iOO., 'm' ._._ ••• _. __ ._.- _. __ ._. __ ._ •• _. __ •••••••••••• .,-._ •• _._. __ •

IHear Sprocket .. _ ,_,_. __ ._ _._ _. __ ._. __ ._. __ ._ _._. __ .

II:JIiv"c: Beft ._ .. _. __ ._ .. _._ .. _._ .. _._ ... _. __ ._ .••.•..•.•..•.•..•. _ .. _._ .. _. lale r iP:u II e:JI' _. _ ... _. _ •••••••••••••• or' _ •• _. _ •• _. __ • _. __ • _. __ • _. __ • _. __ • _.

Claaning m •••••• - •• _. __ ._. __ ._. __ ._ ••• _. __ ._. __ ._._ -,

Drive· Bel 1!;;r8fil_ovaJ ._. __ ._ _._, "'._._ •. _. __ ._ _._ .. _._ .. _._.

DIii'i'SI Bl3lllln.~!lallalJ~n .. _._ .. _. __ ,_. __ ._ _._ _._ .. _ .

Idler PUlls~ RI31i1i1O\'cl ,-n-'-' ._. ._ .. _. __ ._. __ ._. __ ._. __

Icll~ PUlley InBtslistiDn . __ ._. __ ._ .. _ •••.•.••.••••• _. __ ._. __ ._ .. _._~_

Drive BBIt Wear AnaIy:3f~· (tabla) __ ._. __ ._. __ ._. __ .•..•.•..•

1,.10 IPrimary 01181 n .. , N.'""~imi"' .

IM~lon . __ ,_ .. _._ .. _._ _. __ ._. __ ._. __ ._ _.,_._ .. _,_ .. _._

P-rimary Chain T,enslM ~~ble) ._ .. _._ .. _._ .. _. __ ._. __ ._ .. _'"

A.a:!.I~rnerrt _. __ .-. __ ._. ·_·_···_._ _. __ ._.m -._. __ ._. __ ._. __ ._.-

1 .1 ill ~Su5,pemfsion Elamplmgl

,Adj!JN&tments .~.~ .• , •... - .. _ ...• , .. , .. ~i~''''''''-'' .. - , ••

GiensraJ _ .. _. __ ._ .••. _u ••• no •••• _ ... _._. __ ._ ••• _._. __ • __ ._._ •• _. __ ._. __ .

Sus~n Ad.!ustJllEl.llts .. _ .. _. __ ._ _._"._ .•..•.• .om ..... _._. __ .

Setting Raar Shocti. P~d _ .. _,_. . __ ._. __ ._ .. _._ .. _.

SBltiMQ From FQrk Pre:lcad __ . __ ._. __ ._. __ no •••• _._~ ..

l!;;recommslilded [}<J; . IFig SettIngs {iIabIe} .. _._ ... _._ .. _.

Ail!U$tJ.ng Suapemioo Darmping " _ .. _._ _. __ ._. __ ._.

R.eocon'1Ii'r'1~M ·SU$pemion Oampfig

$eMiDgs (tebt'e) . __ ._. __ ._. __ -, •. _-.-. __ ._ _._. __ ._ .. _. __

.~ ~ 112 IFr,om1: Fork Oi,~ Clhan;ge, r •• ~

Fori;. Oil'ChilIn~ .•.. _, __ ._. __ ._ _._ _._.,._. __ ._. __ ._ .. _._ .

D.lg:a;:9-sEill11bl)l· __ . ._ .. _ _ .• _._ .. _._. __ ._. __ ._ _._ .. _

Chain ,artel Re~ CIiI._. __ ._ .. _ _._. __ ._ __ ._

ReaBSemlilly ._. __ ._~ •.•• _ .•.••.•. Or>_'''_' __ '_'_' ._._ ••• _. __ ._ •• _._ ••• _._

1-·16 1-116 1-17 1-17 1-17 1-UI 1-1g

1-1'9 1-191 1-19' 'I-HII

1[,·20 1-20 1-21

iIl~23· 1-23 1-23 1...z3 1-23 1-23 1-23 ·1-2.i1! 1-241 '~~:2e 1-213, 1-27

1.=29 l-.29 .... 029 l-OO

'1-3'1 1-·::U 1-31 1·31 1-·:31 1.-32 '1-33

1 .. 15 1-:35, 1,.;a5, '1-:36 1-3i3

1,.1·3 Steeringl Headl Bearings , .. _.~ .••. ,.~. 11,·38

Gsneral _._ _,._,_. __ ._ .. _._ .. _. __ ._. __ ._ .. _._ _,_............... 1-33

II1iS~ial'1l. __ ._ .. _. __ ._. __ ._. __ ._ .. _._ ...•.••.•..• ,_, .,._, ._. __ ._. __ ._. __ ._._ ~·38

1 • "141· ~Spa.:rik P~'ugS ... -.i" •• , .. , .. ~.~ .• ,.~ _ ..... ,.. '1-391

l~jOO ... uo •••••••• -,_. __ ._ ••• _._ •• _. __ ._ ••• _._. __ ._ ••• _._u ..,....... 1-00

!U

1~e.M!ili,

11 .. 15, ,Allh" 'Cleali1l;er Fill1ier ~.~ •• , ~.~.~.~.~ 11-411

Il'tefl1lQ1,;'f.!I_._._ .. _. __ ._. __ ._ .• _,_, ,_,_, , ... , ,.,., ,., •• ,., ,.,., ,.,., ,.,., ,., •• , 1·41

OJetu'lmg and l~ilJfll _._ ... _._. __ ._. __ ._ .. _. __ ._. __ ._ .. _._ ... _._._ ~ -4,11

lR&tall'atioo ._ .. _._ .. _._ ... _._ .. _._ .. _. __ ._. __ ._ ... _._. __ . __ ._._ ... _. __ ._. __ ._._ ~'-42

1. ~16 Tnr,ottle 'ca'b~;e al'ul Idlel Speed

Adrnus,tm;enl., .. , .. ~ .. ,.", , .. , .. , ..•. ~ .. ,." ,.. 11,·43

Throtlle Oabl_e _._. __ ._. __ ._ ... _._ _. __ ._. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ 1'~

'I(tte ~ee~-, ._, •• ,., ,.,., ,.,., ,.,., ,.,., ,_,., ,.,.""., ,.,., ,_._u_._ •• _. __ ._ 1~a

1,.1'7 Ingnltion T,imj'ng , .. ~ .. , .. , .... ',.!! ","m'~m

Iln:spacril:!n ._. __ ._. __ ._ .. _._ .. _._ .. _. __ ._._ ... _. __ ._ .. _._ ... _._ ... _._ ... _. __ ._ .. _

ChecKing StatiC Timingl_ a , _._ •• _._ ••• _. __ ._._ •• _. __ ._. __ ._ ••• _._ •• _._ ..

Adjua Timing _._ ... _ ... _._. __ ._. __ ._ .. _._ .. _._ _._ ... _. __ ._. __ ._. __ ._ .. _._.

ill., ',llHIeadll'.gilivts .. , .. ' .. , ..... , t •• , •• , •• ~ •• , •• , ••••••••••

,=::~~:::::.::::~:::~~:::~:::::::::::::.::::::::::~::~:::~:::::::::.:::

11."9' Tihrmtle P'051110.n Sensor' (TIPS).,

ItrlSpCC1JOO.,.,.,.,., ,., __ ._. __ ._. __ ._ .. _._ ... _._ _. __ ._. __ ._. __ ._ ... _._ ... _. __ .

ArlJu:siIrnanL. __ ._ ... _. __ ._. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._. __ ._. __ ._._

1-44 fJ....ik4 1'-44" 1-4!;i

1=46, 1-4f1 1-47

1114.8, ~-48 HI8

, .20' :SI:o rag e, , .. , .. , .. ~ .. , , .. , .. t •• , ••• , •• , •• ,..... ~1'-4!9

Gener:al _._ .. ,_._ ,.,., ,.,., ,.,., ,.,., ,.,."., •• , , , ,., ,.,. 1-49

R.'8mm.ra] f'nJfIiI 8torBfI)a ._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._.., 1....:i19

, .211 Troubles~M'lmlng ., .. ~.~ .. , .. , , .. ,.. 1 .. 50

Gene-.ra! ""'U ,.,., ,., •• ,., ,.,_, ._,_ •• _._ •. _._ ... _ .•... _ ... _._. __ ._. __ ._ .. _. __ ._ l-51}

IBngiM ._ .. _._ .. _._ ... _. __ ._. __ ._. __ ._ ... _._ .. _._ .. _._ ... _._ ... _. __ ._. __ ._. __ ._ ... _ '~-:5D

.sr.erter IM'o.tD:r DoP.$ ~ OfJerate _ .. _._ .. _,., ,.,., ,., ,.,.,' 11-51}

Erl!#AO jums 0if61 EIUI: [li.jJes N~ :start_. __ ._. __ ._ _._.. 1-50

.starts, Herd _._ ... _ ... _._. __ ._. __ ._ .. _._ .. _._ ... _. __ ._. __ ._. __ ._ ... _._ .. _._. 1-'..5(1

Starts, ~ul, IR~ I'i'regl!lbrl:f r.lir Mi$.~~' _._ ... _.n._.n._. 1-00

Sp:m;: Plug F.oufs, FI:epeatedI1i ._ .... _,. ,.,., ,.,., ,.,., ,., 1-51

PrEl-Ignilioo or [)Bton~ioo ~Knooka or ,p~nga~ __ ._. __ . '1-51

Overheating _. __ ._ .. _._. __ ._ .. _._ _._ .. _._ .. _. __ ._._,.,_ ...• ,_. __ ,_ ... , 1-5.1

Valve Trnin 1NCisra;, ,.,., ,_ .•• ,_ _._. __ ._. __ ._ .. _._ ... _. __ ._. __ ._. __ . 1-51

IE:reBGSilie '!;Ii'bralion ._ ... _._ ... _. __ ._. __ ._. __ ._ ... _._. __ ._ _._ _. __ . '~-51

E~Jne, LlJl:)iicati(!ft $Y$teM ._._ ..•. _ .. _. __ ._.- •. _" ,., -,... ~ -51

Oil [I~ Mot Rerum To iOiillfan'k. _ ... _. __ ._. __ ._. __ ._. __ ._._ ~ -511

&tt!;line IlJIses Too Muctli 011 or ~ires. ,., ,.,., ,.,."... ~ -5,1

lEriigina lEIaka, Oil From CElBBB, Plr.aht IfkidB,

Hoses,., ,-, •• ,.,.,',., ,.,.,., ... , ,.,., ,.,_, ,.,., , ... "'",.,_, __ ,_ .• _._, ._._ 1-.5,1

Ell3ctriiaal System _. __ ._. __ ._. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ ._ l-.5,l

AIiefR!IDl)l_f' [JC1P.3 Mot C:ha~-,--.-.--.-.-- ..... ,., ,.,-.,.,., ,. 1-51

.M81i'1'\>.."fLor Gh<1:fQe' Rate r6 Balow MOl'lTlaJI_. __ ._ .. _._ .. _ 1-:51

FI!l8J Syst.am _._ ... _. __ ._. __ ._. __ ._ .. _._ .. _._ .. _._ _. __ ._ ... _._. __ ._ ... _._ _ H;l1

FitJlel $ys'",m FkriOd:; ._ ... _. __ ._. __ ._.,._._ _._ .. _._ .. _. __ ._. __ ._ _ 11-61

POOl Fuel E~my ._ .. _._ .. _._, ._._ .. _,_ •. _. __ ,_".,., , ... , ,.,.. 1'..15~

lfrdfililini:ssmn ._. __ ._ ... _._. __ ._ .. _._ .. _._ ... _._ ... _. __ ._. __ ._. __ ._. __ ._ ... _._.. 1-:5:2

Shifta: Ham::! _._ .. _._ ... _. __ ._. __ ._. __ ._. __ ._ .. _._ .. _._ ... _. __ ._ ... _._. __ ._.. 1..152

Jumps; Ol!t'l,.of G~I __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ .. _. . __ ._. __ ._. 1-52

C; I ut clii . __ . _. __ . _. __ . _. __ . _ .. _. _. __ . __ . _. __ . _. __ . _. __ . _. __ . _ .. _. _ _. __ . _. __ . _. 1 -52

:Slips, , .... ,.,_, ._,_.,,_ ... _._. __ ._. __ ._ .. _._ .. _._ _. __ ._ ... _._ _._ .. _._ .. _. 1-fii2

IDrags or IDDes INbt Rele:;l$e' ._ ... _._ _._ .. _._ ... _._ .. _, __ ._. __ , 1-52

Cf~~Br::; .. _._. __ ._ .. _._ ... _._ .. __ ... _. __ ._. __ ._ _._ .. _._ .. _._ ... _. __ ._. __ . 1-52

C.has~ -_._. __ ._ ... _._. __ . .,,.._., ... , ,.,., , .... ,., •• ,., ,.,., ,.,., ,.,., ""L' 1·5:1:

IrragulallllB31daquata BrB~ Ao:Iioo .. _._ ... _. __ ._. __ ._. __ ._._ .~ -52

Ha~lInQl trr'egliliarf1jes, , ... , ,., ,.,.".,.,.,.,., ,.,., ,.,., ,.,.,.,... ~ ·52

SuapemWll . __ ._. __ ._ ... _._.:._. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ ... _._ .. _. __ ._._ 1-5~

i3BIiBrcil ~nEiion P~ms. ttable) _._. __ ._. __ ._. __ ._ 1-53

Rear S~nsicm Pr:o.t!e~ (t.:iblf.l,),. __ ._ ... _._ .. _. __ ._. __ ._ 1-,5.3

Froill' Suspension PicolQIffIS (~~} ._,_ .. _._ .. _. __ ._. __ ._ 1,-.53

li¥

2.1 :Sp;ecimAtions ., , .. ~ .•.. , , " .. , ..•

DimeJii~ns {lab&:!). __ ._ ... _._ .. _._ .. _._ .. _._ ... _._ .. _. __ ._. __ ._.,_, .....

We(lh~ Specilitiali!Jflll!i, (ta'bIB'l'-_._. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ . C-3p.scities; (table}<._._ .. _._ .. _._ ... _._ ... _. __ ._. __ ._. __ ._ .. _._ .. _,., ,.,.,' lire and 1P'(JS:i1iOti (II~~ _._ .. _._ .. _._ ... _._ ... _._ ... _. __ ._. __ ._. __ ._._ TIJIfilIUB v.Bl'llIes ~tc3ble} ._ .. _._ ... _._ .. _._ .. _._. __ ._ .. _. __ ._. __ ._. __ ._._

2:.2 lillie, Speciilii'wtions, , , .. , , .. , .. , , ..

~ne~J_. __ ._. __ ._. __ ._. __ ._ .. _._. ,_,.. ,.,. .. _ ,.,.".,.,', ,., ,.,., ,.,.

Tue fitme.nt- Tu'bBIeae: Cast Wheel!!; ~ble) ._ .. _._. __

2.3; 'IJ'e!JIiMi~i~e ~;demlflca~;D:1il IN umber ..... ,.

GI.e:rueral ... _. __ ._. __ ._. __ ._, ,.,., ,.,-, ,.,., ,.,., ,.,., ,.,., ,., ....... , ... _._,.,_

2.4 'W'hee~l$ , .. ~.~.~ .. ,.,. !!~.~,~.~.~ •. , ..•.•

Ganer:al'. __ ._. __ ._ .. _._. __ ._ .. _._ _._ ... _._ ... _. __ ._. __ ._ ... _._. __ ._ .. _._. __ ._.

i!"tr>l)l.!~tlng.,."",.",",.,,.,., ,.,., ,.,., ,.,., ,_,_,.,_. __ ._ .. _._. __ ._.

Wh.eElJ :5Bn.;,ir;a ~~) -_._. __ ._. __ ._ .. _._. __ ._.,._._ _._ _._ ... _.

2.5 FBiont 'Whee~I~ .. , ,." , .. ~ .•.. ,.", .. , ~.~.~

~1 :H :2-~ :2-~ ~:q 2-:2

2:--5, 2-!5 2'-{;.

2·6, ,2:-6

2·,7' ,2'-,7 2-,7 ;:;':-8:

2-'9

PI~' ._ ... _ ... _._. __ ._._ .. _,,_,_, ,.,., , ... ,.,.,., ,., ".,.,., ,.,.,.,.,.,.,., ,., 2·"9'

Dfiassarnlbll1_ ... _._ .. _. __ ._._ ... _. __ ._. __ ._ .. _._. __ ._. __ ._ ... _. __ ._._ ... _. __ . 2-110'

8i!'!'@.rlngll!'ilefl'ili)1.!'al. __ . ., ,.,., ,.,.,.,.,." ... "., •• ,., ,.,., ,.,., •• ,.,., 2-10

Front' IRiJlior REHliIollal __ ._ .. _._ _. __ ._._ ... _._ ... _. __ ._. __ ._. __ ._... 2-11

CI'~FllngJ rulG InSj:lCcttun .,., ._,_ ,_ ..... _, .. _._ .. _. __ ._. __ ._. __ ._._ 2-11

Asal3liTIbl;)!'_._ ... _. __ ._. . __ ._. __ ._. __ ._. __ ._. __ ._. __ . . __ ._. __ ._. __ ._._ 2-12

l:leaJi1ng Insl!allallOfll".,., ,.,.,.,.,."., •• ,., •• ,., •• , ...... ~_,_, .. _,_ ,2:-1:2

Front Filo.!or In:s~alla'ioo _._ ... _._ ... _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ ,2:-11:3

InBta'JlBtion _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ .. _._ ... _._ ... _. __ ._. __ ." ... ,_ ,2_c'114

2.6 Rear Wh:.eel , .. ~ .. , .. , .. , , , .. ,.... 2-115,

Removal., ,.,., , •. _, ._._ ... _._ .. _._ .. _. __ ._._ ... _. __ ._._ _. __ ._. __ ._ _._.__ :2-,1:5

CJeanirng andlln~lon ._. __ ._ ... _._ .. _._ .. _,_.,_,.. ,.,",., ,.,., ", ;2·15

[lIi~Qiiflbf}' ,., ,_,_, ,_._, ._._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._.__ :2-,15-

AsElemtly ._. __ . __ ._._ _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._._.. 2-1 a

IMlalfa,tioo . __ ._ ... _._ _._. __ ._, ._,.. ,.,., ,., •• ,.,.".,., ,.".,., ,.,.,.,.,." 2-16

2.7' Checikj'ng tast RI,b1Ii1l RunQut ~.~ ,2-11,8

GCfilieral ,., ,.,., ,.,.,.,_ .• , ,_, .... _._ •. _._ ... _ ... _._. __ ._ .. _._. __ ._ ... _._ _._ _. 2- ta.

Rim Lst_e,r.F.I1 PI'I!Il1iOI,I~'.--.-.--.-. ,_._ .. _,_, ,.,., ,., •• ,., ,.,., ,.,., ,., 20-1.8,

Rim Ra.di:al Hl!DDut . __ ._. __ ._. __ ._ ... _._ _._. __ ._. __ . __ ._. __ ._. __ . 2-1.9,

'~!;Iheel RunJ!!ll,J1: fhAble~.-.--.-.--.-.--." ,- ... , • .,.,., ,.,., ,., •• , 2~lH

2 .. 8 Tlres'm.' ... ' ..... "." .. ' .. ' .. ' .. m .. ' .. ' ••. '"'"'.""""~'~"""'" 2-19

Gen~L. ._._ .. _. __ ._. __ ._. __ ._. __ ,_, ,.,_, ,.,_, '",., ,.,., ,.,., , .... , ... _._ .. , 2-1!9

IHl3lli1ovall __ ._ .. _. __ ._._. __ ._ ... _. __ ._._ ... _. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._._ 2-1'9

CI~IF!QI ,and Ifls,pecno.:n, ,.,., ,., •• ,., •• ,., •• ,.,_.,_. __ ._ .. _._. __ ._ 2:-20

Inat:3.1laOOn _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ 2:-20

Cheo;.:tI'l!!J T!1fe L.a:lefa1 Fluoout., .... ,_,._._. __ . __ ._. __ ._. __ ._ ,2'-21

CbEding Tire RadisJ Run.out._._. __ ._. __ ._. __ ._ .. _. __ ._._ ... _ :2'-2.1

AriijI.J~mel'l,"_.- .. _._ .. _._ .. _._ .. _,- ... ,., ,.,-", .... ,., •• , ,., ,.,._,_._ .. _ 2-21

'!NIileaIIBalancing._ ... _. __ ._. __ ._. __ ._. __ ._ .. _._ ... _._ _. __ ._ ... _._.__ :2-2:11

,2.91 Br,ake P'edal , .. , .. , .. ~.~ .. , ...........•. , .. , .. , .. ~.~.".... 2·22

Il'toefl1ll)1,i'3l ... _. __ ._ .. , ... , ,.,., ,.,., ,.,., ,.,., ,., •• ,_,._._. __ ._ ... _._ ... _._ ... _._.. 2-,22;

I~BHatioo ._ ... _. __ ._. __ ._. __ ._ ... _._ .. _._ ... _. __ ._. __ ._._ .. _. __ ._ .. _._ .. _._. ;:;':-22:

_.

p,llge' No_ 2.110 IF'ro:nt Br,ake Muter Cyli~nder ."... ,2-23

~ll\I;)'I,!'ff _._ .. _. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._, -_._. __ .- :2·-.23

Disassembly _._ .. _._ _. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._..... :2-.23

Brake HBJTl.m lewr _._ .. _. __ ._ ..... "u _ .. _._.-._. __ ._. __ ._. __ ._ :2·.23

Front I~_~~ CytOOer . __ ._. __ ._ .. _._ _. __ ._. __ ._. __ ._, __ 2·-.::!3

'Clei5!nlng and IM~iorli _._ .. _._ .. _,_ _._, __ ._. __ ._ _._ :2-23

~""""""'"_'_' __ '_'''_'_''_' __ '_' __ '_''_'_' __ '_'''_._ .. ,_....... 2-.24

FFOOt ~1:J3:r ~ndaf d _. __ ._. __ ._. __ ._. __ ._. __ ._ :2·2:4

BraKe HJ!-nO Lever.. __ ._. __ . __ ._. __ ._. __ ._ _ -.- .. _.- 2-·211·

IM1Blfa1i:oo _. __ ._. __ ._ , ._ _ _._ _._ _._ .. _._ .. _. __ ._. __ ._.. ,2-,20

.2.'1 '1 Flwnt 'Brake IUne' ." , , .. , ~. 2-26,

Removal ._._ .. _._ .. _. __ ._. __ ._. __ ._ .. _._ .. _._ .. _. __ ._ .,.,_ .. _. __ . .2-26

tn~n _ .. _. __ ._. __ ._ _._. , _ , ._ _._ .. _._ .. _. __ ._. __ ._. __ . 2~26

2 .. 12 front IBrab Cia Ii,per' , "."" .. ,

R~rfIl)'i,aJ .•.. _._ .. _._ _._ _. __ ._ _._. __ .-._-._ .. _. __ ,_. __ .

DiBEl~mty _ .. _. __ ._ -._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._. __ .

GleanlFlQlafl(l [ns:pectioo _. __ ._ _._. __ . __ -._ .. _.

Aasembl:.o _. __ . __ ._. __ ._ .. _._ ,-,-_._. __ ._. __ ._. __ ._. __ ._ _.

Insta1lafiOn ., •.• .,-.-. __ ._ _._ -.--.-. __ ._. __ . __ ._._. __ .-", .

2:..1:3 [Rear IBfllke, Masl:er' ICyilinder ••. ~ .•

IRemOVB.l .. _._ .. _._ .. _. __ ._. __ -.- .. _.- .. _._- _. __ ._. __ ._. __ ._. __ ._-

lDisassenl'bty ._. __ ._. __ ._. __ ._. __ . __ ._._ .. -.- _. __ ._ ,-_._._-

Cleaning andlns,pe-ctlOn ...... -._ .. _. __ ._. __ ._. __ ._. __ ._ .. _. __ ._._-

A,sslOlIlfIbIy _,-~-.- .. _. __ ._. __ ._. __ .-.-_._. __ . __ ._. __ ._ ,.-

IrtiS'IiAIiB .ion . __ ._. __ ._ _. __ ._. __ ._._ -_._. __ ._. __ ._. __ ._._-

2,-28 2-28 2'-26 2:-29 2-29 2-29

2--31 2-31 2-32 2-32 2-:3.2' 2-.33

2:.11,4 Rm!1I' B,rake liirl , , .. ".".-. :2--34

R:e]llll)'I.!'~d _._. __ ._ _. __ ._. __ ._ .. _._. __ . __ ,_._. ,_ .. _ _, __ ._ .. _._ .. _ :2-,34

IlIlSl!aJlalioo m.,..-.--._ ... _. __ .-. __ .-. __ ._ _._ .. _._ .. _._ .. _..... :2-35

2.115 FlNJ' Brake Caliper m.m.~ · .. ·

Frernoval _ _. __ ._. __ ._. __ ._. __ ._ .. 1 -_._. __ ._. __ ._.-._._. __ .-

[}is8l5SamlJl:J' .,_ ..... " ..... -._ .. _._ .. _._ .. -. __ ._. __ ._. __ ._. __ ._ .. _ .......

[) e:::lnlng Sind InspeciiiOIil .. _._ .. _._ .......... _.-.-._._. __ ._ .. _. __ ._.-

ASSiB'fIIl'tIly •.•..•. -. __ ._ .. _. __ ._._ .. _._ _. __ .-. __ ._ .. _._ _. __ ,_.-

IliIs'lBl!;artioo _ .. _. _. ,_ p' _ •• _. _ •• -. - •• _. - ••• _. - _. _. - _. _. - _. _. - _. -"

........

2,'161 Firont IFc:rik .... 'n; .. _ .. _ , ".,,"' .. - •••• ~" ..

i3_erneI'13.1.._._. __ ._. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._ .. _._. __ ._ ..

Rsmo'i'.aJ ._._. ,_ -, ._._ .. _._ .. -. __ ._ _._ .. _._ .. _._ .. _._ .. _ .•..

[)isassentbty _ .. _._ .. _._ .. _._ .. _._ .. _ _.- _._ -. __ . __ ._. __ .

oa:fIII!lIBr 'R~ Disa~1y -_.-. __ ._ .. _._ .. _._ .. _._ .. _. __ ._ ....

Cleanlngl and I:nbpBClioo _ .. _._ ....... , .... -. __ ._. __ ._. __ ._. __ ._ .. _.

Assembly ••••• _ .. _. __ ._ .. _._ ... _._ .. _._ .. _._ .. _. __ ._. __ ._ .. _._ ..... m.-· ._.

[)alilpBr R.IOO Aiss81f1bf(i _._ .. _. __ ._ .. _._ .. _._ .. _._ .. _. __ ._.

ForK A.s~mlbly ._ .. _._ _._ .. _._ _._ _. __ ._ u.· ._. __ ._.

Installation ._ .. _._ .. _._ .. _. __ ._ ..... .,. _ .. _._ _. __ ._. __ ._. __ ._. __ ._.

2.11IFo'rik 'Clamps, Uppal" ~md l'O!WeIi'

Hr,jffJo.v@lltlI!;l;(!!~ernbly ._. __ ._ .. _. __ ._._ .. _ .. 0 •• _m ...... -,-_._ ••• _._.

ReB1oora1 _._. __ ._. __ ._ .• _._ ....... - .• , .-.- .. -. __ ._ ... _._. __ ._. __ ._ .. _. __ ._._-

IMbal!a Ion . __ ._. __ ._. __ ._. __ ._ .. _. __ ._._-.-.-_._. , ,_ .. _. __ ._._-

2.118 Steering Head Bearings ~.~

RE!'11l!lWl3: _._ .. _. __ ~_. __ ._. __ .. u. •••• -.-_.-. __ ._ _._. __ ._.:_._. __ ._ •• _._ •• -

Ili1!Slilllla~ioo ~ ... -_.-.--.-.--.-.--.--.-.--.-.- ... - -.- .. _._. ,_ ......... -._ .. -

2.119 Swingann and Brace ..... , .. ~.~ ~.

Gerer,al-.---.---.--.-.--.-.--.-.~-.-.--.- ... - .••.•.•..•.••.• ,-_._. __ ._ _.-

RerTilOl.l\l!ll ._ .. _. __ ._. __ ._._ " •.•.. _. __ ._. __ ._. __ ._ _._. __ .•

Brace ._ .. _._ .. _ - .. _.-.-_._-.-. __ ._._ _. __ ._. __ ._ .. _._ ..

SW!ngiMFfl •..•.••.• ,,-,_. __ ._ .. _. __ ._._ _. __ ._. __ ._._-,_ .,_.-

2--36 2·36 :2-g? :2-37 :2-37 2-36

2~9' ,2-39 2-..~ 2-39 2-41 2-41 2:-<1,1 2:-41 2-41 2-43

2~ 2-4.5 2-45 2-4.5

2--47 2-417 :2-<'17

2=49 :249 2-49 :2-49 :2-50

P8gsl No.

lDisassemibly ._ .. _._ ... _. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._. __ . __ ._,_ 2·50

Br~ ... n< .. n-'--'-' ._._. __ ._. __ ._ •• _._ •• _.~_._ ••• _._. __ ._ ••• _._ •• _._ •• _._ 2-.50

S-wiI'lgaITTil __ ._. __ ._. __ .•. _ _._.-._._ .. _._ .. _. __ ._._ :2·-.50

(:Ie.anlng and InapectionJ .. _._ .. _. __ ._. __ ._ .. _._ .. _,_ ..... <00....... 2-5,1

.A~ .. _ ., __ ._. __ ._ _. __ ._. __ ._. __ ._. __ ._. __ ._._ :2-5;1

~_._ ... _. __ ._. __ ._. __ . __ ._._ .. _. __ ._. __ ._ _._ ... _._ .. _ ....... <00....... ;2-5,1

S'i'tii~rm __ ._. __ ._ _._ .. _. __ ._ .. _._ .. _. __ ._. __ ._. __ ._._ :2-6;1

In!'l!allalloo .. _. __ ._ .. _._ .. _._ _. __ ._. __ ._. __ ._. __ ._ .. _._ .,..... 2-'5'1

S~F!!1.-.-.,-.- .. _._ .. _. __ ._ _._. __ ._ _. __ ._. __ ._. __ ._. __ ._. __ ._._ :2-6;1

BrEiD.B_. __ ._. __ . __ ._. __ ._. __ ._, _._ .. _._ .. _. __ ._. __ ._. __ ._.. :2-5,11

Fin $wtngarm lnapeetinn _0 __ '_ •• _. __ ._._ •• _. __ .,. .. n 2-5'1

OIIl-ns' Filfilig5 {taD'IC, ,_. __ ._. __ ._. __ ._. __ . ._.. :2-52

,2.2DI Fil"Dnil and Rear l$Oia'l,o'r ......... ~".. 2~53

irr.onl Uoolillr)F " •. -_._._-.-.--.-. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ .

1Aen1_ovaI __ ._ _._ .. _._ .. _._._._ .. _._ -_._. __ ._. __ ._. __ .

in_st.allal:iofl •..• ,-n-·--·-·--·-···-·-·--·---·--·-·--·-·--·-·--·-···-·_. __ .

Rear ~r _ _. __ ._. __ ._. __ ._ _._ -.- -._. __ ._. __ ._-_.

2.21 firam;e .. ".~.~.~.~ ~ , ~ , .. , .. , .. - ..

:~:;~::::~::::::::~:::: ::::: ::::::::::~:::~:::::::::~::::~:::: :::~: :::

2.22 Rear Shock Ahsoriber- .. " m .

~ncra --,_. __ ._. __ ._. __ ._. __ .-.--._ .. _._ .. _._ .. _._ .. _. __ ._. __ ._ .

!Removal _ .. _. __ ._. __ ._. __ ._. __ ._ -, ,_. __ ._. __ ._. __ ._ .. _._ .. _._.

Insl'a'Jlilt'iOfl •.•• ,-.-_._. __ ._. __ ._. __ .- -._ _._ ... _. __ ._. __ ._.-_. __ ._._ .. _._.

~~'!'~2·3.lh·rolW~e Controll " .. ~ .•. ~ .. , ...... _ .. , .. ~" ....

IRernov.aJ!llJiiu<E!5i3fT.1IJi}l·_._ -_._ .. _._ .. _._. __ ._ .. _. __ ._._-

CfeaFllng al!l!!;!llnspectio_n ._. __ ._. __ ._. __ ._ .. _._. __ " ..

~btyll~alla1jOf,l .-._-.-. __ .-. __ ._ .. 0_._ _._. __ ._-_. __ ._. __ ._._-

2.24 IClh.rtch Hland Lever ~.~._ .... "._ .. ~ ~

RE!'.nw.vaII1Di~_._._._ -. __ ._. __ ._. __ ._ -

Ass9ni.DlytlliSlalIanoo .... _._ .. _. __ ._. __ ._. __ ._ .. _._ ... _._ .. _._ .. _._ .. -

2.25 Headl ighll: Support IBIl"achet .r .....

R'emoll13.1 . __ ._. __ ._. __ ._ _. __ ._ _._ _. __ ._. __ ._. __ ._. __ ._-_.-

=~~~.~::::~:::: :::::~::::.:::::~:::~::::::::~~:::~~:::~::::~:::=:::

I'n!l1'l.Slra'li'flft ._ .. _._ .. _._ .. _._ _._ ..• _ -. __ ._. __ ._. __ ._ _. __ ._.-

.2.26, FIl~lrlli1,g .SWIP1Port Bliac.het~.~.~.~.~ ....

AeIlilC!'I<III .. _w ....... '" .-. __ .- ••• _.- ••• _._ ••• _._ •• _. __ ._. __ ._._-_. __ ._. __ ._.tIiI!ltall!W_an . __ . _. __ . _. __ . _. __ . _ .. _. _ .. _. _, n ..... " ••••••• _.- _. _.- _. _.- _. _.-

2.27 Handlebar·s ...... _ .... , .. , .. , .. m .. " ", ..... m.~.

Remov,5I1_._ _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _n ",_. __ ._. __ ._._ ••

'Right Olipoo •.••.•.••.• ,,_.-. __ .-. __ ._. __ ._ _._-_. __ ._. __ ._. __ ._.-_.

I(.ieft CIIpo,l'll- _. _. __ . _. __ . _ .. _. _ .. _. _ .. _. - ... _. - _. _, _ .. _ ...... oro •• ,.· _. -_.

In BtaIls:tKrn _. _. __ . _ _ ,. _ .. _. _ .. _.- _. _.- _. _. - _. _. - _. _.- _. _.- _.

~ht Cllpoo _ _._ _._ .. _._ .. _._ ... _. __ ._. __ .•... _ ......... _.- ... _.- .. _.

L.sit Clipoo .. _ .•.. _ "r·_·-· ._.- .. _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _.

2'.:28 Emau:s.t $ly$itenill .. , .. , .. - .. - .. ~.".~ , .. _ .. ,

~emov.a~Bmbl::'I'_._. __ ._ .. _._ -._ _. __ ._. __ ._ ..

r. ufller _,_. __ -.- .. -.- .. -._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._.

FiroFl~ Muffler lMool1t'ing Blm::IrJ'S'JfaP _,_ - .. _._.

RaBll" r.tufiller MoulMiFig atook'._ ... _._ .. _._ .. _._. __ ._ .. _._ .. _._.

E.Xha.us:~ Hea.-der _. __ ._. __ ._._-.-. __ ._. __ ._ .. _._ .. _,-, " .

J\.!J;$.emliJlyJllnslaJl'atioo ._ _._. __ ._ _. __ ._. __ ._ .. _._._-

EJ,;hausl Hsatle~ no •• -._. __ ._ •• _. __ ._ ••••• _. __ ._ •.• _._. __ ._._-

Reat Mul'1reor MOIiUIi'~ 13iIoDl. __ ._. __ ._. __ ._. __ ._ .• _._ .

rro~·IMJJfli[er. Moun~in91 BI\Jitk __ ._. __ , •. _ "'''''-,_._-

Ml,ltfrer aJiid Straps_._ _._ .. _._. ,_ _._ .. _._ .. _. __ .-

,N53 :2-53 :2·53 :2:-5.'3

2,"'54 .2:.5<1- 2:-.."14

2-55, 2-55 2~ 2-55

2-51 2-'.57 2-'57 2-57

2 .. 581 2-58. 20.58

;2-5;9 2-.591 2-,60

:NlO 2-6.1

.2-62 2·62 2-62

2,-64, :2-64, 2-64 :2-64, .2-04 .2'-64 ,2·64

2,-661 .2.-l1i!6. 2-66 2-66 2-66 2-66 2-67 ~ ~ 2-6'7- 2-4Jr

2 • .29 IFoo;1pegJ, IH~IIG'llI!ilird~. tUir.d Mo~nt

~ldP.-'r _ .. _._ .. _._. ,m ... , ,., .... ,., ,., •• ,., •• ,., •• ,., ,.,.u_. __ ._. __ ._ .. _._ .. _ R.'oM'LUv6I Foolp~ _. __ ._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._ ... _. __ ._. __ ._. __

R8JII.0"iIe E-IIeel Gluarrd _._ .. _. __ ._. __ ._ .. _._, .. , •• ,., ,.,., ,.,., ,., ...

HCllI.GvQ MDUiilL. __ ._ ... _._ .. _._ _. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ ... _. __

inat911 F~g ._. __ ._. __ ._ .. _._, _. ,_. __ .• ""., ,.,."., •• ,., ,.,.,

InstalllHOOI Giu<ll1:i ._._, .. _. __ ._ _._ .. _. __ ._. __ ._. __ ._. __ . __ ._. __ ._.

Install Moont_._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ .. _._ .. _._ ... _. __ ._ .. _._ .. _.

pa~~~:~:·F~~l~·:~~:::~::::~:::~~:::~.::::::::~:::~:::::::::::~=::

RemGYB' H'eI;!1 Guard/.- .. _ .• ".,., .. ".,., ,., •• ,., •• ,., ,., •• ,.,.,'

Rar'no. ... a IMbunL ... _. __ ._. __ ._ _._ ... _. __ ._ .. _._ ... _._ .. _. __ ._. __ ._ ..

Install f'o~peg .,., , .... ,., •• , _ .. _,._,_ .. _,_, __ ._ .. _._ _ .. _._._

lm.lallIHS!3i Gwrd _._ .. _._ ... _. __ ._. __ ._ _._ ... _. __ ._. __ ._ _. __ ._._

lJl!!'li!alD Mount.,., ,.,."., ,.,., ,., •• ,_,., , _,_, ._, __ ._. __ ._. __ . __ ._._

2:.~O Spli'ocket Cov,sr ., .. ~ .. , .. , .. , .; ..

iRamlJll\arlD:igs,::;!31IT.1biy ._ .. _._ ... _._ .. _. __ ._ ... _. __ ._. __ ._. __ ._ _. __ ._

Insta,UF.i1jon _._ ... ,., ,.,., ,., •• ,., ,.,., ,., •• ,., ... _, ,.,., ,_._ ... _. __ ._ .• _._ ... _

2.3,1 F • .nder$~.' .. m .. '.m •• ' •• ' , •• , •• , •• , •• ~ •• ,.

IFr'onl FerocI!3~ _ ... _. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ _. __ ._. __ ._ _._ .. _._ ..

lRerrnoval._._. __ ._ .. _._, , .... ,_ ... ,., ,.,., ,., •• ,., , ,.,.,_"'_ ,., , •. _ ..

I na tal lat iD n _. __ . _. __ . _. __ . __ . _. __ . _. __ . _ ... _. _ _. _ _. __ . _ .. _. _ _. __ . _.

Rear r!!:,!nder , ... , ... ,." .... ,., ,.,., , .... ,., •• , , •• ,., __ ._. __ ._'-._, __ ._.

R!3mD¥aI_. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ .. _. __ ._ ... _._ .. _.

F.lemo .... al .,., , .... ,., ,.,., ,.,., ,_,_ ... _. __ ._ .. _. __ ._ ... _._ ... _._ ... ... _.

;2;.32 Be:It: IGuar'ds, +'~i","", ••.•••••• ", •• , •• , •• , •• , •• m .. ,

~I.wdl._. __ ._. __ ._ .. _._ ... _. __ ._ ... _._. __ ._ ... _. __ ._. __ ._. __ . __ ._. __ ._. __ ._._ IlnataI18lion_ ... _._ ... _. __ ._. __ ._ .. _._ ... _. __ ._. __ ._ .. _. __ ._. __ ,., ,_._ •.• ,_.,.,.

"'li''lIf'll'Cllio.- F 11'1

~_. "" '. 1IIIIiIn a .rl n,g , .. , .. , .. , .. , , .. , .

lFIelil'lO¥;;in_, ._,., ,., •• ,., ,.,., ,.,.,.,.,.,.,_. __ ._,.,_, __ ,_. __ ._ .. _. __ ._. __ ._ .. _._ Insta.1laf)Dn _._ ... _. __ ._. __ ._. __ ._ ... _._ ... _. __ ._ ... ""' .. _._ ... _. __ ,_ ...•. _ .. _._.,.

2.34 Intake, 'CCWiII" :A;s.semlb;~ ., .. , .. , .. , .. ~.~.

Ramo'ilBI_._ .. _._ .. _. __ ._. __ ._ ... _,_ .. _,.. , .... ,., ,., •• , .... ,., ,.,., , ... m ...

!n!jtalallOn, , ... , ,., •• ,_. __ ._ .. _._. __ ._ _. __ ._. __ . __ ._. __ ._. __ ._ .. _. __ ._._ ..

.2.35, .Air :Seoojps , .. " ' .. ~.m.m.m.~ .. ' •• , •• """ ••.•

Ft.:Im Air ~p .. _. __ ._. __ ._ _._. __ . __ ._. __ ._ _. __ ._. __ ._ ... _._ ... _. __ ._.

Remov:aJ' .,.,., .... ,., ,., •• , ,., •• , •• ,., •• , ,., ••. _, ,_. __ ._~_. __ ._.

(ns.iBn900n ... _. __ ._ ... _._ ... _. __ ._. __ ._ ... _._ ... _. __ ._. __ ._ ... _._. __ . __ ._. __ .

E:ng:fDe $h~ Ailr ~j)',., •• ,.,._,., ,.,., ,.,n._. __ ._. __ ._ ... _. __ .

R'er'no ... .al_._. __ . __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._ .. _._ ...

11:i~J3~1'I. __ ._. __ ._ ... _ .... ,_._,.,..,., .... , •• ,.".,.,".,:~ ...... , ,.,.,'

Oil Gooier Ai[ 6000p _._ .. _._ .. _. __ ._. __ ._ _. __ ._. __ ._. __ . __ ._. __ ._._

RerTil(jl,;'al. __ ._ .. _. __ ._. __ ._ ... _._ .. _._ .. _. __ ._ _._ .. _ .• _._. __ , ... _ ... ,.,.

1000;rul'a'lioo ._ .. _._ ... _._ .. _. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ .. _. __ ._. __ . ._

2.3'6 'l:ailll frame. amd Bod, 'W,c1rk .... , .. , ..

Di~. __ ._ ... _. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ .. _._ ... _. __ ._ .. _._ .. _ Cleaning' ., •• ,., •• ,., ,., •.. ,_, __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ . __ ._. __ ._. __ ._ .. _ .Assam'bl'j _. __ ._ ... _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ ... _ .• _

2.3,1 FlmnJt IFahillng!, Wllndl).shl~ld! ,and

Miilrrollis .~.~ .. , .. , .. "'., : , .. , .. , .. ~., .. , , .. ,.~ :.

RlelnDl.!'al. __ ._ .. _._ .. _ _._._ _ ,." ,,_,.~_, •• '"".,., ,., •• ,.,

IIWi!lllillioo ._. __ ._ ... _. __ ._. __ ._ _._ _. __ ._._ . . __ ._. __ ._. __ . __ ._.

2.38 Seat ; .. , .. ~., , .. , .. , .. , , .. , .. , .. ~., .. , .. ,.

~d.1._ .. _._ .. _._ .. _. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ _._ .. _. __ ._. __ ._ .. _. __

IHllijOf Swt , .. _._ .. _._ .. _._ ... _. __ ._. __ ._. __ . __ ._. __ . __ ._._ ... _. __ ._ .. _._._

Pi~n Sea .... "."., .... ,., , ... "., •• ,., •• ,., ,., •• , .... ,., ,_, •• ,",._,_,_

V:I

2-68 2,~6H 2-68. 2-<6e1. z-ea 2--61i1 2-6B 2-fjij 2:-69 . 2-&9 ,2'·69- :2-159 2-00 2-M :2-69

2·,1U 2-10 ~ql]l

2-"111 2-71 2-71 2-71 2>-7~ 2:-71 2:-71

2'-72: .2-·72 :2-72

.2·,7'4)" g-74 2-74

2-"7.5 2-75, 2<7.5,

2-110 2-'i,C 2-']16 2:-7tEl 2~·'ffl .2·-7"Ei 2,·16 :2-.]6 2-·7f.) 2-7'6

2·77 2-77 2-78. 2-7.8,

2'-,80 2'-'JJI} 2-00

2'-81 .2-81 :2-81 2-Fl1

1~:eNI!)_ ..

InstcfJllalloo ._. __ ._ .. _._ •. _. __ ,_ ... _,.,,_, •• , ..... ..,.,_, '.'~'.'"" .... '.' ,.

RiClCt' S~t .... , ,.,., ,.,., ,_,._._. __ ,_ ... _._, ._._ ... _. __ ._ ... _. __ ._. __ ._. __ P~n :588.1'..._. __ ._. __ ._ .. _._ ... _. __ ._. __ ._ ... _._. __ ._ .. _. __ ._ .. _._. __ ._ ..

,2'·81 2-8.1 :2-8,11

2'.39 IPa&senge.r Seat ILicc!k .~ .. , .. , .. , .

1rIen1~1 ._._ .. _ ... _._. __ ._ .. _. __ ._. __ ._. __ ._ .. ,_._ ..•. _ ...... , •• ,..,., , ..

Insl;.)!llilltitJr'1 ., , •. __ ._. __ ._. __ ._ ... _. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ ... _._ .. _. __ ._.

2·82 2-82. :2-82:

:2 4i1'1i S'·dl .. :t d

".,- II,iI' ~;I _8'n _ · .. , .. u~.m •• '.~ .. , •• r · •• ' •• ' •• '"

Gei.naral_._ ... _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ .. _. __ ._. __ ._. __ .

Inspection ._._ ... _. __ ._. __ ._. __ ._ .. _. __ ._, __ .•. __ ,_ ... _. __ .•. , •. _ ,., •• ,

Si$S'I.ana flemmrdJ ._. __ . ._. __ . __ ._. __ ._. __ ._ .. _. __ ._. __ ._ _._ ..

sr~~ ~:ch ~.'".,.".,." .... ,.,., .... ,., •• ,_. __ ,."

Side&.1srul1 Disassembly _. __ ._. __ ._. __ ._ ... _._ .. _. __ ._ .. _. __ ._. __ ._._

·Sl~aruj ~$emblY .,., ,.,., ,.,., , ...... , ,.,., ,., .... , ,.,., ,.,_, ,.,.

Sid'.e:s!8nd SiMldh IlnataI18!iol'1l ... _. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._

Sicres:l!arKllnstrlla!li)n ., •• ,., •• ,., ,.,., , ..... _,._,_, .. _._ •. _. __ ._. __ ._

:2-83 :2-.93, :MI;J; US. 2-:B3- 2-84i 2..:E4 ~:-$4 2:-84

3\.11 Speciifieations , .. , .. , .. , .. ~., .. "' .. ,... 3·,1

6E!nl3"l"a!1 (ilBiiila)_._. __ . __ ._. __ ._ _._ _. __ ._. __ ._. __ ._ ... _. __ ._ ... _._ ... _.__ .::I~11

Eiriglne Jgl'1lllon «aore), •• , ,., ,.,., ,., •• ,., •• ,., ,., •• ,., ,",_ .•• ,., .3.-:11

Vahle end \I.aI''i'B' Sl3at ("ta:'bII3'l--.-._-.- ... -.-_.-._-.- .. _. __ ._. __ ._. :3-·1

'ilah,ie (Q~~ ., •• ,.,.,., .... ,., , ... ,.,., •• ,_,._,., , •. _, ,_, __ ._ ... _._ .. _. __ ._. .3-·1

'IJlal!ie ~rin91 ¢.!8ble) . __ ._. __ ._. __ ._ _. __ ._. __ ._ .. _. __ ._. __ ._ .. _._ .. _. ~-1

0uteI V;;rl\!'c $pFin~, (I.<:t'bh:l'l' _._ _._ .. _. __ ._. __ ._ .. _._ ... _. __ ._. __ . :3-1

Rocker Arm (Mab!e} _._. __ . __ ._. __ ._. __ ._ ... _._ ... _. __ ._ .. _._ .. _._ .. _. __ . ::3-.2:

~ooker Ainn {tabCe} ".,.,.,., ,.,., ,.,., ,., •• ,.,.,., •• ,., •• ,., ,.,., ,.,.,., :3-.2'

PisbiJn Amg an Pis.too IRin ,(tab'l8). __ ._. __ ._ ... _._ ... _ ... _._. __ ._.. :3-:2'

Pi\:rto.n {table·) _ ... _. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ .. _._ •. _. __ ,_ .. ,. __ ,., •• ,_" 3--,2'

Cyindl!!~ H!!:i1JtIl (l\:iibli31}._. __ ._ ... _. __ ._. __ ._. __ . __ ._. __ ._ ... _._ ... _. __ ._._ 3.-:2

Cylinder Head! ttablel-.--.- ..•. _ .. _. __ ._. __ ._ .. _._ .. _ .. _._. __ ",.,_,_ 3--2

O}!lillidBI'" (h:lbh3'l' _._. __ ._ .. _. __ ._. __ ._ _._ .. _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ 3-:2

4 Cyli'n!!ili;!F (ta'bl~'l' ._-.- .. -.--.- .. - _-.- .. -.- .. -.- ... -.,,,-. ,- ... ,., ".,. 3-2

coonell:;liI'1g ROO {hlila)._. __ ._ .. _._ _. __ ._. __ . __ ._. __ ._. __ . . __ ._ 3,-.:2

GoonectEg R.\ocI (1'aiIJla)._. __ ._. __ ._ _. __ ._. __ ._. __ . __ ._. __ ._. __ ._ .. _ ~2

H~i;hr~1.!I!lc i!Jfte,r ~!e) ".,., ,., .... , ,.,., ,., •• ,., •• ,., ,., •• ,., __ ._ .. _ 3-3

T~pp~s ~1aiiila' _._ ... _. __ ._ ... _. . __ ._. __ ._. __ . __ ._. __ ._ ... _. __ ._.__ 9.-3

Oil flul1i(p {1ablel_. __ ._. __ ._ ... ".,., ,., •• , ... _,., ,.,., ,.".,., ,.,., ,.,." 3:.3

[ijJ IPwnp {Iitblal_. __ ._. __ ._ .. _. __ ._. __ . __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._.. .::1,3

GI;e,l:,irca~ (table) ,-"'-,.,.,., ,.,., ,., •• ,., ,.,., , ... ,.,., •• , •• , ... ,., .... ,., 3.-3

He-amaas (taiIils·). ._. __ . __ ._. __ ._. __ . __ ._ ... _._. __ ._ .. _. __ ._ ... _. __ ._. __ ._. .$-S;

Flywheel (ts.'ble), ... _. __ ._. __ ._, , .... ,., ,., .. ,., ,.,., ,., •• ,., •• ,., •• , •• ,., 3·3

1P1rnflielEll~ {II.<iMe' _. __ ._. __ ._ ... _. __ ._. __ ._ ... _. __ ._. __ ._ ... _. __ ._. __ ._ .. _. :3-3

Sprooka: Shaft ~ring ~t=.it)6e} ... _. __ ._ .. _._ .. _. __ _ .. , ,.,._, ;:;h;J:

S~: SM.n ~ring ~,~} _._. __ ._. __ ._ _. __ ._ _._ ... _._... S-H

Pimio:n S.haft ItIOa9ring {fEible).--.- .. _. __ ._. __ ._ _._ ... _ .. _._. .•.•.. 3-.4·

F'1~~:m Shan B~FiFl@S, (lF1.'bh3'}_._. __ ._. __ ._ ... _. __ . __ ._. __ ._. __ ._._ :3-.:Ii

3.2 EI1~giUr'ie .",,, , , .. ~., .. , .. , .. ~.~ .. ,.~ .. , .. , .. , , 3~

FueL_. __ ._. __ ._. __ . __ ._. __ ._. __ ._ _. __ ._. __ ._ .. _. __ ._. __ ._ _. __ ._ .. _._ .. _._ ~

G;:I.iSC!Q1Ie/a!oohOli ~1:I's, ,.,., ,., •• ,_, ,_,_ .. _ _._ .. _. __ ._. __ ._ :l-S

l.!ublri'caJiiDf1I .. _. __ ._. __ ._. __ . __ ._. __ ._. __ ._ ... _._ ... _. __ ._ .. _. __ ._ .. _._ _. __ ._ 3-tl

MJustn1mvi,eSIfng •• ,., ,., •• ,.,,.,., ,.,.,.,_ .... _, ._ ..... _. __ ._ _._.__ 3:-l6

G!31I8r:a1 . __ ._. __ ._. __ ._ ... _. __ ._ .. _. __ ._. __ ._. __ . __ ._. __ ._ .. _. __ ,_ _.__ 3i-6

COOlpre5SIOO Tes.t P~!JIiI!li_._ ... _. __ ._. __ . __ ._. __ ._ ... _. __ ._.__ :3:-7

Compr,sB-OO.n Teal: Reau!ts (tabJe) ., .. _. __ . __ ._ ..•.• , , ... , ·:3:-·1

Cylllfl;OeF blatage li"FM.>L. __ . __ ._. __ ._. __ ._ _. __ . __ ._. __ ._. __ ._. sa

Coow'roemn f~~ Aeilmns ~'I:a:b'Jc' ,., __ ,_,._._ _. __ ._. 3-·1

Air lLe8]i,;8g:e li'e?1i ~f.lble} --.-._-.- .... ,- ... ".,., , .... ,., , .;3·7

Di·a.grmsing1 Smilkin.g Efilgil'1.e or E-ilign CIi iCoosurmp'lico .'j-7 AIr l.!eak<'l,,9 '-r:a:;t ~~blB) _. __ . __ ._. __ ._ ... _._ ... _. __ ._. __ . __ ._. __ . :3-1

,3.3, Eng-ina Rotati(ln 'for Service .. , .. , ..... , 3..:8

~~:m~ ... :::: ::::~:::::::::::::: ::::~::::~:::.::::: ::::~::::::::~:::: ::: :;!

:3.4 ,S:tllli'llp;pl.ngi M;cmlicycle, For' En:gi:ne~ ,Ser,-

''!lice' .. , .. , .. , , , .. , .. , .• ~.~.~ .. , .. , , .. , ,.,... 3 .. 1 ~I

lli!!.:l.'9aembti _._ _._ .. _. __ ._. __ ._ .. _. __ ._ _._ .. _,., ,., .. , ,., ,_._ .. _. S-'I'~

3.5, Eng ine l'nst:tjlllaJ~iun .. ,," , , •. , .. ~.,.;., .. , 31'"29

,,!'i,S!;IlP.liBl;Jty _._. __ . __ ._. __ ._. __ ._. __ ._ ... _. __ ._.,._._ .. _._ _. __ ._ ..... , .... , .. , :l-29

Engi~ Prep lw Flc'ilWllI!:a1i(!ft ._ _._ .. _._.,._.,._._ .. _._ ... _. 3»29

InSt8!lIngi E~ine' in FU"Elmta __ ._. __ ._ _._ .. _. __ ._. __ ._ .. _ .• , .. , 3-$0

'!!, ~ C I"·... IH '""' '''';...45

~.'UI' .' ~ IUnuer elaN,) •• ., " • ., • ., • ., .. ~.+ ..;!I

RaI'Til(f!l.,a1 __ ._ ... _. __ ._. __ ._ •• _._, .. ,., .. .,.,., , , ._"._._. __ ._ ... _._ ... _. __ ._. 3-46

F!oc~er 8o~ A~emh&!s .. _. __ ._. __ ._ .. _._ ... _. __ ._.,._._, ._,., .. , j,'-4Ei,

Rocitlsr B!J(i;:~tl6e.s, .. , " .. , , ... , , ... , .. _. __ ._ .. _._ .. _._.,._. ~6,

Cylln(l\er I-Ie-s!l;l k~efF1b&!E _._ _._ .. _._ _. __ ._. __ ._ .. _ .. , .. , 3-47'

1Jiis.3.csa!3li1i1iJ1)" _._ ... _. __ ._. __ ._ .. _._ ... , .... , , ,- .. -, .. ,_. __ ._. __ ._. 3-47'

C1IC~ andl i~tOOl_._.,._. __ ._. __ ._ _. __ ._. __ ._ ... _. __ ._. __ .• , 3-49

C~lind!eJ' Heads _._. __ ._. __ ._ ... _. __ ,_,._,., , " ... , ,.". ,_ .. _._. 3-4~'

Floc~er ,Arm AS$P.I11bies ._. __ ._. __ ._ _._ _ ... _._ .. _. __ ._._ ... , 3-:5'0'

Valws.,._._ .. _._ ... _ .. _._ .. _._ ... _,., ... , .... , , ,_. ,_,_ ... _. __ ._. __ ._. 3-:51

Valv.e ;Seats, ,_ .. _._. __ ._ .. _. __ ._. __ ._ _._ _. __ ._. __ ._ .. _._ ... _.,._ .• , 3-:51

Valve Giuid'e:s, _. __ ._ .. _._ _._ .. ,., , .. , .... , , ..... _. __ ._. __ ._. ;3-.51

V~I!iC Spnngs " ... ,_ _. __ ._. __ ._ _._ ... _. __ ._. __ ._ .. _. __ ._ ... _._. 3-,51

Spark IPlugl Tihraads __ ._. __ ._ .. _._. __ .• , .. , .... , .... , , e e e _._,._._., 3-:51

P1LIShrOOS ..... , .. " ... ,.,., __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ .. _._ ... _ ... _._., 3-51

lRocitlar ArmEl BJiId BU:;.hir'l~ .. , ....... , .... , , ... , ,_. __ ._. __ ._. 3-.52

IFI~C!f19 '\,i'atve- G;lllI!iIes ._. __ ._ .. _. __ ._. __ ._. __ ._ ... _._ ... _._..... 3-5~,

ValliiB :stem Gleilfil:ric;(:S ~.~}. ,. ... _. __ ._ .. _._ .. _. __ ._. __ .__ 3-530

P~l,Jre' F.D.r iUain,g the ~l8y '!J\3i1lle :se.a~ Cwl1'er .. 3-.5".i1,

N6!Kd}1' v.i:ll'i'~' ,S001 QJL1e( ,,_._ .. ,_. __ ._ .. _._ .. _. __ ._. __ ._ _._.. 30<54

ii'ios~liI\l;Jty _. __ ._. __ ._ ... _._ ... _._ ... _. __ ._ .. _. __ ._. __ ._ ... _._ ... _. __ , - :3-.57

Pl!rshi Rod 'C'<n.rer Ilr'l.~l):)lIaliOfi1l , ....... ,_ •. _ .. _. __ . .- ... _._. __ . __ ._.__ 3-.5H

P.u!'lh IPioo SelecOO:n {tablal-._ .. _. __ ._ ... _._ _._ ......... , ..... G-5g,

Cyifilder itl8ac:1 trlstaDa!jj)f1- •. _ .. _. __ ._. __ ._ .. _._ _ ... _._. __ ._ .. _.__ 34iO

Lowe r RJoc:I.\;"i3 r Box H.:!! rd w.tirtlI Uabfe'~ .. ,""., _., _. _ _. _ _ 3-'62:

,3.1 CyI'imJef' and IPiswnl ."" "........ ::3;·63

~movElL'l)jgaaEBmbl'i __ ._. __ . __ ._. __ ._. __ . __ ._. __ ,., """.:"""__ :3.iEi3

Glaaming <olndll~CIi"Ul:l ,.,,- ... --.- ... -.--.- .. _._. __ . __ ._ ... _ 3·65

Ch~i~ i$.s:~BI: SuiltaDB _. __ ._. __ ._ .. _._. ,_. __ ,_, ....... ". S-Ei5

Mea6Uringl CyiI'ldet Bm-c , __ ,_ .. _._ .. _. __ ._ .. _._ .. _. __ ._.__ 3·66

Oeg'lfJ~ing OyfD;li3~ . __ ._. __ ._ _. __ ._ ... _._ ... _, .... , .... , ..... :_.__ 3-66

C~liriOOr IBorc $ef!.!'!'ce- We::,lr I;iJ1l1i~s ~Bb!a}_ .. _. __ ._ .. _ 3,66

fiflil'ig PiBtofij IRings. __ ._. __ . __ ._. __ ._. ,.,., ..... ,., .. , •... _ .• _._ .. _ :S-B.?

1Ri~ E.fId Gap .. _._ .. ,_. __ ._ .. _. __ ._. __ ._ .. _._ .. _._ •. _ .. _._ ... _. __ ,.,.. 3-e,7

COOinactili!g Rod lBu::ihin9l_ ... ".,., , .. , __ ._ .. ,. __ ._. __ ._.__ :3-69

.MMmLDlytlnstaiiatlofl- .. _._ .. _. __ ._. __ ._ _. __ ._. __ . __ ._. __ ._ ... _,.,.. ;fJ-7Jl1

- ,I!i, II 1Iio.' 'I S • '!I<.: .• 73 ,::!i.v !!.!u .... ru::ailli o,n ,. yS'~em"., . ., . ., .. ",.m ..... , ... ii'''' Q

Gh!3citling and Adding! Oi ... , .... , ..... ,., __ ,_. __ ._.,_. __ ._. __ . __ ._ :3-73

GM~lngl 011 :=.il'l!til Fil~e~ _. __ ._. __ ._. __ . __ ._ .. _._ .. _._ •. _, .... , .. ,..... ;3-73

'Wima~ LUD;iiiD:Lti.O'lL ._._ .. _,., ... , .... , ..... ,_. __ ._ ... _. __ ._. __ ._ ... _. __ ._ :3-73

3.9 Oim IHose IR:o~rtiillgl A~d1 Oll~ -

. .... 3. ·,7'4

Reservo.lr ,~.~ .. " " ., ., . ., . ., . ., ,,"' .

i$E'Iieral __ . __ ._. __ ._. __ ._ .. _. __ ._. __ ._ .. _,._,_", , _._ •. _ .. _._ _. __ ._ :9-74-

3,,10 Qlm IPlresslnne Ilndii:oalD,r Switch :F75

GI~JiBraI __ . __ ._. __ ._ .. _._ ... _ ... _._. __ ._ _ , , " .... __ ._ .. _ _._ :3-75

Oil PreSS!!fllE! signal Ug'1'rI! _, _ _. __ ._ ... _._. __ ._ ... _. __ ._ ::3·75

Oil PteSSUiIC , .... , .... , .. ,.,.,_, ._._ .. _. __ ._ _. __ ._. __ ._. __ ._ ... _. __ ._ .. _.. :3-75

Troubl'esh.oo1:ing Oil Pressure Signi1ll Light (tab!e} :3-75

3~ 11 (;1i'"'snlklr:ai51e Br,eathll;!llQ Sysmm "... ,3'-'7\6

!iie.nl3.o:!1 .. , .. , .... , •• ,.~_,_ ... _._ ... _. __ ._. __ ._ _._ _. __ ._ .. _._ ... _._ _. __ ._ 3;76<

R'e.ed V.all"S ReplacQli'ml1tfl'i. , _ .. _._. __ ._ .. _._ _._ ... _ 3-77'

3,.12 OillillnQI Sys,teml •••••••••.• " • ., •• ~.................. ,3'·78

Genergl . __ ._. __ ._. __ . __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._ .. _._, .... , ........ .,... $-78,

3 .. 13 on IPulm'p'"., ,,"' "' ", .. ~,~.~ "'... ,:J. 79

G!C[~crnl ,_, .. _. __ ._ ... _. __ ._. __ ._. __ ._ _._ .. _. __ ._. __ ._ ... _._ ... _. __ ._. __ ._ .. _._ 3-79

R!3f1i1ovaJ!lD.i~tlty ...... , , , .... ,_, .•. _ •. _._ •. _. __ ._. __ ._. __ ._ :S-80

Clettl'Ilngi ::,100 1n!;;pectiDn ._ _. __ ._. __ ._ .. _._ ... _._. ,., .... ,......... ;3-1;11

i\'s::;sliTlbtyJllillSJ!i1IlIa'iOO .. , .... , .. ,., ,_,_ •. _ .. _. __ ._._ _. __ ._. __ ._. __ ._ :3-8.1

3\.1,4 Oi I 'Pi !tef!' IMoulli\t: .. " ., . ., ". 3·82

li3>enera! . __ ._ .. _. __ ._. __ ._ ... _._ ... _._ .. _. __ ._ .. _._ _. __ ._. __ ._, , , .. ,. ;3-,132

DisasEiEilinbly _._ ... _. __ ._ ..• ,., .. ,., .. , ..... , .. , .. , ... _._, __ ._. __ ._. __ . __ ._._ :3-8-2

Cleaning aM 1[1$peafion . __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ . __ ,.,. :J-S;?

Assi31iF1bLy ._ .. _. __ ._ ... _._. __ .•• ,_, .... , .... , .... , , __ ._ _ .•... _. __ ._._ :3-82

3\.1,5 IHyclr,au flc lil.e:li''S "'" ; ., . .,.=" •• ,, 3·'83

G-i!ner-al ".,_. ,_. __ ._ ..•. _ ... _. __ ._. __ ._ _._ ... _. __ ._. __ ._ .. _._ .. _._ .. ,_....... ;;'3-63

lRen1ova1 __ . __ ._. __ ._. __ ._ .. _ ..... ,., ... , , ,m.'-' .•. _ ... _._ ... _. __ ._. __ ._._ :3-00

C!eenlnfll a~ InspectiDn . __ ._. __ ._ ... _. __ ._ ... _._. __ ._. ,.,., .. , ..... ,' ::HI~

installalion __ ._ ... _._ .. _. __ ._, .... , .... , .... , , •.• _._ .. _._ .. _._ ... _. __ ._. __ .__ ::3-8:4

3i.116 Gear'case Cover Aililldl Cam 'GeallrS 3·'85

Gen~f!1 .. _._ .. _ .• _._ .. _. __ ._. __ ._ _._ ... _. __ ._ .. _._ ... _._ ... _._ .. _. __ ,_ .• _ .. " ::3-65

IRen101.!B&!lDis:!l~ .... , , , .... ,_._ •. _ .. _._ .. _._ .. _. __ ._ ... _._.. 3-aG

C!ea["l!f!~ and IlnSPedion. . __ ._ ... _. __ ._. __ ._ .. _._ .. _._ ... _. __ ,_,...... :a-87

ean1!'PiiniOlfI lli;;ar' ICIlefl~f!:Callon~ IMpcEdiiJll!. and

Se!edlion ._. __ . __ ._. . __ ._ .. _. __ ._. __ ._. __ ... ,.,oro ...... ,., ... " .... , ~-a.7

Bwhilg Iinspedlofli aJ'l(!i Flel!ll~wJ1 .. _._ .. _._ .. _. __ ._ ... _._1 :H17

G.8a!r Shalit SpeciliGaliMS, [I.®IC') .. '"'"' ,_ .• _._. __ ._ .. _._.. .3-37

~tlfyf!~allRtl(Ml! . __ . __ ._. __ ._, __ ._ .. _. __ ._._ .. _._ ... _ ... _._ .. _._... ,fJ,OO

3:.11'7' ICil'alll1kcase ..... .,." . ., . ., . ., . .,.................... ..... 3-90

Ganeral _._. __ ._ ... _. __ ._ .. _._ .. _._ .. ,_,., ... , .... , ~.,_. __ ._ .. _. __ ._. __ . ,3.-00

IlJfSa$~eFliibl~_ .. _. __ ._ .. _._ ... _. __ ._. __ ._. __ ._ _. __ ._. __ ._ .. _, .... , •• ,.....:3-00

Gr~asElIHa~ .. , .... ,_. __ ._ .. _._ .. _. __ ._. __ ._. __ ._ ..•. __ ._. __ . 3-00

~istolii Ji3~1ii _. __ ._. __ ._ .. _._ ... _. __ ._. __ ._ ..... m' .... ' .... .,. ,"".,_. __ . ,:3,911

RUing PiFli!)T116ea.J1Dg!ii _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._ ... _._ _. __ ._. __ . 3-$4

PcWilion .shafli Be.ari~ SSleeliUn (table) _. __ ._ .. _. __ ._. __ . ,3-00

~j)ing Engine M,Fiin. Bearingl RaDaEL.. __ ._ ... _._~._._... ,:Nl9.

Check'ingl 'Gonnecliin91 ADdl Sid'£ P't.W ... ,,-,_ .. _._-,_._-, .3-00

A~y "_,,.'"_. ,_ .. _._. __ ,_. __ ._. __ ._ .. _. __ ._. __ . __ ._._. __ . __ ._. __ ._ .. _. ,3·100

Cranicasa H,a'h.iB5_ .. _ .• _,_ .. _,., .... "' .. , ... , .. ,_ .. _._ ... _. __ ._. __ . :3-100

S,ECTIJON 4-FUEL SYSTEM

4.1 ,Sp&ei~~ei9ltion;s ., . ., . ., .. ~ .

Fuel S~B1em ~t~ble) ._ .. _._ .. _. __ ,_, ,. .. , , .... ", ,., ._,_ _.

Fuct Tanl':. CaJ;taetty (t!I,lble-l __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ _.

Ii;lle Speed Adjlli~JiriEm~ . __ ._. __ ,., •• ,., .... , ........ .,. .. , -.

Torque; Va1ues.-,- .• -._. __ ._ ... _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ ... _._ _._ _.

4.2 DynalM.ic ID:lg'I~Dm IFu,elllnjecliolli~ ..

IliItrOOuction .. _. __ ._. __ ._ .. _. __ ._. __ , .. , , ,- _._ .. _. __ ._.

G~r:aJI .. , ... , ._, "'"-, ._._ ... _. __ ._. __ ._. __ ._ _. __ ._ _._. __ ._ _. __ ._.-_._.

Fer IM.OT,a InJ'cnT:1a'ion._. __ ._. __ ._ _ .•• , " , , , .•. _ _.

Tl"tIUblaS'hOc.lllilog .. , .... , .. .,. -,_ .. _. __ ._. __ ._. __ ._ _. __ ._. __ ._.

FUel Injection 'ColillponEfilta _._ ... _. __ ._. __ ._ ... _._ _._ ... _._ .. _.

~-1 4-1 4-1 4-1 4-1

4.-3, 4,..:3 4-3 4-3 4-3 W

~ill

1P\"!jJ4i,INlOc

41.3 DI\a;gno5:tic IlfllrlrCid~:ctionl , .. , .. ~.~ .•. , ,. 4-.5

$~.1iIl PidblemB . __ ._. __ ._ _._ .. _._ _. __ ._ .. _._. ,.,_,.,.,., , ,_.__ 4-5,

No SLart.,., , •. _ ... _ ... _._. __ ._ _._ .. _._ _. __ ._. __ ._ ... _._ .. _. __ ._. __ ._.__ 4,,5

p'iJOJ Perfo:mnanoa . __ ._ .. _._ .. ,_,., ,.," ,.m,-, ,_._ .. _._ ... _ ... _._.__ <'1,,5,

GIlle"", E::Mglne' l.arnp., ... _. __ ._. __ ._. __ ._ .. _._ .. _._ .. _. __ ._. __ ._ .. _ 4-5,

Ri3siJ[ ... ing Prdbl131i1l5 _ .. _,_, ,.,., ,.,., , ..... _. __ ._ .. _._ ... _. __ ._. __ ._.__ ..'l-s.

4L4 Checkingl !FiOt Tmulbl,e Code·5 ...... ,. 4-:6

ChB!:k 'Engine ~riliip_. __ ._ .. _. __ ._. __ ,., ,.,., ,.,., .. , _. __ ._. __ . __ ._ 4-6,

Coc:M liyPe$- ... _ ... _._ .. _._ .. _._ ... _._ ... _ _._ ... _._ .. _. __ ._ _._. __ ._ .. _._ .. _ 4-"7

'G'Urran.1: ._. __ ._. __ ._. __ ._.-- .. l._._ .. , ,., ,.,., ._.,_._._ .. _. __ ._. __ ._ ... - .11,-7'

~Omt, ,.," ,.".,_. ,_._ .. _._ .. _._ ... _. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ . __ ._ 4- 7'

FunotiOOiaI ._. __ ._ .. _._ .. _._ .. _. __ ._. __ ._. ' ... m' .. ' .... , ,_ .. _._ ... _ 4-"

fll3lriFh'ir"l@ Trootie ~e!i: . __ ._.,._._. __ ._ .. _. __ ._. __ ._ _._ .. _._ .. _ 4·7'

Mrtlip!a TraUbl8 Codas _ ... _. __ ._. __ ._, ,.,., ,.,., , • .,.,.,,_._ ... _. __ ._ 4-'l

ChE:d;. Engine Lamp lallnk!l; _._ ... _._. __ . __ ._. __ ._. __ ._. __ ._. __ . __ ._ 4-7'

4.5 ClIlleck IEngilru~, Lamp IC:Rag.nos:tics, 4-8

iFlelrie¥ing TI'D!!Ii18 COda:; . __ ._ ... _._. __ .•• '.' •• 'm ... ' .... ' , ... , ,. 4-,a,

CleT:I!ririgl G!)1;I'c-$ .,., ,.,., ,_ ...... _ ... _._ .. _._ .. _._ ... _. __ ._. __ ._. __ ._ ... _. __ ._ 4.-9'

.4.,16 IBi!i8akout Box , .. , .. , .. ~.~ .. , .. , , .. , .. , .. ,.. 4-10

GEinet'.3!1 . __ ._ .. _._ .. _._ ... _._ ... _ ... _._ .. _,., ,.,., ,.,."., ,.,., m-' ._._ ••• _._.,._ 4- ~ 0

~nsl.iillllal!(In _ .. _._ .. _._ .. _. __ ._._ ... _ .. _._ .. _._ .. _. __ ._. __ ._ _._ .. _._ _. __ ._ 4~1 ij

lRem.ovaI __ ._ .. _._ .. _. __ ._._ ... _. __ ._ .. _._ .. _._ .. ,., •• ,.,.,., ,., , ,_. __ ,_ 4-10

4.7 WI~ggle' Tes1t. , .. , .. , .. ' '.m.m -aa ~.,.. ,4-11

6en~1 ".,., ,., ••. _._ .. _._ ... _. __ ._ .. _._. __ ._ .. _. __ ._ _._ _._ .. _._ .. _._.,._ 4-~ 1

lP.rooad!nB _ .. _._ .. _._.,._._.,._. __ ._, ,.,., ,.,., ,.,., , ',_ _ .. _._ ... _. __ ._ 4-1 '1

4.8 mnUial 'D'iag,nO$liC Ch~k .... , .. , .. , .. ~.~. 4-1:2

eenet'ail . __ ._ .. _._ .. _. __ ._._.,._. __ ._ ... _._. __ ._ ... _. __ ._'"_._ .. _,_, ,.,., ,.,., ,. 4-~ 2'

[J"l3Ignoo.lie Notes ._ ... _. __ ._. __ ._. __ ._ .. _._ ... _. __ ._. __ ._. __ ._ ... _._ ... _ 4- ~,2'

Ojr,wit Di8gJaJiW'Wire Hamesa GooMetor Taflde, ,. 4-1.2

.JtIblriUlllli CMe V'a1ues-.- .. _. __ ._ .. _._ .. _._.,._. __ ._ ... _._ .. _._ .. _ 4- ~,2

~n~laV [liBgl!ID&iic.s. _._._ ... _. __ ._. __ ._.,._._ ... _._ ... _. __ ._. __ ._ .• _,_, ,., •• ,. 4-~,2'

G~f;;lI li1If(t.:rmwti.(!ill . __ ._. __ ._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._.__ 4- t2.

D'iBgn.05!li~ N!J~E!:; ._ ... _. __ ._ ... _._. ,_,., ,.,., ,., •• ,.,., ,.,., ,_, ,_.___ 4-t~

E:ngSne $l:a1t3: l-lar·d (ta!bli3)' ... _._. __ ._ ... _._ ... _._ .. _. __ ._ ... _._ .. _ 4·t2

Engifle PelilolifflaJi1.(;o 1?~lems «a~l.- .. _. __ ._. __ ._ ... _ 4~'1:2

Engine E:.:::.hBuat lErmilEl Bhd. .8f1"1oitls or IFool::; I?~ 4-1.:J,

TroubfB Co~ ,a:Ji"l.d F,aufl: CofIaitlons [table) _. __ ._. 4~ 1.:3

WI~, HliIime;a8 lOiJflliiBetola. (tabl!3I)- .. _._ .. _._ .. _. __ ._. __ ._ _ 4-1-41.

D'iaJgn~ie Chr.l(."k. ~P,~i1 ~ Col :1:) ~ 'char.ij .. _. __ ._.__ 4~'1S.

DlEign.o:3liic Ch.eck (P,BI'I! 2 of:2} (flbwld.haFl!} ... _. __ ._.__ 4-1'6:

4.'!'j ClIheck.IEngillne L.amp Nol:

IlIlIum inated ,81: KEt,' ONI .. ,." ... : ..... , .. , .. , .. ~.~ .. ,. 4-17

Seneml . __ ._. __ ._ ... _._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._ .. _._ .. _._ .. _._ .. _,,, ,.," 4-1'7'

DiagnostiCs ..... , .. ,_, ._._ ... _._ ... _. __ ._.,._._ .. _._ .. _._ .. _._ ... _._ .. _. __ ._.__ 4-1'7'

DiBgn.oalIic Tips __ ._ .. _._ .. _._ _._ ... _.,._._ .. _._ .. _._ .. _._, ,.,., ,m. 4-17'

Q(ia!±lnoo~!e 1'1IJ00e$ ._ ... _._. __ ._ _._ .. _. __ ._ ... _._. __ ._ _._. __ . __ ._._.. 4-17

Wjr-a, Harnaaa GD~. (tabla'). ._.,., ,.,., ,., ,.,., ,.,., 4-1.6

TCSIl: 4,9. (~I(I!Il <:hart) ._. __ ._. __ ._ .. _. __ ._ .. _._. __ ._ .. _._ ... _. __ ._._.. ~-1'9

4L 1 II) Cbeck ~nglne ILamp Onl

C~nJtI,IIi1U)DUSIY~ ... , .. ,."',.~.~ .. r ••••••••••• , •• , •• ~ •• , •• ,..... 4-20

6ienat<l.1 .•. ,.,., ,., ,.,., ,.,., ,.,., ,.,_, -e e ,_, ._._ ••• _. __ ._. __ ._ ••• _._ •.• _._ •• _._. 4,..20

Di::lgrtDsI:i'cs _ .. _. __ ._. __ ._.,._._. __ ._ ... _._ .. _._ ... _. __ ._.,._._. __ ._ .. _._ .. _._. 4-£iO

Di:rgn~liC lNores . ._. __ ,_, ,.,.".,., ,.,., ",,,',.,., ,_ .. _._ .. _._. 4.-00

W11lD Hamess Con~~, (tatle) ._ .. _._ ... _._: .. _. __ ._. __ ._. 4-21

Teso1' 4.10 (fl(!oW (hart) . __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._. 4-22

4 .. ,11 E1ngill1l;8 Cln'al'1llk$ But W1illl Not Start 4.-23;

GenernJ .. ,._._. __ ._ ... _._ .. _._ .. _. __ ._. __ ._ .. _._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. ,4-23

''i.!ltl

P.~ge'IN"'.

[Ji'a@nosti(:S •. _ ... _._ .. _._. __ ._ .. _._ ... _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ _._.. 1-23

D.iii1gnCiSli8 Nol:Ei::; ... ,., ,.,., ,.,., ,.,., ,_, __ ,_._ .. _. __ ~_. __ ._ _._.. 4-23

Wife' H'I3i m eaa GOlllfilBcibJIia. (tab 1131)' ••• _. _ ••• _. __ • _ •• _. _. __ • _.. 4-23-

TiMl4, 1 ~ {pat11 (!oj" ~ ,("IllJW dhal!l\l._._ ... _. __ ._. __ ._ ... _._._ ~-25

Test 4.1 'I «P.BI12 of:3~ (fbw 'DhaJtl, ._. __ .• ,._, .... ,., •• ,." 4-26,

Test 4, 1 ~ ,[Pal1 :3 m;$) ("iIl)w ,c:hall) ._. __ ._. __ ._. __ ._. __ ._.. 4-27

4.1:2 INo 'ECM POWe111" ~ •• , •• , , •• , •• , •• , ••• ,"' •• , •• , 4-21

GEiriat"8Ii., ,., •• ,., ,.,.".,., ,.,., ,., .. ,.,,,._. __ ._. __ ._. __ ,_. __ ._ ... _._ ... _._... 4-.28

[iiagno81i!:a _._. __ ._. __ ._ ... _._ .. _._ _._ .. _._ .. _. __ ._._ .. _ .. _._ .. _,_ .. _._" 44IB,

Diagnoole N~es . __ ._ .. _._ _._ ... _. __ ._._ .. _. __ ._. __ ._. __ ._. __ ._._ ~.-28

Wir,B' H'aime38 Comn&ctol;:;, (tabll3'J _._._ ... _. __ ._. __ ._ .. _._._ H9

Mo IEa~ PO'NFlIt ~rICI!N Ii:Mn}".,., ,.,."m, ._. __ ._ ... _._. __ ._._ 4-3.0

4.1,3 IFueIIPr$SiS·ulfo$ T'e$l: , .. , .. , .. ~ .. , , 4-31

IIn.spectjon . __ ._. __ ._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ _._._ 4-3~

[Ii~ri!J:5.1ii:8 .,., ,.,., •• ,., ,.,., ,.,., ,.,., ,m, , ....... __ ,_. __ ._ .. _._ .. _._.. 4-3.2

DlFJgFlJD:3ljic: Na.':es . __ ._. __ ._ ... _._. __ . __ ._. __ ._._ ... _. __ ._. __ ._ .. _._._ 4-3Q

Wire I-t:lirMM Co~, (~Dle) ".,., .,. __ ._. __ ._ .. _._.. 4-$$

iI";e~' 4.,1:$ {Pad' "I of 2) (fbw ch811) ._. __ ._. __ ._. __ ._. __ ._._ 4-34!

Test 4.,1:3 I(Pal1I! :2 dII: :2,) ,(.!bW Oi"laJi1, ,.,., ,.,."., •• ,., •• ,_.. 4-3.5

4.1 ,4 ~I:ne Speed Contr\o~I , .. , .. , .. ", .. , , 435

AQjuslm.efil1:r3._. __ ._ _._. __ ._ _. __ ._._ _. __ ._. __ ._. __ ._ .. _._ .. _._ .. _._._ 4-:3il

4.1,5 Mllsilflllre , .. , , .. , .. , "' .. , .. ~."' .. , , 4-37

6sner~L. .. _. __ ._. __ ._. __ ._. __ ._ a , _,_, ._,., ,., •• ,.,., ,., •• ,., ...... -,-, ,.,_.. 4-$]"

MI~r.e Al 1d7e. !JIl Ulnd'e.r lo.sd ._ .. _._. __ ._.~._. __ ._. __ ._. __ ._._ 4-37

[Ii'a@n!J~ _._. __ ._. __ ,_., .• ,_, ,.,., ,_,., ,.,., ,.,., ,.,., ,-".,._. __ ._ .. _._.. 4-$'

Ot.iBgnoal!ic Na.':BB . __ ._ ... _._. __ ._ ... _._. __ ._ .. _._ _. __ ._. __ ._. __ ._._ 4-37

Sp<l.rl;. PI~ C~ ('bbte).- .. _._ .. _._ .. _._ _. __ ._.,._._ _._._ 4.-37

Wir'B Hamase GD~. (tabla,. .. _._ .. _._ _._ _,. ~

lI"es1: 4.1.5 I[Par.11 L}f:2). '[fl\l:M 'D'hFir1}. __ ._. __ . __ ._. __ ._. __ ._._ ~-3g

Test 4.,1.5 ,(PBE1!':2 IJ'l:2) {fbw IlihM},._._ ... _._."_, •• , ,, 4-40

4.116 "'r'Q'uble· (:'>ode ill 11 ••.•••••• , •• ~.~.m .. ' a • 4-41

Genera!- .. _._ .. _._., .•. _ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ ._._ '11-41

Thiri[lttre Po!iI.ioo s:moor •• ,., ,.,., ,.,., ,.,., ,.,., ,", .... , .. ,_._ 4-41

Ola.~nostEs .. _. __ ._._ ... _. __ ._. __ ._ ... _._. __ ._. __ ._ .. _._ _._ .. _. __ ._._.,._._ 4-41

[Jijagrloot'iC TipS ,:,;.,., ,.,.,.,.,.,',_ .. _._, __ ._ .. _._ _._. __ ._ .. _._ .. _._ 4-41

D:iegnoalir; rNOtBEl ._ .. _. __ ._. __ ._. __ ._. __ ._.,._._. __ ._ .. _. __ ._._ ... _._ <H-1

Wjpe H'amess C(ln~ors [ta1)le) . __ ._. __ ._ .. _._ .. _._ .. _._ 4.-42

'Code '~1 iraBl: ,(PBI1: 1 of:2) (iIm.'i' DhaJil) ._. __ ._ .. _._ .. _._ ,4--43

C'-Jl)da, ~ 1 TCS1. (Pill:l: 01'2) ~ ehal!f.l.- .. _._ .. _._ .. _._ 4-44

4L 11 'lrio'Wlble C(u::~;e 113 ."'"., •• , •• , ••• , •• ,.~ ••.••.•••• ~. 445,

iGsn!3mL __ ._. __ ._ .. _:_ .. _._ .. _._.,._._ ... _. __ ._. __ ._ a , _._ ••• , •• ,., •• ,.,., ,.,. 4-4:5

O~n ro.,!), $P.rui!Ir ._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ 01-416

[iiB.gIiID.&.1ic:; . __ ._ .. _._. __ ._ ... _._ .. _._ .. _._u_ ... ,., •• ,., .... , ,.,., ,.,., ,.,. 4-4:5

O!agnoellc 'TIp!;; ._.,._. __ ._ .. _._ .. _._ .. _._ .. _. __ ._. __ ._ .. _._. __ ._. __ ._ -i..-lifi

Oi3gnlJ'Sfic Motes ._ ... _._ a , _._ •• _ •• , ,.,., ,.,., ,.,., , .... ,., ,.,., ,_.- 4-45

W rie Harness [)onl!lerl1aIB (table) ._ ... _._ ... _. __ ._. __ ._.,._._ 4~ti

Gods 1.3- T~. W~JtI 1 UI'f:3, '[1fOW oe'MJ;1]i ,.,'",., ,.,_,,_._ ,4,47

Code t3 Te.<lI' {P,FiIli!':2 of 2). ,(flow ,dh811} ._.,._._. __ ._ ... _._ ,4-418

God8 1.3. T8SI: {PM :3 aIf :3, I[rtow ,eMm ,., ,m, ,.,., •• ,. ,~~49

j

,4.18, lirou blle Code 1;4, ••.•• , •• , •• , •• , •• , ••• , •• ,........ 4-6.~1 4.2;5, TlroLlllb:Je Cod:' 36 .' .. ·l.' •••••• t •• , •• , ••••• ~ ••••• , 4-15,

Glenel'l3ll_. __ ._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._ ... _._. __ ._ ...

EIlIginc: T;ernpC1W1Jw'c :ScnSI)F ,.".,." ,-, .. ,-,_ .. _. __ ._ ..

Dfi.sgnCEllics . __ ._. __ ._. __ . __ ._._ ... _. __ ._. __ ._. __ ._ ... _._ _. __ ._. __ ._. __ ._ ..

()'1~1)S'1i(; rIPS , •• ,m.,., ,.,., ,.,.,., .... ,., ,.,-~-,-,.,-,--.-.--.-.-

DiB.g!lilOB.ti:c: INotes .. _. __ ._. __ ._ .. _._ ... _. __ ._. __ ._. __ ._. __ ._ ... _. __ ._._

i!:~ine T,em,peql11;Jre ~nsoF $pealf.k;srti'O'l'is ~sble)

'li'il"a iTJalill.8!iS. Goonac.l:or:s l'<1I:ile) ._ .. ,.,.,.,., •• , .... ,., ,.,.

Oode 14 Teet (Part 1 of. 2) ~liJW ~rt) ._. __ ._. __ ._ .. _._

CI)([C 14 Test ~Part ,2' ,I)~ 2) UI(lw dl3Jrt) ,., •• ,., •• ,-, ._.-

4- "'19,' T·"I''I'1I<u~·..l,"", C·"'1'·..Ie 1,i!=, -- .. - .

• ll. II ~ ul!§p ~. ~ lll •• l •• : •• _ •••••••• I •• ~l3iil!l3.iI3.~!

Gen.sral ... _._. __ ._ .. _. __ ._ .. _._ ... _._ ... _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._

I:ntaka Air Tamp6:iatul'B S8n~o1i' ,_.,., •• ,., ,.,.,.,., •• , .... ,.

IDra>gn~ ... _._ .. _. __ ._. __ ._. __ ._ ... _. __ ._. . __ ._ .. _._. __ . __ ._. __ ._. __ ._

lJIii:!lg~jt liips .. _._ .. _. __ ,_,.,.,.,._, •. ,_, •• ,., ....... ,., ,.,., ,.,., ,.

Diag~iC NGle-s _ ... _. __ ._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ ._. __ ._ ... -

1'rirIa1.a Air TempIYa.-tu.re Sensor S~liOi:!oonS (~~ W!Ile' Harne$S CORIlIectJ.JI$ Clif.ll;ile) -_._ .. _. __ ._. __ ._. __ ._ .. - 'Code 15 Tes.t (Part ~ of 2} {llow ~hart), __ ._. __ ._. __ ,_, •• 'Code, 15 'fe!:l1: (P1.lIlI: ~ of 21, (rJr;rw ch;!lrt) _ ... _. __ ._. __ ._._-

, 41,~20 lr,o'lIJble· ICode ·16,., •• , •• t •• , •• ' •• ~.m .. ' .. ' ••.••.••.•

fi:enel""d.1._. __ ._ .. _._ .. _. __ ._. __ ._ .. _.\ .. ,_. __ ._._ .. ,_ .. _,_, ,., •• ,., •• ,., •• , ....

!;:a~ry \I~.ge _ .. _. __ ._. __ ._. __ ._ _._ ... _. __ ._. __ ._ .. _._ .. _. __ ._._-

Diagrnc:;IiEs _ ... _._. __ . __ ._. __ ._ .. _._. __ ._ _._ .. _. __ ._. __ ._ .. _._ ... _,_.,..,.

Dtagnoouc l)4ote!j; ... " ..... _._-,_. __ ._ .. _._ .. _. __ ._. __ ._. __ ._ ... _._'l,l'i,l'ire IHa.JinSS6 Connecl!Jf'S. (abla,)· _ .. _. __ ._. __ ._. __ ._.,_, ... ~e ~,e, TesI' (1':=.111' 1 of :2) ~ GhaJill _. __ ._. __ ._ .. _._. CtiltilIe Hi, T~' {Pad·-2 er 2). (lIOw ehai(l., •• ,..,., ... -,_.

4·.21 'liro&rab:le ClOd$$; 23 and 32' , .. , .. ,.

G811Sral __ ._. __ ._ ... _._ ... _. __ ._. __ ._ .. _._ ... _. __ ._. __ ._ .. _._ ... _. __ ._. __ ._ .. _. __

IFtornt iFIJCIIIi1ijccto:f' (C-ooe :&3) and! Rea_r Fiuel

Iinfedm (Code a2) ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ .. _._ .. _._ _. __ ._.

[:Iii1l~OOS1jeS .,., •• ,., ,.,., ,., •• ,., , ... ".,. ...... ,-, .. _._ .. _._ .. _._ _. __ ._.

OiB.@nosmc Mote;e. . __ . __ ._. __ ._ ... _._ .. _._ .. _. __ ._. __ ._ .. _._, ,_, ••. ,.,

'VIIiIe Hame!ilS ClDnru:'£fal'B. (ta.bJe) _. __ ._. __ ._. __ ._. __ ._ .. _. Code 23.132 T~ (PM 1 M 2, (1bW {:nru1) .,., ,.,., , •.

- Code :2:3.t32 Teal! (P.a1'1! 2 of:2). {lrm't dh8d~ _._. __ . .

4.22, Timub(l;e C'Od~l, .24 amd 25 ., .. , ... , .. , ...

G~raI .• , •• , .... ,., ,., •• ,., ,.,., ,.,., ,., •• ,-".,-""_._ .. _._ .. _. __ ._. __ ._ .. _.

Front l@nifJDn Ceil {C'oos, 2i11·) and Raar 19nr~iof1l

COIl ~C(lC!e 25~ ., , .... ,., ,.,-, ._._ .. _._ .. _. __ ._. __ ._ _. __ ._. __ ._ ... _.

[ijagn.osIlic.s. . __ ._. __ ._ ... _. __ ._. __ ._ .. _._ .. _._ _. __ ._. __ ._ _. __ ,_ .•• ,_u.,

DlagfIOstrc·Nme:s; ,_.,_. __ ._. __ ._.::-_._ _. __ ._. __ ._ .. _._ .. _._ ... _. __ .

Wi~ E-il8I1!1iElS!!i. CennecfDrE (liable' .. _ .•. ,., •. ,., ,., .• ,.,.,.,

Co(f.e 24/25 T~! (fl(Jlll mart) ._ .. _._ ... _. __ ._. __ ._ ... _._ _._ .

4.23 Timu'bl\e Code ,33, t •••• , •• , •• , •• ~ •• , •• , ,

Gelfi.iEir:IilI_._ .. _._ .. ,_, •• ,.".,.,.,., •• ,., •• ,.".,."., •• ,., • .,_ .. ,-,_ .. _._ .. _. __ .

Fuell?'Mfnp ._. __ ._. __ ._ .. _._ .. _. __ ._ ... _._ .. _._ ... _. __ ._. __ ._. __ ._. __ ._ ...

rugnlj(Ji~ ._ ... _,_.,., •• ,., ._, •• ,., •• ,., ,.,., ,.,., ,.,., ,.".,., , ... , '_,-"'.

Eiisgnnsti'i::: INbteoa .. _. __ ._. __ . __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ ...

Wire 1Taa~. GonMctvFS (l.a:tltc.~ ".,., ,.,.,., .... ,., e e ,_ •• Co~ es Test liliJW cliJart) ._. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._ ..

4.24· Trouble Code· 35, .. , .. , .. , , .. , .. , .

6afIBr<!lI ... _ ... _._ .. _._:.,_, •• ,., •• ,., ,., •• , .... , , ,.,., ,., •• ,., •• ,-,-_._.-

Tac'home{er ,., , •. _ .. ,-,._._. __ ._ .. _._ .. _._. ,_. __ ._. __ . __ ._._ ... _. __ ._.-

IDiIlt"Hno-stios; ._. __ ._ ... _._ _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._ ..

[liis.g:Dostii::' lNotes _. __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._ _._ .. _. __ ,.,.,

Wil"!3l Harness G'OOMC.rors tlabrtit) ,., ,., •• ,., ,.,., ,., •• ,.,c.ode 35 T,est mow chart} -_._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._-_.-

·<Ii-filD 4-5ii .<:~9D 4-stl 4..5.ID -di-5lllI o1!-511 4-52 4-53

41-54.· 4-54 4-~ 4-54- 4-~ 4-54 4-54 4-.55- 4-56- <'1.-.5·7

4-~. 4--.58: 4-5e1; 01--.5a. 4<59' 4-'60. 4-ti1

+62 lj,.fi2

~ 4-63 4-&i!. 4a65

~-€l6 ·4-66 .~-OO .4-fj7 ·4-&

MSI ,4.-6'9 .4-6,'9 ,4,$9 ·<:i~69 .i!!,·itl -4i~;;r1

4!.-12: ,.:iI~72 4.-·72 4l~'72 4k·n oiI!-.i'3 -41-74

G8lilaral __ ._ ... _. __ ._. __ ._. __ ._. __ ._, .. _._ ... _._ .. ,_._., ... _._ .. ,.,., ,., •• ,., •• ,., +--75

Caml.s~nc; Failur,s ._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._ ... _._. __ . ·4-7'5

CatlfI s~,ne Fai~.Ii\e ,., •• ,., .... , •• ,., ,.,., ,., .. ,., •• ,..,.,. .. m .. -, .4-75

[J(iaglMl&'lics _._. __ ._ ... _._ ... _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ ... _._. __ . ·4-7'.5

Dlagfll)S'1ic. r\tol)'tes;., ,.,., .. _,_ .. ,.,..,_._ •. _ .. _. __ ._. __ ._. __ ._. __ ._. __ . ,1'!!~1'S

Wi're Eilamn.e.gs. Gonn~&JrE (IIat4e, .. _._ .. _._. ,_ .•• ,_ .• _,_ ... , ·4i~·76

CoOe ~ 'II"e$~ (fan 1'1,,1Jt3; 'QDrTtiniJu:sI:f.'~ {lrow ,dh8~ _. .41-·77

CiJ'Ge :l{i lia{5~ (tan 'd~ nUl. ,I'fLInJ trIO", c.M:11). .".,.,' 4-,10

4.26, Trou'bl;' Code 44 ~.~.~.m.. 4-,791

'Giene1E1 _. __ ._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._ _._ _. __ . -'11-.]9

Bank Angle' SI31iVSlJiI" ._ ... ,_,_.,., ,.,., ,., •• ,., •• ,., •• ,." ... , ,.,.,' 4-79

Diegnostica; ... _._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ _. __ . 41-·19

LliagttlOS'Ii"t; IN'o'Iai1; .• ,., ,.," ,., .... , •• ,.,.,., •• ,.,., ,., •• ,., •• , ,... 4-,79

Bank Angle· ·Se~or 'Ilcrllta.ga {tabls) _._ .. _. __ ._. __ ._. __ ._._ -41-79

WiliQ It-Iaim~. CUilnae.b[nS l~a~,., ,.,_"", .. ,., .. ,., .. ,.,. 4-80

Code 44 j:e$t IjPart 1 i[j~ 2) if.IlDW mart}_. __ ._. __ ._. __ ._._ 4-31

Gode·44 Test ~.P\art .2' i[I~ 2) {ilow' ~rt)_,_~.,.,.,., •• ,.,. 4-82.

4,.27' Trouble Codes 52:J 53\!! 54, and 56, ·4-83

Gen.e'riEll _._ ... _._ .. _._ ... _. __ ._. __ ._ .. _._ .. _. __ ._. __ ._. __ ._ .. _. __ ._._ ... _. __ ._._ -4-83

ECM IF<tiuFIOI , •• ,_._, , .... ,., ,.,., ,.,., ,., •• ,., ,., .... ,., ,.,-, ,-,. ..... - 4-·133

4.28 ,'r'oultde' Cooe' :56; ~,~.~.~,,;.

Oen.e'lal _._. __ ._. __ ._ ... _._ ... _._ ... _. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ _._ .. _. __ ._._

Gam ~ Fii:IIilu~ _._ .. _. __ ._._ .. ,.,_.,., ,., •• ,.,., ,., •• , .... ,., ,.,.

I[J.I~niJB'lics .. _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ . __ ._._

oriillg~ic: NUl.~5 ,.,.,., ,.,., •• , •• , .... ,., ,., •• ,.,.,., ... , ._, ... ," .. _.-

Wire' Hamaea COOITIBCtor.s ttabla}_._ .. _._ ... _._ _. __ ._. __ ._

I;))Jje 56 (Part 1 of 2') {C]ow' chRrt}-._ .. _._. __ ._ _. __ ._. __ .-

G.o-da.56 (Part ,2' of 2) ~1!Jw OO\;lirt}_._. __ ._ .. _. __ ._._ _. __ ._

4~29 IElecl:aj'on~c Cont~cm M;odu Ie ., .

lRemooraJ •• ," ... ,_ .. _._.,.,-_._. __ ._ .. _._ ... _._ ... _. __ ._ ... _._. __ ._ .. _. __ ._. __ .-

Installation _ .. _._ .. _._ ... _. __ ._. __ ._ .. _._ .. _._ ...• ,.,.,., ,.,_, ,.,., ,.,., ,.,., ,.

~Inl Tahle fer EOM OanneotiJt" [1.0] (BlaDk). __ ._. __ ._._Pin, Table: ror EQM Gl)nroodOf l1 ~ I (Gray) ,-_._, .• ,_ ... -

~a.:30 Cam PO$illtiinn SenMIf a~nd IRotor

RalinlJlolaJl_. __ . __ ._. __ ._. __ . . __ ._. __ ._, __ ,_. __ , __ ,_, •• ,_, •• ,.,.,., .... ,., ,.

filemO¥;;iI_. __ . __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ _._-._. __ ._. __ ._. __ ._. __

Ins.tallaiipn _. __ ._. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._ _,_ .. _._,.,., •• ,., •• ,., ,.

41.;31 I'gnition Co'il ' •..... , .. , .. ' m ... .., .... "· .. ,,; .. ~

TroobleEihOa-ling ._. __ ._. __ ._ .. _._ ... _._ ... _. __ ._. __ ._ .. _._. __ . __ ._. __ ._. __

l~iliM C'tiiI PViimry Clrom 1i'e-s~.,.,., • .,., •. - ... - .. _._ .. ,_._ .. IgniOO'I1 Coil S<9oo:ndBIY Cirruit TesL_._. __ ._ ... _._ ... _._.

Tes.l Hesul:ls., , ... m,--·,,,,,-,--·-·--·-· ._. __ ._. __ ._. __ ._. __ ._ .. _._ ..

,lgni1:i:on Coil Sube.1ilution. . __ ._. __ . . __ ._. __ ._._ ... _. __ ._. __ ._ ..

ReFflI)·'!\aJ ., •• ,..,.,-, .. ., ... _. __ ._ .. _._. __ ._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._ ... _._.

Rsmo'i',al_. __ ._. __ ._. __ . ._ _. __ ._. __ ._. __ ._ ... _, __ ,., __ ,., •• ,., ,., •• ,.,.,

tn!1!~n _, __ ._. __ ._ _._ _. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ ... _._ ... _._.

tns.iBIaiion _. __ ._. __ ._ _. __ ._. __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._'"_,_ ..• ,_,

4.32 Oxygen Siensor , , , .. ~ .. , .. , .

GeneraJ ._._ .. ,_._ ... _. __ ._. __ ._. __ ._ ... _. __ ._. __ ._. __ . __ ._._-._. __ ._. __ ._. __ ._.

IR.Ef'Il.ovaI .. _._. __ . __ ._. __ ._ ... _._. __ . __ ._._ ... _. __ ._ ... _._ _,.,.,.,., ,., •• ,.,

'~ernov.al-._ .. _. __ ._. __ ._. __ ._ .. _._. __ . __ ._. __ ._. __ ._ .. _._ _. __ ._. __ ._. __ ._.

installation _ .. _. __ ._. __ ._. __ ._ .. _._ ... _._ .. _. __ ,_ .. _._. __ ,_, ,.,., ,., •• ,.,

4.33, EliiIlg'ln.e 'lempe\m~lIJr,e Sensor .

Elilgins, Te.I1i!J.Sf8J1UIiB Serlmr, G8IiIBl'""ciI_._.~_._. __ ._. __ ._ _.

1fIB1T1tI!/.all_._. __ ._ .. _. __ ._. __ ._. __ ._ ... _._. __ ,_~_,_.,., •• ,_, .. ,., ,.,., ,.,.~., i'rlS'lI1J13i1fofl , •• ,., ,.,., ,.,., ,_._ ... _. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ ._-_.

4-84 4-84· 4-84 4-84 4-1;14 4-85 a-ss 4~B7

4-89 4--S§' 4-:88' 4-!9Qi 4-'(;11;1'

4-'91 4-C91 lj,..!Q'~

4<'94.

~95 4-!9.5 4-$1.~ 4-9.5 4-95 .4-S5 US 4-96 4.-9-6 ·~6

~-97 .~ >\1-97 .4-97

4..fi, .t,j.$S 4-00 ,.:;J_

Pa:1ID9. Nu.

4.34\ Ban k ,Ang~B Sensor, .. , .. , , .. , .. , .. ,....... 4-1IDD

GeIi1Ieral " •.• _ ....•....•...••...........•..•..•.• , _ , .•... ,..... ...•. 4-100

Ramo,..<1II , •.•..•.•..•.• _ _ _..... 1\1-100.

Inst.;!!iaOOn _ _ ..•.• _ __ ....• 4-1QIJ

4J.35 Intale' Air Tem[per,ature SemSf.H' 4-1,01

G!cnetll:t __ _ _ __ _.... 4-1{11

FlBl'TlIJIiI'aIL _ •.•.••.•..•. _ ..•. _ •.•.••.•..•.••.•.• ".. 4~'1 0(1

InstaJllEifion _, .., _ _... 4-11J<1

4.36 Th,ro~le [Pq3iiitioni Sensor .........• ,.. '-,1[ 02

R6I1I,OYaI.............. <'I~ 1 oe

Inst.5!lIa lon _ _ ...• _.... 4·102

4.37 Coolmng Fan m,"" •••••••••• , •• ~.~ •• , •• ,.~.... 4-10G

Gerwl'a.1 r' _ •••• _ •••• _ " ••••• -...... 4·1 ro

R'eIiilOl,l';!l:I ~ _ ..•.•. _ •.• _ .•.• _ .•. _ •.•.••.• _...... 4,·103

lR5!aHa'iiOO _ _........ .•.•. 4·100

4.39, Fuel PlI.!Jmp ••.•• ~.~.~ •• , •• , •• , •••••••• - •••• '".~.~,~ 41-1 ft4.

ReI'1"lQ1.i'aI ..•.••.•.••.• _ .•.• _ .•.•..•.• _........ .•.•. .•. 400105

Repair a •••••••••••••••••• _ •••• _........ ••• 4·,,00

IFup-1 Pr,ees.ure RegulatOr' Rcpla.cellTleJll1'.................. 4-100

, ....

low 1Fu. Level Sensor R~laoamen .. _ , 41-106

'F"ooIIFi er Rapla.cem8l1l ,., _ _............. ,?-100

FUBI SoriBen RIl:placetment _., _............. 4-U11

Fuel Pump- ,Speeif~G ~ tlltOO) - ••............ _..... 4-107

Installation ..• _ ...•... ~ ..•..•.•..... _ _ __ ...•. ......• 4-1(19'

4.39 [fuelll'ar1llk Ve,!'n: Valw, , .• ~.~.~. 4-1',0

Gi;!nerral ..•... ...••.•. .•.•. 40111J1

R6iilwal _ ,.... ...•... 4-11 I}

1rt."1talll3.liiJf'i ,.,. •.. ...•. ...•.... 4-111J1

4.40 F'IJI el Cap' R.taini II1Q[ [R[I[ng •••••••• ".. ,4-11[ 1

Re,1lKJII<l1 "...... .•.•. .•.•. .•.• 4~ il1 '1

Irutc8Ha'iion ...••......•. ; " " _ _ •........ _ •.•.......... _.... 4-11 '1

4.4!,iIJ TIll'lottle' Body >BInd InmJke'

ManltolLd ." - _.m.m ~ _ _ .• , •• ~.~.~."' ~ 4-'1 '12

Gil3flElrai _ ..•.•• , •..•.•. -...... 4·112

R)erfililJl;l'.F.II _ .•. " •.•. " •.•..•.•..•.•..•.•..•. __ .•. _ •.•. _ •.•.••.• _..... 4-11'2

Repair , _ ....•.............•... _ _ , .....•.• ,...... 4-1';4

1hrotlle' Poaition SeflSJJt' _...... ~-114

4·11<'1.

[R~ir _ _ ....•..•.•..•....•....

Testingl_ _ _ '" •••••....•...... _ .. - .••... __ .•.... _ .

tnl:oi<LDalii)Fl •... _ _ •... _ •.••.•.••.•.. , .

4·115 4·,116

4.42 Inbl[ke Leak Tes'L., .. ' .. m.~.. 4-111

uemsllB.l _ , •.... _ _ _ _..... ,4-'117

leaK T,ester _ ....•........•........... , -_ ........• _... ,4-1' 17

P.~Ei l.i!i~., _ _ _ _. ,.. ,4~'1, 17

Te&"e~ ,Asee_nilbly ...•.... _ _ _......... -41-'1:17

Intc8kB Leak Tesl _ :. ,.... ,4~'111i$

41.,.43: AiirbQx .••• " •. ~.~.~.~.~ .. , .. _ .. _ .. _ .. '._.m .. '.~ .. ,... 4-119

Vsrd, Valve ".

G®nir&te,r _ _ _.

Installation __ _ _ •......•. , " .........•... _ •.

Vent Valve' " " " _ - _ _ •.........•.

Canister " .

[HOSI3i Ro!.J~ingl. , •........... _ _ _ •.•..•.• _ .•.•..•.

SECTION 51'"ELIECTRIIC Sl'ARlER

4-11:21 4-1:21 4-'1:2.2, 4-122 t'I-12.2: 4-1.2:3

5.1[ Speclllii,cations, ....• i. ,,~.'".'".'" •• , •• , •• , •••••••• ~ S~1[

SIMeli Sj:XldIlcatlons (laDle) •......•..•. _ _._ •. _. 5·,1

Sei"Yte WeaJ Umi~ (l8ble) . .•.•. .•... 5·,1

Torque V8.'lue~ .LOon ••••••••••••••••••••••• _ •••• _........ ••••• 5·:1

5.2 EIKt~ic Starter Systeml ' .. ' .. ~.m.~ .. '..... 5·2

General _ _ .•....•..•.••.•. " •.• ~....... ,5,-2

'Wimg m~r,<lms .•..•.•..•.•. , _ _ _............ ,54:

S1:arter Relay _ _ _ _. :;i.-2

Sta:rter ~nberloc.k ~ ~ n.... 5.-2

OparatiQn , •. , .. __ _. ...•. 5--2

5.3 SUt dln,g ~Syst:em lJiagnosis., , .. ~.~. 5-4

Di8f!lliD6.1ics .•..•.•.••••••• ., ".... . •.•. .•.• .•.• 5-4

Di<lgrlostlc Noote!l; 5-4

Starter T~ 1 _.... 5-4

StarUilr Tcsl 2: ,$ol'eDl;lld[ laidB ._......... ...•. .•.• 5-5

,SIi(!i rte r Teal! 3: Rela:~ (:1 i I;; k;S.. LOO •• no...... :5-5

S f2I roo F TE!:$l 4: Nc.1hln 9 CticIl;EL .•.•. _........................ 5-!13

Stc8.rtar Tesl 5: Still,rtCF ;$~lns.1But DoSB No:!: .Eng~ 5·7

$mtter Te.::l 6: Stcart!:ir StaII5 IX Spitl'::; Too SICWJI~' $- jI'

:5,,,4 StaM,er AclI'vartion Ci fCjJJJIits , •• , •• ~ •• , •• , •• , 5i"18

.........

,

,5-"9

5·9' 5·9'

,5-11 :5·1 '1 5·11 5·11

5-1[2 5·12: 5·'13 5·1:3 5·1:1 ,5·13 5·'14 5·,14

5·'15 ~-',:f!j ,5·:119

5-2:1

Hetliloval. •......•..•. _ .........••.•. __ .•.••...•• ~-11'9 Giansliil •••. ""," ••••.... _.... ...•. ...•.... !j~21

Hnapection .•..............••. i., , _ _. 4--119 Ol$a~~ •... __ _ •... _.... .•.•. .•... .•...••.. 5-21

Ilrlstalla lon, .. - _ •... _ •... _ ............••.•• '" .on.... 01-120 Assembly ••••.•.• " - ...• _ .•.••.•.....• ;........ 51"21

4.44 IEva,por,mtlve' Ernie_ions, C'O:MI'QI~,

C:alif,o:rnla Modells "' .. , .. ~., .. ~.~ ......•. ~ ••. , .. ~. 4·121

General.... ...•. .•.•. .•.•. 01-1:21

Troubleahoo1iri{l " •... _.... .•... 4-1:21

H8/OOVa! '.' .•.•. 4-1:21

,$,,5 mag nos11§{J')mu"bleeshoo'tin;g .~.m.m

Gal'leral .., .

VoOlliF.lg:e ~ropa _ '" _ .

,5.6 Starter Svste-rH 1[$$1I[l1gl., •• , •••••••• , •• , •• m

~Oil Mo~on::yd'-ef' Tests ........................••.•..•.•. , .. _ .

StBJilsr Rela)' Tcs.~ .•.. m.'············-···· _ _ .

Slal1er Current D:,raw Tast _ , _ .

.5.1 SI:~n1'er' ~.~.~.~ _ ".~.~,.,." .. , _.

~noov<l!1 , •• " , ....................................•. _ ....•••.

ies1ing Assembled SlBrlSll' uo_·_···· .•.•..•.•..•.•.

IFrEliij f!bJrlning Currel'l" Omw Test .....••.........•....•.•.

:$1a:rt.E'l SOlen!Jid _ _ _ •..• 0£0 " -

Solenaid PUlI·ln T,e!rt. _ ......•. _ _ ....•.••••

Solenoid [Ha&I·in lI'es;\ .

So Is ~\ll)id R:e.11"lm Te$1 _ ..

IDISEIs-aembty. [Inspactitlli aMi Rej:l;;ltr •.•.............. _ .

A.i!i,s:er'l'l'bl~, _ ,.

Inst:l.llal:ion _ _ .,. _ ....•..

5.S Sfa rter SoleImlGid .•. ,.+~~ ..... , •••• , •••••• ~.~ •••

Pa$liNO\, SIEClrilON 6"'1DAfilIEfrRANSMISSION

6., 1 Sjpeclth:::altlllQ(lfIs._ .. _ .. _ .. , .. , .. ~ .• , .. , .. , .. _ _ .. ,. 16-1

PFimaf'j' IDJii.ra S~tafiDns (tahla). ._._._._ _. __ ._. __ ._. i3- ~

Fi"nallDrii.re S~CRUQnS [(tattle) ._. __ ._. __ ._ _._ ... _. __ ._. 6-~

~l$siOn Sp<:6IitafiOFIS ~l<:iliiJ.e', ._ .•.. _._ .. _, ._,_. __ . 5-~

Wei: Clutch Speci;licafion8 (tBb'lEi) ._._. __ ._ ... _. __ ._. __ ._. __ . is-2

Wet. (.1urtch $pedjlc.atJ.oFi!;: ~ta~~-"'-"-'-' , ... , ._,.. ,mo' 6-~

TvrqW-8 V~IU!3:S .. _._ .. _._ ... _. __ ._. __ ._ .. _._ .. _._ ... _ ... _._ ... _._ .. _._ ... _. __ . &-2

16.2 Prilma:~' Ch_a:in .. _ .. _ .. t •• , •• ' •• ~.m •• '..,.","., •• , •• , •• _. 6-3,

GemeraJ "., ,.,., ,.,., , ,., •• ,., ,.,., ,.,., , •. __ ._,._._. __ ._ ... _._ .. _._ _.. &-3

R'ei.rnoval _._ ... _. __ ._. __ ._ _. __ ._. __ ._. __ ._ .. _._ .. _._ ... _. __ ._._ .. _ .. _._ _._ iJ,.,::I.

I?rirn~:ry !')ov.er __ ._ _,_, ._._ ... _. __ ._ .. , '"' ,.,., ,.,., ,.,., ,.,......... [ll-4

Prinlary- Chain ,ArljWS'tSf .. _._ .. _._ .. _._ _. __ ._. __ ._ _._ ... _._ ... _ 6-S

Installali'bl'll .•.•. .•.•. .•.•. .•.•..• [6-6

PllimBIY 'Co1ier.. __ ._ .. _._ .. _._ _. __ ._ _._ .. _._ _._ _. __ ._. __ ._ _ 6-S,

6\.3 ClIIuteh Release .IMeeh~nll:s_ml ,. 6-7

[Ii:saS~I.lI .. _._ .. _._ .. _._ ... _. __ ._. __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ ._ .. _._ ..

CleaJiiingl,and Ins;pectio:n . __ ._. __ ._. __ ._ .. _._ .. _._ ... _._ ... _. __ ._.

A.$sembi),' _. __ ._ .. _ .•.. _ .•.. _._ .. _ .•..•.

6,A P\~imary Drive1Cl!uICh , .... , .. , .. , .. ~ .. , .... , .. ,

G_elTisral __ ._._ ... _. __ ._. __ ._ .. _._ .. _._ ... _. __ ._ .. _._. __ ._ .. _._ ... _._ ... _. __ ._. __ .

Re~~~~:G~~:~~~.:::!.:~::::.::::~::::~:::~::::~::::~::::~:::~:

iPririiCill"'l ChaiWOri,.,.13' ._ .. _. __ ._._ •. _ ... _._ .. _._ ... _._ .. _._ .. _. __ ._ .

AsSEt_lntil'!( _._. __ ._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ ._ _._ .. _._ .. _._ _. __ ._ .

CIIJ~CIiIIPa~ .

l~aJl'alioo _._ .. _._ .. _._ _. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._._ _ _._ _._

16,.5 T1iaril5mli5ShDIiiII., •• , •• ~ •• , •• , •••••••• , •• , •• ~ •• , •• , •• , •• ,.

General _ .••. _ ..•.•.. _._ .. _. __ ._. __ ._. __ ._ _._ .. _._ .. _ 15-23

6..B Ca_se: DisaS$embly' For ,'ranSllfliti$$ionl

R:eilllilolYall ••• _ •• , •• , •• , ••• , •• ,..,.., , •• , •• , ••• , •• , •• , •••••• - •• _ .. ,. 1tii-:24

IRi'ght GrBn~ca~ iRemGV8IL ._._ .. _._ .. _._ ... _. __ ._. __ ._. __ ._ .. _._. $-241,

61.7 ,'r,l!IInsm!lsslrm Dlsa_ssembly, .. , .. , ... , .. , 6.=27

iransmiSSion ~d.1 FIt!1i'Ji LaR Cr,an~~ _. __ ._ .. _. 6;-27

Maimharfl' lDi'sassem'bIy_._. __ ._. __ . __ ._._. __ . __ ._. __ ._. __ ._. __ ._ .. _. Ei~

~nin@ rmtiIlllispcl3diDn ._. __ ._ ... _._ .. _._ .. _._ .. _._ ... _._ _._... &-3:2

GounTI:!lshaift OiSElBse:rnbty ... _. __ ._. __ ._. __ ._. __ ._ _._. __ ._ _. __ . ,S.-33

Ci'eeif!lng rulIillnSj)ceLiOn .•.•..•.•.. _ _ _ _._.. [6·33

A" ........... ' b~in c .. ' 0.4_1,

6J)i TIi"alifl$miM!iGO ~mJ _ ~I:r i.""i~' !UI--.;!I

Main:shaft Assambl:f _ .. _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._. __ ._ ... _._ 6-3;,!1,

'i)ountelfShafl; Assembly.. .•.•. .•.•..•.•. .•.•. .•.•. .•.• 16-35

18.9' Mai_" Drlive Gear .'""~ .. , .. , .. _ _ , .. ~.~.~ .. ,. '6-36

R4;1~1 _. __ ._. __ ._. __ ._ .. _._ _._ _. __ ._ ... _._. __ ._ .. _._ .. _._ .. _._ _ .•... _ 16,36

Diaaasembly . __ ._. __ ._. __ ._ _._ _. __ ._. __ ._. __ ._ ... _._ ... ~._ ... _._ _._ .. _ 6-:$;'

A~~ ._ _._ ... _. __ ._. __ ._. __ ._. __ . ._. __ ._._ _. __ ._. __ ._. __ ._. __ ._.__ 6-.37

Insl)f.lllallol'1l _._ ..•. _ .. _. __ , _. __ ._" m.·.. !l}-::'j7'

6;.10 It',an$!M i$$ionl Ri~ght GalSe

Bealrillngs., .. , .. , .. ~.~ .. , .. _ , .. , ..•.. , .. , _ .. _ .. , .. '"",. 115i-39

IF! eflil o-vaI ..•.•..•.•..•.•..•.•..•.•..•.••.•..•.•..•.•..•.•..•.••.•.•..•...•.•. e.r-39

Im::taJlaficm ._ ... _._. __ ._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._ .. _._. __ ._ ... _. __ ._. f;!.-:S9

MainEihsH Sth Gsar 8a!I Be.aring .. _. __ ._. __ ._. __ ._. __ ._"._. D~

GollllibBr::ihaH Mas~ Bearing ._._ .. _. __ ._._"._. __ ._. __ ._. __ . 6~

$11ilit j1!IruFn N~la, 8eating _._. __ ._ .. _._ .. _._ .. _._ .. _._ .. _._.. 6-\39

IS. ~I ill Tli'aniSmllssl:01lil ILel: ,CtI"

ti:!'.·_AI.11

B~_r:ir'i,gs , •••• , •• , •• , ••• , •• , .. , , •• , •• , •• , ••• , •• , •• ,. D "f

IRan1ow.1._._ .. _. __ ._. __ ._ .. _._ .. _. __ ._. __ ._"._._ .. _. __ ._._ ... _. __ ._._.... .•.• 16-41·1

Mfll Fi S h art and CutifI'tGFSfiillF1: B 13 crRn 9 a _. __ . _. __ . _ ... _. _._ _ €i-4 ;

.shift Drum Buahing _. __ ._._ _. __ ._ .. _._ .. _. __ ._._"._ _. .•.•..• 6-41

lnstallatlen _. __ ._. __ ._ .. _._ .. _ , •.•.. _._ .. _._ .. _._ _. __ ._ _ 6-,il.1

IM'Uin~h~lft and G!J~: IBeamgs_._. __ ._. __ ._ ... _._. 6-4 ~

Shillt [l!rum IBushinQl_._. __ ._. __ ._ ... _._ .. _._. __ .,. ._ ...... m •. a._. 641

6.12: Tiralrnsml\ss(lon IliiIistaUDti'Or:!ll ~ •• _ •• "' aa- 6-412'

l'n~all9rtl'on ,. •.•.••.•. " .•.•..•.••.•.••.• u_._. ,_._ ... _. __ ._. __ ._. __ ._ ... _._ ... _. ,6.-4:2

...__ dI .... ...~ hh.r I'" }I,"""

ShatSF FO_ltril:I, an' .:.rum ~e!'1'i""J' _ _ •. _._... "' +n '"'

l!'WaJ~ IRigttrt Cr;rln~ .. _._ .. _._ ... _. __ ._._ _. __ ._. __ ._ .. _._.. 1ij-45

16.113 Sh iftte:Ji' Shaft Iinstallation ., .. , .. , ... , .. ,. 6-46

IlMif a II ali Ofll . _. _ ... _. __ . _. __ . _. __ . _. __ . _ .•. _. _ .. _. __ . _. __ . _ .• _. _ ..•. _. ••••• •••• iB-4]6

6.11,4 Tr,ans!mlsslol'!ll S;procket .~.m"i_.. ••• 16-.4'7

IRe.rnGvaI ••. _ .. _._ .. _._ .. _. __ ._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._. __ ._ .. _._ .. _._ .. _ 1ijl-¢7'

inataJIlstion _. __ ._. __ ._ .. _._ .. _ ... _._ ..•.•..•.•..•.•..•. ,.._ .... _ .••. ._._ .. _ 6--48.

SECli110N 7 .. iEI..E,CTR_ICAl

cS-111 [13·-·11 [6-12 Ic-·'18 16-16 6-2tli

7'.1 Sjpeclflcatloli1li9 ., .. , .. , _ '''~''''',i •• i, •• i.

Ba1rery {l<ilita} .. _. __ ._. ._. __ ._ ... _._. __ ._ .. _._ .. _._ _._ .. _. __ ._. __ ._. __ .

Spark !Pll.lg!!; !ll:;iI;Il'e) _. __ ._ .. _._ •.•.•..•.••.•..•.•.. ,_._., •. _ .. _._ .. _ .•..

AI~l!!rOOo1J:ili {foIble) . __ ._. __ ._ ... _._. __ ._ .. _. __ ._. __ ._. __ ._. __ ._ _._ .. _._._

Regura'bJt" (!sbl'e) . __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ _._ .. _. __ ._ .

IgnltJ{Jn CcilllRes!sta11lOO {lat*,,} .. _ _ _._ ... _._ .. _._ .. _._ .. _._

EI!3dliiru:1 System (lab6a) . __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._. __ ._ .. _,_

Eiulb C-hal'i (:tab"ie) , •. _ .. _. ._._ _._ .. _._ _. __ ._. __ ._

Torque 'V'aluas_. ._._ _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _ . ., ._, ....

1,.'2 Ilg-nl'tlon SfS·,tem , .. , .. , .. , .. , .. , .. ~ .. , .. , .. , .... ,,~.~

GeFiel3i . __ ._. __ ._ .. _ _ , _._ .. _._ _._ .. _. __ ._. __

liri:lUblashOO'lin@ ._ .. _._ .. _._ .. _._ _._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ ... _._.

1.3 Ilgll!ilitionlHe-adlllight lKey' Swi~h .. , .. ,

GansliRt ._.:~._. __ ._ .. _._ .. _._ .. _. __ ._. __ ._. __ ._ ... _._ ... _._. __ ._ .. _._. __ .•..•.

Ignttro/ll tGey Swi~m ~~~ (t-.oibla) ._._ ... _._ .. _. __ ._. __ . 'In;iU(a1Df Msl'kel'B (table) ._. __ ._. __ ._ .. _._ .. _ .•.. _,.., •.••.•.•..

ReFfJIJ!o\aI ••••••••••••••• _ .••••••• ,_ ..... _. __ ._ ... _._ ... _._ .. _._ .. _._ .. _._ .. _._ ...

c\i~!3mbly._. __ ._ .. _._ _._ .. _. __ ._._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._ ..

r AS!lemt;.1y _. __ ._. __ ,_'" _ .•..•. __ ._. __ ._. __ ._. __ ._._

loo'aJfl3.tioo ._ .. _._ ... _._ .. _. __ ._. __ ._. __ ._. __ ._ _._ _._. __ ._. __ . __ ._. __ ._.-

7.4, Sparik PI:ug Calbl'e5, , , .. , , _ .

G~l!Ie.rHI _._ .. _. __ ._. __ ._._ .. _ ...... _ ... _._,,_._ ..•.•..•.•..•.•..•.•..•.•... _ .•... _ ~..a1._ .. _._ .. _._ .. _._ .. _. __ ._._ ... _. __ ._. __ ._. __ ._ .. _._. __ ._ .. _._ .. _._ .. _

InapEdian.. __ ._._L. __ ._. __ ._ .. _._ .. _._ _. __ ._,._,_", .

IflSMlIalion, •.. _._ .. _ ... _._ ... _._ .. _._ .. _._ _._ .. _. __ ._. __ ._._ _. __ ._. __ ._. __

Spark PlUg CaNes; iltBbf.e) _._ _. __ ._ _._ _._ .. _._ .. _ .

7'-'1 7-1 7-1 7-1 7'-1 '7-1 7-1 '7-1 7·,2

1-3 7-.3 7-;.1

1-'5, 7-5 7-5 7·5 '1"-6 7"'7 7'-."7 7'-1:}

7-9

7-9[ T-!il' ;r-m 7-'.[0 7-10

':.:1

Ih~Na_ 7.5, Stauter Interlock ...... , .. , .. ~ .•.••• ,........... 7-11

Ge'IiSral .. _._ .. _. __ ._. __ ._. __ ._ _._ .. _. __ ._._m ,_ _. __ ._.__ 7-1 ~

Starter CllfCun __ ._. __ ._ _._ .. _. __ ._. __ ._ _._ .. _._ _ .. __ ._. __ .. _ ..• ,n 7-11

11g,nitit:liR Circuit _._. __ ._ .. _. __ , _ •. _ _. __ ._.__ 7-11

SlFlrrer Irner10cK 'IFn.')Iu'ble.shootil!l,g i(mIii6a}-_._. __ .. _. ,.,.. 7-11

Ois,gnoeti.CEI _. __ ._ .. _._. __ ._, _ .. - .• _._ .. _._ .. _ .• _._.__ 7-1:2

Ignl1ln'n Tea:~ (iflO'N msf1j)_. __ .. _. __ . __ ._._~ ...... u •••••••••••• __ 7-1,S.

:8trJJi'I:6lr licsn ~PM 1 oC 2) ~flfWl ma~ __ ._. __ ._ ... _._ .. _.__ 1~1 a

StaJrter liest (P,BrIi 2: ai' 2) (IlOO dlIa"' "_._._:. __ ._ ... _ .. _ .. _ 7-14

Tcsl:ilTl1JlA:el;llaoemenJ' __ ._. __ ._. __ ._ _._ .. _. __ ._ .. _._ .. _._. '_m..... 7-1 g,

Side Stand Swt1cl:J .• 1.. __ ._ .. _._ _ __ ._ _._.__ 7-16,

c:luroo.h SwitCh .., •.• m."._.-_._. __ .- .. _. __ ._. __ ._ .. _._ _ 1-161

Ignlllon R'e'la1t ._ .. _._. __ ._ .. _. __ ._. __ ._. __ ._ ... _,_ •. _................... 7-17

Ks)' ,sw,-Lctl ReI.1!J1' ••. _._ .. _. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._ ... _._ .. _ 7~17

r.hin Fuse ._. __ . __ ._. __ ._. __ ._. __ ._. __ ._ ...•.•..• " .•.•..•.•..• _. __ ._. __ ._ 7-17

I:JIiittdQS .••••••••• "t ...... __ ._ ... _._. __ ._. __ . __ ._. __ ._._-.-. __ ._ .. _. __ ._ .. _.- 7~1 S

1,.6 Clharg'in,g SySI:em , .. , .. ~ .•. _...... 1-19

Gene'lal . __ . __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _. . __ ._ .. _, m......... 7-19

JiJ .• srmaiJ:lij- _._ ..••••••••••• u •••••••••••• " ._. __ ._ •• _. __ ._. __ ._. __ • ._ 7-1 £lI

1.I'000~ge FlegulBtOF _._. __ . . __ ._. __ ._. __ ._ .. _._ .. _. __ ••. ••.•. ••.• 7,-19-

TrOObl~tlOO'ling , _._ .. _. . __ ._. __ ._ .. _. __ ._. __ ._. __ . . __ ._._ 7·19

8a'ltsry_. __ ._. __ ._ _ .. _. __ . __ ._. __ ._. __ ._ u ·._. __ ._.- i -,19

WiFing _, __ ._. __ ._ .. _._. __ ._ _. __ ._. __ ._ .. _._ _. __ ._._ 7·19

V~ge IRegulBiDf Inspedioo __ ._ _._,...................... 7-19

Test (P".ut 1 of 2) tllOW cn.art) ... or;-'--'-' ._._ ••• _._ ••. _. __ ._._ 7-20

T,cS! (t''a11: ,;r,: Q'f 2.) filDW dlartk-.--._. __ ._ ... _._ ... _. __ .• , ••. _.. 7-~1

T8SiI·in9l __ ._ .. _._ .. _. __ ._ _._ .. _. __ ._. __ .. _. __ ._. __ ._.. '7'-23

Vdlta:ge IAegula;cm B.leed Ti3<5~ .,. _,_. __ ._.. '7'--23

Milliampl!e~e' j)Ja'W Test ._._. __ . __ ._. __ ._ _. __ ._. __ ._. __ ._ .. _._ .. , 7'-23

Total QUI'sn IDla,w Tes'l. _, •.. _,_ .. _. __ ._. __ ._ .. _. __ . 7'-23

CUFofe'llt and VQlt?ge, OillpUl: TEGli _ ... _. __ ._. __ ._. __ ._~..... '7'~

Voltaga Outpul T85li _. __ ._, <00" ,_._ ..• _._ .•• _. __ • ]'-24

S'latOIi' OhecK .•.•. · ... or ... --.-. __ ._. __ ._ •• _._ ... _. __ ._ •.• _._ •• _. __ ._. __ • 7~24

AC Ou'tpl!Jt: Cbedk. ._ .. _. __ ._ _._ _._ <00 _,_. __ • 1-25

7.7 Alte:mat:or , u~.~ ••• ~ •• , •• , · •• · , •• ,. 7-2ti,

ii=teIlilDVEI liIDi':saase rnh I y _ .. _. __ . _. __ _ _. __ . _. 7-26

A"'rJ~ ,_, .. _._ _. __ ._. __ ._. __ ._. __ ._ _._ .. _._ .. _. __ ._ .. _._, .•. 7-26

:stalor _._. __ ._. __ ._. __ ._ .. _. __ ._. __ ._. __ _,_ .. _._ _. __ ._. 7-26

claourmg ilFld Inspe.o1jon _. __ ._. __ ._. __ ._ .. _ .. _._. __ ._ _._ .. _. __ ._. 7-V

k!*!mblyilnEltallBtkm _. __ ._. __ ._. __ ._. __ '.m , ,_, __ ._. 7-27

'1.8 Voltage' R.le.!g!illlalo.li' •••• , •• ~ •••• ,." •• , ••••••• u

Genera •. _._ .. _._ .. _ .. _._. __ ._. __ ._. __ . __ ._. __ ._. __ ._ _._, .

Ramo ... aI_._u •.••.•.••.•.••.• u ..... _,-_._. __ ._ .. _. __ .-. __ ._. __ ._ _._ _._ ..

In~lIaOOn _._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._ .. _._ m -

7-28 7-28 7-28 7-28

7 in. B: ..,.,-, .' 'Ie' JbJ'l' .

rc;;i1' QIIIJIC,1')I' a ,~e.5." •• ," •••••.••••.•• , •• ~,~,~.~ •• , •••

7-:29

Fflsl'Tio· .. ar. .•....•................ , .. __ ._ _. __ ._. __ ._. __ ._ .. _._ _. __ ._. __ ._.__ 1..;28

In$ta'IlBtlon _._ .. _. __ ._._ _. __ ._. __ ._ _. __ ._ .••..• m _._ •• _._ _ 7-:291

- 7'.,1I[t11 BaMe"II'l' .· .. · .. ,.i~i~.~.~ •• ,."' •• · ••••.•••••••• ~.~ •••• ,. 7-,3.1

GJeFlent'l .•... _. __ ._. __ ._. __ ._. __ . . . __ ._. __ ._ ... _._ _. __ ._"._.:. .•.•..• 7~1

BB.ttery Eled~ AfllJjot~s ~la~}- -.- .. _. __ ._ ... _._ .. _ 7-.31

eam,ct'y T~lng.-,- .. _._. __ ._ .. _. __ ._. __ ._ .. _. __ ._. __ ._ _._ _._ .. _._ .. _ 7-~~'

VDtmeter Tesll_ .. _._ _ .•.. _. __ ._. __ _ _._ _._ .. _ 7-32

LIJ'tl(iI Test •.•..•.•..•. _ .. _. __ ._ .. _._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ .. _._ .. _ 7-~

Votlmetar T~ (laMe) ,.u •••••••••••• "'_. __ ._ ... _._ .. _._ .. _. __ ._ 7-;3.2:

Battery i.ood Tesc {.Ie) ._ ... _._ ... _. __ ._ _._. __ ._ .. _. __ u. 7-.s2

Oi'soonnecciiJl'II 8Jil!llI RaliTI!lIi'BII __ ._. __ ._. __ ._ _ "]-83

C~ning BDIlIlnsp!3CtkHi . __ ._. __ ._, _. __ ._ .. _._ 7-83

xll

Ba;:~~=~~_:~:~~:~:~::::.::::: :::::::::::::~:::-.::::.:::::-.

Charging Balt8l}r' - .. _ .. _.-. __ ._. __ .. _ _. __ ._._ .. _. __ .

6aJtery Charging Fk""lt8:ElTTunes {!iiilif0) •..•.•..•.•..• ,-_.

BstIscy Qablsl Rout'ing •..•.• m .. -'- •• _.-.·._. __ ._. __ ._. __ ._. __ ._. __ •

BatIei}!' ID$I:'slIa'lioo and lGoonl3e'OOn, ,- .. -. __ .

Sl:J;J;;raga' _, ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ ._ .. _._u •.

7-341 7-34 7-34!, '7-S5 1..:35, 7-:35 7-~i3i

'1 ~ 1111 Headl'lg"hf ., .... uu ••• '".~.~ •••• , .. , .. , .. r .... "]!.~.~ 7~3'1

6anl3t"<fL_.,_ .••.•..•.• u •••• ,-,,-,--_._ •• _. __ ._. __ ._. __ •• _ ••• _. __ ._. __ ._. __ ._.. 1·37

Hep-..dllg t Buloo. __ ._. __ ._. __ ._ .. _._ _._ _ .• _ , __ ._. 7-37

Removal _. __ ._._ .. _ " ••• " _._. __ ._ _. __ ._. __ ._. __ ._.. 7~37

~ ..•.••. _ _._ .. _. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._ .. _._. .•.•. 1-36

1,112 Tall Lamp •.•. ".".~ , .. ' .• ~.mi~.~ 'u... 7'-39

ReIn01l"r:!ltDi$2l.~ty .m ..... _. __ ._. __ ._. __ ._. __ . . __ ._. __ ._.__ 7·39

AssenlbIylIllil!i11a1a.1ioo __ . __ ._. __ ._. __ ._. __ ._._ •••.••.••.•. , •.•.••. _._. '7-·00

1.13 TI!IIrn Sfgllnals,.~.~.~ .. , .. r •••••••••• "'.""m'~'" 7,'-4.0

Re:ri1i01.fa1 . __ . __ ._._ .. _. __ ._. __ ._ .. _._._ • .., ,,_,_. __ ._. __ ._ _ "-<'iI·O

!3UltIs _,_ _. __ ._. __ ._ _. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._. __ ,_... 7'-40

Froot ._ _._ _._ _. __ ._, ._ , .•.• _._. __ ._ _._ .. _. __ ._ 7-40

f:ie'aJr _._ .. _._ _. __ ._ _._ _. __ ._. __ ._ _._ .. _._ _._ no .. -.- 7-40

IRSJaliatioo ..•.•..•.•..•.• no _, ._._ •• _. __ ._. __ .• _ •• _. __ ._. __ ._. __ ._ 7'""12

Front . __ ._. __ ._ ... _._ ... _. __ ._. __ ._. __ . __ ._._ _. __ ._. __ ._. .•.••.•.••.•.••.• 7-42

RS81_. __ ._. __ . __ ._. __ ._, __ ••• , , ._. __ ._. __ ._. __ . ._ 142

'7.'14, 'lilJlin 9iig na~ Fla.sher ,~.~ .. '"~ ".. 1043

Rcfl'l4y .... al _._ _. __ ._. __ ._. __ ._ _._ .. _. __ ._. __ ._ _. __ ._. __ ._, .•.••.•.•. .•.• 7-4::'3

lllE'lEllailiIlllfl ,_, __ ._. __ ._ .. _._ _. __ ._. __ ._ _._ _ .. __ ._._ 14.3

'7 :'15, Hlandl~alj" SWlb=1nes , .. ~ .•.. , .•. ~."'...... 7-44

Rama'i'al _. __ ._ .. _._. __ ._. ,_._.,_ .• _._ ""._ _. __ ._. __ ._. __ ._._ 7-4-41

Right SI:Ge, ._._ .. _. __ ._. __ ._. __ ._ _._ .. _. __ ._ _._ _._ ... _. __ ._. __ ,_.. 7~,

left Side ._ _._ _. __ ._. __ ._ _._ .. _. __ ._,_ on •••• · ••••• ·.-._.. 7--44

tns'lalaliUn ,_. __ ._ .. _. __ ._. __ ._ _. __ ._. __ ._ _._ _._ _. __ . 1-45,

IRi'@'ht Side _. __ ._. __ ._. ,_,_ .. ,_,.uo ,. ·._.·._._.·._. __ ._. __ . 7-4S

lL,e'i't Sidle . __ ._. __ ._. __ . . __ ._. __ ._ _._ .. _._ .. ,_ .• "... .•.•. 7-4.50

7.,16 Sipeeolomele'r SensO'r ' ....... " .. ,....... 7~46

i

f!lamo'l'.iiLI ••.•..•. _, .. _._ _. __ ._. __ ._. __ . __ ._ .. __ ._. __ ._. __ . __ ._ ... _._. __ ._ .• _, 7~8

In9'l:allatio.n _. __ ._. __ ._ _. __ ._. __ ._. __ ._. ,_._ _, __ , •. ,_._ _. i~5

7.,17Ins."tirumenlt Mlodtlilal.~" •........ u.,".~.~ '7~47

Gicncm ... -._ .. _ .. _._. __ ._. __ ._ .. _._ _ .. __ ._ _._ .. -. __ ._ .. _._ .. _ .••. _ ......

RamC'ilaJI ._._ .. _.1 _.-_.- -.-_.-. __ ._ _._ _._ _. __ ._.

in~Ut'IIf.ltion __ ._. __ ._. __ ._. __ . __ ._. __ ._. __ ._ _._ " ••• n-·-·

Ch e·c k .. I •• I •• I •• III II III II III ii ii:1 iI-!I! !I !!!!I !ll1II!_ ••••••• [ •• ( •• I ..... IIl.IIJ.IIJ.IIJ.-=. •• - •• -.

GenetttL::, .. _._ .. _. __ ._. __ ._. __ . __ ._. __ ._. __ ._. __ ._ .. _._ .

Ti3<5.ring .. _ .•..•.•..•.•..•.••. m •• - •• -· __ ·_· __ ·_· __ ·-···_· __ ·_···_· __ ·_· __ ·_·_-

SpeadOfin!3,lSIT Operafion T0SII, .m _ _._ _. __ ._. __

SpcedOOleler. "Ir e$t HreqUe'l'lCY (tablel'_._. __ ._ .. _._ ...... SpeedD4llilatar. Needle SM;;e:p TIil:St ..••••.•. , .... ,- .. -._._S~dOt1i'lI!:ol,Cf Sensor i1e$t._. __ ._ .. -.- .. _ .. __ ._ .. _. __ ._. __ ._. __

S~fIfII1elBf Test CllBrt 1 CflowcharlJ) .•••••••.••••••• SpE!edomBi8t Test; Chart 2'A (flCiwdhaJ1) _. __ ._. __ ._. __

S~.omets Test cmrt 2B (Ilow CfKlltt~ on.

7-41,7 7,-4.,7 7,-4,7

7·48 743 'jL4S

'-48 7'·46 7-49 749- 7'-00 ,]'-51 7'-52

~Ii!iNOi.

'7.'19' Tachometer P'eHorman:ee Ch:Mk 7,··53 AJPPE NDI'CES

Ganar:aJ _._ _._ _. __ ._. __ ._. __ -.- .. _._. __ ._ 7-53

1I"e!;t1ing ._. __ ._._ _. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._. __ ._. __ ._. __ ._ .. _.. 7,·53

[lipel'illiDI'ii Test_._ _._ -.--.-.--.- 7-.&3

j':;IchOllTIe;!e~ ,;i1!;DaJlr,ai::1( TolemlilDM ,amd

CIJFW'aISiIJfi5 (t-olbli31} m ••••••••••••••• -.- •• -.--.- 7,-5.3

sweep Teat,.. .. _._ ... _. __ ._. __ ._ _._ .. _._ ... _._ .. _._ ... _._ ... _._. .•.•..• 7-54

7 .201 H\D:~nl.~ .. , .. , ,"~.~.~,,; , .. , .. , .. ~.~. 7,-55

'Glene.r;8I_._ ... _._ ... _._ .. _._ .. _._ _. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._..... 7-55

R:e~J •. __ ._ .• , ., •. .., -,--.,.--.-.--.-.--.- 7-.55

i~aJla1Ioo .' _.-.--,- .. _. __ ._. __ ._. __ ._. __ ._. __ ._ _. __ ._. __ ._. __ ._ 7,-55

Troubl.ealilootDg . __ ._ .. _._ ... _. __ ._._ ... _. __ ._. __ ._ ... _._ .. _._ ... _._......... 7'-!)i;)

7.211 IN'e:umalll'ndicaltor Siwiit:ch,,,mmm... 7,·57

Gel!ler-al ... -.--.-.--.- ... -.- ... -.- .. _._ _. __ ._. __ ._. __ ._. __ ._. __ ._ _._ _. __ ._ 7,.5,7

T~in9l1._._ _. __ ._. __ ._ .. _._ _ -.--.- 1-.5,7

R.'ernow'\llnsW!aI;lQn _._. __ ._ .. _._ _._ _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _ 7,.6,7

1.22 IMaill!llF'~_ 8!'1l,d Fuses ... , .. , .. ~ .. , .. ,...... 7~5B

Gene.ral .. _._ ... _. __ ._. __ ._. __ ._ .. _._ .. _._ _._ .. _. __ ._. __ ._. __ ._. __ ._ .. _...... 7-5e1:

li"uOO$" ••••••• - •••• --.-,--.-.--.-.--.- -.- ... -.--.-.--.-.--.-.--.-.--._ ... _ 7-58.

Mailll Ihuaa ._ _. __ ._. __ ._. __ ._ _._ _._ .. _._ _ - .. - 7~s.a;

1.23 IMain Wij!re Harn.$S$, ,"~.~.~ •. ;........ 7-5'9

Gene:r-al ..•.•..•.•..•.••. -" •.•. --.- ... -.-._-.- .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _ 7-691

R'en1.oVaI _._ .. _._ _. __ ._._ _. __ ._. __ ._. __ ._. __ ._ .. _._ .. _. __ ._. __ ._........ 7-591

1n.slBllialiQriI .., •. -.,.,.-.-.--.-.--.-.--.-.-- ]...16-'1

7.2,4 Sp:rockiet Cover WI rilng , ... , .. , .. , .. ,.. .... 7-'64

Gan6if8l1. __ ._._ •.•..•.•..•.•..•.••.• );; •.•..•.•..•.•.. .,- ... -.--.-.-_.-.--.-.-- 7-64,

,14.111 Tools ., , .. , .. ~ .. , , , .. , , .

A-1

B. ill Amlp, MultUock: Elecitiiln1cal

,CO'l!1n.ectO{li"S ""u~.~ •.. ,· .. · , .. , .. , , .. , .. , .

H~ ~Pin Temruinal'::;,_._ _._. __ ._. __ .•..•.•..•.•...•

IMllFJlllng ~el).\~ln TemWliEiIB . __ ._ _._. __ ._ .. _._. __ ._ .. _._ ... _

GrWiipjn 9 IIMil! rid e 0011 S .•...•.•..•.•..•.•... "'" .., •.•..•.•..•

8;..1 18-1 IB-1 IEH!I.

8:.2 lJeumch IElecllii~1 C'OnneclttOr,s .•

61!!t1ct,a1 _ .. _._ _ .. _._ .. _._. __ ._ .. _._ .. _._ _ IB-.5

R~iaaEB8.riilingL.--.-.--.--.-.--.-.--.-. __ 18.5

Ren!QV!~nst«lllngl Sook$-.--.--.-.--.-.--.-.--.-.--.- -.-.-- IB-S

IRBln~nstaJlingllflili'll!:i .. _. __ ._. __ ._ .. _._ •.•. _ •. _....... .•.•. .•.•..• 16-6

AS$em~I!JSball!!'1.g ._. __ ._. __ ._ .. _._. __ . __ ._. __ ._. __ ._ ... _._. __ ._.__ IB-7'

Cml!i'ing In.strucOO.nG ._. __ ._ ... _._ ... _. __ ._. __ ._._ ... _. __ ._. __ ._. __ ._ ... _ 18-8,

8·.3 P,B'ckam ElectJri~CI1I'Cc:lnn,9tcilrs, .,. 8--1 II)

Gel16:i8l1 . __ _ -.- -.- -.- .. - B-Hi,

lP,ull-lo-Sa9't T18l'1Tlinal:i •... _._. __ ._. __ ._ .. _._ _. __ ._. __ ._. __ ._. __ ._,,_ B·11

Roefl1lQVing e:(tE!m;;.1 L=it.l;:h Tlifle _._ _._ ... _._ ... _. __ ._. __ ._.__ B-'. '1

lBe.lsJq lE:dBfmlllatm T~ .. _. __ ._._ .. _... .•.•..•.••.•.•• (!':'-11

IPusJ'I"M-Seat iermdnals .,_ .• _._, __ ._ .. _._ ... _._ ... _. __ ._. __ ._. __ ._.__ B-'l:2

Re~g Push-'l-o-Seat Terminejs .. _. __ ._ ... _. __ ._. __ ._.__ B-1:2

1rns.'aJ1intIIPuah4o-SF.la'l Terminals .•.•. .•.•. .•.•. .•.••.•.•• lil-12

Crin1~g Instn,Jatit;lIii!l; ._. __ ._. __ ._. __ ._ ... _._ ... _._ .. _._ ... _. __ ._. __ ._ ... _ B-1.S.

81 .. 4 IEleclmrlml !Cofillneci'kuis •• , •• , •••••••• '.lOOm 8--14

Genet'$1 . __ ._. __ ._ ... _._ .. _._ ... _. __ ._. __ ._. __ ._. __ ._ .. _._ ... _._ .. _. __ ._. __ ._.__ B-1<1i

Eladri~1 Gat'meelllF aiiId ILocatiUFI T®le' {tatJ!e) .-,. ~14

81.5 Iindex tOI 'WlirillPlQI Diagnlln8, "'"., .. ~ 8--116

C\.11 Metric ICoDv,ersions, .. '.m ' .. ' •• m.~ c-- 1

M'e1ric Con .... eraiona {tab'la') ._ .. _. __ ._. __ ._. __ ._. __ ._. __ ._ .. _._. G- ~

C;~2 IF'astener iOliqjue, 'Val ues ,".", .. ; .• ~.~... C"-2:

Eng,liah,lorquB Valuei3,_._. __ ._. __ ._ ... _. __ ._. __ ._. __ ._. __ ._. __ ._. G-2

MlBIJ'irt irtlf'CjUJfll V<l.1ues ~)" •.•..•.•..•.••.•.••. - , 1)-:2

IDI,.1 IHose almdi Wi~e R:omi 1'19 .... u,'m~.m iD'-1

.....

I'

NOTE,S

1

!SUBJECT

'1_1 G!3neral __ , , •• , , . _ '" .... __ .. __ ... __ .... _ '" .. __ . , , •• , , , - - .. - - - .. - - . 1-"

1_2 A1.~id ~'eqt.¥r.emeJi1t3 __ .. .. __ " . , •• , , . - '" .. - - '" .. - - '" .. - - .. - - '" .. - - '" 1·2

'1.3, Car,s m Mold'Bd-in-Ctl&Ur Body !Panels __ '" __ .... _ ... __ .... __ , , ••• , , •• , 1-4

'1_-<II, BaM'ery Majn~eoonQe _ .... __ .. __ '" ... __ '" __ .. __ " , , •• , .. - - .. - - - .. - - '" 1-6

1_~, Eng",Jii8 Lub~iof1l SystGm _ ..•• ", •• , _ '" .. __ ... __ __ .. __ '" .. __ . 1-8

1_6, B~, Sy.stem "alnt2nal!We' _ .. __ ... __ __ . , " • , , , - - - - .. - - - .. - - . 'd-'11I

'1_ i" lrir'BB and 'l.l\lba:al:; .. __ ..• _ " , , •• , , " __ .. .. __ ... __ .. .. , , •• , ~ -19

1_8, Clutchl •• , .. __ ... _ '" .. __ '" .. __ .. .. __ • , , •• , , .. - - .. - - - .. - - '" .. - - . ~ -2:0

1_9' Drive. &.It S:.'E.tenl .. __ .. __ '" ... _ • , , , •• , , __ '" .. __ .... __ .. .. __ __ . ~-2,3

1.1 I) IPDilaf!f Ohain '" _ •.. __ '" .. __ .. .. __ '" .. __ , , , •• , , • - •.. - - - - . 1-2.9

1.1'1 Swpension ilampjng Adjl!l!3iJiriient6 . __ ... ,. , , , .. - '" .. - - - - .. - - '" .. - - . ~-311

'1.'12 IFrmll: Fo:rlk. Oi! ah~ , •• " , , •• , . .. __ __ __ _ . , , •• , , , •• , ~-:30

'1.13 $~e~g iHe;s.d BBBlDgS. _ '" .. __ ..• __ , , , _ - - - - .. - - '" .. - - - - . ~.:]8

1..14 Spairk PlugS •• , , " _ '" .. __ __ .. .. __ '" .. __ . , " • " , , • - " .. - - - - . ~-M

'1 ,"1 !5 AU Cleaner Fiter __ ... __ _ ..• _", __ ... __ .. .. __ '" ... __ '" __ . ~·411

1,:16 ThrnittlB Cat1I!!! ~nd' Idle :Spee(LA!l;djU8'bment _ '" .. __ ,. , " _ • , , •• , , , e - '" •• - - • 1-43

'1.1HgnlllonTlmifig .. __ __ .. __ '" .. __ '" .. _.", ••.. --_ .. --'" .. -_ ... -_. ~-44

1 :1 ij; B-ileaidtightoS __ '" .. __ __ .... _ " , , •• , .. __ __ .. __ '" .. __ _ " .. __ " . 1-46

1.19Thro,UleIFlOsi1:ronSen$or(TPS) '" .. __ '" .. __ _." ".," __ __ .... __ . 1-48

1 .2.0 &lnra.gB .. __ ... __ . , , •• , , • _ '" .. __ ... __ __ .. __ '" .. __ , _ •. , , • , , 1-49

1.211 TrorJJtr.le~o(j~lnQl . __ .. .. __ ... __ '" . , •• , - - .. - - '" .. - - - - ... - '" . 1-M

,i

GEINERAL

11 .. 1

,~,~ ifQ[11!!IW' tli1e lll~ed 8sf!i!kis, SOOlllila'inl:snam;:1iI! a\iIIQCrn· I1IiISmlirlimil:s. Ilali:aa.l_M IIih~ a:rree:t 'Ine Sii!ife' ,o;~~tl!l!ll!'i of tlite mcrtorq'e.le and 1ille per~1!lI1!!.a11 'we'I~Te' '00 ltIIiJe rid ar, FliIi]· lur,e' 'Ii!!! ki ILew Il"eCD IJlIIITIe:md s_1i D:n:s! !IXIU rill 1f815.11111 inl ill eaBI ,O'r ~E! r iU!!Is Ii nj;u tJ;.

:8E1l"i1iM ~ralitJns ID ee lDeoorffledi tJefo~ f:u~bD_liliiBr dalivery II NSP'ECTI NG

;eA:!' ,gpecifi'eoril in the BPpieaWa 1iT1!JdEi1 ySaf PFlEDELIIVERi' --------------------

AND SEruP Pi.tANU'AL

S,EIRVICING A NIEW MOTORCYCLE

TI;)e perrennanee {If new mo~o~e lnitia1 aefliEe is, rsq)!lil\E!d to keep !llBl!Ji3.1iI'ty 51 -[mID:! BJOO to eJiiSUr,s p-ropi3t" 'E!miOOi(WJs ~~l.C1frJs ii)J)c~ion.

Afltar a n6'N ~rcycls' has 1013130 ~ri'.i1;:f.I itS 'l'irM 11000 mile-a, (UiOO Km), and! ,at eMel)' ~Or) mile (4!OOO km) in~sliV8.l hraill'ler, Iha:ve a Buell dsmar PEiDlJfI1i1 ~hs, saMF.l, ~GralJ(lns !Isteo ~ i[ab'le 1-2_

SAFE OP'EIRATIINGt MAINITEINIANICE

CAUTIOi'!!

• DD liIot' mll3m;p;t '00" ii8-1i1.glirli!1iI ,cn,[jne II'l~dI tii!!!lta .. R'e'11!},i'llte:nlngl ,iI:alil ,~sussl,snlJins, d'alJilsgslo

.. Du:rilillg iIiI!3J initisl ~ J!JOO rnii:1iiI (1'600 IKm) !:I!I\e;;ik--iln pell'iiOCi, lL!IM: oli"i'iy Ha~!eyJ~1lIli!dSlI!;!lIll Z4)W~ e:ngin_i9 0.[1. FaII~Jre. te IUse 'Ibe' fiBiI:cmmaoolMll iIl!ill will fN;!,:(lt in ~riI1IJlJfl1liJililil[ bliMk-inlOf '1M e~g]1i\e eyllpc:leli'$ sm1lj:klsron ~,Ing!l;_

lit. careful chedl;, iJ~ 'Darllsil'1l eoquip-rn6frt i15 n&il3~r).' alter perJ~ 01' SOOF.a@e'. ,an~ _ueruly be~.en m=gular ai3fl.l"Wa Eter!i'Bls, to d_e1Erm:ns iif ,s.dditilJilfil<!ll m:tintenaru::IO!' is required.

Chack:

2~ Drive tlelt 'to.r 1J'1:().per ten5:lon ;end! ,oondilion.

3.. BI'BkSB, :Ei1i3eringl and thrnHle [Dr f'E!8,POMi'itii"'ICSs..

,4·_ 8ral!tE! ilui:tl. leW!:1 WiW 0(1 nClill 00 , ~r.::!uIlC tines and -tlttDg5: ~F le:=.ik!L Al'a1Ji check bmkB pads, ,arU;jJ rulJ:l<r.3. 'roI 1N8ar.

5. Cables {or ~ving~ mmpjng and! hes, o.PS1atiOlil. o. Enpe ail and tra:n~iDn fluid lBVEls~

7'. H'ead!an!p, pasging I'a.'mp. tail lamp, lbrake lali'iip aM tum ,~m=.lIl[jp8"Ia!lio:n.

X,B9R'T-OOIL SE,T

1"IiIe. Buell :XOOH ,oomes with i3! standard IDOl ::;S~ (soorad in tlile iII'urIK) mal cons.J:s~ ,o~ Ihe '~g=

.. ~. SPanlijBF 'INrBJocb

• T.a7 roax \IVrefl!ch

• lixlf Kiti IF'oucti1i

ILeak' IDye'

When using IaEik dye, with fhs, lb'lacfu ligi'll: leak ~LBttOr', ,aCJ:d '1114 oz. (7.4 FfI J) ,I)~ ct!Ie. for each 1 'i;! u art {Q.9' lite r) of 11 u i dI in. the s!;'&t!3rnibsing chsck:a;jJ.

FIL,U~D' IREQU~IR,EMIENTS

1 .. 2

IUni;te:d Sm,ms Sysl\em

Ur1~ ,I)O-II~fW!~e ~ciH~! ,8[1 'IIuJd wlu:ms, [I]8al6.lIlem61lM'S in ltaiJis, S!3l"!1!itlal Mcili'l11la1 <lfI'tI ex:1)Q"~dI In Unl~1 StatSI!I, (IUJ.$ .,) U 11'11 iI:s-;f)f -ITI i3'Bl6iUT!3\. SEE! be law:

~

• 1 gilllt (IJ...S.,) = 16 ~Iu[d ouncss {lls..)

.. 1 ql!farl! (l!.S.) = ,2 pinla (U.s.). =: 32: [I, CiZ. (!U.S .. )

• 1 gaDun (U.S,) = 4 ej)l.!tllrt"S !jlI.S-) = 12i;!; 'fJ. oz. (IJJ..Sc}

IFIIlIfa ¥OIlm1e meaWFernent~ ~n tb~ SEiNies Manual D;bjo' Ihe metric ay.s!lsm equi....aI!31i11s. In 1fLa ma!riC S:,-,S1.'cWI. 1 I!ter (W = 1,000 rrnillilirer'S ,[!fit}, Shodd you Reed te ~rt from us .

. 1IllI1t:::km-mea.:3W"lE! to m!3~riJ::: 'Uni~F-:rne.<iI::<urB' (01 'l'ice ~~, rerer llU IhI2: rdIlff!Nln~~

.....

• 'flu!d! ,o~ (U.S.) ):' :29....51"4, = milli16slTS

.. ~ (U.S.) x iD.~,7.3 = ~itel.s

• q)!E!rtB tu.s..). x 1}_946 = lilIEl1t~

II! g'<lJIMS ~u,:S,} X 3.765 .:E: I/te'Ia;

• millilfu!ra, x Ot{!i:]OO = ilui!ril iJIUI"ICSS ~U,S.)

iii lili31i'lS l'l. 2. ~ 14 = pons {U.s.]

II! IIlelfS x 1 £15,7 :: 'I)!_"lI!rI!!;j; (U$..).

• I!!e~ )( 1J'.:2g4 = g;illo.nB (US.)

PIRIIMARY ID'RIIVEI' T,RANISMIIISS,ION FLUmD'

USG onl)' $PORT-TMN$ FUI".IID (Part Mil,. OOB!i4-9B quart si~e or Pari! No.. !SS85\5-'96 'gaJ!t;.n Si~~).

Use iI;Inl:t 'T'YflE IE F'ORK 01 L ~Parli No.. 99a.®4-E!O}.

BIRAIKE FLUIID'

iD',o. IF; 4 br.~ke. ~llul~ ~F!I eau~ i'ni.1:aticn ,of eyes 81iId ,:!;t;jli\, and rns,y' be hs~lIirIlull iniwalllc'l'f&d~ II' ~fi1iL!1 mlCMllnl: 'O:~ '11~1\d is, ,:5wa'IIQlNCd\, indl.!lilie wmlt~n!!l lby stilrll13niata~;inQ 'two, ita'bilI;!8Ip0.0n.8 ,m :Bslt i:n liII'EflBB5 '00 'wMi'ii'Il w,;!!Iler. 'Ca!! ~ !IiIi!!iI;::kif; In cas"" ,01' QOliItKt wlln ~Id~ lOr ey~5I, 'H~1hi wilt! IplslilJ' of 'W~~. Ge1 J!fI.edlesl s,fi:el!'l1l'on 'm~ 'Sjes!. Kt:i[p laMKE, flll.rII;n aur OF mE IREAQI1II OIF CHIl.DReN, Fa'U!lL1'e ItO; iCiI;Impll!J!' cDlI.hl fBSl!Ilti: iin dQ"Cit1ili ~~ u.110'1:JJ; In~u,",.

Usa C!nl:.." 11).Q,lIi. ,4 ~HlI'AKE, IRW[jD1 (PM' Nb. gOO/3-~}-

1-2 200;3, Sue'11 )jJ~9~~ ~l!!!ll!il:eT!ls11l1!:!1!i

FUEL.

Use, a ilJOoo ~Iity unl.I2<E.'I;Iedi gasome (91 pump O(;.'taii\illl i""!iI high6'l"). Pump ooi1ltlilil i5 ~ ocMne FllJl!fitieT ~FiSIila'Jtv ahnwn on ~ne g£I$ [pump'. See :3.:2 ENmN E fur 13! d!3t.ailsd exptlfl~fiOr1 ct' r.l!1~rf'lali'tC IlJeIis.

lise Ine; p.r'-oper g~d'e ef oil "tor tiitB I iJ!II\!!3 st mlii~ral1.ilp!~ eo:p~ed b!3fiur'13 h ueml (;iiI (;hailtiJ8'.

lin it Is necessary '0 ;M:il;l ojl I;IG Herl~-1D8JI:tdron ail ia n~: ;;Lvsilai;lE, USB< 8JiI ail CBilifiBiil ~or 'di'~t;:J Ciilglnc.-s" ,Aeee,PtR'ble dJeoc:l efi!Jlne. !Oi! ~:=itlon8 il'l.(:ll;fda elF. CF-4, C6...::1, and CE-lI-4. TIile pr,sfened '!,;'ioroositie:5 lOr' '1JiliI:i diesel engIne Q!!~J In liE!~inQl ,o«Jer, arc, 20'W---5IJ.. '1.!5'I,IIJ-4(l ii!1'iO 10W-4{)_ At ths iIl!fS"t Q.PIJ(!Il1!;1niL¥, !;:I;!e SJ Elue!! dJ;laler to cilang,e Ib<Le.k. lID 100 pelDBn~ Hadey-iDa'i'iC[MI'll ,oill.

OO!JD
H ;!iR.1.E 'i"'" IIAFlIIJElf - l~li wu;l'J:(l'Jil
mIl1,!l[).SiJH 'FfPi ~srn IIIA\lII!I!Sii:!NI AMElIENiI' SlAM,S
RATlNIIii ~P"'l" ~~
,5{j. F
HLD.lI!.!uli-GrE&! BIiIb'.Il'~7 ~
:!3AIE HID 300 E.mt!~
10'i'i\:iO We)
Hll)~ll1l-G~ ~' /ib:rm ~IJ .
~ i'I)~ t4,·G) Q;oo.;I
- ~r!U.
HI.ID. A~ilJJJar ~ .$AI:'
- ~IEI~ F\i)i)r
,5{J! .J.!!9
Hml&.ift!;jm-t~i!"I '8A'E: 1 .... 3l:iii ~&f ~
,fill< rn7"C). l'atJle '1-2. F.ftegu~iJr !entice llntervalls.

-- i '1 Il 4, " .4 50
1 'i :2 2' ~ ~ ;J ,J :J II!
.~ 2 ~ 7 0 2 ~ '7 Q ,~ Ii, 1 • :l .I 7 0 2 ~ 7 ,0
0 ~ I~ ~ n ~ 0 ~~ Ii 5 " S • ~ (I ~ g ~ 0 ,~ ,0
OOOME;]EIEI Enii:amN~ ill D i[i 1]1 D Qi g ![i 0' '0 !J; e (I D ID 1], D Qi ~ ill '0
,~ Ii if! ~I D r:1 n • g' 'g III 0 ,,:, e ,~ al D 0 D " ,~
SiEHYICE QPiElRATIONS mJ ITR ... flil ml mJ ml mI =! ml I mJ "" .. i'i"ii l1li ml mI mI
1 1 2 !O' " :!I ~, 4 04 5 5 6, r; ~ l' 7' II
(~, chan code IbetllJw) ~ ~ ,~ ~, B 0 4 lEi :i! ~ ii t ill i Il pJJ 4 ~ 2 I(; ~
'" Q' '0 Ill' 0 III a if! al D 0 n " ijl ,g III Ii Ii i[i D
0 a, 'D Qi ~ Ifj 0 '0 0' Ii !Ii a (I ~, D (!< ~ fj 0, '0 Ii
(! a, D " D " Q ~ 1;11 g !I Ii IC! Il< D o D " ~, 11;1 g
- 1m k:iIIi llirn Ii:m 1m bTl m ~-'" lim l'J:m - "" Itiii UTi iIm 1oJII, ImI kill 1m!
~.,.-gniif; (;IiI ~ n ....... - R I I'i I Ii'! I H I ~1-1 HI. ! R I ~ I IA I R I Wi
1 I~ ~f~blimcr, ~ u ~lIQui:&iI. I I I I. I I , I If! I r
Fif:;~~M~\~n~z. ~ I I I ~ I I I I. ! I '! I I I I -I I I I I I
'Il , A A ~ -" h I'" A A iii A
. J.IiIl: j:m"~ cj'ian. --
Ir~~'~ I I ~! I I
ct!.;J.[!)=.c lu.iMI IUIIlI ~ (!."!i'" - IRI!
~lMMm - Ai Pli IfII RI HII R:I III I If! I RI IAI
plug.
~17i1~~. - I ! I I +
~FiU:iI~ - I A IA - FL ~ lA -- -
.3~i"!J'IKI'l!.I:$~i"!I1~~).. - It ~ Po It. ~
~~ ,ellJjn:l iIl~ ,:;p:o:oi ~ I I I I - I I I I I I - I
~11!eWl~~'Iiz.!;J'. ,:( ::q ;( !'l. jfo, ,:11: ;.: :t x ~,
1IIl! U:&!l iI'W11lQ GliW'~ A A, i'; ;II ~C i;. It!. A ;. ... Ii
Aqus'i diiim Mii3 Gtial iSttil€i - A ,A "', A ,'" A A ... - A A A.
UMa!: i'Et?j" MQ ~ rn;.r IPUN!}\.IF.II!~ belli !iil'Kll1II.lflr IKI!~ ,
I I I R I I III I I R' I
I9BJ l5.COO Ill!. (1'II,I))lI~, r
~'Irenr< IO£IJ !'RIff 01'Gl pr=lJm uid ~ 1r$:lCI. I I I I i I I I I • I I I I I I I I I I !
>i'-'-=:l t41 Cllcillf m . x_ ;l :0; x )\ X X :Ii - "X X
:!'.
VlISJj!J'€i 'lfORf f(lr[ CilL ); '" -'I.: x: -1+
- Oimii Ei2"i1!' IFiiii ~I'I~~ ~iiill:a o2I1a1: - I I II I I I I I '1 I
~, Il(lifi'[ E!I"I'l1 FiFiJjJ nl\UiB' !!~JJ~ 0YIJd =ttIr 1o.1It»911" ~ I I I I I I I I I I I I • I I I I I
1E:;Jks; r!ref'J" ~ mi~ (40C(11illl~ {III" '1"iMJo ¥W!-rs.
UI_'S.~"lor!l!~~I'gqu.~i!i.!5Ijn~. I I - r I I I I I I I a , I • I I 1. I I I ~ I I
~"fIII UTa;<:; IDd br.ikc sr.;1!lm lor ~ I I I I I I I. I I I 1 I I I I I I I I ~ I
['J~ fn:nlIi-re'.mJ ijliU)d I@~F, ttil'dllil .:i!fllm1f"mtle.:s, ~
~ ~;Jl:!1G. ~ iIamI ~l!f), ~IDti:!~h'OC ~1u:!I ~ I1f~' IL 11. Il IL IL IL IL I. II IL III.
~ ~lrlg tr.~}. --
{;hll'd}; iflihln.~ old IifiIj(ijj Miihmrm.: ItiiiTli!I .::or~, I='_".e I
~-...m, 'fri:n'1 ;mil] m;u .aD1III, !J1i'I>-.er Il,MI ~ II"pIR ~ . T T I T T
[lin r~ ~;:mIJj, ~ n:arCi, ~1116; re;:u~. -..,
Inr.p;d ~kl: CI'TO:ik I£litl iiiId te::!f fiilo;!<! 1M, ijflliJc:s;"
'I'rorit '!tUM. IW ~ .;a:I1l:IU!;! ~1E111i, ~l ~ l!: X )Ii :( x x x x. x x x 'X )( x; x "I. x X' x x x
mniUlITg. 1-;0:
H.oorlIl!!I:IL ~ 11: , :!I:,- l{ X 1!. x ); Jf( :!; A 'f; ;I[ x ~:.: j( x .II: !\. .i'i.
~~i':
1-1~8,tr~ry~dI!iII1JIl4"0I!~. R-~ er oh~1I'. A-Ai:tW- D.- 1J4=~ ().be &~_
1!..1L:u'b:mz~....a:h~~ITI'. T- T~'KI~DqUA~ 1(. I"o:l;;flElr.L
- I

GlEN EIRAJL

Special ,r:are andllma'irrtensJ!lGe' are r,aq,llIired rnF the mold'ed-inrolor bOOli pancJs. lhal are ~af1da~ on yoor Elue!lX~R' trnO'to're'jcJ B.

lM'Q'Jde(li-ll!l-·oolor SU~ ~k ~l~ pr..lntecdl sur~ tbut ara' lOOt. ThI3I 00 I at" pjgrTilBnt Is lITli:o:ed in '!r!,'illii 1hB ma'lBriii:ll w11MI fhe· part i's. lfflaoo, I'Iii1t ap~lit1:G {rver the surface. lM'dIc!e~lor [!If.met=:. r,eq)!lire ~renl' ma.1meI:lsniJi3' tlha!n paintadl ;surfacss IlJ' maifirtairi 'ltiIeir' Origiri<tJI ~hiM. lusing mr:::.1h~ !hal 'WOrn (;In [!IEIlntedl·~uf~.ees may lruil'll the fi'niah 08: moSdsd:-fi.oDloF parta,

I USe ,C!!II ,~1b1i3SjN,e· Pli'Od!lle1$. Of power.edi ll:!u:,"~l equlpJlilen1l: willi csuse· pi:!11111lSJ'liNiIt C08lJi1siil!:: !ilsma~ to l1i1.o.ldBdkin·

. (;(IIOl bll:;lCly 'IMn:e'lS;. llJlte· 1i:In'IY ~!'Ie 1i'e000!IIl[ifi~ded mtl'll;!li;lU:c.tBi 81i1dltecm.:nlqU)3!6i ol!ltlill)Bd ~n tltlis :EiS!l:iliiOJili to Brwiidl dama9" I~ rnolld'e;d~n-e~I'(Ir tUlil~ p:inel$_

R'ECOIM,M EINID ED iii FIlODUCTS

if'rOOucts reeemmended 'Ill)r ~he lJt"!l)'J;ler eare andil1'iF.iinlenaJiiCB <[J~ lITIatied-~r bocI:t pan!3!:E !dire awiabla' at :FOur Buell 'O'efller andl ,:=..re il~ below:

'.' Harl!3y Wash {Part No.. 007~ 6...oo} Ijff H<liiley SUFI ~!il

,(Pari' INo.. '9.;lllf!6'Y-gifl;} ..,. §

• ' lHarley Gloss, (P.arti: MD.. 9'<1627-00)

CARIE ,AND MlAJIINiTE.NANCE

Wsshlln:9

2. WBffi ~/ith Harley 'Wa.GIi'i or Harley' Sun '!.I'Ili3iih_

4. Dry wUh a !!::lean cha;lnl)ls or ~ dry lriIi=Itul13l 'liI!eF ~

11-4 2(1i(d lBllIell1 'l(Bgs:il= Ms~ntBnSnE:S'

'U~ ml).lI;!edi-lrtt-oolor ~ oonels ro.metin1ee ha .... e a al!sf)[: ,dha.ge ~h8l: iaItiIl'8ct:s, dust. Applying I-fulJrl!3,:P' 61hJs:s. 'orr I-brley Glaze P.l)II!1llI ,aM $eal@.nt ~'O, mo~-I~r '!:tmface$ will €I I i min at B tIhis. oen d i~i 0 n_

To. kaap' a hi'gIw gloss finish on IiiliJld~-iri-Dolr}j ~1'I!31:S beL'W3~ washi~

1. Spr~ I-t3irll3:f G10ss onto Sllliifa.IJa i:(ndl 'll'rips mh .. itlarlrn eert Fla~uraJ 'ltOer ootn ~ liial!fey $otrolo.lh-

MaTE

2.. Respply HarlElj/' GIOSB I3S dB:;cribe;;ll albDl.!B tD lkEBp :5!l1J'races. !lOOKing! their Illest.

P'OlIslhl'ng

~lIshlng moli;led-:ln-ooIOf Ibi;id~' ~e18 resufls in gr,esler sur'face gLbss i:lind a, pf'otscli'l's ~.

1 _. Appff' Ii-li1Irl\:vr GIrl2;e' Ifl.Dlish ,;;;nc:ll Sl9:alaJlrt ''''.I!aF!I s.ix.lib1)nllllS; OF as IlEqul're'!!!l tCl' i<lBep md.lded...fi.;oo.lcir penera, pro.tedEdi andllookin@ thair b6Gt.

:2_ C~n and! dllY surfaces, 10 be pa6slh:ed {:see ~.

:3_ Appl)' H8IIey GI8ZEI E=\t!li::;h amd Sealant ;JJ' cls'aJii. ~ OOm.Den~ Clf)(!h ,or. ~ponge WId appty te ~1,Im..ce w[1h :=.i light O¥srfa:JI\ping mnbon. Maka ::;UI13< to ~lJIIIEir.:ll1l araas .

4. Let HaI'l'By" GI~a l~ and S'E!alant dry' ID a Ih81iB and 00fIi crdli Ii6iSidue wifh i:I! ala<tn ::;tIrt itilb1h 'Dr !Harley S~Uit

To rBlITlDW l1i1ioor scr:atd1e.s 'from body pansla;

1. Tii;I r!E!FrlIO"I.!"e IIgh.1' sl!1.l'fF.ioe scF.Ei~ and I'1lIhg;, me Harley' SWid CIJiid ~d.1ch Ti13aknali.' ;:lli. r91j!JmIi1Bri~l

2. Make :::.ura S ..... irll ci:DtI Bc.rabtl'ii lrll'Ei<!llmetrt is. ,~iedl ..... ith <I rnolst cloth and ,by nll!Jld (Mt b)!' ma~)_

3. .All:tJr sCf;:Hii:h, I!)F rub, has DW1I ~iFCa, poliSh smboo IIgJrIl~' mth Harte~ GI:=..ze.

M'aJor Sem~'C1i1I es

.~

Th!318 is. no repair pD'lXB1ilUrBl '[Dr :S6Ii'8r'BI;~liiIsdl aurfaees,

~81l31~y' st~oh-8dllbodiy.lPanB1s riTrUBt [bEll N:i~. [iii

BATTEIRY IM,AINITENAIN'CE

1.,4,

,GENERAL

~u~. JiIlOtmC)'cla ba.'lfam::s are Pef,rnensl'lll), .JSlCIiBJeCl, maln1Enar\it~ii'e.eJ lo'3hie-r,eg~, ki3Jd:/It;.;]Jd:u!m ;And! aul"uliE: 8Jtidi bane.riaa. T e balJ1r,lij.cs are shipped pra-r:harged afJdlr<eady to ee p 'Inro seMe8\. Do oot afOC:mp'l: to t;tpen 'Ihe;se barlf!3~ 'ror Em)' rreason.

£:n~eet the ib:qte'IY for da.rfli!Jg9 or I~ {rind] fo:r CIBan, F1()f}- 0iJ I'1'"I:lId&d IOOIil n B ctjo n S:

.. .AI! Ihe 11]1l)(1 III (lleOD km)' Barvios interval.

.. AI every ~h:t:!"!!luled ,sarvice iinterv.al iItlere:;ltter.

~-

'''WARNING

AJII Dilliwiss, ,c;ontal)"! eIeCb"dyIB. IEIBcaliOly1e, !~ 8i 8t!I11i'nnic otetdl ,~olJ,!rllfm that: lis highl¥ 'itcli'J!'C!;!lIv,e, aool can ClaIDe' 8Efll'ar,e !i::belfjti~m IMiIrlllS- 4wkill IOOlda,ct W:llih sWn, a:Jra;Sl~ aM c:lo.tllIlm;g~ Avoid sFJil1aglii. Ii; .i(!t$ 'M!'JIr, proL9C'ti'W ,faoe sltt'iBild" rn'bbe.r~ Slovelii aJ1ld prmBdhM ,et:odTlln,g when \'lO'!'IIJ!r.tg ''''''ib lImttarililili u A Ift.!iiifllin:gl [lBIt)e1 rs a1i1ismad to Ithe. tnp af IIDB' biittiteliV. See ~lgl!1re 1-1. New!' IItm-ove: w,Bmnj~81 1'a'~11Ii'Om b!1l!:IWY., Ilt'altUJia, tg 1'E!<tCiI ,l'.Indi uooNBi:l!IJ:nd 1Ei1] I~ 'eaUlioos. colil'tai'r;.9d1 In \II~llfIIln!!J. labal barliJr1Ii per1,(W1T1~991 'iIiJy swce (1ft bEftle'rias. CiIXII[!d1 n!&'uU I~ death ,or se:riO:iJ~ tnll!1l1}1'·,

BOlIU;ery [pIliBIBJ tsrminals iir;:d reBated ,ac£26IanrliB$ CC!fiIg;Jn Isad 1111001 IBird com;ponent5i, dM!micals, k.1i'II:!!m'I10 ~e- Slate o-f [C;a111'amla te i!:i!i1Jl8e. mn.esll and l:ilnh detects o.r othe.r' IIBprod~iiv;f3 Iharm. Will_hands afite:r lflilooJinS.

,,-- ..

' ....

Table 1-:3. IBattery El~ectr'o iyte Aliilltldotes -

-~~

Flush 'iII'i1h wate:r_

IlfllEmEll

IDriFt..;. larg,e quantitie5 '0-1 milk or wa.1Bf., fI;)!!~ by l'I'Ii~ [ali magneSia, ve~ble oil Of booten eggs.. 'Call doc'I.tlir' iifnfTIe~

flwh with wa.1Ef. gst imlfnc.(llate medil:aI aMErnliJ n.

-

BAlTE RY TEST~NGI

S.!39 T~ 1-.4. The, vofimetEiF tesIi pfUl.limes a ~raJ Ini:rll¥.l~Dlr of batlsry oon ·00. C~ me \!Q~g~ 01: the !battery 10 veriry that it Is In ;;Ii Uiill',{. ifuJfl"y charged o.on~on. If 'the iJjlE'Ti circuit ~di3ODnnaclBtlll' 1,I't;},1tage r~dl9!ll ia, tialow 1:2.£iV; el'laIge Ine batte!)' and then r,sCheck the \iOO:age a'fl:e, the battery has sat fur ooa to I1.ro 100 u ItS. II iI:he '!!Q Iiii'!! 9 e I!B3!I!I i n 91 ia 1:2..:BV 1[1 r ,a.t:!<Ne" patfOfrn tne tl)adl tP.'3II' daeuiliadl un.aar 7.'1 (i) w..-na;'r(.

Table~ 1 ~4. VolUmemr Tea~

1:2..a 1 iliIr'%
1.2J9 75%
1.2.3 :50~
'12:.<0. :25,%'
1"_9 {f% BATTERY D'ISCOININIEC:TIION AND REMOVAL

AWARNINI:;>;

A I'way SI, !IiI1!tfii!l!I'I1'lec1! '!he negalh'i!)!' luttell'lJ ,e;:lllilie n~t, 11 tliu! PO<Si!l:ii""C oalil\llIl me~h!! ,~el:i,'t<I!l:l groulid mlti tlliS Ins,9wtiw i!:l3bla i'fls.taIJad, 'lliia r'El3ll1~IJilg 'SF,lsil\Ka may eause' i!l1 bl3,1ite1l1!' ,eXP[lO.$it!lIMi ",.nlen ~1Id11i\e$ult iJ11 dealJil or $erl-ous ilnJr'liir;i.

,2_ Uliltf.; read! ml!3DEir Jnd re:roow fu,a.flSIiY l'I.E\Qsfi1le cafufe

'[b!ao'X) nom M!lCfi/ FI~li!ie' H rurminaJI. .3., Pull back tarminal olJ!.'8r beet,

4. lIJiiWl~d [il.il;[enl3f ,i:!lfIlI ~O'i'~ IJiiiftsry posili'1.8 GCloli3> (Ired) from ~er:v IPOo$it~ ~+) ~ellRlinf.!1.

:5. Unhook strap' andl r13IinG'iIB ba1:lIEfY.

'CLEAlNiINGi ,AlND' II NSPECfllON'

11. B<l.tfll3ry'~ must be C1ei:lll ,and! d'~ Dirt, and elE!ctro.1yt13,on tDP< oaf the b131~1)! can C;3~iIS'e b:::l~1)' t.n $eld:-di$ohf.i~. 't:1!3ar1 b.:rtll.l3ty fop' 'With i:I! :solutioo of I:!<a1i'n@ sOOa (:sodium bic~rOOnate) andl ~te'f ("5 teaSflOons Daklng ~ R)!eF q!lf.a.ri!' or titeI of \'!.'alter}. When ~he 8ol1ll1ioo stope oot'b'ling~ rll!l.$e off 'the' ib~ wlrh ~I"'I walei',

2~ GIBaD eBbll3' iOOnnectme and Dat'lE!fjI' terminal\3, using a WJ~e Ibrush or ,~fIi:!~eF, iFlCffflO¥e ail:! oMJdrulon.

8c Inspect tha bEitt.ery screwa, clamps and cables, fix break,a~e, ti)Qse CMflcetfm'is aI}ij cm0St!)n" ~FI da~

,.:Ii. Oiieru, ths bane!)' IPDBti3, fur l1I1e!ting or damage OI3rued Iby o..arligtnarli'il,g.

5- II'II:::~ ~he oottery for ,olsoolorajl~ ralseo 't(tf.I (!oJ a 'iTrJrpad IX dI~f'lJItl3d1 case, whir;h ~ht i~ic:L<te that !h6i batb~'JY has beefillrooen. o.vel'hested C!F ar.rewhl31ged"

'13" Iinspr;:;;:;~ Ihr,ll ba'l.ber:.o ~ 'fill craoks 1::.r leaks..

'''_

SlORAGE

A:WARININ'G,

-- --- - ---_. - -

A MaljIl!I, :S.be ba.hoas. wlilene thBJ' &RflllliOO!: be, fiBamed by Ii:n~II!\!r.en.1, Cl!)ntact wl~ tlilie l:I~ry':$ SililHli.lJIie., ael!dl ,coil.llill I'iE!:SU 11 i Ii1I d a aWl 'D:F sa r i'o U I!I, i liI,iuT)!',

CAUTION,

Tlhe el'ec1!lrei~a' tfl i!Ii dlsi!;:har.§eEll bl;ll;!tell'lj' wUI tll'eeR 11 ,e.~p~ed ItO< tll\ge'Z i iii g ib9m PEl roabJr'&Ei" IFf'Bezi ~I may CI"B.d1: ~!i\ie 1!:I~]te!I'IJ il;!;!!!S:e' ,:;tad! bUll:l:ltle l)a~llI' JilII&te~.

Ii: the mt1ibJrlc!iD'IS d oot Ii!ta C!perated 'klF 'severa~ molltlhs, ~ WS cr.urlngllhCl winJJ!lii' MMOn" r~Ni~ !fiB lbafIBljl' fRiilllI tliIa miJo.icrcyd.e 8Iiid j'ul!y marge_ See ,_1 [) BATIItI'W.

Sea HgurtB 11-2. Sstf-di8l!:harge 6 a Mlina] ron.oiflm and! ~r;s; I))OFltn.!OO!;ty ,at 11 ra1B' mall d~Cfil® 00 IDll W'fIbi!!!nt tr,l~ff'lpet.!ll.l!ll9 and I11s h:.1tEi1y'S :&.l£it.e ,of ~rge. lE!a..,iell'ieB ~~ i'iJi :;Ii '~ster ~c at higl1er ~ '1.'CrnfX!i.l~. To ~ illie ,d-dis-, charga' rata, store lhErtte.ry in 13, cool (lIIDi1'lree2in!;l). ,dl)' pl:;l~

Ctlilf!i:li3 1f1Ei Iballl:ei.ry 8V!31C,V Ilillmfh iF ::;tmadl at tempe.r.alur!38 ~Iow IQIJI' F (1 ij' C)- Che!roge Ihe batlety mere UC~U'ClII'IIy il stored! in a Wd111i1 8iei3 <:!.bDW 00· IF. (1H,· G).

NOTE

'if"iIlIIiI H-D' BaUBYy T~A.u.i'Qt.Ii\:dic Baili'e.!y' c:1:Ja;rge.r (PIN :9.~_;:t,f,T~) may Df,!' r/Sed 10 mmm8m ba"l1'elY ,ailal'ge tlf' ot;.;~ p~ d fuJ'l8' wiifwu~' t.iSJi: Of Qli:Ejn:;J',fiJ\fg.irJg Of' 00iJ-, mg.

When re~uming a bart!;er,y tQ ~N"loe after ~_Ol"affi, fUlly ,Charg~ 'the 1J<iitb3:ty:. see 7.1 e ~.

BATTERY IIINIS,TALl.ATI:ON AND CO!NINIE,ICTION

1_ Plaos he ~i.J1Jy ch<ltgCQ ~ellY m 1ba ITJD.UJi11.iflg !pOSition, 1e1rnlflaJ, ~e to the, rear of' ~CIe.

2- Hbok rubber strap at(Juf'li!l ~ 04: battery.

-

, CAUTION

ODJlliIsct 'UiOI (:UI~ 00, the C(Jrr.ed: lba'tkilij!! temllneJa, (Jf' d!!nilage '101 the m[)tol"J;)'ltlC el~mleal system will QUlJ.! _

r

-

AWARNING

--.. AIn!~)"$ 'C~f"l21Ied lIIe [pcsimivs Ibattelil c:3~e' IflfBl:. If the PO$~ illval cable :sl!llill!.!l'hil oon~~ gKlunEli '1iNiJj,1iw Ihel ,ncglMl;ye ca"ble inslru~d!. lI!Ie l1e!liul'lilng sped.s may cause ~I ~'m;pl~ SIOD whjdl cooJJ:II I1s:!iu[t I~ d~'tiI'lID'r ,aeriicus, i1iJ,i~ry.

CAUTION

.._,

Ow!illtighwnlng rutenl!!m CIIJ!Ii damaglll bittlery tern"[JnalEi.

J. Irlsen ~9t.eD!;lr thrn. bailer), pooit:l\!'e cali!I'e (rad() ~to ilhrearled ho18' OIlDillll:eflj.' po~i1i .... a (+) ilBrmlna,1 ana flg,hten tastener to ~.iQS lilil-lDs. (8-11 JIlm}.

4. 11!tS~F.l1I terminallXf!l6(f ~L

5,_ Inserl Ja.:sI£lnC'J LnIl'OU battery negaJiive cJlJlc' {lb'1aCik) mto

'Jnr~:;.dI;ol!I holel 'lJi batiEl1Y n~J.i;,!'e H termina and tiYht~ fa.:st£lne1 to 72-00 rn-lba (8-11 Nm).

6i. ,Apply EI I~ ODat oi ~um iellV.or OCIIJO:E.jon relFlrdilru

material f(l ooll1l OO1lEty tarminsls_ •

I AW'AFININ'G

Aft:e:r irJi5tiailin-.gJ seat. pun upward Olil fr'OlM '01 !!liEst 1001 be SUIIE- II! lis IDldk,sd in po:r;'itio.n'. mr Se3t lis 10000, H Qr;mICl ~!'! it

r : dUli\in!jjl '!Ief't'I~e o:perStili!UlI I3.1iId mtUc '[Ji\e irldler. lJ;:aulSintil ~I!lSB, .of CiIlRIrof wliiiltft cauJd lIeaulli in death or Sef'b.ils,

iinj~i)I:. :J'

\.. ...

7. Install ~t. See 2.:38 SEAT.

. ....

ENGINIE, IL.UIBR'IIC',ATIO'N :SY',STEIM

11.5,

GENERAL

In::ped! ®.illineB and fiL1sr for le.3ik.s:

• At ~ 500 mi r2~OO kmlln:m~J sel"llioe and! >Ef!le'l'!( ,2500 mi (4!O00 I4?m) 8smes, interval.

Cbsnge i3l'1@ins' oil andl ~at unrier no:~11 $efVIeE!~ oongitiona 'ii'l warm (101 mod'erRte '!emperatu)Bg;:

,. A.t ~ 000 rni ,(~ 600 km) inilirll serilicc, amll '~ ~~ lII1i f80iJO ~m) sef'ii1ce' Int!;!N;i1 ther,eaiter:

Change Eflgina oil and filler ul"Lder 5e1Iere ~s:er¥Joe' !C(!ITIgitiDns in waiWhlI Of fI1IOde;ra.tP. 'toe Fi1\P e raJlu rea. (:EBV81ie dllit. te'I1iiJB ra- 1IWeB ablJlila BoPIFJ2~. tl.!oJMs.ive Idll~ ,or speeO!;i: In eooD95;3, of !(? mph!100 kFi'i.ltl):

• At 1000 mi p 600 km) iMfaI serviM oCiIMl,CVCI'if ,~5QIJ. mi (4000 filJn) seMce' Interval tliler'e::,ltter:

NOTiF

'NJT:1' ,00idN iffte' 1We!flfteT, the ~~I ,rhe r.eoommended w cl'JaRg8 ~1 )Ij 'lfsinITe ,u.ssd CWy I&r $iI-i't'llt I'WlS In (X!Jld lNSorlfler IfolLiSi' 1Ja~ me ,~('!, {}iJ rifflmea folI'O.!"I3 iffeqHSlltry:

'elM E'cIKING ElN1GIlN IE, OIL LEVEll..

;J'

An ~utare ,engil'le 011 I~I [!BF.iding canl onlll' tirE! ootamM with 'the, engine at no:rlililal'lJpeIa~ '~rarlilFC {lOOt Check}. nL"oEl ~inc' w;, FeI.llJIIII€! ;til 1(ID!}I;!r ....raJ\ID up, peri'oo illl lOO.'IdeF temperBtulrs8.

FOi ~·rld'.e W1ISPeC1i(tfll, Slfl1(Dly \fe1fif!P.' that thare are IIlO' 'oil ileskoS 'from Iha ,oil. fiItJ3:r and oa li'Jf~ pOOl' 10' II)pera111'1fl '!he, fI1(;J1C;Ji;), ete.

• IPelt£nr11il,B loot chack 01 Iha, ,engine ('Iii leVel .at ea~ 'fuel 5ttJp\

IC(lI' lit'Ot ttlLIO-w nat IOllllel'e. Ito 'r.11 ~o.w' I@WEf'IITIISr,,",'D:nl di'po, ~IDk., 1i'o do. SD mIrY IrBElw'll in !3_(j1uilJllwnt uruna.gtl ~n(!lto:r llilillllill[netioll'll.

CAUfION

161c nol: 0¥t::ff11:1 IOU tuk. iOIwril'UIIII\.!!II,i;K11 tS;r;Jk [l]8.y 1l"e81!111 in 10111 ,el1r)'-ove~ t~ ltIliIe ;slr '1;::1'e:sl!M!!~.lBqulp:[IiIsnl: d'aJiI1i!1g.e.' itiIM,ato,r !&j,lllIp:I1liE!n1!' llillSllil![nciioll'l.

l[)u' 111m ,SWiI.e.b oil tJlJanfl$ IIPcfl$Qrimlmatety Ii!eCSUS9 ;Imms, mils 11!libBlI\IIict cltte:m&~liIlly when milUlitl~ U:s!t. ,Q!f 11tf,e~Qi~ '0-11$ lOr InlO~dletell!l:e:n't @Il~, ean d's:msl!JB ~he !3iIiIgi'na.

Rida IIliIa-::OF.Cyde 'for ap:prru:ima1Ely 1{1 ni.imJll.Qs to ensure the iQ i I is; h ~ an 01 '!:he eTtI!]1 ne I $ at n OI"lmJ ope J'8j i n 91 talillp e raJ! u ra

1. lihe motol"C'jlole mum lbs, 00 l8!i8lgl'1JUfild. on, mr;;; ~. stand~ 'i'lli!ih 1fLe angina ,olr.

;2. see FI!lIJI.U~ 1-4. Un~ a:Iiid re'lMVB dips.tiok: from oil Isnki\Ewing;a.Jrnli 'iillaf ha6e. W(pa' ,dipsra. Clean.

3. Inserll: '(:)iPS~iCk IFltll) oll tank 11l1ei" h!l)le, s.cr,ewing dipatici!; in oompl'ete~ 00 NOT OVIER TiIGIfTEM.

NOTE:

The' ;!;,.Ilf'..a De.;;wee.r.I ma' upper Bf.la laWBJ' ~CI;!i'OO m~ .!8 /hs' ilJPSYil'IiI'l@ ~t:.

4. See lFigura 1-4:" Ulil&;row ~M ~eFl1lO1.i'e dtps~lok andl note ~~L

i3!. Oil lev.el ,81:murd be mtlii~"i Iht;ll ~FiItiFlgl FlIDJ€ (between UPPef ;:llflO 1'(!fIlef registta1ioo IImIrks} IOn dl pal!i ol.

D.. If IJillevef LIS, b@W ~ reg!s1J3itl(!lll m(l!rk, add ionlij' eJ!l!!!iugh eil ~jJI brin,g ,oillllBval bsru-een lower .<lJ'I.d u~r ~r:atiOn nlarns:.

',,",

CHlANGllNIG IEN'GINE Oil ,AJNC' flllLTER

Rids miJiiDreyda kir appl"QI(irn<:rte,o/ ~ 1]1 IffiiflulCs M emur~ !he QII is 00t ana ~he. engjne is :;II: normal opBl'Bfing, ~Bmp8'Ii3.twe_. TI!I'In e.ngine off'.

.M.J1F

S~feaI ~l1eel 00 lil[,Dr pJsc8 ,roi.s:sOf jack und6i'·ja~ point.

Drain in;g 0 il

1. Sec Ft~ure 1..;;3. ~tare 3J s~ ~ine~ LIDIlIBF fhe ~in IPlug~

2. uS'ing a !fW8; jj:}. ~, ~ove 'O~kTllDiI,lgllFOm under oil 'tcEmki'awing3.'lm. Wipe a:rry a'reulillulated de'blii!;, ft'Ot"n~, ~lic ~Iip 00 min plug~

3. ~ ~ure' 1-4. Un.:scJTeW end Fell1lG'ile dipati!::k fr:orn ,oil iill hola em mp o.l: oil tiBnl.Js.w.ingarm_

C!harn,gl~ng FlJilm:a!"

Remow chin r~(iring See 2.~ C!i-I!N FAI ~tf!fl',1l_

$€'e A;gl,lre, '1-5. !Plen1!J1VE1' oil filter using pli'eir.!:. IX tlEilt 1ytI-e all P,IH...lIEFl WHE~CHL

Glaan r~U~r ~~ comaet surface {11'1I ,I)r-an~. Suri8ce !;ihdw&ril ~ amoolh 3DI!I ifreo3 at an.:t dabris at" ,okiI QOII~l mOlf9 ri ill.

,Apply a. tliJin firm of clean Elfilgin_8I ,oil to iiltSF :gasket

RiJur 4..0 ("lLJn~ {O': 12 litci) (I~ {)Joan efIIJlne !l)IIlntolni!!W"Iiter 'when dlanging oj] {un.tillilter is BJ!itIil"OJ.l:i~ 112 r~ ..

ScrBW lilfElF onw aOilJpfer' ILlf'ltillilr~F gasJ.;:et ~ ,pr-.f.lnkcase sunace, ~otat!;! ilil~E~ anefher 112:-314, tum by ffiind'_

1.
g.
~
3..
4-
5..
6.. Ba, a,lll1\B nD (Jill gets tOO 'Iii I"iB J!l, wtJ!3fiI diang'ing 'ml ,af1Kl1 iNlter. lrII':JeUo:nl wi'll !:Ie. adwi'W!Y ~dI whl\Qh lOiIay lleadl tD kJ.:siI; 00· 00011",0;1 wlilidiJ tClj)'bdd fBS-'I.iIIti: lin d'liItiiItf'll er StmQoi.!l$ [nllll",-

,,,

Rle.pmaCIf:ilIQ' 0111

1. In8t2!JI draln plug,

2. FliP OIIlanl< ~1li1l:0Ug]i1l !Iller ~~~ICk) ht14e w[lh reeomrnEDrilad 011 from TabLe ~,-5c Oill!ank '!J.Olpaairy Mlh iil~B~ ct1~e is; ap~lmalel¥ z.s quam, (2.4 li!En:i). and ndOOa8 tha ..;ji.o 'IJUI!Iii:6\S· ~o.. 12 fitar) plj~ inlo· fhe· lilter. AJw.:J\1'!;J; ''o'erlily pr,oper liiat aClle¥Ell 18'11 dipB1iok.. Dc oo~ ~Brlill.

:So InE\pect o-ring 'DIli dipEflEk for rips or teara Heplaos as, ~uiFOO.

MJTE

Por ease ,ot·lrmalitflltxl, ~y (iil i\Wfut' Iilriri ,eN Gl'eBn BIlI¢ne (J_ff :1'0 rh9' dipafi'cJi. ~_

4. fnB1:a.El dipatick intn oil taJilkiB't-.ril!li§3r1i1l fill hole. MaJke :ru~E1 dipSliek 'is insIDIIMl oOO~le~ely. 00 NOT O\i'ER TIGHTBJ_

5. Ramove lah ririls oil tDOCIl!3t" SiJa-op. .sea :2.35 A'IR scoo=s.

~. tn~eet ,0111 ,ooolet" tlns klr debri~ or damage. IBIow out ,an~ d6liri:; i·rom 'fin::; witl'l ~P,lii\l!!~ air ~)f(tm, 'tI'!e' !F!sloeo~ the, tOOID.lBr ;[iuw.ard ..

7_ Wipa up; <my ~19d oil on mulllc~.

8. S~ilI1 ;engl);)e. \i'ef,ffy ~hal' 011 ~e~l'Ie $igna.1li'giirt;[in linstruman] :w,ppiJllt ilUms ofiI: a:ter a 'Eett.r ssoonds. wh6fl engine speed is. 1000 RPM or ~

9- Cheo'k foe" ,aU le:;lt..s a!: oil iilter. drain pl!!1@. hnaaa and oil

'00(11131 •.

'1 il. 1'r:r9.tsIR ,chin :~iler .. Sa9 ,2.2;3, CHIN FAJIRIN6J..

11. lliistal~ air 5QOCIp :2.35 AlIA 800OP8..

12. [)1'Ie~ fOOt) 011 le¥eI. See· CIi-9ECKI NG EOOINE OIL LEVEL

.....

:2-003I~u!3l11 XEl9IRl;cMaili'rl-sn\aIi'iO~ 1-.'9

H.D. Mulli-GraQe SAE Bal'UW E:rosl-
IHO ;SIlD -dOr
1OW4l!1 {4"C} I'eIirt
-
H.D. Mum·&~e ME Abcrve
2~ H[J :360 401 Good
r- [(4'E)
tiI.D. flcgt!!k:ir ME Abi)w
_-
Hea'""l 50 HDJ60 [5D Poor
tl~q
H.D.~ra~ $Ai Ahav~
., 60 HD.300 BI)~ Poor
t2l-Cl Qperamng RenlJE'

.-

-, _.

IBR.A.KE SYSTIEM MA'INITEINAINCE

GENEIAAIL

• At 'E!\!l3f'l1 SOO{I mite (0000 km) sel"ilioB 'inbery<lll 'lht:i\CilItCr.

!Ii Whi;l1il storing Ot' fJ.lffflOliling tM ~qrOle ~(Ir the seasea.

IR~ 1O',0.1I" • .iII, II13RAKE IFLUID;:

Ftron~ brake hand 1B1le'1 and Il'eSf bl'Bks foot IpsdlaJ must hac1.'!3 ,<3, litfn I'e",~ '!o'i'h:In bra~ .am.- <.lpp~" rr nOl" bleed ~m as ~rt~d_

'J!Il'- ...

• At ih9 1000 mile {1 000 km)' s.sNiOE! ~nterv.:,:jl.

'.' AI: weli}" 25lDD ~ (4000 fm) s~ in1~ ~h~teL

IIiiSpEiot caliper artciI r:rBS'b3f ii:-'llinder ~i:1J5 .1Hd i\"t~ as It! q,ui r,E dt

.' At tha 1{!OO mila (100D bii) :::Bl"i'iDB ~rlTrl1.

• ' At S¥Bf'j' 2600 liTiil~, ~4000 IkIm). s@f'\'ie.e' in~ewa! lhelfE!"8fn:ef-

• 1E'If8l'!f 2: yea 178.

".-.. Ii' O'ete>rminlngl pn:;ib;ebi~ !l;:aJ!l:3.e:3, of poor brake atpel'Blionl, SS9 Tab3e 1-!6.

BILEIE,DIN G B RAKJES

ID\.o.lF. oi brab ifiIuirl can CiilUM irri.t.Hiun (J!f ~s mill ~$lIdn~ 3nCil m~v be' 1M~Im1uil 11' ~~~II'owedL .1' I"rge' I3mOl.m1! i(1f tftIuid Is :SWB1Ikwied~ ioolJJ~1!Ii wmitiililg Iby a.dmim.'i.s't8n~ 'IWO' lM'baesp$Oins.; lOiI' ~It 11:i ;Bl >g'~" '0011 warm watEr_ Cs'11 ,s dD:G-' klr; llili CiilEB' >Of il%!filIBb'Ii willi ,:skilflj all" t8j'0:!i, tll.lSih 'l!Nf!h pte~ of w!(Il!r: (iie,t l'iI'Iedl~131 13.'titellLtl!l!i1!'l IDr e1lE!s~ ~EEP' IB1RAKc fL!J.J][lI .oUT OIF THE, REAtI::lHl OF" CIH]LDI1i[ElN~ IF'aUur;e, tl!;!l iI?O~' oOl!lldll're$uift llil de;!l~n ,o:r '~E!rr~U!il' 1'1lI,lu1'Y.

Ne~ mix llilull.'Ii: 4'lINfI!h oll1E!f'lbrsb!i'lIuids'Csull:h!il1!i Ill:I\.liJ,iIj; ,S;),. Ul!le iIlilili'lf D.O\.T. , b~lilII!iB,1l1:t:iid in mlltotcyCI:e$ th~1: S(p«'itiJ 11;),.o:'Ii; ,4, iiliJidl ltiilill '1ft a, It'&6eltVOlr tot:ll~ Ulooll!lg dfttoerelll"t 'I:ype-s 0'1: flllliiCIl ma,y ,i!J!iI¥tflI'"!!f!1y ;dee! brakIng gb![llY I;Im:l le~d to In~e 1.~Jlul'e rMIrII6b ,e~llI!d r,e!ll~1I! In ,deslh !IU ,ssrif@Iil;::;t 11!'Ij,!.IICY:

11:J)$e @litly 1r.e~n, UlI)Qt;mltamtns:tei;! n(tT. " 1,1'1!I1E1l CaDSi of fllllidl ltIIiJat liIaw Ibe9nl IDglI!iIiliid IrtiI~)!' M'I'tiii bt.mi1 ¢.emil:!lnti~ Inatad 1tJ,y moila'tlllr,s in ilJhe air !In diirl!" USB< of !lXlni!sminsll3d Itir,~ke.1iI).!lldl m;:l,y ~(iv,eli'$ei¥ ,a~ I!)I;'j'I'klng sblil~ ;p't'lg ~e~rl ro Ibf:ab t'aiIII I1B' w'hl!1:h !1:"OIIJI'd f!3!s.''Lillt inl !dl9.illh I1liIT :5Bri:o.us IlnJ~rJI'

Use !Il!I!I'I!II' 'll:i!lIprpN CIl1U~ branJi!lI w.&ishelr8 (Sea, Pal!its, CBtlillog II'Ort IPotIit IN:O .. ) WitIillII:Ml:iIi. 4 I:Ir,~ke Irolullil. JE'ljli'ille~ sllt!e.r l!)~m:I(O washi:!1l"8 ;SIN! 1!1II11 oo:mpa1!r.lde wllh flO_T_ A, '1I1!IJd ,sml will nei! MiICIII p"rnp;eml!jl' ~ar tims.. f-ailwiiJ tl;) It:Ci'Ii'I$l1y mEr¥' a(!l~etw' a1iteet i'JnJt!ng ;:I_b!lt~ ,!!Inal !'ePdi t ~ br.,(!I~e' 1!!1llur.e wJiJill:li1 !IXIul'rll Il"eBuit ih desth or' :EiEiri~IH!18 injl!Jry~

!CI~ ibr'l:Ie $',J~em oom:pcnenH: WTllI!! !Cfen<ll_;tI.lJiea 'l:I~o.hoiL IDo, not use mi".rneJsl-lil!mBe cleanjn~ aolve:nts, I!ItlIm 13'S! '!iJCiSillI[ine ,1tiI~ iPaint! Uii1'lnar. Illig ,Of DilinQ~-bEi_se ~a.:I\lant5 ,el;l\!l!ile!i!: ,I;fet e r I e r.!;!ll~ I!)'I' r,u,b !1Jer !)8 rt!;!: lh81: 1!<'@n1!IJrIl,le!il, <!Ift,e r ,a~mbly, Ihi~ may 1f!E!:5l1Jll in im;"Pt",~q' br'ilD 'Dipe;ra'liiltiili1l whllc:.h if:ol!l'ld Iresu~l: 1111 dlN1ih o.r ~r:ilous ImJullY-

AWAIRNIING :

A!1Jm..Y~ Ms! rr;o!tOI\Clte.M b:ra:kOs at low ~SpMd ,alb:l;i' sCm,", ... Illig gr' IbI~ln.g '!iY9'-tem- '1ii!;!J I~~nt dl;!l;1'$ ,o:r ~~!j, injuTf, BU8'11 D'l6!Gommsniis ~haiE 'ilil brab repailrS Ib;ai piEiF"' 'kIr1it1.ed by i3i Bl1JI!ill d'eal'e~r or 'D.the.r 'I:Jua'lif.i'edl 'lediJnlcJ'a:I'l_

CAUiI"IClN

(:'@V.'e,' meld'ed!.{I~@t.or' ~ull'it:ii!lees ,itM right IiIU!ldie:l:iu :siwikihes and lI!IM i!:S:fB! 'whsn r;EmllJ-'ilin~1 looske l1E!seil"il!ll!l'r tOOYer o1MI otCOOiM!iJ ICI"Q,iF. 4! i!)Ii'OiRe' ifllui'c!l. Sf)ill:ingi 0..'0',:11. 4, brake 'ftujd Oll'i mclliadl-iin-cok!r' Sium.ces wilG reault ~nt 'I::OS,' melle '1!li;!i11i1~.e., $t:iIIJI'I'i!!j br.,(IIilie' ~llul'(iil tOft !j!IAlehe$, I~"!i .... en-, dliir'tI'te:m linl1li\pe:ra't'iw"

~

lI-U

Tcrble' 1Hi. B·rak:el ir'DllJlbileshaotlnQI

------------------------~

CHECKFOO

OONlOOirlONI E~i~ 1ev~F1Pl'dtcJaJllrn.¥e1 Of' :sp:m!Ji fa 121 ..

,Air in .syate:rn.

Ma::;b;t,r c:\!fi.nd I'Jf I (iI;I;I" e n fllrld ..

IRlElMED'III"

BI~ DrBke{,5;).

Rill mas! 8 r cyli Me r wilh Lllltl'i'Q1IE!Ill b Ira k"e, flUld.

~' I--------------------------~--------

lneffecthre Ibrake _

leverl'pad al troWEl's to I im it.

'Dl'Iano:riFlgl OOUFld, when brake iB 'Worn. pads,

,aPP,tied- Worn IJ. sn~ tmNngs L....x!ae moun'ling baths., 'WairpOO~_

I e'l'fe~ li;ir.'lke _,

I EJ!le ri'padaJl trdi1ll3~ n orillEl.

IEllead brake t,s)..

FiI!! me;!'ller cylinder \\iith approved bliBks, flUid ..

lRi3pla.ee brra&;a !Ja,dG.

Aeplaze, rotOli' aM bU$hl~ as g~'iliig hle n Ibar.s..

Replace roi:orr.

Piston ClIp DOt'runmiooing!.

--------+------------------------~

[]!iE.torted er gli1Zed roi)1)l)r: Replace. rn:m.

l!lIis'tclfted,. glazed or rontami'm1:eoil! Aepl~ paos. braJ;:e. IP ada ..

1Low' flOd laYel.

BIi<lM' 1P.acr.s, drag QFIJ fWOfwill iilD1! retract.

CUI1 in master ayliriClli:.r oot l.!IOCCiVel'fhg In!;lflect mEflHlta aytinder ..

I"SIi9f pott.

Re Sf b lIl3.ka p.edal 1ift'k:8..'QEI IlJ u~ 01' ~meF!"

~

liiiU mai5faIT c.y1iOOE!r' mill ~roil@lj

bliBks· 'Fr.Uid., <liW mtDcJj S)'"SteID.,

Rebui((l cynndef-

IEUeed;ng F'mnl Brake

NOTE

H'ytfIaI'I1Ic b.r.s!ke fluid b,Iadrie'I-IypO (lf~'IDre ~r. run 00 ,USEloI fa 1m ffte bmke ma'StEi,F cylinder UJrQlJ¢l ,rhs b!seder ~.fve rt ~ cyfin'dEilt .r;c:scnonfr (liil1lBr is faIOOvsdl ~o prt:'W!nt pre5S[[riGJJOr~

1. Sea figurE! ''i-ti.I::'J!;;i1 end af-'tfaS;.ic tubin~ O'fer !'on;- caJ!per bCee.d81" vahrE!; ptaeo Mher eoo in a dsan OOI'1l:3;lner. 81.a.f1i1 i1'J:().~Qle upright.

CAUTION>

. ~.--..

rGgwr mClhled-lliI-coIlil!r :s;urfaDills Mild II'ilglilt IitalilidleDat sJAlftches. ,Bool lIJ6er elIlf9 when ~llI1o.vl'ng b·rak.9 li85ervdlr '!.l:l1J!lor Md ;a-tli;£log nOLT. 4 IlxBb 'lI!.i.ld .. $,pi [[lng' IOr.O.'f. ~ Iill'1!l!ke fluOCl 00 Ir:rflliiil:OQ(fj·ll\'II--Oo~I!l!I.r. !3Url'S&Sr61 Ifl"jll liMilflt !I!! efkSIil'iMlc d.amage,_ Spl][lng fu;ra~ 'Hllliil!l on $WItches, may I'SIliller 1h8fll iIl»DpBI"ilti'i'Qi.,

~~ c:.o.v.e:r Wdy SUl"taces, night h.=.ndJebOlr m.rlt<:bes and insLfumenl pan. to pmtact from :spillb.ge .

3. S~ Hg;tlIr,a 1-,7_ Re~ ~ lasteners frorm ff\[ln! niasler 'grfiI'IdCt" 0Q1.l'e!"-

4.. Add ItO.T. ,4, DRArKE IR!"U[D 0 master c:yfinrjCi' reser'i'tJir'. BFI~ fluid level to wi-hili1l 118 -Ii. ~,'3..2 mm] of moldedl 003a iinE.'ids front master cylinder:

NOTE

Do not feuse ~ fIuid_

5. lJep:reS!l;, rslaaas and IJil2fl t"to'Jid br::=.ike handllswf' ~o [:JlIjll::9 rlj'trt~wIlC p:re~.

16. Qpeli1l liItaedef 'i.'aI,...t .alXJtft '1/2'-;wm oountBn::Iedl.wlse; brak4li nUiClI vdII flow from bleeder 'Il"illYO aM Ihl'!!!ililgh tubQ_ When bl'8!a leval' has moved 112 ~D SI4 oti i~ 'fUll [;!lmge ad' tr:"diWIl. dose !Jlel;!oer 'I.'B.I'ft! {d~l. Allow !l)m.ke ~elf to return dDwty tu ils re'!ea£ed poaitkm,

7 _ R.epE!aJ, *it8~ 5-6 I..mill all air [bubbles al"'9l p~'L

8,- TIght,an iroot caJi[!i'Bf' tJl(:;(.'dcr. lial'ofeB (metric.) to 3.&00 111,Ibs. (4-7 Nrn)_

Sr. 'Verify master cylindi3i Iluidll~1 as described rrn sbsp 4.

10. Aftacll OO'I8.r '0 rrorrt rna~r cylindlar relMl:rYOJr and

'lighl:en lastener to 9-13Iin-lb<&! (1.0-1.5 NFfI)- ~

'1 ~. RBroov.e cover from rtiIOldeo-ln-oolar BtlrfaceG. rigtlL 1'Ia11- dlooar ~ltcbaB and irTIE.1rum6rllL P3J1!CI.

,:J'

Bleedi 1'191 [Rear Brake,

Hydnw1ic ,brake ntJidiW~I'1YPI3'pr;eSBUre 9flUWfl'li!'ffl' ~fi1 be ,LllXla 10 Iffl ~e ~.~ I'I1sslar q.iI\'»e.r rJumlYh tfre tJ.'e.9ttar v8}lte ft mas!ef' C!jlinder,~ r...OIlE'r is I"6¥1'I'CMlld 10 pr~~' P i"SSS LrrizoHirm.

1. SSe F'!!!lure, 1-& Install endl 01 ~ie lUhIng mrer rsar calipBr Ibletedl31' v.ak"e; [li.3oe olhetI and in <li dean C'(!IIiJta.inar. ~ IIII!MO'IC)'cle u,prigilll.

-

CAUTION

ODVe U m ctl il:iI e eMM.;OOIIo ~ 8 u1'fB.cs IS an ill 1\1!!!]1tti It1a mrlle nil r Siffl.;drlES and usa Cill1B W'1'I~m r.emmri'lilg brab i1Cservdlr !c()~iI!'r and ;;m~l'n!!iil iO,.o.. iI'_ 4 b.ra'lllB Hui(iJ. SpmJn!J 10_0:,1; 4i br;ao 'IMet @1fII mcldBdhin-lI:ollt:!t" S'Url';!I"Qe!il wiU I1B.l5ul.t tn ,eGt-, IID;:.Ir;: den:utg;e. ~iIJ[n, brake fluiidl on :sw;ildites !'Y'II;fY IrEn-' dM 1lhem i1ilop;er.atIVre_

:$_ s89 FigufiEI ~.9. FterrKl1.l"e cap and gasket IrOl1!1 rear IlIt3.oe.IBr cYlind~ rp.3svoir.

4_ AtI(1 D.O_T. 4IBRAI!(JE: fLUID to, rna$1er cyfindar rg~ewolr with mrjio[;t;~ ~rtgn1: (not on mEl:5];loo1- Elling iIluXd level betw"e . uPpBU anClI(l!N.er markE on ~r-

5. (l E!fI lie ss, reIIa 83e <Ii n d '1flM.l~ Ii1ii) 11;1 brEI ke p€oi!la I to b u i I (11 u p IirydT"dlJlliC 1.1'1;e~e.

6- Open b1aedBr votive about 112:-t1lJm WUi'lteroir.d;wise; IbraJ<.e luld will '1'lriJN 'from blrilCder 'ri(.iiv:e and Ih~h l.uDing. When brakti pedal has roowd 112 tOo 314 of i-s fuJI r:8Jlge (l'r travel, dosa ttaed'al v~.I'Ie (ct~:>8). A,'1101N

b~ ~ IPEd'a1 c· raturn SIO'WIy. to Is releasedl pesitien, ~

8, ilghten raar '~.lipr:tJ ~leeoe.F 'i'B.I'oI9.B (metJi~) !(J 3fj-61;1111il1- 1b5 (4·'7 Il,fm).

11;11_ AtlBch OO\I"6JrS to t"N!W-I cylinder r'sSBMirs andl lights, cap 00 re;::..r rnE:~'t£!r cyfndl3r' FCselN"Olr 5lE!OlJIrel:J'.

AWARNDNG

Afb.:r in!.&fil[lirtSl ~', pllIll IlrpwBiTd '0'111 Iftr:o..nt (Jf !!leal: 'In be wile I,t ~~ liJC~ed lin lposilion. fI' se~,t ~s loose, it oooldl $111m rIiIuriin!J w'n'i!t:kIr rOpe.rallO:f11 and iliifiUil9 the rld'er" causi':ng JDSI5, ,Of rt:Onlrol Vi'1'dEh CIJII!Ildi I'rBSU 11 In l!:Ieallh 'OF lier iuus ~nj;uiry;.

H 4 200S BooB XB'9R; M:![n.te:nan.ce

.:."

BRAKE PEDAL ,ADJUSllM1ENT

Aft,ef oom:pi~tln!J re;pa'irs or breeding Ute S'!;'i"l'em, always '1:i!!is1! ImlmreyGIS b[a~eti. ,l!It ~OW' $l~ iii brail;as aM not IiilliJilllii.tn1fl!l l!)I"o.'PE!>1'I!iI' ifiI" II:waJliing 19ftii'ci8lilr!:y is ~~, '~r11li!J 13 t h ig h :apes .. C<!\!Ildl lie $'" I t 11'11 de I3lih lD:r;8 ar ieus ililj i.if)l'.

C h eel!; reai r bra ke p;iEid aI (J pd>m'll'On:

• DelOre every ride.

• AI 1he 1001} DE (1600 kID) soeace IntelVEiL

• AD' every.5000 mile t8llllOU klJI) service in'I:elVail ilhBreafl.el_ 1. Sea F~ura 1-10. Me&.~e distance irom bo'Ifui'lil of mas-

er C'I'fOOer (i) ito canter oIlkm'liilr adjusler rod clevi8 hola (5).

;1. if me:;isurement is apprn;t;irlililll,el!l 3 In..

p'7 rnm -fI- 1 Iffln'f). l;J~e' pedaJ Eidj~ma:nt is net neeced,

D. If m~rriE!l1iI:Einn is ,noti '"~tl- I $peeblioo.. adjuot bt"aka padotl.

NOTE

~ FfgIJre 1- II'}. Mlfflmum 8.ilcrrl/B~ pusifrot1lttr~ engagemC'r'11 irJs.ids· cJevis(4).iS 0.24 1rI. (6.17 fflIliI'_

2_ Adjus.t make pedal.

8. see E=iguJB 1-1 0.. ~ locknUt tJ) nila, h:i!lI'ldirig rOO ~~us.ter' (:2}. MD¥EI kwcknUlj away fr'!:IFn lr:tp' 5;1Jrfa:.!::e ef turn bud'_,;j~ {4).

lb. lilJf1'lI"QQ sdjUBber to Bat pe6all1E!igJM.

e, Re1urfl Ikidtlnu~ lJ) to fit 11Ush FigafiS.t lop ,surtace- or dlfWiS.

NtJI"E

8J;s(k6 pr:.rJa11l~ n" fn:e play s~.nt

1. Sono:m !IJ.'i' ms:Bter cyliooDF :2. R 001 ad jU1i'm ~

3. "'O!ekl\'l,J~

4. Ci6flfil6

!5i. C. lev Ils Dlnl

,2003 EI ueill :XB9.R= IM'aim!3fltlm19 ..... 1-1 !;j,

,AI'WavlS, te;plEilli:tII br<ih padS In IOGf!IiI!;!II'e'te $e'!!iI; 'fQ_~ i!:mrec.1!: bra:hlBI gpaJ,BJio:n. N!3,~w re;plalt:tII ,jusa ene II::!nke D~d. F~II- 1lIf8 Itol in~tlil[1 Drr8I!i.!31 p!ildl5 <is, a :!:ira! &Oulldl r.esuLt [In tdWIil OJ'

I

01'ieck brae' Ipad.::!, fur minimum 'lM:knB:xi:

S!3e Fi(lUiB 1·,1'1. 1~,lJra~ p~'Itf{!amrlage 1,')(1" e~Ms \Year. R.'e'p I at. !3' oolfl 1P.1CllS as a s~ il '!'!"1OtI0Iil ~rial f!!f eilh.er pad] is worn ED (I .. MO in, t 1; ,I) f'nn~~ QF less. Ir IhlS aflilOunl of .... Bar occurs, 'l'f6ar gl'OOVl35. ""'ill ~pCat from 1rildl(i!!1ll~ ri all BlJ rfaee,

BRAKE ROTOR THICKNIES,S,

100, nO.: ~llow ibliaK'.e' ~IUlll:l'. i:)e~rln!!l g!l'e!!!~e, ruhrlcar.1.tSi, et~_

~ . 1-,..;1. .. I '-.. I""""'_' , ..... 0 '~"''''''''''I''''~ _""","",,,,,,,,,,,nil,,, I!!!r. ~

ILD !IXIR J:I.'Ii'L IliJfil_ f"".... WII':' "" ... ~' ... "':;p 'u ... , ... , .... ',!I'I!<'! ...

lI'"9duc!3id lbirakiing ability 'will QGGu:t:, wh'leh 100\!I1d! resun Ilfli dBatIiw iIlI~ :senO"u'5 imijurry.

~ . M Ba:5111Ei ,(\[Ito r 'INclI;n 1355 .. HGfiIillDe rO I\tI r i r fIIi1llilf1n1trml '(1'1 I ok.nesa is leae tben 0.. 1 a: in. (4.!5, I!Ii1m). R!3~ dri' ... e Ilushr I~ fagtenera~ wash.er!l; aJTid ,springs whEfilE!\i13J rob:iir ~ iiq)1l.10cd~

2. Check rot-nF 8UriaDa. Rep I aes if 'UBIfIBdl or baaly i.>J:::otQd, ~ 2.5 FRONT WliiE:EL Of ,~Ja IREARJ WHEEL ifo~ Iprooe·, dl!r:ltB.

11. Fili eti Qi.nl mMell'ilaJ

2. WeBr gKl!l!lli'B'

3. BEile.ltLili\gllifla'tCnill

,f

BR:A.KE: PAD IRE:PILACEIMENT

.r--..

Front Pad RemovaW

1. Sara; f'igure 1-1.'3. n..oo~I1 pin (1). but d'.o n.ot remove-

2. ~t!tte "meel's SD fut ~e~ is rentJ!!redIIbBt"'o"E€fn rolW liOOunlingl r~CFlif!l$ '2J_

3. RE!1"fiIi!l1.I'e liJIII;Isr mlipar moun1ing Ias'tener (3) 1hat ·E~.Ir'B:£; rulii'C1 to ~Or1(!Iower. I

4. ~ Ibut 00 no! Per'JIIr)1I'e !J.Dp-er ~r rooun_:ing lastcFJet' (21 'that secures ea (P8[ to lurk &owe.f.

5.. Refi"lO\(!.'!: pin (1).

1$. Rcl9te ca.iip!3~ o!JlJlll.Ci'dock.Votse ito allow s.re!355 to outer pM,

7. RemQ1.ie fIU1e(f pa~ j'J'lJtIii rig ~t~.

8. R8move inli8i pa_(;! from left -s;de by pulling rearward\, mtaJln~ pa!lil 00 degrs!3:G. andl pulEillg ilhml;lgh wh8e! open· ing .

. r ....

Arent Pad Installliation

1. Pium piStons in !,!,11th suifsble tool such as a dean [paint sarJ;lper untiI'fully saaW m bores, as (:l3.1efUl oot to earni3.{1B rotor.

:2. installlllew' il'lD2r side. pGfd from Ian side of mo.'!orcycla :3. In$tslllAew ootar pad lrom rignt side of rootorqrcl!3.

41. S8!3l Figura 1.13, In~ pin (~) mBking sur'9 i! ef1IIJSg)2.3. hOle· on bo;h [p8d's . .andl'i:jPring Clip'.

5. Rota's, oaJip81 ,c:Jodrn,Ils~ to ,align mOl!llill:ing lilrsLcner Ihole. lil. See ~ure '1-13. IIiS! all IU¥ieF ea sr IliOOunJingl fastener ~2).

'7'. T~1'1'ren bO(h ~Iiper IiTlcmti~ rast&-.i'lCFS (2) to :3.5.-3] ttlhs (48·50 rim).

S. Tl{lhtEln pin (1) to '1 H s 'it·loo. ('1.5-20 Nm.'.

NOTE

A:ltold malcir.Jg h'ald 'S~ .(r;Jf 1M IIFSt 100 miles 060 1I:ffl!) to aD'oo' illI_ lIflll'ke {)ads' ID "we.i3r.irJ~ properly oo]l-j ~e .r:otD_r.

1. Frcont i::i!I~ ~per p'i'n IP I L!.E:QI

2. ltiI:otor mo.um!:ng tt!l~I:eflIeJ" :3. lCallper mournililg ftiIEIsnBf'

1_ $~ F~Jre, 1 -'114. AemCl¥.!!! ll"e.sr csllper pJn !plug! (2) and 1~1~,

2. RaJnove two I11OUn.'ling 'fa&Bn~ (1) and] brakE caipBr

earner ;assembly IFOOl rotor,

:l. Re rTICf!.I'8 pm.

4. Rl:l1i1!::f!AIi P-(;I;)JIIFi'. 'IIiI'(;! ~rm <xM 'rasteflC1" ,QI'II S'i\I~nm_

5. Li:tt caliper IlIp and off of rotor.

G. RBITiI1,.1'1,ITli irlll€r .find! i[llJl8~ paos.. OOiFig 'C<:1 roru I 001 .0' (li$lod'ge ~ springJ-

Rear [Pad [In.a,taUa,tlon

L
2_
-3.
4L
5.,
'\ 6.
7.
s. Cham. 1hat 'forward guilfe clip' is. pmS8Ilt.

S9ri1> Figlll'l'E! 1-15.. 'cneek I.M~ pad .spring ~ p!'E!$entS h ouIId pad B P ring beo!::Gni eo d i 81 od'g;ed, in 8Il3.1] lA'iih 100!i!I ~ IOn piWln sidra. 01 ~r,

Push plstQn In INiU"i sl;Itta'ble' tool suOh FJS ,8 dleFJfIJ l!l'Sim scraper until 'ull)' :seated m oops.

I r L"<:i1i!1l1 IIi,n iI IiI3 r an CI oolr:!i bt'a'KC- P aes

See Figure ~-14L lnstall pin (2) malo;i~g aure p-jn eng:agsB hole 'on b~h pam;.

install I)l\'(:tke camer wt.h mo, Rw.!lJntlngl fasteners (2). Ti9hte.n la&teoarE D,24-26 ft-lbs (33.-35 Mm).

Ti~1StI pjn 1.0 11-1.5 n-Ibs {15·20 Nml,

llnstall pin plug (2Jc Tilqhten plug 'b:!! U3-~5 In-UI!IIi (2- 3 Nm).

NOTE

~~ l'l'/(tkll¥J ~ro ,stws f(.ir II¥! tm'lt 1{.1(,1' mI1E!s ('~IfiO km) ro allow I.NiIW b.r.:iIho!;! pads to ~ar in" pKJpfJyly Will,1h8' .!ttW.

IRJ!lIIr CS:'l~peT rnonm.ting 'fa1iltenelllll IRI:Mi' C;ai~pm' plIn plili'$l

FJ;gur.e "I-Hi.. Resf' elan PSid Spniing

TilRIES ANiID W'HEE,LS,

1,.7

1 TllRiE INFLATION

- -

AWAFliNING

Ii)o !not Inftlfts 81lW 'lire 1ilis!f'D'J11!i1 its, miUilmum Ilnllidloo pr'BI!I~ ,!;lIIre ;,1$ $l)eci!led !l)n 'lfre sddawa'il. iD1l8rillrll'<ftij:Jn filiflY IIl:aUa9 til'B 'lie s.'IlIddlillnl~ Clt;'I'late Wihlelil ~ul\lillre:!l;ult lin dB'ilthi er ,:!; er I:ou~, 1l!iJ UrN'"

Gtiaoo til\B pr'BSSUI\E! .:lind ~d.

'.' IEh31br~ C\iC~ rice.

'.' At the, ~ 000 mile ~ 1 000 kim) ~l"i'iOEl ~. '.' At ~I)' schadUled 'lServioe ill~1.

em C C K iI'o r PJO:p e r I'rom anoriI PB ar iii lie P ra :»\II['e:5 lMlIC n II res are cald, Compare PF8S5UIiQ agaiFlst l"a'Ole r-v,

\

PR!i$$IIJF.lE FOR SOla RmlNG

PRESSI1l!HEM GIY'W,F.l'

I--Fl'Orl'

313,PSI t-----+~

aa PSI

IRi3'<:lJ

:2:48 kPa :!!62kj;);:,I,

litRE, REPlACE,MENT

Tire 1,!,'i8aF ind[ca.I!oF bar..; nil appear on 'tlr,'e 1:re.9d surfa.oB5 when l'/:l2 I~ (III IP..sB of 'tin3; tl\Badl reumaD;.. Amms (In tire sidewall::; F.MPlJint !hx:<:Ilii)f'I 01' wear bar in..cflca:bJlls.. AIw.:li}':5 ~' tires tfronl, B'SrviOB bax.Il3' they rnact'l iItte ~TI:"'!a1!lI wesr iwrlic:vlJ:)r OOI'S p1.:3.2:!O'r an incth ~1$3!rl pail!':BIlriI d'EipIh I"I3fmilillil~g).

New ~11fE!'S, ,:=.ire' neede'd, if 811Vj!' of tha, ~ c~l!ll):n5: ~ist. '1_ Tire, 'WSBf indrea1nf bars l:Ii:i;;,;~rnr;:, 'i'iS'iDle Ij)n 'the 'tr!asd :e.uf'-

~

~

2. ilre ,oor,ds !!!IT IIBbli'E ibBooms' Wsi~ lhrtlQJh ~ :9idIaw:!IIi:;. ,SrlilIgs or deep 'C'I.Jts.

3. A bumP'. bu!:Je er split iin tfu.e lill3\.

~. PurH:ib:lre. 8U~ or' CIIh~ damage t(l; the 'lire kit camooot be !'E!fIE! I red.

~~~

a SiiQew.a[I

4 7LUB

L';-~ [:-J.;:;

--::==--=- ...!\.

WHEEL BEARINGS

NB'I!~' use 'QgfilPIfe$~et! e'ir' to, ''aplin-drY'' Deariingl5" Very high lilea~'ll1Ii!I :8peadlS, ean dam<l919 WilI!!Lbrr.e~te-Q ~:;Irllil!!!l!3_ spinJilin$ ~~rlJ!!J$' wftlillCii;lnlj~d air can 111160 CiliblH ... baari:l'Ig ibo i~ s.,'Part. lNiiIielii It;(lult:l resun In !I;i'eatlili o.r, aedow:" inJ1!I1'Jt

GhQ(;k Iron. ~M rear wheel ~rin,~ for waar:

• e~!)! thme-:=.i \'Ibeel is aBmovadL

• 'When Bto:ringl ~F r.l3mlJv'ing If~ l"fi"Iu.lflfJC)'de '~r ~he se:=.ison_ Chsdl; Iron!. m.ccllb8BJ1In!J=

• AI' ~I'Y 5000 mile ~8il)QO bm) ,ElEINiDB ~l:;;;(r't<l.1.

Chedt: rear wIileellbBillfmg:

• ,AI wl!!IIY ~ 00iD0 m.ce (116:£100 krn] aef1lice in~al'\!aL

Ch~ whe-elli;l!e:=.iriDgs "tor '11138.1 and iOOfiCISit;n. ~sWC ~y or roughnsss mdiGi:lf.es wrfi bearln~~ Replro=. baarings in sets: (tflI'rt

C~, !raH$ff!IS!3lofl fltlllorl revel:

• At Et1!!3fY '1 GOO mile (1600 k<ln) seretce Irrt..;!I'\IFJL

iii AI, ~ry 5(t!l)!I) mlie5: (6(Jt!¢l km) Beni.ice intenial 'ibc;fiEIiilfte~', tR ep'1e De ~J'BR3.Ii11 i asiDn fl~:

• At the mOl) mile (~600 1!'Jn} $~ inlenr::li..

• At tE!v13fY 51lOC1 mile (0000 Ian) servioe, inteNEiL

TFBmmissiDn rJuiai c~ is ap~im:=Jtel~ ~ _o iilIuart (Q,9,5 lIte.r}. f,Dr beet reaufie, drain lluidl while hr)t

1. iRai;::e' rear wh_eel oft' floor USiI)g lREAR WH Eel S!!,,!IP'PORT 8TM[JI (PaI1' N'Q., 8-41 '17,1j} Thia, plB\'.smcS ~1'BFIiSmlss10fl 1II.~id from tspilmg o.u~ of this dult;hl ins.pr.x:UOf'l, cow r O;P 8 nfig.

;2, $ee fig,Ir,f,! 11-1,8_ I?tJsiOOn i3! :E,lIIib""tila conlai'li)Ei[, lllAde~ drain [plug!. A8m!J~ ptug ;;l[~(! drain '1']1J1dL

'\ 3. Wt~ an~' 'rur1eign ~li:=.i1 lrom ~he rn::.-.gne1ic dliBin phlJ8' iRem.tsJiJ pl~ BMltig,htBn ~!J' :29-31 n"",M (39-4!~' Nm).

<1,. 1R8f1i1.llIi's IhlfF.i"oi:1 ~4"aMrs and! washers trorn c:lutm inapeelion c~r. PiP.rnJJWe ,ch..rtm ifTispactioo COVEr< witl'l ,gasKet j'l1Jiill primary ~.

CAUTION

ID'O, 1iIQ)'1 ~er!iUI 1he '''~n5l1li11!3s'I!ll!1l1i with iil'lllidl. OV&rifiilli~1 msy csuss, mlJllh cluf~h '8fi1gil~fitI&JlJt ,i!IIli'idlI1!leeft1J)'e'le iEI]!3:- 91iljQ<i.jfjJ!Ilinl!lnt" Itl!ll1elill Cll:i!ll ,:;!in~r, dlffll:::1lI1ty Ur:Ldi.ng nsuhaII 811: !l!1i1;.glme Ml_e.,

:5. Se8 F~Ur;i;ll1~t9, Mel s pO IliIT-TA A:N s FWID (Part No,.

OOa5<:l,..91J quart size; Pari! No.. 98$55·96 ga!IOFi sIre) a'3; f0qUi~ unll! IIUI~ level {S) i'g e'.-'en with bottom of dllbth diaplva>gm ::;p~ (2'-

6. :sea, F~um 1-,17, lRS4aill ,c!~ iFIBpediDrT. ,oor.ref tightsn~ 1hl"BE! mstEmirB 8IiId wa::;h8'IS to 7-91t-lbs t 10-12 r4m).

7. Clean u,p any t1uiail1i12lt m<L;f Mve Sl)lIledkil'1l muffie'l_

F1!g1!l!'e H 5k. lFluld 1L~1

.........

A,DJUS,l"MENT

GhMIc: ,r;::ll)tm a~'lment

~ '.' At hel ~ 000 milS ('1 ,,600I'fI~ $P.N,1De IntBfWI,

• .At r;w(:i)! 5000 mile, (9,000 km) 8elVica iri!E!r'VilI-

tf I;,;llrlIth sues uFiOer load or .mr;sfls wheli1l rtElh:!'a~~, nrst !!::heck Don~J'[]IIc:able'~.rflCnl. 111l7o=.I.1Jfe adjustment is wilhin spC-CI!Ieauens, :;idttBl cl:utt::h medianisrtil <:!:.:i, ('J(.'Scrioffl belmN_

When nE'Ii:i3GSilIl)'. lW1rieat.e cable, wi1h ILUBIT-fI, TURJILilI CI-lAJ N AND CABLE. LI!JBE (PBrl NJo. H~..;a9.6!Hr.5TV).

'1 . Raise rear \\rhe~ 00 'Ioar using REAR WHEEL SUPPORT STAND (pan ,Nn. 8.-41 ~ 74}.

2. See IFI!iJ!.lrre ~ -~. Slide rubber boot t~) ~r;d to e!(pDSBI adjus;te.r lrili€denism. ~en [am run (3) from Mjt,!lSW ~4). llIm adjl.l8ter ito .s,OOrit8lill ,oable' ho.uSing urnll there, is a large amount of fre8' Ipla\!, at dUtch h:;loo ~Br.

Sea H!!iILilra ~ .1{, Refl1JQ1.l'E!' three 1lti.1Ener:s. BDtiI was tl ers nom ell.Itd"i mwBCt!.OO tOO1I8r. Ae~ l:JUtch Inspection O!l'il9f' and gas.~ rrolll p;",irnAry CG'i\sr.

See Figure 1-21_ RBI'T1C!Ve Sf,JIirigJ (1) aM !Qd.;pla1s1 (2). Using 8, flat 'liP .saewdrlver,lJm s~1ino amm (:J.) cOOfIrerdockwige until iii 1ig1Ti!1y baftoms.

Tum B~1ing :5OI"EW' olodkwisc 1 t4 fum. Im<taIIlcd;pl'ats :and :;,pri~ on ~In~ 5cr,ew :Ham. IIi hex 00 kiekp41;te QQe~ rocrt align Ml:h recess in ~ F<'IJ'FIp, mta'le .B~in!;J

SCrBW 1t.loch'WiSe unlll It aBgnB ..

NOTE

Sp~ InstiEJ.Ws iiJJl ilJ.I1tbiJam side (yf hGit ltJ~e_

3.
...-...
4.
5.
"" J8!l1lII'lUl:

A djJ.[l smr

F~,ure ·1-.21if. Ctu'tdh Cali'ile ACljUS.''e.l' PirIei:iIlam,lI9m

D IIa p!;l riB gIT!! iIIi pri IiIlQ L..DC'kpla'Mi AdJuBlln!31 SClf13W

:2003 !luall XS9R; IMwinlen:;ioee: 1-2~

6. &:jusa~E! dutch, hand iev.ar toO m.mmuliFl limit !hreB !iITl!2l5.

This sets tliie baJIl3.nd ramp' machamism_ IP .. outer cablE! oono:!!.llit and! at the aarne ilims' adjust 'CElbls· ~juater !D prn"/h.'Ce '1 /16-1.1a m. ~ 11 .1;3-32 FfI fIiI ~ lree play a~c! IJ t(:h nan d I s"r r; ArljuBt.as ki II D w.s.:

a. . See flgUiC 1-;22" Pull ~ctrule jertd 01 ~.~ hOUSIng) awa:..' from b~ Gap betwi3efl ferrufe. and br:acka~ ~IJI(!I be 1n fHIM In. (1 J6-3-;;!' f!1IOO).

b. .s813< fi~f'B 1-20. Set fuee IPlay [by ~uflllin91 arljus.ter 1(4)_

e, Tlgl'Il.B.Il,j:fm fillii. (3). ,i:1g~ atljul!if-er {4)_

!l;L Slide boot (11 'Oller canfe ~lJsteiJ mech~. "- Change or :=J~ ,r;;mS!TiI~1l tHl;_~ Jf lI'!eoe~ry .

.s_ :SS!3< fig!JJEi t-'l7'_ I~alll clutm ~ioo rOO'I'~r and galEIk'ell!l'Slr~ three f.::I~~ners ;rrIld wa$h~ and ~1gnten to 7- 9 lt-lbs (10-12 Mm).

'9. C~ CI'Il.!,tel'i ~ nee ~ Sec ~cp i:li ,[jb(r.Vc"

, ....

DIRIV'E IBELTSVSTEM

1 .. 9

GENIERAL

Th~ drive batt snsion 00 a ilICW belt '1,11111 be oonaideri3.tilEi lig'ht and will Il)()$el'1l after ,BpprmirnBll3l).' 1 000 iIIil~. line drive belt tensKm is aul:alna1lcil!lif acjusted by thai idlEm pullW, Axle I':IlIgnmern ia DOt ,~1~,

Chad;, drive Del! at1Id lI(:I!er pu _ 'oond~ioo:

• AL l1'Ie 1{100 mile (1 i$OCIlkm) .eervica irni.erv.a'l,

• AL ~I"j' 0000 mile (aOfji) krn] ~ i'r\1.e.tv.aJ.

Replace 'd!!lVe'lbet~ end idler pulley a.:5SE1nTI'Dl!I;

'.' At e¥el)' '1.5000 liTlile (24000 Kin) seMce interval.

IN·SPEC:llI0N

[Rear Sproeike,t

NOTE

11 ,t:l.lrome ~'ps Dr gr:Jf.JgSs fa I,Elof' ~t are /.f1Ige enough ,I'D tJe f?mrn fut III Ely wm Ie:m'e 6i p.!i'lt€!fliI 00 ilTIs ,tJel1 fcOC:'E:1',

'1, Jns:J;lect e'ach tooth of raar sprocMlL to'l'~ B.. Major toofh liblila~re_

D- l.$ge chroma ~ wil 'i s.Mrp, eCl~ n, GiJlllQl3:'li ~ bY hard objac1E.

d ~Gessf,ve,l{js!l; ai' chroma p'l<!!ling [see :Step 2}.

2, To, cheDk il'mromB pfating nas WCffl (iff. Plir.Flg a ooriba Cit aharp ik.Jni7f13 point M"~, 1t1e bennm c!f <I !ijI'tlove ~"2) (between MO teeth) wifh fnlSdium pre$S'I~r;e,_

a. If sttObo' or tn.ffe paint ali:d9s anrnss gtoO'lol'e "",:!thout digging in or ~ ;:tJ v~ mark. chrome p.lii'IJffig rs~HI,g~.

b.. tf scribe. or knife pClinl 'dl~ Inl ;;1M leavaa .til ~ mark. iiL is cun.flg the bare BlmUnum. A I<nl£ie ooinm wi not Ipenetrate the dir(1mc p!atlng_

:3_ R.eplao-e rsar Si:'~ If l1I1.r itooth damage 0(110$3 01 d1:r.a rna exiSts..

Drive Belit

Saa Figure '1-27" IFl!:\pect dJiv.e be(t fur:

.. CutB er lIl'iusuB.1 'fMiIilIr lP~ncm$ (lifI bath aides, ofJ be'tl

.' Ou~ eage ~lIiMg (8.). SorTilE! b~1ii iiS cemmon, !but il indic.3!tes [hill sp~·.F.ire, rriiss1igned.

.' o.u~c surface, for aigl!li3, ofJ :sf.lJn61 pllll1durc ~'7). ,~ erackal damBge ,axis$ Itmat ooge- at bett, re,pIBDB beJt - - Q(fi. ,ate I \i'. [Damage til) oemE~ of beft wi require oott ~ ~n~ evemlJa.!lj,r, bum when cracks e~~ 'b!!! edge Gif be2i:. ban, fOliI~ is. Imrn'inen-.

.. Il1IStl)e ,toathed pDrilioo). of ball [(N' 1!I!'i~ tenslt:B corda (nmllilally. ecwerodl by n.ylolilJ la~r and 1I::l[:d~ltir,yletiC tayerjc Thls CQl'1drtion \Nil] reautl iI11 belt fill'luFt} aM In~_1es .... rorn transmission s,prflCkJ;}t teem, ~epf.a~ bet!: and brcUiSliflis· siOrli ,spf\OC}re.1~

• ~flS of pullillture Of cr:a~ et Il'Ie ease of ~he beEt t£!~h_ Re,pIMIO! tiel ~ 'either oondilion am1:s.

[Idler' IPu'lle,y

Irls~ i r pUlle-y full signa 01: WlE!V6fl '~, fx.c'esshre ll"ley er I"Il)l,Ig~sa: lindical:es wonll::!Carlf13S. FI~ll3iJB idlB~ !pulley' ~ an aEl58lll~_ 800 Io'lIowlng ~ioo:.

CUEANING

K'l38P din, grease, ell, ;'"{fld Jj'ebns 'Off ~he, be.1t. idl'er pull~ ,aM .spr,OOJilllS, Clean he drive bell with a lITiilCl soop a~ 'iN.!01:el 9f.!1F.Iy aoolli'oo ,88 Ireq!lliretL my 'Il1Io~hlw. Do Ino! immer.se bell in soIuIilm.

D,R~VE BELT R:EM OVA.l.

~ _ Plane a ,~slJr' jack l!J'H'Jer Jacking point a.rnd raise p~ill wheel off gf!J!!Dd. For loca.Iiorli (II ~ing ~Int see' F.igure 2'~8..

::s!.. PlF.lllO'!.re' right aide rid8u Iootpeg: sup~n Ibrack:el_ See :2.29 lFOOliPiE:G" JilE:E.l ~UAAO AND MOUNT_

S_ RB1M"iI!3' right passEng(::J ~!;pegl '~!\ppa.:.rt bm!::ket.

.41. See FigUIB 'I-:~"'_ FI:emo1.reI 'f('l[ln~ :;~e't c~r (5). by PBrilOIi'"mg 1IlS'tene~. See :2.30, .sPROCKET rovER,

ncrr,r;::

TM ~r chin falrfl¥1 (;';"Sfi'.nBfB rnus1' DB ,F6¥T.I~d W ,a~ the mom EifNOCks~' ~, FmrJ1 !l).eJl' ~A~Nj (4) will' ~n,gJB OOJ C1Ii'~ I'!'Q.( .tie' rEf.tlowed.!it i1ll"s i!ime..

5,_ SCI';:: Figure '1-2,'~. ILoosen raar ,axI8' [pinch fil.!!itsneii' (2},

EJ... Loosen raar i3i:de P l' ~ppl"l:l((jrnately 15, rQt;;l.tiClil!!l; to allow IPartia11.ansioo to De r~~ i'r0ll1i1 raar d'rii,!e :e;ystem.

7'_ R£~ Idlf!f IPulfEj a!~ernbl)' htt reroovi~ nllfl.s @~ ,'i'i3.6her:&. Se!31 IDiLER puLJ.Je ..... ~E:MO\i'Al in 1_'9 IDRIVE BELT ,s,YS'TBMc

8e Sse Figllitl l-,g4. R~ low.er bet~ guard {3} by' rarnevIngl fastaners (iJ.l-

91_ RarTilCfll9 upper belt g;m~d I(~ e'l by remGVing 'fa:&8nB'fS (7,.-

Tha ~ ,oon ~rQ J.s ,jJ't=Jr.hEd:1'o rhe S'II~ b.r~ .:i!J]iJI if:S'n oor. be ,1'"6w.)D'VEId ffWn rvGfJJi:;.£t:!' 8t' mrs i!i"mf.!'.

10. REHlil[l1,i"8 ~O'Irifn 'brave, See ,2'_ ~ 9' SWINGARMI ,I\N[). 8RACE_

,8_ .R:a1i1iOV13< fasLBna ~ ,t B) an d s pa"Ce1 'co 1I:=.t r (:2l hElt'i'fEEill upper !;lett ~rdI ~1 ~), mer beIt gua:ro (1,) ,i:ltltl S\'MgErm bnaca

bl ,A!ICW! Iinne-r i;ie2t IguaJl'll!l (I} 10 drape.

MOTE

Ifmar lJi;;o,IJ':Q!!tilfiL1 {toes i'I"(,(f ,~ ,rID be remOG?3d rD mroove IJdt:

Qr .IP...<.If' w.i'Jee.\.

'11. Remove uppel" t)ett ~rd (1 ®} Iby removing 1ol:5'l.F.l:nCrs (9) from 8l\'ingarm br~

When 1!lef'!'!(OVtl'l!!l 1!;!Ir, 1'n9ta111Iilg bait" dD flot lbUd 1tiI~ 'tW1:fI' belli, p8r1ial:t!jl s10Cl.9 baH: 'o-ri'tO ~rodte1' 'I:lndl'·Ii'IOII- wneel or' bsH: lCI'am~ge· wtll Oseil,lr:

112. -S_e lbi;!l~ hum spromst 81iId I\EII"I1IIJl.Ia

DRIVIE BELT ~NSTAillAnON

CALnlION

Vilhen r.E1IT:I!1!I"Yin,g or. iIils'ha'lli'ng belli" dOl Mt I~d 1!;!Ir, twl~' baH', pi:'irliill:t)l' sfikle: tiel!: il;!!n.t(II !!i!pJloo'ke1l: .8nd! '-KIll'" wliKM3l or bell: d'am8ge' will ooour;

1, ~e lbl;!l~ GlliIto 8p~

2, See lFig,lJl1;! 1-:24_ Insta11 1JIIIP8F lIJ8l~ gDo1FdI (10), to ~- 81m iIDraC8 tig;hteJiiing, 'f"diSfeFirM'S ~9) nD' 1 Mo' !n-llI!;!. ~ 1- 4,Mm).

1';z4, 2OIlI13, EiueJI X1B~J:il~ IM'a'lnli3fil81lG9

,3_ !LOOS!3!')' ~JI ::;wirigID\in brace- ~e 2.19 S'WIN6J!.RMI AND BfiACE_

a. lPoai!iDn. tba mar lb!3l~ giWlrdl (1) ~n(!l upper' t)e'lt g ua F(II '1 0') (iftt(!! ~'ngfj nTI_

itI, ~nstall fa*-ner ("8) a.rnd ~r eellar (2) betw.Mn uppar be:1t g:uard PO}, inner belt waF(ll {11} and 's<ningEl nm lb raea.

,4_ InsljaJI uppar lbell guPJip(j ~ 10~ ~ tl~l'iteF1 tii=J~el'B m to t2'-36 I I!1I-lh 8, (,~ -~, Mm).

5e Tt!]i"rten BWingsl'lFl IN~ fastenelfS to 25--27 IHM (;34- ::37' It.m}.

Ek I ns!<'IJ I !l::;i;,iCt' belt iQUam ,(:3il ::,iOO tighten faatenem ~ to ~,~'-3J3 in-lila. ['1-4 Mm).

1'_ 1ns!8Ji' idler pulle')" ,8SEemtJiy !igh!.MiIlg ~rs and m.J~~

to 33'-35 1~·IDs (46,41,7 Nm). SI:"'!€ ImE]=; PULLEY

INSll"AU...ATIt)N in 1.~ DRIVE IBELT SYSliEM_

a. See lFigure 1-23 .. ligJirtelli rear aOOe f11) r,o 4a·52 rt~ (65- 70 Nm).

9- Tighten rear ada pinoh faaten8[ ~2) to 43-45, 11,' I bs (540- 161 111m).

1!l. Rota!te rear ,\\h8!3i ~IJ '!3nsure; Ihe. ~IL ooes not make v'Jsl.L I;Ile· or al.Jol~ ecmact, It may be nEiDaEBB::I1f to IOOsein belt 'guaro~:;) ~D' oO'Idjur.J lOr' IPro~r clelliffiLn,*-.

111, See ~l.Jre 1-24 .. h!lst-BII 'fr,anl '~pr'DDllEl oover {:5) by tijht'8ning fas.teTitE!r:; iIJj, 12-36 in-Ibs, (1-4 Nm}. Sep. ,2.:31;11 SPiROCKfT OOV!;;~.

12. blS'l.aJll el~if1i UtlrlFig bs-te~r:!'I; and tigMen nD ~£ imHlbs, '(ot-5 Nm:~ .. Sa!31 2.:33 miNi FAIRING,

13, 1.j"'[~))1J nun!: $I~ rI~r 'footpeg moorrt and ~hten iaE-t!3li1- '81i'S '~IJ 1108-132 in~lb:s, t 12·15 MIlIl), seeaas fOO'"]FPEO, l:'IeEl GUARD AND MOUNT.

14, Imail ~ht ~el!lger fua-,1peg liTIoom.. USB LOCTlliE 2,'72 8J'1.d '~i 9 h ls n. fa;sf a n 6V.;, to 25.;28.- 11.·100 (34 - 36 NlI'I\).

1. ,A.xf:e

:2~ P In.e'1'I boll: 1c!;j !iteli!eiI"

-,_. .. --

.2

11"1 .'._'~

;0 -- ~:.:.----

.Q .

.. ~... ,---

...... --~ ,.....__,------_

I ,

I

,~/3,

~~~-~~ .. -.

:__.-r::""_ j - .. - - -

l<;O' ......_,~_~

/ ,--

'1' 1

/0·--- . 8.

»:

11. rnnw beIIt oYMIlI 2.. Spacer cellar

3i, L'OIiIiIe!r bell! guard!

il. F rn m bell 'Q;1lI iCU'dI !5.i. Sp!'CIdre'll ~r

Iii. Sp rot::ke.t CO'Il8T tBSter.i.9 r'S 1. a.oweii ben guardlfsstene:1lB

8.. Up;pe:r lbelt glram fas18.lillJf$, short 9.. U p;per be 11 9 Lta lid fJl Bl:B:n.iIII'B, 100 g 110, Up;pw IiliSll ~!Wii'd

ii'

:2.003 Buel! ){B9R: Malnb!f1lsl1I&eI 1-.25

IIDlJER PUlLE,Y RE.MOVA1.

r. See· Rlgure 1-25. Loosen rsar ..uile !pinCh tF.Istener (23-

:2_ l!.nth1Ga~ azte aOO1u:mnately 1:5 rob3.'lilJm' Jo rcl~ ten"Ii JTOI1l drWa !ball.

.S_ Remova, Iro1i\1. sprocKel 0Q'IIe'I_ Se,s 2~aO S1PROCKCT COiIEFIi.

.... _ S ae F i gUiC 1--,~ 6- FL~..IDl:1'IIE' i dIe r pu "i3If Ib r:a.dk.13:1 n ots a 00 \'i'a'Shers: {5} "rom ~!Jdr.:; ,(3l.

6,_ SliOO taler [Pu"ey blEiJkE~ (4) off sMls {:3).

6- I~: p.u"EIj' by ~inn~ wtte;el m Sind cbBmin,g !Or wJiaali bearing w-eaf.

7_ If fJiIJI"8)i' 'wMellll'leeli:t re;pla.C8malil'~ remo¥a 'f:"o:lSlcner (6), IN.!!!!!Dar and nuj ~2) fWlfl iialer.IJl)ile,. bracket (.II) .amd dis'e.:lrd Wheel!. Replace with new'pu"ey mJeol (~).

NOTE

r~~ jWJi'Ie.:y wheeJ ba8~ aoIl'1' 1.10.1' fj:[)' lcpr~ ~epa.r.s!rB.l'.lt

1. tiLde

2. Piim:h b!ilil± 'l'"ai&1"ner

IDlEIR' P'ULLEV IINSTALLAT~ONI

1. see 1F1QIIJ>e 11-26. ns new or existing puDey 'Nt-IOOI '[1 "

if ll\Elni~, ~M Ilglillen wa:9her aM nut (21, ...maal las'tF.1iI8F (S) W 00- t2.o [1iI~1iJ!; (11·14 INm~.

2_ Slide i!:Car ~"ey bt'acIret (.41.), ",ashe. ,and nLJm (5) en to SW(lS. (a) and tigh~En, to :33-:35 ft-lbs (·45-4'7 1N11'l).

3.. looaJU 'fron! '->~t Co:..-eF_ S~ 2.3® SPOOaKET COVER.

Neveii'" tlghlEI1I ifBlilli ,axla, wifli'il ~W;in;arm !:ir,aee !l'em~e:d ..

4. S'*' Figul"8 ~ ·25. Tigh~on rear a!de te .~ ft.-Iba (F.5- ro 1"41i1l).

5. Tigh~EIli reer aAe pinc.h ~cner ~) to 4(1-.45 'ft-lm (54- 6<1 Nm},

t.llat.&

t, Wih.e.:ell 2~ Wh.eliill nut

.$.- :Slmf

.4., l:dle~ pUlle!f Ib.~~t

6c I'd Ie r p nliia ,,·lbra:dke.1l1l1 01: iii m.tt wMlne:r

6. 'WI1B6!II'fa&'MM~

..

,~

(1)

(~)

(6)

~)()OOOOOCl

$p:roe~el:

Side 1m Bellt

Taible' 1 ,·S. IJ ~·\jI\e IBe~it Wear Analy,si$ illrlJ IFlgure 11,·2'7. IlEQUIRE:D ACTION

I IPA'f'fERN 100. N:omo,f!.I
1 IntB1TrB1 'o()lh oroJCk$ 4beirlilile)
2 iEi'il8rn..'!!1 tooth ,CT;ad!o;s
::J t.'issing tea1h
4 ~C' - ping loot :::;eriOOS)
t
:5 Fuzzy edge Gill!I'd
6 H'ook WBill'
7 SLoner ,Clam.
B Be'iQl ",,-ear (~rdI ,ed'!:J9 ooily) ___ +-1 OK_" _'to_: r_un. OOL FOOntror (:'1lM'Idifion REI p Illi;(!' 1:1 ell'

Repl~:ce bet!:

OK IIi, rulili., IbuI: moM(lJ' Q)F1dl1lal'li OK ~D run, !but momlOi' 'oonc:ll"ioo

Ri3~be'Jt

IR~ oolt II (iArn9gi3' is 00 the'~

-----~- ~----~

OK to run, b~ RI(!IfiIitor cmdili1m

IPRIIM.ARY CHA.INI

1.10

\ INS PECllION

Oheck primal1j' chaifTi IBlil5ioo:

'. At iha1 OIOCJ mi!:o {l;ilmO Km} service IFftoeI'\\BL

.• .A:_~ e'Jery 5'000 mile (i3iOC1O !lIn) s8J"'i'ioa Dteill.Pll

ihBra-rJft9r:,

See FlgIlIre 14'8. 'Me_sBW1131 pifirnal'jl' dh<1:ii1 ~ ·through tliiB' ifllSpadior'11 tt.:w<!!!F ctlJCnl~,,!'I,d).!L'II· priirnal)" dh8ili\5. ,lOt ~Iiilg ''!'e 11! ca.1 frt:!,e p)ay :Eip.Bcfficali!Jft!i~

1_ See IRIgUCB 1-28. AEHi'lO~ L'I'm 'i'MtenefS, w1~h cap1i''i\E! 'WaShers and prlmBJ!l( chailii inspection oowr \'tWill ~!i;'kel from liliI'ilJil<lll)' 0;U8~,

2:. S ~ F I gJ!lI>B 1-:29... Oh!3cli: pmtal)' chillril I.e [;1$.1 ()ft W 1Ill.eE.:;LII1~·1@ '!\CFtieal nee play.

a. ~I=.!!;:ure' '!leTIi!:aI fre8' play ih[J[lugn ,dl'lillfll Ins,peaoon CO'il!3 r !J PBftI i n Ql.

0\ ~ engine to move· IPrilillBl]/ dhailiil roo a dti1erem ,p1J:5ilxm en .sp~~.

c. I'iJesBure 1lEI.J1'iru.1·h'B9 plaj1' :s~lllfI1Ie!j;J eF.idh ~im8' 'IN illil IP r1 f'fI ruy chain mlJl.i'E'!!ll 'so tIiiErt 1fu.e; Im.eiilSLI re m 001: is taken with ::;~B~ 'l'lIl.t:.ltoo 10, me lightest chain pesmen,

3. The ~!I:I: mE®rur'BmE!nl i~n ir1 SI.Qp 2' ~.I!;!se within tM' spceirlCi:llt!li)f'I::1; ii~ted b'i li8b1'e 1-:~"-1f ~, adjust 85. d9reribed w008r' ·1.1~ PRIMi!ilR"'rI" CHAllII ~ ADJU\ST·, MENT.

NonE

Ihe, inlr.'al p.r~ dt.l'il.! ~1 free P,W ~CSJOOn' ~ ;2;11 ,rJI'ID. ~~r'i$ 114-''"'<2 in.. (S.4-t2..7.mrn) w.!l'liI ~ c¢4 ,snpins'. The 114 ill. (ilt4 mm) mLtJitJ';l[ml ~. tlJ.I1l'y S/ktI!ts.cJ .5I1·1he a!)$OiWJ'e iIt.Q11t~tS_r:·pomr:· fn i1ls'driw:. .13'S· ~ ~.I'J.~iz1iU1 klCfiJzy e.Q~r: ff ,a' ,ci.t.ai'fl' .i!r&s' 1666 ff.t.Il'i 114 In. (6.4 mm) wrlic.;tl ~ pJoiIy (wi1f1' a (:OJIj en.~), aqrust {ISS v.my til') ,rhE1 "field" ~tjoo fiJf .:l.'R-1l2 in. (9.!H2: 7' mm) .. Ths' ktiJsar ~Il"Col1.itm 'wNJ' awJd QIi'e/1Jgr:tteIJirrg. '~miyi't.!' ,t;rIhMl1'se- ·00001f ,dr,iring ,a~6m LI'&irJ.g i'i'O.rl·~l'y·\e~.r.n,e_nt &no! mai'JM;ld;;.

4. SeB ~UIiB 1-:28c Install IPrilfnaty ehajjJ IflS;j;lectio~n om.ref and IIJ as Ket u) I'_fl rna r.y 'DrI1.!'ef 1!1'.3 iog iIJNtJ fa5. tene i'S WlIh .capli'i'Ci wash.sr:::;. T~hren 'IllSte n erg· 'OC! 4'IJ-OO ilit-lbs {5- 7f11.1m}.

-
ENG]Ni!: f,iiilJ~g IPILA¥
TIItMPEHMi!l!IRE
-
'Goldl :3/.8-112 m. '9.:5-12:.. 7' IliIJrI
Hat (oonnBI runningl 'U4-sm in. 6.W.5mn~
tel'l1p(!r'ialUFe)
- AD~USTMIENlT'

NOTE

Jt '1f!:........riit0'ttl ftri!t'!' pMy ~}mtit!.lo'le. ~ 'WIIitm i!t.J~ JJmJrs _qpef'iffe,d, ,rhBn ~ Cham ,131'i'!ltb.r ,cham o5Iq'pstar ifn:I 1I'YI:Jji't.! ~' .:lc.J'tJStr1iie1J~' ilmrts\ R&pJace pijrts as ,n~9-f.I_ry $ef! (itt PRJMARY CHA'JN.

1_ See Flg)!l1e 1-:S1l. LoorEIen l_oX:knut fill. 2:. Turri ,~irl~ ~~8r));;;;r (2,;

a Clock!A'iBe rffilWaJd) to redUDEi i'ra8 ~:

1:1\ COiJnt,crel~isc (Qurwar(!1 to iFLC~ 'Irree' pl;;lj1'.,

::t Tighten loo1alllt (11 'bl;I al-:~5 ft-lba ,27-34 IN'ml-

1,. LO!Cklflil,J~

2, AtljusJ:i~QI ,S!l:l"'BW

r».

SUSPIEN'SION DA,MIPINGI ADJUSTMENTS

1 .. 111

"GIENERAL

BamN eval Lla.\ling 3:1'ld ,sdJl1Ii!l'lllng 5bl:s,paF.ltii~1'II ~Ings. ~E!ck tllle liEIoIDIlql'CI:8i'!$1i!i'e!i;. fll'e:9 muat b9 iin gO!OIii.! ~ndiltion ~n:dl properl:y iml'af£!d" FoiUII[!'e te f:hE!dir Hila IiI1ilS !COuldl result ill deilUiJ (iol" ~~rloua iinjuTJ.

Malfe' a Sl!J3p€1.fIE.iDn ~ef1;i-S In one or 'L'm1 IC&:;J.;: meremerns. AdjuSlil1'lg mare ~han ana or ~'I'O elidks at J':I lime 'may calt:IP. yaUl ![J, ,B'~ 1he IMst ~!J!JIment. Teat ride atklr eac.:h 8!dju:strllC1ft, When an adjuatrment makes 00 dlft~n:mci3J., [mm to tha IPrB'IioU5 atijuSlment and 'rry Si dif.araru, ~Pj:l~.

Ii' bi1lh ~adl .adJ.l!I3tl'liE!l1~ ara cOFfCCt:, and you ha'i'i8 Ihl3i rebound and oomprCSSil).1'1 d~Ililping set at' he 1ildOfy. ~ IilJEiM'oo j)r)1~1S, ~hp. ~ shouOO :naFI.(J~ aoo ride prnp,eri~ I~ ~u ",ish iID fino tune fue:g;e Batti~ 1D9y can be. diiJangva accocd1ng to 'the toaowinQ proceau-e3_

NOTE

Evaluating and ,C1lclrl9»'J.l1 rh.~ reboond and ,OOi1W-~o;:ion' ~Ing k a 'liB1'}" sOOjscliw ()fOCe'SS- Ma~ 'L0.'.3~Jss arlOcr ffl'D1~8 ham:Wm.!l' Wlder d"JfteIl31'i't c.;~sr:a.riccs. ,APllJlUI!I'Gfl< all d~ C(Jrefu1Jy and cctnsu/J Ttlbt'e ;H j.

SUSPENSION, ADJIUSTlMENTS

Settllmgl Rear Shock PlreJlload

The J'acw;rv se~ Is ftl. 1!BJF1p pomoo f/fl PUSi{iQfI ~ the 'sliest ramp' <i:IIndl ~i'ij'mum pr'elood). Ssa Tabla 1~~ 0\. lOr ~mE!ndeorl apliimg ~d.

1. Remo'tIEI scat See asa SEAT.

2, see ~1le' 1·:U. ChBJilQs' 1fiB sptiingl preload elf ~uming ~hel IPreload adjuSl~r al li'le upper pari! oi: he moct. wilh 1M $HOO< SPANNER 'II~ENCH (HIl-9470i}-S2Cj1 i[j~ !he'",,'ral1:ch inelu(l'e(tl In \he' tool [kit

31. ium adjuster ~D aE!"Hin.g S~i feel In T:::ible 1-10.

RoMIf;9 ;),i)jj!.Jster clockwisel to increaaa pllEIhJa(d.

I). R~l£! adjuslBf c>:M,lI1terdod(r,!,Il~ W decrE!'.ne pralbad.

,3. 1~t.>faJI two, fa~nera, Elndl,E<9a~.

Se.H:itll,g Flmnt fc~k Preload

1. Sse if" .abls 1,11). Check nI_!IlI1ber of linea (3) .!J be ~ 1o:r '!tOl,l~ !oed mnditicrn_

2~ See Figulf8 1-32. ,ACIjUSA IPrel(lo;ll:d by tuming the adjuslBi nul (2) wIth 8i wJ'il'!nch.

-

AWARNINQ

Atwe!j!s adj:u:srt 'eatiJii b"ll: !~I"l!;!! Jtlhe. !38me :&lE!1:ti1i1l!l$. Uns"lin aa,liII1rne>nt be1lN~n 1'e1it and lright 'om 1l1~ IeSD to :& lillaa, lof ICJ[Jmml "l'I'lith OCi4!Itr:ll !'eSlul'l: ill daaUiJ OQ" serLoUI inj:U..,.

~ow IBue111 meR: IMaimsnilfie.ti 1-31

Ta1ble l-110. R:eccnrnme,ll'u:lled SlI!lIIspe:nslol'ill Sat:ings

"

RrDlINiQ (:O:N!DImO~

'1

From SsHinlil' (Nll.lf'IiIltIe~ 0" IIil'1;lB8 ;6/h.owin:~

Ride1, 1:50' IDs (13.8 k9~ OJ lesa

-

Ridc~. 150 - 100 100

(,~kgJ

(Nol:e; Ih:iS is t118 fatbtJry 'BeUingO'

IRle&r Se.Hin~ ~fi1.'mJ;ll

p [).8 iIi Ci I!'i}

5

HideF. 100 - 21 Cl! IDs (92-95 f:,;g~

Rider. 210 -:250 Ib5 (95~ 1. 1:3 f:,;gJ

Ril!laF*P9sae~r:+CEirgQ, 250-325 1m (113-147' ikgI) WilsJ!

Rlder,..~eFi~r'''_cargo., 325-390 Ibs, (~,4,?-177 kQO' ~a!

,:J,to 4 4
5, ,~,
~
,
'6, - .:J ,8

G\{\'!J~

IIJptllJ 410 ~ (186 ~

of ridl3f+'tP8~8H.!:argo.

~ ---- --------,~--~--~~~--

fr

PioIUirnil!lIm 1P;F8l~[I #iod'juSiIiTI&IfIl (IRlamp N!I(mDs~ '7,1' Mlnrmum Preloadl .!l>fl~u.gtmi:!flfD: ~F.I\!I!m[!l! Number 1}

R~b;Oufft'lil M,juw~ S(;i\Jii!-w

:2~ PIl'EiI'08d AdJl!J8ter NlJrt

,~. 1l'1Otlr l!ine~; 'VlSlbae (l!'~l)'ry $emDg~

Adjusti no SU$pensJ~o."n Damping

See Table, 1-1 ~ _ lI'ilIt re.:cCtfflmemfed rai::loufild ~ OIJmpfeS~ rlampi~ settings. for 1RI.i\iQlJS road and I'iCing ooniarllS are gTt,!'en In the iIable.

\

NOTE

A~ 'Tum SStl'il'Jgs-r in T.:rbSr;l .. -m are' ':l'1\II11S ,out u.om m~imum", Iha1 tl5, timr. ~fJli' illll'Jl' a~l· 5"CIT:1W$ Iftn','f ~ (rmtiJ Ln9Y stop). 1'}~1J r.um .adjustment. ~w.;: w.tmt,eT;l~ the' .!m1'OUI]1.¥J8r:ifit.-""(J in l'ahi'e r- W.,

SeHililg Fn;mJt: Fo~[( liRlElllilIolIJllIdilDampjng

1. $ee figure 1-32 .. Using .. ~jllIIef, ~lJm the alotlBd dial (1) cI\x:kwis.e1 u i'lil n s-loOps. This B tha IliIaDVJI!lit'l re.ooum;ll aa~lng s.eit~.

2. lihen turn the r;fa1 e.,rjun.teFC~lse Ihe raoorTiflilib:fldedl alfl0.l.Jnt !iiPeciified i I'll T:!lib I Sl 1-11_

'Senllng Front lFr;;uk ICampns.sJ!cn Da:mpil1lg

L Sea Fig:ur-e 1-3:3. U'singa, screwdriver. tl!l1n tile !'lillfieolj dial (:I~e unti it stops_ Tnls Is the m:::ll!:imum ro-~ioo dampingl.scttJflg.

2- "ThP-n Ilum tha dial ~IOCkWl$e 1he reoomrnandad arTilOwnl spectfte;d k'I Table 1-11 .

Satltl'ngl Rar ShiO~k RelbIlilUlliiJIl Oampllilg

1_ See Fi.1lIur'E! 1..a4. ~ 8. :3CrEwdri .... ar, turn I.M $I().1toed dieil ,~Ise mtil it EItopS_ Thi!!i is tlte IIrl6xfmum 'l19.boI.JOO damping setting.

2:. TIl"!en 11i.1Jn Ihe, dial rn.lUnte~ the ~m8nded 8JTloU1i1l, ~riM iln Tal:!fe 1-111.

Selit.lng IRe!n Shock Com~r~l!iS'ion O;.amplng

~. See Figura 1·35. U~g a ~cfrivar. ium U·I(:: S1\lJtted dial Clookwi!*.! until it stops. TIIiS is, me rnatdmum oompresSiOn d'l3.1Ilping s stling.

2. Thl3lil ['urn me al~J oountarclcd;.wisB he recommeDlllad amOUlllt :EpE!{ili13r;:i in Tatle H 1_

F.iglllrB 11-36. ~e.e$ilng Re1Ir !Shook CUrnlpre.sSio.nl AdJuslw

200,3, IBua.11 XB9Iti~ M"jli1t9ii'i1f'ilOe 1 ~

'la:bji& 11·,11 Ill., RJ8co:fI1l'me:ndad $!II.iU:ipe,l'U:;iJOIill Ua:m,prnng :SeHings Co!lln:tell'tchx:lMlsg TliJml&

\

R'l:dlngtRoadl Condl~lons

Front F'O~ks

,A!i'8Fa.g!8 roa.-oo., but hig,h prekl_sd (2-up ,Dr lhea,'i'lj Il'irle'I) AU:F,!f"a!J,e Roa(fs" S~fI1l"W"1g ~N'cttc~ !his jS ill;;;; f,a,dlJJf'j' '.:iatqJ

--+--~

~i3~'EI~ rough r<o:=.Ii;I's, more, Ql)I'miti1:t, less spol1

iRlilt!ell.[nd C'o.mpl'I88l!1iilm IRl~lI.Irirl" Co. IT:! pll"e5l!il1 O:I'iII
~'4 '1/4, .9J4 U<I
314 1 HI.4 1
1·114 1-'1(4, 1-:5J8 '1-1112'
;;? ;;J-1i2 1..at4 2
2'~, 4-~ 2-3Ia 2·1/4 ~ -"

FR.IONT FORIK. 'O~L CHANGE

RE!I)laC'e ifork oil.

• Ait 'Ei'!.i'Ef'Y. '1 IOCIOI} mile (.:32,{lIJO Km) $e!lIVioe· intarval,

• If kirk fu a0.mc~e4 In WBter:

I'!I~

ff ~ rJW fs fJI'ftUJ~r ,aBr.ElrBd or /i¢JI brVWll irt ~ rhEn' it h$$ been CDlJl'aminatsd l.if rwor/ur. 1I11"NS fta,VPt3rrB. rep1aos' the f:w1I: fJ'i1 'SrJ'r.tis.

Disassembly

NOTE

R'~~ r~f ~J~n..m_r:I' se1itin:g.s oef.m;e' ~(!'f~

1. ~[]!'fel ifmnt furk .. SEtS RBi,OVA.Ib m .2. 1,6 ffiONT FORK . . 2_ SS9 FigllUJEl ~ ·37. ChlR!!) Ihe FOOK TUItliE IHO'LIJ'!;RI

TOOL (Part No. HD-4 ~ 177) in a VI~p. arocI ~sJII h up~f Irool1011C" In 1be holdin,g tool.

1. Reb(,1l!lml ailjllJ!!rtsr &C_1I1JW

2. Snap lIiJii,gl

a. PII-eloadl 8_dfU8'bE!~ 4.. Fork 'Capl

5. fifa raClI plliJS

6. F'RIOQdI'wa~fi\;e~

7. $I Ild'eir p11 i;I kin

FIgure 1 ~_ Fmlil: 'Cap AEssrnbl,

4. Remo'lC [prelOO{l :=.i~'l3r ~ [by il:umin91 l1:.tlllD11!<i;J\Cb::k.wiBa.

After My unIt'ttro~ fJIreiomJ eq'ju;ster .(3). garrlI'y pull O¥~ arJ}U..~

5. ~emO¥f.! klrlI: cap (.1) i'rnm cutar tube,

6. See lFiglJru ~ "39-. MImie· the i1tJrk I3BSiElrMty from Ih9 rJOld~ Dg tool and ool1ilprB~S 'f1Jt'K in '1.11!e R).!'!jK SPRmGi COMPRESSION TOOL

7. See HgUJre' t-40_ Hclij daI1i\PEUi' tOO a~ {3) and 1B.Ii\Cl'tIB' fud;. cap (1).

.rw::trE

See Figure 1~O. & CilP3fuJ r10r ro ~m~' {}n;Ioa.d pjnB (2) wfJiM' ,~_g ,r1Itmj:;l'eJ' f"Cid .5'B;!lSfllbiY (3).

a.. 1REf1jJ(WE! preloo.'ij washer {4) and slider pis.'Inn (:5}.

1", IFOJi'IK ca:p

2. IPrreilil)_sd pil!11;J

3. IElam;pe:r rod iCiSSem'bay

~. IPttAI!lIi!I.c:I wuher

5. SlIder pllstO'fIr

Figlll1'C ~ -4Q. Hohl]pg IOmnpe:~ Rool Assflm'bf:(

:2003. iBusll m9R; IMiaiinlmhMc:e ·1..,sS

9. ~ flgllJ~ '1-39. Ut1COiffIpi"ess iIOrk aa)ij i"OO"Iffi'C IFCiIll FOOK SPflII'iG COMPRESSION TOOL

IDrn!'n .and Re1pl:am 0111 "

1_ S~ FI~Rrle 2-4:2_ (;rveI ~.iA g!!af!, refJi1cwe s~l!'!g [~!j.],

spring collar {116j1. 8JiIiiIjJ drain "fork oil.

.2_ D<rain remaining folJ-:: ail IIDy pumplag iIli1e. !!iIFJrnplngi rod ;a p- p1I(XKIm ate I~ 8: ro 10 u mes o r iJil1j I darn pin g PO()] III CN"e s freely.

. 3. lli\at£ill the ifroot futik rigJrt we up, in tliJe. FORK ruBE IHOWER TOOL {P~rI. No.. HD-41 ~ 77}.

4. lPoor"7 02~ C2.0tI oc) inro the fud;. pipe,

:iVDTE'

!!Jss ~ TYPE E" f=;0R1{ all.. (pan: No. 1fD-~4..-8(1j1.

1!;. Gompll=.te[y cornpresa frent fad:: and slawJy pump tJiie ~per JOO @lXPro\4liim"k:2y t2·-·11!5 tif'OClS 'Oli' .llInrili'OOf'$Mnce is ~E!lt.

7. See IFIgure 1·41. A.dj~! "foffi Oil ~BI wiiftJ RROOT FORK.

Oil lEIiEl. W,UG.E (IPa.rt No. IB-.S9OfriOA) ·so ~hal iit iB 4.6 in. (1 ~·8 lrunll' 'rrom me.: ro~· Qf rne TOIik uee,

I~

_-' :2

-~-~-

11 _

"""'- r-: "....---+-

1---:

- .... __

-..,-

4'

~--- '.i\.~ ",-> 0._~ "'~ .~~~.~~~~

1.. OI!Iter 1l!ibe 2. ACljU!;ter

3.. Dal1l1per' 851!i1emblly'

4. FiO'J1i: 'D"i I 11!3¥8'1

8.. sea Eigura, 242_llnBtalll ~ling (16ji. and aprDg collar {1:5}.

9t Mo'iEI iIOrk ~BI1lfufy from holdi'1'I@ ~001 10 tha FORK SPHJOO CDMPRiB8SIOr,I,I TOOL

RhSSm1i1bly'

1. See. Fig~re. 2.....'k2_ Il'IStall pr;elOS!!!! 'washer (!;i) and! ~er ptS'kI n (,e)-

2. Si;liEI Ftg u 113' '1140_ Holdl aaJiT1jJS[ rod and m..laJl kirk 1[3P' onto d'a:mp9r r,ndl aasernibly ligntenVilg to 22-SO 'i\t-G)s; f.OO,<:0 rtM).

NOTE:

S'!':!, I"..al'"?fi'n i!iIDi' ifV @/~'we.[(.iad~ ~'I~~ ~'f roo ~'"!:..~ f3J"

.a. sar.lllFiguN 'll~£L hilj5<~all' prebad a.dj~a~ [3~ back '~O' rider SI!EpEi ne..io.n se1t i n 9a .

~. AppI).! I'WI-;; oil ,oli' ~t greasE! to ,o-m.ga on preload adjuster Sino Iln~1I p'Ieloa.d a.J::dlu~ter ~).

:5. Iinstall ~ riingl ~21-

16. inSUliIi r~' 1IO!1!i. $Be, IN$TALllffION in 2.1116 FOONlT fORK

. __.

\

\

\ \

\)

1. [Pr.e'load iildjuslflil'

:2 IP!'eload ai;l]u!i1N o-:rililQ~

3. [lFilJrl:...lCBp

.II., IF(lrl4:: eap Hl'ng Ij. Pmelnad waMSf' [6. :~iiridsr pi51Di'II

1'. Inner !tnd'e~r p'1&'ttIn o-ring

,8.. :!i1i9llP ri'ng

'9[, IfI'e'tKJu!iW[ adj;uste, il!.S$eImI;r;I,

('~

\

\

\

\

\

~ ,12

./

(::7 _ l$

\--14

\

\
\ \
\ \
\ \
......
.......
....... \

\

\ / .....

\_...../ 19. $1!DJlpel" ring!

:~n. [RBfI~o:r ,assemb'1y :21. $[Ide· [ooshi'lilg

:2:2. GlI.lids[ bu:5fiJiiiO

:23. $etd spaoer

24. rOi [I :1iSa'!

.:2's, [01:1 .:!;!l!a1 s.'lo.~r' Irt~1 :2 til. I!)u"t!iil~ I[

2:7. Srids[ [po;ipe

11iJ1. ILl'aITil pall' 100000ut

~ 1[, Damper rOO 89!3e:m'lIly 1:2!. [Ce:nm:1I1 11;81 P l'ate

ra [C&iJI:ng w~$.her

14. rtel'lter bOlt

15. [etJUarr ~ 6. :Spr.il1l9l

17. $pllii9gJ .pm ~ 8.. Outsr :ruMi

Th-e steCti)g llICacI ~l'ingson lha XMR. are S!3a!ed, angular GIJ'II'".tac{ ~arings and 00 not require' ,adri'itiOOlFJlllubril:alioo.

Gh6dt; stesm,.g hesd bearing! reaietanoe:

• ,Ai 8VElry SOoo mile {8Il)IXI kin) ElelVioe mteM'J1.

.. When, ~,In!=ll er lter"flO'Ilng me ll1(1otofJ(;:rciC lOr iIfOOI seasM

IN:S PECTflON

NOTES

• Ch.c~ tMI i!i'h<0.!'lIB c.:rblss do nol' bind when meas.u'ing D"'03'.rmg re.8iSJEN'ICe_

.. S~ IJrrud be.:rni-l.g.5.' JP3 :sealed ,smif do oor. .l'8qui.rB ~ lOOriGJ3i!io.n.,

• Si'sarin~ head D6;3\1ing reais_rBnce i$ not ~'@.We.'. ~ce l:te&~ ma-~' 00 .rl0\l mE:lft\l' .resisla.r~GIEI spsci"fic<J:i!ioo.s'.

:2_ PI:=.ioe, a scisser iOCk YFld'c'J jwtking' poinL ,mid Ilrlise f,f'O[l' whesl off 'grtJ4lfild_ For loca!Iioo of jacking poim see Figl!lIe 2-9~k

- --

AWAFl:NINIG

$teeflns li'IiI!lII51I: lbe smoolJii 811101 'fr!!3Q wilh lIiIiIl! Ibioojn~ O~ imert'SIl1EH'liCS\o Anytlitlng Imerl.eii\lng wltar! ~1:ee1i1l}!;!1 ~~y~em !Dper.w.~ m~ eause I~s:!;. 'M wl'tiUGI eo:n'hrliiil, W(l1iGih oooidl r,s:5ult iin death I!l!~ 8e'J'lIJlW~ Inluli'lJ-

3.. Check: sliset"iing starn bearings lOr I'II!!!tCh~ !)yllJlmllnQ fmn~ wtlee! Iwll t"igllIL aJOO IhQlII\;}'rlIRa:per:J~ iI'lnsOEIssary.

4~ t\r~ p!ru::e. wooel 1'<l£iI~ :5Lrdigh~ ,i:lh~'d <lfIIiI 'Qr:alIDir:ig Ibofh flJlik. sEs. Bit 1he OOtI:cm mova, oont-Etndl foiward arid IbFiDk t('J ch~ ior ~eef~fI@ ,Moo ~

,5, Th iI~ for correct ::;tselliog hea-d rasiEitS.1ilD9 WIn hem) wheel all the wa1J to ~ ril!lh~.

6. See F'igul'P. 1~. HUQIi I3l S[Jiiflg :~ iIlIoo. 1M hC4c iil~ ~ k(l(IL w;la 'With :seal.e 00 d6gItE!sS from fullk leg, pUll front wheel 10 ,cent.er PQ5:!t&i)T1.

a ll ::;noufd ~iiJ:IiB a .~Ilfffi a4: 7 Ib8. (S.2 &;gO, 'to ,Pull fmm wheei no center,

0, Il stccl'i~ h8~ rBsi::;1.iJJoc;e miCi35.UI"13IiTl!311J.t iE, net ~ spee!ilcatton, see AD..!USTMENT

7_ 'IN,hellJ adjustment iB oonqrilEfba, a1ilar:h c:lu_~Dh ,cable· and adj:ust See, 1 .a CLUTCHI..

Fi{!ull'E! 1.-4~. MSBlIIlurln~ ,Sleoe_rilll§l Hei!lc B'e81il1ng fM:!; I:!!; 1<lliIlti1li

,A DJUS,lnM EINT

1, [I~ach duiLch cabls at handlsbar 8IiId ensure, that thrn~ csbles do nol' bJnd Ibeful\F.! rneaS'Urtn~ steer1~ lilead Ibcati~~ilinIj8'_

2. Rem(l~"\c S'~ring ~St8rn FlficIii 'f,-ffifElni3il at upper 'fortk clamp,

7, SeE!' Ftigu6B '1-43._ Hook aI :SP'l,ingl,~!a linto ~he ooJe in the lront a)1Je- Wit~ :scare '90t ~~ccs rrem rod. fElt{:l, !l'lilll "El1IJn~ 'lIheoal ~jJI oantar lPosiftlOn_

:E. The oofJEd' 1I'ta£.j&1BFWi3t ia bEitwEen 4.:5-cc.5lbs {2.(I.,25lik'g} with :3J mslriml,lm Ir·e~l!)!a~ (Ii "7 mrs. (3:.:2 Ikg},

If :rha rom3.c.1 :spscifi.cBJioo CBrolOO DI3' .aci:lia.{,,,fl, ifhf.' ~reerlrifJ hf.'ad' ,~rlng.$ ~~m 00 ft¥iJ<:lacd. SiM 2. te STEERJNG If.EA.19 BEARINGS.

9- Once, eerrect sr:ccFi~ IfLGad f'~SiS'lilliiQ:iI tlf::liS. b88ll 'l'sli:li!3d, 2PP~' lOCliTTIE :2i'~: ;0 B"l:eEri~ stem pinch, ooit., InslJall aMI ~hl'en 1.0 17'- ~ 9' 'fil:-Ib:s, (.23:-2B NlI1i1l-

to_ I!(ppl'lI' IL'OCTlliE. ,272 10' Im",'iBF rnl!f,;, ~mp. iIi=.i~er$, InstSll 8.1lId tl{«l'Itcn ~o 13-1.5 'I1-I~, '(HI-2!D NIii)_

1 t. Whell ,adjUs.lmemt ija, oom[:;lIE1~, :=J~ dutcn ~ ,~ arJjus'L SFlii:1 1_8: GLUfCl-t

IJINSIPEC110N

.. IRep_lsos e"I.!l3l]{ '10..000 liIlile {,ll6,OODIklfr:i). ,~i'Ylce ll!itel"!.'al.

.. IlJ$e' ,only Harle¥-~ 1ClR1.2A ,sp.ai:k plugs (P~!1' Nn. 27,6.7·1-,01 KJ.

t. RBllLillfilE!' leH side, ,ai~ SoOOQp to 1!Iroe.£5: iFIJnt c.yIi'oosF :spark, ph.JQL :See 2..96 AlIR SOOOI?S..

::'3. U$lng o!'.i siS in, tim: and WlEinD.h ,and &'8 iin" sj)~ r.*!Ig socket. y\Bi'IiII)l,I'(!: r~l)nI spark PJl!I!].,

s. IR~1101lE!' <1Iir [M.~ assembly, See, 4...4~, AI f:lOOX.

6 [Ir.50M~ e<!ble 'i'mM I'Mr -g:pEIr\t: plug! (llEe B.Utonlo'li'i'€ a pa r k plug oolJ;l: If'iE! I1iICI1I6iI Ii 1ili!J0I1i r,l:i il Il'Cq uii"e.o)-

7. Using a .5.1.8 m, wl)be!'e SIX:ke~ ;;mel 1:2 ~. extension. ~~~ re3f' spark plug.

B. SI!!C" fi@UfIC 1,-"- Comp~e :!{OUr o.bBslVBfiDn:s of 1M pUg o!!isp!J3ilcE with ~he d'BSCri'piium. previoo::i Dcl~

.",.....,

aJ. A WEl~, black ~ shllW (:!e~t en IPlug base, elEIQIrOO.e!l; :;1M ceramic inaulator tip iindic.ates an oil kiul6lril plugL ThIS ,oonrr~ioo ma~' be, cal,J~ed by mae or nnO«'l 01 Inc: '~:: wrom ~iJna. W,lJroli piSl:ol)n rling$, warn 'll'BlwEI, W!Jt"n 'o\al'i'a guides, WUfn val¥e S!3als" i'.:I! ""'E!uk Nr~ry COl a faulty Igl'lf'lloo sy&lsm_

b.. A OTy, 'nully (If ooo~ bl:;ick d'epDSit indimls5 an ;:fir" I'uel mi:rtu.1\B that iE tOD rich <1Indii"or '~naiI'le' h;lll~ klF 8)iOSsstVE! Ipaoo::iS,

e, A light 1Jroim, glassy ~I)SIt looje;(lj~ an ,OWf'ooa-tei;l pl~. This ~itiDn may be a"OOJ'llil~niM ~ cracks in Iha ilili!!illh[;;l(r er [tIy a-roS'lon ,oi' the elac!rtldes al~d is eeused b~ an air-mal !iri{OOIlJre ilhaiL it 100 I~,n" a, h.ot-i1unning e:ngiDB, 'vaJvs(;. nol ~ OF in'lpropaf ignition '1B1~. TM ~y depooil on tha apark plug! iiS ~ ,oondltdor when hot and r.na~ mUSE! Illgf"!-speed ~iring., Pi. plug ~h aroded! 6!edlrcoes, heeuj{ dapo;:ii:s Dr a I::r<It.k.OO ins.ul'a1N fIiIl)st ba rep I aea d,

d, A lPiug 'l'd1h1 8l ooite, ;rellaw:. tan Of rusty ~m p~-

QerY' depooU' indiC8tB~ balanosd ooriiibuS:IiUll, ctean :!o-

oft' Sp;ilJk plug depo:;i;E 13.1: rlsgllJbr ini.e"r'l'.:1ls.,

9, If the. [plugs. require cleaning be:l."rIwn tllt1e-tJJ;1!1; ,andl raplflccmenlp1ug$ er.e 11Ci~ s,VBilabJe, procl3eliil illS ft6)W$=

a. Degreae.e iring Mel Or Stn'ITK pb.1Ig mfig ELECTFtI-· CAll CONTACT ctEANEH. Oli)' P!U~1 wUh eoen\ presse(l an,

!)_ Use Si hin fila to flatt81~ sprulk: plUg ~s.. A spaffi plug wtlt! Sh@Jp iE!d'~ [)f1I it<& Bt~r~ lfet!![uire:3. 25--40'% ~ 'liring! 'lio:J~e tMtI;rT1 t;!ir'Ie wi1h r'OV!Mea eo.gp'!i;.

1(L If Ihe p,1Ug8 canriOl M eicanee, repl:;lOE! wl1h iOR12A $[:'MIJk pDgS {Part No. 27671-V1 Kl-

• 1_ Check Bledroos 'gap. WiI1'1I a wir;e-~e feeler ga.u~ Gap Sl'1OOld be (1.(135 ~. (0.9 mm}.

rz, A,ppl,)' [LOC"fITE AN'f1-SEIZE to iJhreails of .spar!!: plu~.

Ins~1I ano -ughten spaJk plugs to 11-'18 ft-llis (15- 2-t INliTll_

NOTES'

• :Slmii' 1fIrt:'~g rear ,spafK ~. Ml'h 3t,g" fWllw.~ DeiI¥J ,car:s fuJI no t fIJI cross. r.l'"la:!.l'd.sptl fI(; prtrg_

• Start f-mnt epadf plug M'ih ~

• An e:t'J't'nsJ'f.!1'l' maybe nB6.tied to push on &iff ~f4Jg 1xJa.r tD etl!$oWi;! ir is ~ properly.

~ s.. Coonect .spiilrY.. p2ug c:atJtes.. Verify 1het ca.t!las 8f8J S~I ~tv oonll!EG'!Bdto coil and Spa1k.~.

14.. In:at~1I .left .EXle air ~0Up. Soo 2,:]6 A!IFi :SCOOPS. ~!i InlS!all air '00::( assembhj. $2e 4 .. 4:3 AlflBDX..

After l'nebllli'ng .l5aait, p:bIJI tlP~ air! froirrl of ~ 'liD. be .suite [It Is !(Jekedlll'll fjl!l!liltlcn_ L'f SiSet is l(lolSBI, it'I1:Ulllhlil shift <flur ng vehiCle o.pe:rra1!ilC!n ali'Kll til'af'itled'le' rrilder, caus'inQ kiSl6 of ,oo.n'l:rnl[ 'wn~11t ~ol!J!d [result In death or se:riObl$ IJ'I.II!I]'Y ..

15.. 1~1I.se8t. Sea 2.311: SEAT.

_- .....

AIIR' CIL,EA,NIER FIILTE,R ELEMEINT

1.,15

'R IE M OVA I..

- -

CAUTION

IDo IiItM' HUiI artgi:ne wlltMom litter elemefilt in ,p.1EID1i1. IDe.tIr!~ eo:uh:l be dl"e!wnJ i:nkll f!Itve IiJn~iM C3U!$lng dSJnI!i!)EI.

Cbadl air ~rt9t filter Clemen:

r -, • IrtS.~ aI 1M ~ O(lJl)! mile' (1 S()Il]l Itlm) ssrl'iClEl iti'~J ;;il'l!!!!

;art BloBry OODQ mile (BOOO ~fI~ 5~ In: Enral tharea'ifB.F,

~ and ofC!p1aC13' air cleanSf fNh11 ~tefolr' .mf.I_1"e ol'i'er.l "!ire m~ ;$ mfI f{:J ,;'l' m.t3ty ,~t_

i

2'. Reri'ilO'!l'e four 'fas,1El!l.er:E!, nylooJ<iSJlIoFS and intake OOIwIBr ,ase9"rnM]l, s.ee 2,3411'\11'A11<E: OOIiER ASSEMBlY.

3. See. Fig!JlIlB '~4.S_ Remov9 fuel ~ 1'1Itll~ (2) from v.apar ~ (3) ~no groove 00 DIl' ,0 air bmc. 00IIQj C'1),

4. See. Figure 1-46, I!.!nla'l,ch s!~ la~dhin91 tabs (4). ~M r'OO"IOYC air bl]'.( CQ1.IEi!'r . rem basaplate_

5, See Figure 1-47, Ramrntei 'Ihe flloor ~nt (1) ifronl ~late (2~, !Iil$~ and rEpl'a.ce ii ~!i,

CAUTION

'CUEANIIN'G AND IINSPECTIO:N

AWAANING

IlJIo. 1lI@1: U!3e tQ,SIBoflin:e rD:F 5!;)hr~rlll:$ 101 ,el'eal!li tli1re 'fil±er elg. 1liI8filt. WIl;Jfi]eillarnll1i!ll~e deslllin@ ElQlililifm ma, ~I.!~ BD IlliblkE!, system 'fire whi(;lh CiOukll ... e~iIi IIlI deediJ DII'SiElriO. in,jury"

,_ Cbed;, t~ e(eme:,nt. 1-'10.1'(1 [liter e!emenl ~ to EiIrong llight SOlJl"DEI, TIM Clefllenl' ean be oOORSidarar:i suffieiclll1y d~ If IIgJrrt is mITolunly v~ Ihruugh the elemenl_

2. lhon:JOghly clean baseplate, ,andllnslde 01: ~ir ibm(.,

3. See Figure 1-4.:8, MakE! sum 't\'(O Gr-anhil;;:a~ breal:hE!r' hOSES (1) and iHIak.e alF! sensor (~l :;Ire CBp'i1..1J'Eid -n easeplam b. - d vaIocIIy s~ (,2)-

1. Ai:rb.o:J( IOO'IoIW

z F'u.en venl: 'lUbe

3" VapD:F'mw-sr

o:I!, Aj!"b·~ ~1' lat~1ti IH'Im

IMIIt B r eII!3fD8 1M ~ep!late' 8~~.e_mIiII!f. ,/C!iroo\X, 1'af~1tII1RtJ$ {6)

FtQ,uI'iB' 141 .. InS'I_lIledi All' 'Oleane:1" lilltsr IElemanl:

IIIN$TALlATIOINI

~. See Fi!;lllJ"e 1-47. IPI'ace firlm- eleriielll t 1} on 1b8.E8plate (2).

2. Sl!!e Flgll/1e 1-~S. Poiiifun ait Itxr~ ilX!Wer (1) '1J!ief" b~I3" p1ste. Make sure a!r iIlI er remains corractiy pOOmQn~.

:3. Imsb:lll <liF 1M.,;; oove:r I!!tjI ~ ~ larCh Mbs (4~ to baseplate..

4. Pooilir;tfll·tlJe[ vent tube (2) in giOOliC- on top o~ air box BJ1,l;j conned ttl r ud !ole rr~ 1oIEI1\i'e. (3). SaDiJlI13J woL ltib e m 'oIErrt val¥E 'i'IiIh 1i1i!I!!"W caIi4B lit},

S_ In:sI!a.1I -f'lLa1re ~er: sssembL)' wiEll lOur il'aS"tem!rs 8M ~n 1!.'J!IsThSI'B. Tig.h113l11 t\sten.ers m 12-·3iS i:n-lbE p .. 4IINrn)_

, -

i ii. WARNING

~'H:w tn~til~, se-a1:. PI!.IJI U,!l''I'iICI1fU 'Of'll trom.1: 01 ~st ito, be !!ltne it is.ltJOke.d in Ip.!O·s.t1b'1- H: seat ii8.loose" i;t couldl $tI1tI: d uri ngl ve'nlelil! 6penliiD:I1I snd sttlrlte the r~rJ' csusi:ng I~!il to,f &cnll.ro.1 w'hli<:h OO<\iIldi result In dss_'hh ot -S!l!rl:<iu!j injury_

G. Ins-La sear, See .2:..:38, SEAT.

Breaihsr IiIIll!S!3S l2) 1n;'M!(e: !;ilr !;ileml~r Vslrn:i't¥ stil!i:k

TIHROITIL,E C,AB,L,E A,NID ~DLEI SPEEIDI ADJUSTMENT

\l"HR,OTIlUE CAB,lE

- -

AWAiFilNINQ

T1hf'O'tt!e e#t;ies, ml!l:!fIi lIlot 11XII1111iilQlirI: wMilI h~ftdletJaJ'B, are iullftlratil h.!Ill(Y to II~fi ,ar 1I'I§,1rrt rorill, is:'top:s. SG ,SUIIe wlre1Ii Bod thnmDsl 'Gabl" S ~!Ie rOl~r 0.1' f.mk: Btops, ,id: slfl~i'i1i'S1 head Bill! 'Ihey wil~ !not be [jJililCMdI whe!!l t~ [Is tumBd agalnsl :stops. Steertn~ rm.uBt be ~rnilll!irl1TJi rDildi rree wl'lllli 001 tiJ.il1ldililg o:if inm 1fifC:f't'f! Jte., AFr!lflblngl inlMsring wlthl $~lI1n!:ll s¥stam ClpBf,illioo 1iTi~ ~U!12 ~OBS. m' ¥Baidsl 1&;0'1i'i.1rol\. wl'ddl lOOutd Il'eSl1Ilt in dSi:'dfl or' ~I11II!!1I!.t!li [Injury.

--.

Mh engine I1Di1ning., lum handlStlaip IhrolJgn 1J~1 rangB of l1J'awL ff ari· speed ,ohF.lnge_3 dUImg 'his ~r. turn ~ngJne OPF and B.dfuI-st tlhrollJe eaetes 2::!1; foBowa.:

1. Removs ~irlJM ill1d ~Ia e. Sae,4L4J AIFlB();(.

:2. seQ Fl@Ure 1-49.loosan c:a.bre ,8rlj,u!J9~ ~ ~ihldk disc), on each c8f4B.

:3. Turn .edjM3fBrE (tho ~) in direction which willi shor1l.Cn ~ il"H:Jusini)3- to mini'murn IC:ng;lh.

4.. Pciim front 'l't!bEie1 ~ht head. T~ throfll9 ~ ,gnP'tb fI:rJIy open ~OOi oolt! In [I)CIsroo:n.

5" Tum at:tJl~er 00 Ihrotfls control ca1)le until 'lhrotiUe earn stop 'tuuches ,~op [plat.e. Tighten jam nUl. 00 thrr..tl1e contml catlle <.iJdjuSLcr; rel'~ hl'"GN"tla roIl'll1:l1l ~,

is. Tum h<uf~leb-a1's n~ to Iijht. Tum a;;ij-u::.1!fli ,on ii;lIe' con· trnl cabls' m11il[ eoo !l)f CfJble OOusII,g just touches 1"iiIe cabl.e g.I!IiE.

7, TiN~' aM r,elease nhronls, oorilr;OI Wtp a lew urnas, Thru'l,· 110.' plate rnust [rerum 1:0 idle posili:OO each 'Ibm!!, n~Js grip, i5 ~,II his B na-: ~he case, turn 1) rer on idle lOO1"I1:rol ~ ('-'ihurtenlng cable h.otJ.EMg) urifil tI1fmile' Jt001roI unctions prop€ily:.

.s. T~n c~ MJu!;;ter b::k on 'idh31 ,oontr-QI ca.b'Is.

R:echacIi; 0 P 81iClli 00 QI'IltlrotiII e, oorrtro I..

11;). 1D!WIE airbm:, ~pla1C aOO Intake rover a:5.'5Bl'I1bly, See -4.43 AI ROOX,

IIlDllE SPEED

ChOCK engine Idle speed and a.-djust as reCjuirod:'

• Ali EWBI)I' 1 00l) mila (1 00l) Ikrr!) :servlee intefva.t

• Ali Elr'ery §J)()O miles (-81J1JO km) sen.rioa fitervaJ thl3f"€lafler.

IRegulBlf i~ spEied is. 1050 +J- 00 i=l:P .... Se~ idls' SPBed uemg idl(: adl;USter ~'1j)wn in Figure 1-00. Tum adjuster clock:WE:e to iooTaBEB idls s.p~ or OOUITt.,~rcloci'lo.!JiBa [} dacraaBs ~ '-'li<t.·C(].

1,,17

IINlS,~EC-TIION

Check iQJiiiOOn ilimin,g:

• M evary UIOOliO l1I1ite {~60aO kJiB) SC1"!.licCi IntemJ..

• AJtc-r ~ r~11 ,(j~ Ihe earn ~silioo aemO'l_

CIHIECKING STATI:CT~MING

i ACAUTION

A l:way SI, w,eBT ll=l"o;pe:r iElJ'all~l:iD:nJ wIiIl3fiI d'rrllililg.llRlrif:1SI delilli'iti, r.t'L~ I\CltiUIit 11111 m:lnO'~ O:~ !!FLQdera1e' tn,lu-I'V.,

Carafull,' dlfiilll tileI'D" ,apJitlylli'i,'gl mintMum lli!<~!fl!Jre, to ~ual peneb'ial:e ililme_~ plaia ClIJIil8r" ,A:pplyi:ng lultll riill!IC:hl iP'fewur:e iMl[I"~IfIASe. esm "~f1:I\cin $eMo:r ,sn~~ 'dmer p:late.

NOTES

• It Is i!!I!)r'J]~~roJ;Smalo'C!,(f.)e'sp5!rlI:~iJ9'wdstarnnil'IC me I7(i~JOO .sro®M ,rJf iI'fJe ~~ ~r m i!tJe .f~

fo~,~~-

• Do mAl' ~v(!' ,r~~ iIimfi1_g lr:t~(!!CI'.kt.11' i!iD'IIEr ro ch,eat :ihe ;5.1E~ limmg:. If i\fm.in.g .m.!lIS.!' M rom;it..l'e.:if, the m..~ plal'e. Wi1M' then be ,~~d.

'1. ~Ise rear wheel lusing a lift !JII .r,ro..;in91 llIOint. Tis down

motmqrcla 'for aJikliti1Jnill sup~l'1i,

2.. RslTI[!!,,'B lirmingl in:spaCIiOf'llPlug,

J.; IP f&::t:: r ra n S m 15;$1 00 In ~h Ig ear;

4.. F.laiBa aide.stanril.

MJ'fF

Sfde$land~' lYe ro.istUI 1.0' ~, i1he ~ mte~ ~ ,rem

5.. Oonm.e.dl,l~il:al T~iclan 10 ([ala pcYli on ma;:o~.

Il 8ueet'lDe $ta1Jc "fII!ill'ing'IProoedt!ir,E- screeJ1.

7_ Tum am ig,nmoo i3JiId ffi®'!.!8' lhandle.bar stop Slii.'lteh to tne r~ Ip<lSitiOn. Wen lor 'rue I ~riJI;l cycling ito confirm ~ni-, tion is active..

8.. TurifW w gently b1!lmp Ihe 'r~el In 8, 'i'mirwaro direcl"Hm w;:ing tliJe. rear 'l.-rliiselL ~ioo tIiJa 'fI]rn~1 me mru:k at ths' '!,i'St]f laR ~B of tM' inspectIon tJo!e-

9, H ~M' ~!f!e' IS ~ up' 00 Ihe oompresaioa :stroke flJ~ ths' IFOONIT (oorn:od,' ,tllit'lf::ie.f" iIfIC stFeei1l mlllbe· d'i:3-plstjf-. In~ LJ:jN - ,I) '!.i'OIts 'with limin91 rnilBl'k at IafiI: edge ![If 'WinCf.oW,

1,10. GteoIl'lly hump fl:ywhe€ll kin.-\,,3Ird iin 'Iiny iiner'~IfIC~S,

1,1. :See lFigur,a 1-52. If ths' ~lalit liming is ctlt'roCt. Ihe screen will ~il.lt:fl roo, IHIGH ~ 5 V0lts, at lhe' preciBe' mctrne:nt [h!31 timing mark exactly oanbars in th!31 in:s,p!3Coonl'iilild(l!,i,l.

11:2. If engine is, coming up' 00 ilIi.6i ~OOlptii$Si.OO Slill(l~ for'lhe' REAlR (inoDirEdJ cylindar" tno screen 'lNjll be .gis;pla~ingl HIGH ~ 5 'I,I'(i(1s as iIlmlng mark is; jnrat ~ info. Wsw <rt I~ ~ge· IOf, 'Ili1'l00w 8IiId 'Will snilDh Wi lOVll • {II vorts at same point as ilhe limingl maiit: wntmues th;rQU!lIh '~he winOOti. ~n lfiiS iiS ,ob$ewect IUI1fl n~wheel ili:ifl"tEirdi one

1-4.4· 2O!lI:3, aucm )',lEl9~~ 'M"II1II:elrIsflill:e.

reYQ!U1Ion'!O' !bring engine to oompliBSsiDl'1Istroka liur 'front cyJindar_}

NDTES

• fl1rfftl~ mallL oo~t* IJt)/ro Lo;: ave.i'Shot, 00.mp fIywhBar b.a~,<dg t,iJ]' IDC mBnJ,;' ~ ,Clf IB.fJ' 8~ OJ,irJ8pect_1(.i_i'l' wifJ(i'QW <1'lM TI",-pesr:' :rem- b~' JiYW116'eJ' irJ' iMvarol CoormaI7~',

• :Nevsf ,Col:infm:tl' roiillti.l"ii:9' WhITe' brIi'l"J{lM:g t.'y.wfiee~ ,ba:dcw8m8.. 'J"iI'liS rIViN ~ you Bi'lI,~ .r;eadi-np'.

1:3" If 'Iillilg Is Ol)~'" In~1 fimIig Dsp9d1ilJO pll!lg and 'IigftlSr:li'to 12!l-U1Qi iin-lhi!5 {14·,2)]1 Mm}, lin liming Is not 00ll"red'" see AOJUSlf TlMlMG in tfuis. :e.edlioo.

,.-...

'ii'

AIDJIUST'TIMIINGJ

1,
\
:2 ..
:.'3-
-41._
5. IRcrncw:e 11ml~ plete OO!.i'8r:

131. Dril ri'ilE!~cS n.c4diFlgl·!:tJe 1irnll!lg ~ oover.

D" Usingl,i=.i !hiJ!Jf,;. 1B1IIIWVI31 tinJing p~re ceeer,

Sea' Figure 1-:55c If tiJNng is a~ ~rnElrk appears 00 19~: ~ (;Ir ·wiMcm;J rqf,i=.ite ~imingJ pfate DDUrLtl3R;locK't.!1Se-

Chedl;. timing. Sea CHECKING STAlilC TIMII .. hBL

:88'0 F~i..Ire 1-5fj: .. If nhming iB ~BfIriIad (mark appears 00 Irigl'Lt &de of lSjnd~) rotate Ilml!'1r11 p-~j'e Olooi;:!,!.iiS.B.

~·ntrmlrn.g.

/

Fiigl!lrB 11-'56. ReIM,d li1fi1i1tn~

:2003 ilbl1jl(11XS5lR; IM~II1iI~sJllce. 1~

II NS- 'P'ECT- - 10- N

,,-- -

.. ,wARNING

DOl not m>OI!!!L"I"!JiI i~njliQonmg-lii,t t;WJldil WiJin~ 'to! ,c;ifi'tiLiiM\l'terM UISI aublll'ma'i:i"C--!lJt1l hBB.dlignt! {samra. IHli~h "'I:i~bi~Lty ill;; !liD IlIIlIpmtan't co:ns'ldel'iallo:m trJ;ir 1!l'Lmli;!l~le. I~dell$ .. FaI]UIl'e 1i!l! Mit-Eli lilSi!ldlig'fit IllIIii Mall iliimM er:n.llld mlJ~ iiln ,;:!_cciditlfit, r.eS:U!l'!IlSlIIlli 4es.!In <CiIr ~~erl'ou$ ,InJury.

,. ~n ihera is a change il'1l load (s.-ddin,g 1~8.g8., etc.}.

1. In a roea.lioo wT~h low light dr:B!.-\, aI ihmizDfllaJl lme on a s.c:r,een er 1fIf,i1~ th:=i~ IIil~,r~s 34--36 ln, (a~1 (:1111) aOOve' Ilow.

2. se,e Figl.llB 1-&7. P.n~oo rnQbn~le· 2~;i'ft (7.6Irn) ~ I re m a se ri:I-8iiI Of 'iTrl!I b!f r:mEti:lS U n31 :the Id i s.tante of ro m tll B 'frofll' ~ 'ro, the $Cl7eer.w'wall-

3. 'i.lerililf ,oolTECl!i'lnl1l.t ,Bmll rear-lire presaure, ,See '1_" nFEES ANEI WHEIa$. -

4_ Lw'lll 'i',Elhic;I!3' wnhl rid'ar~l3la@'Em'ca.l{I!J):au:!ItB'5slJliie&.

We_igh!' wil1 ,ool1i\Preas '&IEhil:::le' ;ru~nsiofl slighn~.

5e 8~ndl mobcrcyeta l1p.rigl\l: 'I.'riih htOfl1 fairililg .aimsdi B1rajght '~.

He Ciita~ LOW be_am (righl: lanE:} tli:m .aligj!VIIB1ilt.

a. :see pilgUFe 1-56. TUm ~nitiOn ~!mitd'l 10' 16N. $et R5indlEbsr lhs~mp swib::h to lOW beam poaiHofl_

C'. CheeK ,tIlilt 'IJi1i9 ,ooFl"aet paU'tiirrl ar ~ht is a ooublcli'I3et~n~lar patlsm and ia af(!nad with _ horizon-· 't.f_IlllIne'>l;!!J: shcw,m In RgUf'e 1-57.

Ii. ~t hBl3.dlign.i: ,aJi'gliime:nt. S8131 ,ADJLfSTMlBNif which foliO'NS.

a... SI361 FlglJIra '1-58 .. Set narndlabar haa;dlsmpi snIlDh 'w HIi31-l :be-allil 'po$ttlon-

NmE u..w.OO.:litilIil'J'ill'p M_D'~' iN~W.a.

lb.. CIiIe.dO: that ~he cauoEot pattern ef ligfut B a circular p.:rIilSilll .and iE, IDB n [8 F8 d 00 tItJ.e; 100 ri(zD fils] Ii I110B aE s.hcwmlln Mglii'Q 1-57.

c. Adjust MWll:Imp ai8f1rriIM!. S8e ADJUSTMENT see1ii)F1.

1-.45 :z,rnaB: Bw:ell XEl~R::: Mpl'ntensnce

Hof:1ZOnl,U LiJrIa; 9~il!l.

~ _ lH:iglil bel3m

:ii' I!.Ow liJ;9aml

A.DJUSliMENT

HIGH! ~FI'! aFif;l LOW beam ha...e iMe.:peFii;l':ent adjuster saew8.

\ S9ill figm~ '11-55"- The HIG1-I Beaml Mj!lreW m B on the I.Iiill ;',IIW 1h.e lOW Be.am Mj~ter (2). is on the, right uJiWe!'Def,ltlii the front t.::r1Fing.

If neadlslIT1p' requil188 adjusbiln9fl'l" perform he fuIowing: lWJ1"fi

.. To t~f lJ~mJ tufilil ~Usrs.r dm:::k~o.

.. Th I\<1f.!;O b~n. ;Rim EHljuarBr COUliI.~_

,.-.

,~

H .g1!! Il:!eam ,adJU8iteI "Iefl;lJ low IbBarn adjuster (r:lg~1)

1=1!JllIfi:!' 1 -S9.. H8iId1am;p H8QgJU MJIlIS'lrmeJ'lt

STOIRAGE

1.20

\ GEINIE,RAl

-

A,'d"J'AR NIN'G

Ga:sol'lne' h; 1I3rnma'ble,_ [00 om 5fg:f1Ii m~yde RIilI'i:ng !QaJ&Q'Ii:fiJiJ inl tL1I!k wh,li1Iln the hDIiIiIBI ID:r '9JiI~e: '1iI!Iher.E!' IDp9I1I fi'8JIIE!:S. p'iJO'IlliighIS .. $p:;ul!;!3, ,ar elecirj-c m.oki11t5 ~~ e' i:Weaemt. Ilni;ld~ql!lllte' safetiy pr'&C:;![(wllons, IR!lY reeuBEIi 81iI aul:dent whim uyld Il'e~h ~n dearth DF :s,rtlitiQiLil$ tnlul'Y-

I ' 1ba iIDCI1:awjdle - I not l!!e qpemlEd .' r :sewr<lJi IfIOfL!hs, ,$.!I1II;ft .BE: dumg fhel wil1-,~er ~~OO, ~hl!!'re BIB ;S8Ysr:aJ Uli~ VIr-'l1llclTl ~lJld be d'Dne to p:rotecl, parts ;agaIMii eerrcaian, 'Wo p~ the battery and In pliE!li'E!nti 1M bUilGu_P of g and wrnrah in ~ "usl syStem,

1_ . '~RII "uBi tank <Uflrd aM ;il, ,gasoline 8ta!bili2isr. USC one of the ,oorTiilllerciaily a ... >ilIila1:ie ~ ne s:1abi'Jize:rs ~ 'ItIe Fi'ilflnU""D'bJl8ra, ~n5.1rui;liOMi. Hun engine um,il ~[(:(d gas:oEne has had 8i cll~ to l"Eiilieh 1l.re'1ln}ec1:JJfa.-

2,. Fill the {Iii tank., See '1.5 IBNGINE LURRICATliON SYSTEM. Ren'tiJ!le a~ plUg! the, lilite laarli~ ~1i'C011 'the, all 'lB.nk bottom to IDe oil pump 'fe,ed 'fitiling. This pr,e~$ ,6111 irom seeping pil1:5'L IJi'M} check ba into ithe ,oil [pump, and! g ~hi3' ,en,giine fl:ywhelill oompartment

3, iRem()'i'.E! battE'IY EIJIid aHPg13 as oeed'ed In main ilLilfl [M' ;;:;00VC1 'I,!'(ItIa~. See '1 . ..;1, MliTEFf:Y MA~NTtE:t"-ANGE.

4. Remove, fue apm IPluglS, ili~ fJJ 1f!N r3 irilEi oi ewgiFl(:; (Ii iif'fto eaah cyli_r BJiid c:rank Itle: ,eFlpe 5-6 IiEI«Ilutiori$, ~in~ si:la";:: pluga. See 'l, ~,4, SmiRK PUUSS.

6,_ ('.hed tipEliliflallon- See 1.7 TIRES AND 'WHEELS. Ii the motorcyclBI will blill $lore(l ilbr an eJrtand!=d PEl~ of llme', ~i:il!Ir,el~ auppor1, hal noo:lni'lCYele so that all 'W'Eiiighl is G-ti tne 1lre::::,.

-

AWARININGi

lDo In:oteppl)" 'iIiiJ 0i~k1' I~ke lIoto:rs, 'Dr bral«ii [~~. Oil (ItiJ Ibr.~ke pede, rde.l¥Bdes bli'a'lnng effle!e:nq and l!;',iilJ'i R$uit l)ft iii iii aul'den'!: whlldrn ICDu'Jd rBIS-uti! iln iileath li;!!r. se:rioos ilijU!'lr.

7. Wash rnoWed-in-coior B.1iIC:I ehKm1e-'J;llated :surfaces.

A/pp4)' <II ~ht 111m Il).f Dil to e>:pos€iill w~ted ffif!1aI surboe!!;.

,8_ Ii rilotorcycie Is, ~o be rOO'II8l"1E1rl, USlf£i a miaterfal trurt 'i'liII ib re-alne. :!mCii a'S light Ci1JFI'1'3S. PIasiIi:c Rl8!'teqi al s iItm dn not breefhBI priJtfFloole tne ilDrm811ioo ai eooUeFisatwn-

IFiI:EM10VAJL IF1R)OMI STORAGE

a.wARNING

I!ilter eJrIlteoo'e;d[ pBt"iod:s, of Si~e' iUi-d! ~r.lIl!T!r. te at<arli. ng wlT[ide. p'!aee ~~!!I1IIII~I~on iin giUF, rd'i:!it::f'lgttge' iOlllJldTi and push ve'h'ill:l9 llQel( ,il!Jnd kirlh a taw 'iiliTIiiMiI tD 19:1i5.'Ujle' p~r' i!:Iutc'h disan!lJll!JlliITlliitfll:. [1n'ipI'Qr-tel" dutch dleen-, gagemeli1ti could[ li'esullll'll death or aariow; iinjul'}t

1. Cha:rge Slnd[ insiall lJ;1'1fer)'~ See 1 A IB.ATllERY [MAINTENANCIE.

2. [RemlWB and in:spaol: :s~rk pl~ FI'e,plaoe if l1ecessary. sec 1, 14 SPA~K PWGR

:$_ I!'!sped air f'iIte:r elE1li'ten~, R-e,pl~ce I~ lIiIeiJE!S9ary. Se81 "_15 AlIA CI!..EANlE;:Rl FIU1ER: Element.

41. I luel '~nk was rdr:einer1il, fill f!.Ilfll ~af)!!; ~h ~ em ~ne'_ 5_ II' oil feed lin81 rrrr<:!.S, ~ (!iH ,or. plugg:ad, IIJn~ i~ ,<Irid ~eQCInn:Eo!:lj.

6.. Shirl ~8i engne and nm !JI1JIa it reachBs nOlilir""dI ~t.atIngl tempemlulB. Chedt; tfluids ;['PI(;i retlll te [proper [8\i"i3ls, ifJ r13qui~MIo

a, ~ engini3! ojl level S~ 1.5 ENGINE W8fUC-ATION SYSTEM.

1:)" Ched!:: 'lmlilEflliBEfion fttIIid [len.n3:I. See ~.6 CLUiFCI-L

7. P-arforni (J~ the f:heck!3 m hel PRE-RID N'G CHECK

I.JST BiI ~he OHni2M51M'a I ual.

vo.

~ Eilue91 XlElHIlR1 M\a.iJilbmome.:e '1..A,9i

'TROUIBLIESIH,OOfINIG

GEN IFIR:AlL

The '~ {:_Mck ~ ean 00 MI~'ull in Ilocating most ~P81f>. atfig iIrol.iIble8. !ReIer to Ihe ::,I~r~priAt.e seC1ion~ kl Ihls Sel''llfce' Manu;!! rer ®'l'ailedl P~rildu[oM.

Starier Meteii' Does NI!ot Dpelll'Bte' ,or Does Not fUM IEngi na 'OV'elli'

1_ E:n~e :s<1ap ~let! !Ill Off' lDosl!1OfI. ,2'_ Ignition lke!j S'W~.h. ,niJol' ON.

::Ie Disch~d(ii~1t8FY or kiDse i[][ ool'1l'O!liled oonl!lB[iliOR3;. {SOlenOId! ~~~

4. $tart'eF oontrol relay 01' ool~id nO~ l'unl;itiDlii'~.

5. IElectJic. atEiril'er shafl! Iplnl'(!fiJ ge,;ll IlIO't ;enQ<m'lfI@ or QVerI"!ArlI'1QJ Ii:llltlth ~in91-

16. CllitI'Cn IIeVef ~d ~f1. VChicle, 'iFlli"lclJkaL "7. Starter interlOCK ,cl~ooit rnaJllincl.il)F1.

Enigi'ne' Tume Ove~i' B u~ Does Not StlilJrt

fflJ'TE

$&e 4. 11 B'lGJNE GRANJCS 8U]!" WlLt NCJf S'JJ\RT to« spe. ciIiC' ifes.1s,

1. Fucl Utf'lK Cililpil.Y.

2~ IllSth_argM Ibr:.Ji.'e"r\!'. 1!Xts8' or tii!(\[Ikerl ~tHBIiY terminallOO'llnecoon8.

3. Fooled :Spo'Irk, plugs..

4~ wO(io$e' or ~sno!1ing spad!. ~Iug cabl~, or Q;lij~ncelit1ns. s. Ignition ilimlng ~.(dty out -or MJustment

IQ. tecee wir,e cennecton at COl or OO'llCi)I' coof'lccliU.n Of

plug 1b8~n ignition :~m;or and module, See Section 4.

t. igl'iilioo (lOili na4: 'f!!JIdi!:lli1Ulg.,

S. l@n~IOO f:"fIoC1ul!!l illO~ IUr'itLitJniFl9. 9. 19nUloo ~enS.QJr n~' ~1J~lon"J.

~O. Slidking ~r dlBlThf:!!:Jed '!If!1\ie (iii '!o'fI~

11. Enqine '011 too I)eaw 'wln~er Qpmm:om.

12. flgnition ICilrwlt Inle~ rnWiLlDC:llon.. 1:1. MD oullput 'I'rmm 1Ih.e ECM_ ,see i:l"e9ler.

14_ lnadequabe. fuel IPFeSBUre, in fuel IinE!B (pa-aEiible, leaJ,;Je

,See d'eeller.

15.. CtuggrJ;td IlJF.l:! rm.'EiJ. See C!ed1!3u.

~ 6i_ ~g6G I'uel ilij,EidCf8. Sea d8a1er:

~ 7. T~,pM bWilk anQla ~sor: TllIInk.e)" iI.o ,OfF. wait ~ 5. :esc-

ends, and then oa-cK 10' IGN ~1fI1.'C; stan tliK9i.

UI. liP SJ;;;4l1OOritaSt idle ao.rew nljl: IS8t pl1JI!ilE!rl:,>. :S8B d!3a1ar_ m., No mll'1p1!rl: frem GMP sEnSOr:.see ds9le~.

20. In~r,a~ 'flJle! IDump.. See deaJer.

"11-50' :2.OOS, El:ue'11 XlB9B~ Mia IIliI:eiil S1lI1!:l!!

~., :SpaJl plugs in bad ,oom:liIioo:, IiIave irnprapeJ gap at" .Eire

pa 111 all}r l'ol!lJcid.,

2. Spal'k plugl 'c:.Bble~ In ~ ~!~lOfI and! SMFIll'lg.

:3. B.:rl!I.81iY near Iy disc h arge d.

4. Loose 'i'iIie ~e~ at Cine Qr 1M ba'l1ef).' I.ern~iFlaJ)S. a'l.

oOil! >I) r a~ pUg bBlW6eIl it! n i f}[l n :E,EiIlSO r an dl IiOOd ula

5. 'ThronJ.e ~ nOol: adjustCfj OOl'1'i9C'1D}t 6... r..gnrfion 'C'DllllIQt 'IUF1~f1lng.

"7 Engin!3' oil too De!avy !;winter o,peralioo).

s:. Igl"ll!1On IMI lirnM Pli'I:lf'EIrI:f. SI3I3' dealer.

9_ vapor 'llent 'llBI\Ie pJug~ Qr 'f1.lelltne' ~ (iofI' !'e$trletI~

'1'ltCIIIow.

1 D- '!.i'I.i'aJe.r 'Of ,din !n 'fuel s-yS1.'c.tli1. 11_ Air Iaak at in!£ike 11!1::,1n:IfoI'd.

~ 2'. ~s ~r~n~

~,Se TP s.en~or al!l!!ilor 1'ast ~!e ,SCf~ not scI IPr~i'l:r.'. Sl'1!t;I; ae.al~_

14. 02" litt OF ET ~~ di!lmag~ IX rlriI2IlFuncti'ooingL 3!313' de.alsr.,

staris B·ut Ru ns, IlI'f,eg ul\e.rity or Mllsses

~ .

fflJTE ~ 4. t,:5 M'lSF1RE IrX ~r:i1iit ,~~

'1_ Sp;ark plugs in ha-d coodiOOn er penial]{~- 2'_ Spark pkJ(I caii!EtB ilill bad oondmoo am:! sOOF1!ing~ J_ ,$pIlIJk pbJ gap,1OO ctoso 'O~ 1.'00 wi:OO.

"t I g.n iiion QiIIj] not fun c1iooii n g~

!;ic i~!!))n module n~: 1idnc1ionfig"

'cc I gniOOJl S.efl!S!JII oot fl.mctfm I n!ilL '7 _ IBstteIy IilB9rl:J" ~i~hargedl

.a. [Iamagadl "",'irs, o.r looss, ,ormn_ed!iDrlI 81: Ibstteqy !sl!I11in9ls:

®.rooll.

!9. inl8mliHEiJlt short ciirooit dl!r.e ~D' d8m8.gBd wile i'rul!lbOOri.

110. Water or iljil1. -1'1 !'Uel s~em <lnd. Ifi:rlJlU~ ~ orf;illar.

111. Vepor 'i!Bn~ ~I!ie g!lJug~.

1:2. Throttle IOOfTI1ro'Js jmp~ert;~!' adjustcE!d_ 13. Air reak: aI make rnanikild or air filmr., 14, tJ-amag~~' er l~iJst 1t<l:'IiiC;.

15.. 'weak 01' Ii!tIOk.eJiJ ~IMe ~P-4"lings.

16. l'floorr8ci 'i'211ve tiliriiingL

17,. 02.. IAT or ET 8Sn8DI'a, d:.rnsgedl or m~iDnfig., :see

de.aler.

16. liP :&ensor f10~ sel' P~O~I,Y. Sec dcaJw. 19. FUel tevelI too, m. A{ldl 'gasOli'ile.

2~ IMperallve iiJc.J In.&cdof. S,ut. ,f1(JQJ9r.

21_ OMIIl\J~ IlJF.:!J ~i1Irlk V!!Ilil'l: '1.!l:l.h!!3, 'Di pfid'ted '!IEfiI: 'fuJbSL See'de®er.

....'

\ 2. Piston rir'1OS MJ;Dy wom m bl:'Oksn"

3. 'IlB1'oIB atBI11I S!3"'~ oom oO~ oamaged_

4. 'Ili:"l_l:!.re guid_e8 IbBrlJy \mrn.

.5.. :Se!'1 SeQ rs dB.11ilB ged ..

PlI'e- Ignition or Det.ona.io"n (Knocks or Plngfs)

1. E;t;l:lEtSSi'l'(! earbon deposit: 0IiII p'~1.00 lMar:i or ODJT~-Us'liOO ·t;:'hembef_

2. f~.~l'J"ect hast ~ sparK pUg.

. . :~C Spark p1l,Jg~ DOt tiring ..

4. Igni1ioo riiiliIing adVanoe!lL

05. 1F1lf.e1 adillIir,il rallng 'too, Ieiw.

16. In; aka maliIi~ ... aeUl,lm ak.

Overheating

'1. Imsufticien~ til $Ij~ or ,DiU na.'l: ciw..J 8.~.

2. Clogged Or' Wi'IlJa!;led 'llnB 00 Il!(I1 cooler.

3. Cooling fuJi, n'" I)),]:)e~ling propality.

4. leaking valvas.

5. H~ carillon dBp~.

[6. IlgJiliU'oo lUning remrded.

1. ~l,Jlic IiftBr rne~ lunc:tlOnl~ P'Jopedy:.

2.. Bl3:Iiu PIJS!"i IUdL

:1. Gillin; tam gears OJ' C8J!T1 buShings 'WO'!'n. 4. Roo'kar ann bIndlngl [on ,Bhaft

Excessiy~e, Vibrmloliill

~. Engine. li!3-bi1r:s loose, Ibn:Hoien or 'im,pmpGrl).' spaced.

2. I solalor me umtifi1jjj ast,01OOr:s 1(I(1!!ie.

S. Br0k!3n r:ruIDe.

r;omta:ry chain tJa;d1~ wom or __ 1m. 'li8ht as a resu'lt ,oi insuffICient h",bl'lica1ioo.

6. IntBrrt!l.1 emgine problem.

7. YillnBels rl.01.l)~ C(lflroBCU~.

ENGINE LUBRIICATION SVST1EM

Oi I Does [Not Retu nn 10 Oill nmk 11. 0i1 fan K CitIpt'jI:,

2. R!3funl pump ~fB i:b:1'1la.1I!3dl.

3. 0i11eC<!1 pump noil: 'Ii!mcIiorn,fig •

4. lRestri~ 00 lines or liHings..

Eng'in. Uses.Tioo [Much Oi I of Smokes Exeess!ively

1. Pismo rings bedl~ WOIlIl or D~I)Ken. 2~ ~ stem ,seala worn or oorna!;led.. 3. 'I.Il:!I11le g)!lidsa worn.

[Engine [beaks 011 from '0818.9', Pwsh Reds, [Hoses.

1. Loose ~11EL

2. Im:par~ S!3e1 at gaSKe;t'iO, p.ush rod 00\'l31i. washers, etc. b <00 IIoca'IDg leaks. l!J!!je Bl_PLOK WGHT LEAK DETEC· TOR {f!\:frt No. HD'354Si'}.

:3. REGIlricied oil wlUrn line to ~am...

4. ~.ricled bl"!3a1.hCf P'3SSF,lg:e(:!!;} to air deaner.

ELECTR'lrCAIL SYSlTEJM

Allte rna toll" Does N,o"l Ch:8 rge

1. Ragdaro~·rec1lifieT moWla no~ IlJFlct}l)nlng.

2. Rcelmer oot .groundedl.

;3. iE';nglfl8 gJOOndl mpa Ih:tosc or Ibmk€n.

4. lOllEs or brok9"n 'i'iire:s Ifli ,otlF,l~ circuit

5. :Stator oot fundliOO'lflQ. [e. R'otor net fuoc:'I:i ooin g.

Al.terinator Cbarge' Rillte InS. IBel~o.w Normal

1. ~gu~-l;:ectiiief rnod.ute I)tIL rliflet1'(mlng;.

2. SlaW nat functioning.

3. ~otor IiiCI1 nmctioning.

4. Weak~.

!5. 1..00!3!e CIlMIEiC'Il 001&.

FUEL SiYSTEMI

fue.~ Systeml floods '1. Inlet 'Kl1VC s1kfclng.

2~ I at ... a.lYC ~r VEiI'a'8 seat worr'1 -OF dama~.

3,. Dili or ~F 110_ matter ibahl.'98n va1¥:G andr Its $JEst.

1 , 00 ~.eRSO'r d.8niJ<!I~p:l(J G:r ma~Dl'lEg (bike rul'lJdng rich}. Sea, daaJJ;;.r_

'J'-.

2003 :Elui!lU XB9R= MalMenZ!!nce

1-',![11

'TiR'A1NiSMllSSIQtNl

Shifts tlsiI'd

~ - Clkt:ch ,C1raw'ingl ~hU!t.

:2. Shifter klrk!!; ~'n::::I~ iransrnlsslonj damaq~,

:3. ClJIIn!3f5, 'r,rom o:Hi shifter ,ahltm oogs {In!ilr:le' trf,lnsrnis-

sloo).

Jumps Out of Gear

11. $b't11e~ paWI'iq:.i'op;&rly ~LlsLed.

2. Shm:a~ '8n~ginQl p-s:rt:.=I; ~1'IIS1d'e lr.anSFflISSfo;n, il):JCll~' oom ,~roLilnd8d.

3.. Shffter ~ l>en~,

4,_ D.a!m.agBtd 'g;e.ar.B..

_-,,-

C'ILlUrTC HI

,Slips

1. CI'IltlCh ~IS imp~rf)' adjusbed_

2. WOIiIii i'riction iPIBfeB.

D;ra,gs or' IDoes INO'~ Release 11, CIIJ~eh C(ln.1r'Ols. ir'rnprn~rl\l adjustEwill. 2. Clutdi pht.es ,g.re~sh.lely W~.'Ii!'ped,

CfiI;arHef:S<

CHASS,I,S

1'l'Io'ICI- 1- II ,..... ' it- B' k' It 1Ii!1l ,

_ ''I;!Igu ar ma .... aq,uaJ..,;:' ,r,a! e C!lill,C,~

1_ Ml8s.ts" cytiruder low' 01'1 tH~.

,2'. Brake liM OOOftaim:; air btJD'b'JaB 0'1 mnisture. ..3. IM~e~ {IF "WrIccl ey&1dElf ,pisto.n 'i'lNiIl.

4., IBrake p;::.-<t:iB IXNE!r,edl with gJe'E.l!'ll!;! (!iT C41.

,5. IBI'f,lKe p;a;.d$ oo..;)jly wom ro' lIt~il1iilJlm lining 'lhil;:knass.

6. Brdlke 1i01.tJt" badly 'w.o.rn or 'IA\9rped.

7. BiffiKP. M~S dlraWing tit c~:si!18 D.[.:I!~ ~r:ake ifadea, dUe ~D haat !buildup}.

~, tilS'IJIIMian!, Drdl"lffi p!3da1 OJ hand lavarr free pl9y ,(bral<:e d~).

itiIaril;dlingl 1'r1regu larl1lles

1_ 1fir-es ~~roj:lCrly i~aI_l3dL see 1.7TIIREB ANDW1HBELS. ~ root 'IJ!ii'erin~lBte.

,2. [LOMB' Missl aide. T~ri i'rant SJxIe '!Do :S!;!-4:1 'ft-l)s (53- iSc INlI1l1l- TT~ rear mle 1(1< 4s..52 IJ:.oIM (65-70 rim) ..

;,'3, lEl«;cssive ""'h!3e1 h_,*, futasring P.ley:.

4. lAi'ms and iIllfe';:"':, (It.Irt-sHI'1Je ~~,s (life ruoout shouldl oot IJe; mors 'IhiiIn {I-_(I80 in, (2_0\3, mm)).

:5.lRims 8.1Tid 1tres Otr.t-(tol'-lfOOml' 'OF '~OCQntrit witb hub tfir,s Ii'UMuI5lto'LIIld 1Il1J~ be llitiJ118 Ihan 0..000 in. (1 ,.!j. mriIl)).

6.. l~gUlar!Or l)eruoc:CI front fif'8 'Ire.a!d "'"ear_

"(

... '-

Tks' and whEElJ unbglanced or lNei~ lID wrj)F1g1 Si'OOol whael

8~ .st-ee~ Mtill bsarings m,pqo;p81!ty ttghtened OJ' WIN n, Sae U,3. STIEERIN~, HE:ii;[) B£,A.RINGiS, CMtk 'fat" IProper torq u 101' illid f'spl\:l£e 'i'1lJfilil Ib881~ngs. See 2_17 FORK iClLA!MPS, 1JF'~IE1R AND LilJ\IVER

'9_ 8hookab!iOfbar or:froort fo'rkra, ,no~ ~'unctIoFlIIi1(1l !f\i!) rrflaJ I).'" 10,_ lHeI3iV'jIlroot en(lliooding. N'()n·sI.r.:tJiidOiJtd 13q;u.\PmtEm~ 00 'Ihe' loot em (,SUGh .:IS neav.y mdio 1'BC8i'i\EiFE, extraJ Ilghting eguipfiIl!ml: or !uggsge} lend:.=:: 1"1.') cause Ul'!~ h;.:uocllin!!l.

'i>

SUSPENSIION

The iliJlIQ!Ning tablas. list pro.s.sibl'e SU5f.1ElnSiori <:md oper<iiLmg ,trou~ and ~heil probable csuaaa

Whelil IMiIcimg s:djustm6frts, remamb(fl 'inCFe' are' two meoriliurns In se~ up .8 Ibike, IJeome1Jy and SUSP8flSi.OO, 160th

\'oomrpori,iiJIlffi work loge'lt1e:r ~use SLfSPe-nsiD".n is a part oi geome1J]:. In ordar tn .ool!J8 han 9 pro1JIems. II lIS bnMrtl5lnl to diagfl.i:ll!i.e the' p~m"S ~me OOIDIIe'- (:h;rrt!I'ering, sliding or a f1I IIIiIDl:! mfn rtaliIle fs etin g I3J'8 au;;; pe1'IGiD n -DBbLOO, i'ia FI !:I ling a.nd i3J :swiUlQiri!i)i i'((;:rk are geo met r¥.-related , bum often 1iiIa59 ul'VtlB.l!lted mEiracteri~ can i:xl sol¥ed P.y suspemi'Oii a(1)ls1men'a,

iFtOIIJ BLE51¥100T1NG CONUmO;N

8fo1c 'Wa'1I0'r.'i'S m~ougb rums,

H=ee Is bose OJ' vag !lEi a'ffe r Ib LI 1iiI,P::;, Wheel ~end:l, to. "pogd"' after Ipa8s.mg 0\I'!3!l a bump', This is, f'I~iw[lble' Dl' w.atd.ll1f19 me.

b&B OilirrtimCla to OOuipDe ~ i~ 1I'<l\!'ltillS ewer ~P'e lltJll1tl'3-

---------------------------4------------------------~

Wh!3EI] IBSI!i'Dm::l:a1~ bump', but ooe:sri" wlUm to. gJO'undi quickly arter ~ Thia is. IReiiillJOEi rebound daI1'i\Pin!}.

FflOr.e ~umed over .8 serias of bumps I3IiId is cftarn refOt'i'OO to as ~IFig {1'.(fmrjer

The biloie ibotlDms out or •. while oornering.. Iincrease 'oollilpreas:'i!m damping.

B&.e has iIlOCCCs:sIVe' IDroJ'ie dive.

r- - ------------------------1

HUJi1ih riCfiil, panlCUlarfy iiNe'l wastJl;io.ard !3uIifBoes.. HootJiOO COO"IPre5S!OO ~g-

Bump!!; l-iJick 1hrough hBDllllaDaJ;s 'Oli" ,s.<aat.

~nsion seems fl(lol to re~pt:!iIiId to bumps. This is. lE!VidenoEid Ibv tire' d~l]tMg (.a

m O'l'e me nt wJih sm riI: shu ke <uflilfd h i@'I r re Q ue..n cy), 1itro u!#l on rne:r:a: 0. r I!r; j/D1ting tha rid a u (JI.!l;!r ,rrOugh I'f!IBi:Is.

IDcuease tliia camptBSSioo damping. If 1be FJUlblam per-Eis!s, d9crGillOO itCDouwJ (;l;:U'Il.Plngi '~f a 't~er rel:lQ\mr;ll r;::;Ite. Le!t;l, spril'lg IPrelm1li may ailre help.

TiROUBIJE.SHOOiliTNG CONDmON

.AILMIllISTiMEiI'!.Ii'SOUJmON

"iP>lJr:riipingr on I.M ~f" eeears When YO~I ;!'!Ire· areelE'Jailing oot of a eornes, This ~Ji[jbli31iTl8 oX:CUIm, -n 'bNIJ. 'IlaIiEr1ii:;lS.

1_ Th!31 lirsl Iyps' ~ 3J IfOO'IIel'flefilt wIth a II,';Ifig Btro'ke and a 111gb l:re~~enGlJ'.

2.. The. ,B.eOD.fid llBl'Sioo nas a rtlt:!VEiIffi.elilt IN i III aJ S M on S1roke i1JJ1d ~1'I1'feQl,!eFlnl·

11. Thel,EihI:!Dk is noo ::;<[IfL I~s-e IlAltl'lprossiOO ct.:un;Pif'lQr, 11' the ,Fid~Er ts a!lr138.iiy Ei9t 'to the maOO'mum. s:dd mora, ptelOili.d]ro I.M ,spring ~ooe MF! ~ulIT1j_

2, IF! It!!.$ case ~ sh~ is 1'00 hard. o.~ cornprsaeinn damping.

-

'The suspension ~. too solt ~a.se COI .... ~IOO Clamping.

-----------------4------------------

The :;u:;,pan.sioo is ~.oi;li haM,ID~rrrose OO!'!'li:lrE!$sll)n ri;!amp-

Ing.

l..a:ck, of II ria fa ed'rt3~cto;_

Slidin!;J dWif'lQI rnrr~ring~ Slil:tll!'l~ I'iIlIliY ~Ir goD.ingl into the eomer or a~r;Ei'ling rDLrm of tba ccwn!3u.

1rab~e 1-'4.. f'ironl SuspensJ:(J.ffI Problems

ADJlU$,iMENT SOlUTIONI

TROUBiLESlH.oonNG IOONDmO'N N~' abwl'blng bu:rnps..

A ~ ~nE:iDn is a bslenoe bEi"tw'eBlli dampingl and tra.c:k oondIti'OOi. lFinding fui& b~ ~ui~, ~pl.o:rin91 all p!JGS'ibJa ~SSi:oo ~"'fIil:gS,

-----------------+------------------- ~ -- -

La~. of t i r'8 feeiiilb BelL

11!ICrea5!3 oornpression rdatnping.

T1 re s I i d'e;:::-

2M3 Buell 'XB9R:M'ainIBnam::e '1 ... 5:3,

Ii"

\

CIHASSIS

2

2.1 $~c:ationa .. __ __ __ __ .. __ , .•••..••... _.

2.2 Tir-e- Sped IcatJon$ .. __ .. .. __ , ..•• e • - - - - •• •• __ ••• __

2.3 Vedirida Ih;I:'&/rtificabon r.fulllOOe~ _ .. .. __ __ .. - - _ .. __ .

2.4 Wl'!~s/ .. - - .... - _ .. __ __ .. __ , ..••..• - .... - - .. - - __ .. , , ••.

2.5 1FnJl'1l 'l,l'l,l'heal " ..••.. __ .. .. __ .. __ •..••.. - __ .. .. __ ..

;2.6 Rear 'Wh~1 _ .. .. __ .. - - __ .. __ __ .. _ ••..••.

:2.7 CheekingJ CasL Rim Filidoout • _ .. __ __ .. __ .. ,. _ ..•• " .. - - .. - __ .. __ .

;2.9 Tires - ... - - .. - - _ .. __ ... _ •..•••..• - .. - - - .. - - .. .. _ • , ......

:2.9 Br<:!lM Pedal _ .•.. __ .. __ __ .. .. _ - - .. __ .. .

2.10 IFront 1Ekoa.\B Master C),lirlOOr __ .. . .. _ __ .

:2,11 iFi'(Jil'l't Bfal:;e!...h:! __ __ __ ... _ , . __ .. .. __ .. .. .

2.1:2 lFront BraM C~r , .. _ .. __ .. __ ..•• " ..• - . , - - .... __ ..

2,13 Rear IBrai!1e l~'t;!r Oytindet' .. __ ... _ e • - - - - •• __ •• __ ••• __ • ,

:2 .. 14 R88r IBr:akB' Lina ., __ .. .. __ __ - __ ..

2.1.5 Rear 1I3ra(l::e·I~lIper __ .. .. __ .. __ •..••. , .. __ .. __ .. : __ .. __ __ ..

:2_1H Front f.olii. _ .. .. __ __ __ ..•• " , , .. __ __ ...

:2_1'7 Fork Oiarnps .. Upper 8JillH.!ower •.. .. __ _ :r .. __ _ ..

2.1.8 Steer1~9 t-l~ BeBri~ __ __ . , ..• _ .. __ __ _ .

:2_1'91 .8.wingarm ilillll Br.ace . ,. - _ .. .. __ .. ..•• " , - - .. - - - .. __ ..

221J1 F{QnU;nd Fiear Ilsolai!Jt' . __ .. __ - .. - _ .. __ _ , .•••..

.221 FmflilB . . , •• " ..•• , . __ __ .. __ ... . , •••..••. , __ __ .. _

,22,2 ~1,r ·ShocK A1J;J!;ili;Irbe:r . .. . .. _ •...• - .. - - .... __ .. __ __ .. _

2'..:2::1, Thrtlnfe Con'biol , •••..• _ , .• __ ... .. __ . , ••...••.. __ __ .. _

:i!..2410iutch Hand iLeve:r _ .. ..•••.•••. , • _ .. __ __ . , _ • , ..

.2,.25 Hea·i'l'rt ~pClfiI: Bra.ckat " __ .. - .. - - __ .. __ __ .. _

.2,..:26 Fsirirng Suppoo Brru:;I«!~ __ .. .. __ .. - - .. _

.2:27 Iiandle'bl;l1fS - - __ .. __ __ , , ••.•..•• , . - - - - .. - __ __ .. _ ••..•

2:~2a. EliihausJi SystBm __ .. .. __ .. __ _ __ _

2_29 1FOO~j)CQI. Hee! Guarjj, and Mownt . __ __ ..•• e - - •• - _ __ •• •• _

2'..30 Sproolre.1: Gover . , ., , e- __ _ __ _ _ _ •• __

2'_3.,1 Fen®r:s - - .. __ __ .. __ __ - - - - _ .. __ __ .. __

2~.32 Be4t Guards ••..••. , .. __ .. .. __ .. ..••...• _ .. __ __ .. __

2'.·33 Chin Fairing _ .. __ .. _ .. __ __ .. __ . , •••..••

2..3.4.Aiib!J;( CI).\,':er _ .. __ __ .. __ __ ..•• " ..• - , . __ __ .. __ .... __

i?:J!5 AU ~s: _ __ .. __ __ .. __ __ _ , " .•• _

2..36 TBiI Fra,nm and] Body lJiJ.gffl; . __ .. __ __ .. __ ••••••. - _ .. .. __

2,.37 front Fairing,. \1'ilnhihiBfd. and Mi~ .•• ,' - - _ . .. . .. _ ......

2..38:seat __ ..••...• , .. __ .. .. __ __ , - _ .. __ __ .. __ ..

2,39 P'a.9aengaF Saat ILook: __ . , .••..••... __ __ .. __ .. _ -

2.40 Si!ilBslaJIId _ __ .. __ .. ..••..••. , - - - .. __ .. .. __ .

:2-'1 2·5 :2-6 2-7 :2-9-

:1}-15 2-18 ;2-19 :2-22 :2-:23 2·26 2-·:m ,2·31 . 2-34 . 2~36 . 2.-~ :<!'-4;5 2-47 2:49 ~'-5..1 2:-54 2-55 2-5.1' 2'..J5.S 2-59 2-4':5:2 2""64!· 2..6.6 2.if36 2-'CJ. 2·71 2-7.2. 2-'7.4- 2-'76, 2-'75 2-77 2~·1iI1JI 2-H'1 2-1;12 :2·-83

2,,1

\

_.
~N. MMI
:52 . .0 11:320
3'1.:2 '7ge
4..'1J' 102
3c2i ®4 TrBiil

WEll~iI";;'u.S\' iMO:!LI~1L$ 'I,I'iIJ:d.WiOIi@ L

GAWR _. Firont G.A.WHl _. Rear

LEIS .. KG
4I!l,:;io .202
;650 .:3a5
:a25 141
525 .238
405 1M N.OTE

GJUSB '1..·e111'.::1I:I' W8.i,gt.1 Ranng .(G'!/VVR)' (m~l i1Jl'o.~: ~8d IVd.lfCk:io wcJWi',Q' aoo ~Ilt;ihig ,a:rooas Ax19 WejghJ' Rat.ir:l,!1$" fGA,'WR;;l Bra. giLl6'l"l 00 Sf!' imiJrmrrlifm ll1e.car .l't.lC:I:lteal 00 i!f:Je s~ l'leM.

If raasrn i :;.:::iun

--

IF\fe'llfaflk; (he:_ ~ef'ilel' ------~-------+------~ IR~~ 1'uei Igh~ at

~-+--------4-------~

OilT~rik ('i'("'el' - to r II"IOl!ll1aJ aa c: h ang B).

FolikOil

14.0

L5

'Wheet~ ~--------------+-------r-----~ Seat H'-€!igh~'

-

GMlInd ,c;e~

2.4

14,~

SOa.JO l'UIi:!~NG

SsIlliiBBEl Soh}

i---------~

IFron,t

~nIDp' ,spoliilTlID!: Rs.dlaJ [I ~,2017lJ1 za n' ooroFY

_ R.'e.a~

Eiwi lop' S pOOlTiEi:( ~BdiBl [I nl~5 za ~'7' W07U

.:36, p·S~ ~2~a: kiPa)

:3.8 'P:S~ (2f.]2~)

IMM

_

F!Fr:Orrr FI~I

Lateral

FlEAPi: r--

RacR'.ll

I~'

Do Mil: i.n~ltt'te anr ~I're ~o;m.d 111:8 maximum iftf.li!lliolill p:rBIi!8Ur8 III!!!· :sp!iIOifi!3d ,e.ril hr,QI tJilil!itwa'U" Ovelliinlt.l1i~on !1i!~ ,e;l!lUse. 'lire l-o ~l,!!iljli;I~m:ly def,1'ate· wlil]dJ ofM,.IIIliIlll"esull in dBatiIil 'D:r :BsrilmJls, ilil.iIlJ:l'y"

TORQUE VALU ES

.A.il'I:IOK '00¥"E!i '~tel!ler.s; '112·atllln-in

I -------------~~------~

A.iJtlIom 'l3ilil,eoo r' 12-'96i i n-l.ilI<5

Axle pi~ rastcn&, rear -4Ouffi itJJM

I ---------~--------~~

,Axle PIIi'tth ~eners, iront :20-22It-rlos ;;:7-30 INm page 2-141

I ---~--+-----------------------------~

Ala:le. ifroot 39-4 t tt-fuEl .53-55 Nm Af1.TfI~IEZE, ILrett handed thread., p:eflB ,2:-8

BanK a~le' ~'!lefl!i!D.r '12.J6 1"",DSi 1-4 Nrn I pag;a 2:-60

- ~ -----------------~------- ,+------------!r-------------------~

~l giJ'a'rd. umer 12-36 iJiJ-Ibs 1-4 foam I page 2:~1

I -------------+-----------41---------~~--------------------------~

13m'kB hrliiiJllCVc~ I'!~ ii(!.~rB 80-90 i'rnl"lDfj; 9-10riNJn lPeg;e 2:-25

I -------+-----------+-- ----+----------------------------~

Brake lamp ,:swiICa li:i.stt::oeF, 'lVant 7-110 IIi}-{[bs o...B~'1.0 Moo jp.;;ig:e 2-2-~

I ,~·l------------~----------~ --------------------------~

~ke line pH:lamp ~taner, frtlInt 36-m) !'ftI-I1i):g:4-7!'\1m p;;1.9.Q 2-213

~,

Sri'<:iKc: line p-da:mp &a~r, 'rear 36..00 1liI-II:Js ,4-7 frlJm I(lSge 2-35

I f-----------~--------------------~-----

~kta; ~J rfasten·e~ :2.2:-24 H·lbs ,~IN'm I LOCliliTIE 272, paga 2,-:2.2:

f -------------4------------1·,

I Brd.ke pm ~rlgCf set, m:mt --+ '1_'1-_1_4_lft-_lb_-s_, --+ 1;5-19 Nm l ~ 2-:29

ItIIrake pin bangs set, reat 11-14 ift-Ibs 15·20 Nrn I ~a.ge 2--3,7

8rake pk1J ~g. rear 22-26 1;n,.Q!):s: 2--2 NIiTl lPegiE' 2-37

-- ,~-+-----------+--------------------~---

BraKe res~r la5itenEiF., r;aar 96-1:2011n--fbs 1 '1-~4 Nm IlPag,EI 2-7.8

CaE,pBF tJan,fI!;) ~It. froot 1 &ero R-IM -I--:r-;22--. -:2-7-'INm-----eI-m--Bt-li-c,-IP-age-. -.' -2-27-'-' ,----------~

~ --------------4---------

~ Cdtiper lb.an10 l)i)tt., r>ear _ 16-00 iIlIIM 22-:27'IN'm_1 -II-paga--. _2_. -,_35 1

Cafjper 1b~;U OO'tt, 1~E!ar 11S-2O Ift-Iba, 2z..271(\fm page 2-$

C~er tJleeoor WJW8 ~6-6!llI [~b:!;!i 4-7 Mrm Irmeiric., pagl3l ,2-·23

-- --+-----------+-----~~--------------~---

cacer ClI/mef", rear ,2,4-26 iI1-lbs S2-S5 Nm page 2-16

- ~;-----------~--------------------~--~~

C8J!J)e~ fasleners, 'il1Dl'li 15-1'9111-100 :2:!l)..:25, Nm I page 2-29

~ -------------4---------~ ----------~----------------------------~

I- ~If rniIOumlng 'l'asI:-ene>riS\. front gs.,gjl" fi-IDs 47-,50 I\bn _I ~8 2-,29.·

C~elf moun: ing larg.s l'asteiil(lr, rear '19-2' ft'-11Ds 24-28 Nm page 2~a8

-,_

\

IliliEMS,

_-- iIiORQUE

NOfiES

Ca1!,per IDi;Il,JrL~lng srnell festerilBF, rear 14~1 S '!l-IDs 19-:24 r-Im page :2-38

I-

JC:I\ii'II L.1iOOg ii'as'l:eDers 36-48 iMbs, 4-{ii Nm IPage 2-741

I-

C1utc1i ~10 p-c'laFlll]:1 1.2:-36 inrilbs, 1-4 film Ipa~ 2-S3

I- -----------------------------1

Clutch 1B!le'f clEIJ1ippinGIiJ rastDnef ::Ill-«! lnr-!1b!!, ~7 Nm page 2-'5S,

,----~----------__e------------~

ClItch lever ~ ifBsterulr ,39s4e irr:lbs, 4-5 Nm I page 2-158

l-

E I at; ~ro n i e coo'I:roI modlJl'le if@B1:e'1iI81i8 '72.'-36. if.iirll iii :!;, >5-11 I'f,m ,p8 ge 2-Ei 1

..

Engine. sJilru;:udl air ~ 12-3.6 in-ilbl!i, 1-4 Nm page 2-7i6

~ -----------+-----------+--

E:d"i8LB1i Ile.eder mounting rru'l '72'-96 Il!Ii-!lbs 8- ~ 1 rim ,page 2~7'

I-

F:airing ~'POI1 bracket tlstener 16- ~ H ft:-lbs ~-,2a I"lm ~e' 2-g,2

I\-

Fbsbsr fBBtaneli 3(l!-4(,I1r.t-!JIlB, ~ Nm p~ 2.i8Or

F~ 1Il0'lmtras.ene:r.s, rider 1<08-132 in-Ibs 12-1~ INm page 2-68

r;- I~ c - -- .------------------- __ -I

F~ mount, i(lBSEe:ng;e:r 25-28, flt.-!oo. ::M,,38 rim LOGTITIE 272, ~e' 2-00

Forrik,tap, 22-$01 fI"lba :J$.4.D. N'm page 2-4.2'

---+-----------+------------------------~

Fr.'iIilk 'DenIer Mil 22-SQ fl:-Ibs 30-40 NIn p~ :2-42

'2-2 2:M3 iBuslll :XB9R: ChiiS5i5

IIiliEUSi

17-19 EL~

~~~-~

liORIlVc

1Nll~n-II:I:!J;

~ ~ ~ =- --""::----If-"-

4~H),1 'I'I:-In:s;

F1'OI~t iOCllallj1f Ibrae_~: 1i1)i)i.m~ingl 'filll;., tenar

114INm

l!..1(:e~e pfale'l'$teners;

Mall'1l battery grouoo ~e~r ~ 1n-lb!5l; ;(:1-1 '11 Nm

I--'~~------~--~-+--~ ~ ~-

Mast.Br tylino'8ll:miijo' lootl, Iron~ 16-20 'Ft·1l:liS 22 .. 2'7 Mm

~;i;l:-36lnKlbl1l' 49-:51 'fft-I~

1-4 Nm l(;i:;l~ 2--S$

6B,+68~ ~ N'i1i1 iocrrrs 2;22,paga ,2:-52

Fuse blook and relay l.3!S;';Bners

7,2-00 in;.[lbl!i 8-1 ~ N'm pafle 2:-62

,24-26 ft-Ibs ,::I~ N'm LOCTllE ,:±!:72, p::lflt8 ~

-1--------1--

244.\6 It.-1M ,a:J.-35lNm LOCTI"'Ii'E' ,271, IPago 2-64.,

Headlign.t fastenBrs

HeadliglTll: aruppclrt Ibl'8ckeit lPivot faareners

72--<9Q, 11n-lba ,a~~ 1 Nm

~ -

48-'7.2: iin-lbs !5.!ll"Mll pr.:tlgE! 2"6f1i

page 2-51

72--'00 11n-1hs! s- 11 Nm page a-sa

~- ----~~-----~-----+---------------~

~,~n-Ibs 4-.5 IN 1111 page :2--:62:

pS,ge :2-7,13,

~ -- -

rront 1!YO!aW soobbef, IJl)fIer

Froot iSolaror 1fI;read'ad 'i'r:ams' iinaar1:

IH;;I11id I eblli r I!JII p!l)fI tfasteJlle r, I eft

r ------

Hill'KIlaboi":l.r tli~ llaS'tet;er, rigi'rl

4-5lNll'n

page :2-7,1;1, ~a 2~2:7

MEi~ C1jJlm;if!l banJo, ibal~, rear 16-:21) ft-llit.a. 22--:27 Nm

~.~ cy;Uni;lef ~ '~-e~TS, ~lront 9-~ J lIn-1M '11..11-1.5 Mrn

r- ~-

Ma~l'er ~Qef fflOIJfi\1lng '~ene~ 413.-72 in;-ll!:ls, a-~ 1 N.m

raar

MtJi1l19i' rnoUl'lliFI@ blook ~.I3!1\ii3r; f!i1:lfirt :MuRl!3f tiillJun_~ing blOOk h<s1l3n.er; II'e.SIT

g!)-1tO fI-lbs 7-8 Nm

22-25, '1l"IM 82-:36- fl"IM

pa.ge 2-'13-7' pagea.61'

t08-,120 in:-!Ibl!i

41;1-gtJ) Ih-llil!ai 1120·144IMD:i;

1:2-,14 l'i!m

S-7 rim

14-11;) Nm

Oil iiilrain pl!lf§

pagsl:2-67 ooge':2-'~ pagQ,2'.§1

:39'-42 Nm

p:lge,2-81

IPaS$e~f' seat la'_tch

PiJroI':s.IiBH' pindh IfIoI1! 17 -19 'it-1J5

;'-,111 Nm

- 1-

R::,i1lFi aIr SOOOf.! 1 :.NJ~, lill-ibs

~~----------~----~---------

Rl!lat rHnd'8i 'l'i::iis:sner 1:2-36 'R'-Il!S

pr3:gB 2-76

page' :2-,71

:341-37 !\1m me1ric. IilB~ lI.IitllliiElW, (lage. :2- ~:3:

Itkrklr mountingl 'faateriera. near :25-,2:7 'f:t-IDs 341-37 ~f'IiI m~;. RC~ !Him new" p-a,ue z,,~~;

~---~ ----+-----------~----------------------------~

SafeLY inrarr~ las.teoBr 7-10 iIiI"'D5 I[l®"~ ,,1 Nm p-age 2-6i9:

~i003 IE!lu!l!!ll1 ,XS9R; t:na.5S'is 2.a:

i'I, L

r$eaJ~a~i;!1l'£

------------------+-----------~

$I'IOC~ a_bs~er, Igw,':!r

,Shock m"!.lmirlg 1..1S'1:ooer, upper

Shock 1l'Sl1tOm r88SI!'l.I1JiJ laSsl1eJ

page ,2'-51 [paQe ~'-'55

1------------------------ --

OO·12.!ll1 rMD~ '11-1,4, I'fm pt.3.'Qs :2-33

Shock r.eaenrOO clamp, rea!r t2,1l-14.4, [In-I])$ '14-15 tIlm pags, 2-7.8

----------+-------------------------------

Side-standi bracket fasteners 25,,27 rl·~ 34-37 Nm page 2:-84

--------_r------------------------------~

Side-stcandi pi''«It 00IIt 18-20 rt·loo 24-2.7 fliJm page 2:-&1.

----------------------------~

8id~!aMl S'lIi!d'J Ia.sre.ner ::II:;;-iiO illl-I.bs 40'] iNR'I ~ge ;2-M

------r-----------+----------

5,procket 0DV8 'OO!31'\a1" 12:-36 In-!b$ 1-.41 N'm lOc.mE :222. pagu. ,2·,70

I-------------------------_r--- ~+_----------_r------------------------

Sprocket fasranees 35-37 rHI.1$ 48-51)) Nm ReplBoa wiIh ne-w., page 2-16

Steeri~ starn cap 39-412 fil.·IOO 52-~7 fliJm page 2-4S

------_r------------------------------~

Stee~ stem ~ E$1:ener..... 17,-19 ft-k 2;3-,2.6 ~m ILOC"fITlE. 272, paga 2-45

---r-----------r----------~ ----------------~

.sl'l~ngarm OCdCEi 1fri0Wi!iHg lastcoors 25-27 'ft~3; 34-37 Nm IP~ 2-:51

1--------------------------+- -_r----------_,-----------------------

,g"",jngsrm pi1.rDt :shaft 24--26 'rHoo :32-35 Mm pag:a 2-51

Switch housing il'aE.tener.;, rig' t 2~3 ill"FltI-$ 34 N'm pa!gsI2-57

'--------_r-------------------------------I

T: 00dy WiJr&. ImtNIH 3&48. ili1-l1:!$ 4-~ N'm ~g8' :2-78.

------------~----------_r--- -----------------------------~

12-3S,lllI-lbs 14, Nrn ~e 2-,79

1:7-191 fl:-lbs 49-501 ft-fus,

2",3-26 Nm 6S.00 Nrn

21,-2J 'fl:~ 28-,3~ Nm [LOC1TVIE 272, IPagJC :.l-7:e,

T~ clamp 4O-.45tl-11l!r3. M-S11 Mm paga.2:-67

Tum :signals and[ raflecturS 25-2e In-Ih!!; :2-.':3, N'm p:tgsl,2-7'8

1--------------------------+--- ~_r----------_,----------------------~

\i'i3hre·Btem nu~ ,4()..44i in-Ibs 4,-5, N'm pagBI ,2-20

Tail i'r:8.JiTls, to i'I'ilIT1B

r----------------------------

r r-;

'"-

lllRIE SPECIIFICATIONS

2.2

-

,M. WAJRNI NG

IFllles mum be oortnJlctl(y ll:iiI<1.ld:Jcd ~ wheellll1mB. Ool¥ tfiti 'lires [I$ledl ~n the ,ftI!lTIEifTI: ibab.'les 1b9low eM, be llJleed ror rep'18.OE!rIJliMilt. Mii5ma,I.'dI!Ir.1'!:l1 tin!!s Bllld rIma can ~u_ I!.i!~mqe' 'to ~he tlJ.e bead ,dUlint!l Iii'i,OUfttlng. IUlsll1l!!J. tiTas oltli3i 'lhao t~ 5jtJ«lfJet!I 'CiIIJ1I '8dvE!rBB~ aIi'f'ad motoreyslie hanClJln~ ,eini;lll!;::!lliulEi Il'I!!8ult in ,daillh Of HmiOUS InJllIry:

SEta F~IB 2'-1. Tin;, sires {!!~e molded oD'n the sidliu.ral Rim sire snd Ci!IIifto.uIr :!!if'S arkel:f on Ilfro liilrS exterllX surface..

Example: IM'Ii' 3_._5 x ~ 7.01 DOT

....

• lIT ~Eli£is he' rim t001oor.

• as, is the, 'IIridth of the ~,dl,sea_t measured WIi D:be.&.

• 117.0 iis the nOlrnal dlamelel" of the rim in i~ lineaSl"Ired at 1fia irlasdl.e:eat i£3. tw.

.. liL:IOTi rnaans that the rim 1iJi1E181lS [lO~I1MJen~ of '1rSnB",PlJFiaijlJlil ~ctal Mo~r \lehicle Safety 8tamd'<:l.Jtl:;;,.

See "fatilE! :2-6_

Table 2:-'&. 'lhre Fiir1menrt-1iubeh~$s 'CU,t Wti!;eels

\VH~EL SI:lE ILPO$mON

CONfOUFiI'& R[MISI1JI!:

1lli.33i.

1 ~~ 2.Jt11 OOO'i'FY 1.80155 zn 17 [I~U

11 in. - From' 17 in, Roor

MT 31i x '11_0 ocrr -t--

MY 5_S. x '17_0 OOT

RIM '!lAJL,'lliE:

IIrlIOIlJE: DlA.1MEH1R1

OONLOP' SPO'lRfliMAX RADIIAlll TiRESI~

0.33 - .

V'EIHICLIE IDE,NTIIFICATION INUIIMBE,R"

-,

2.,3

GIE~EIRAL

TI\ti lull r:7' digit sMaJI 'or Vehfuh:'t, 1000nli~CilIIiU.n Nwnbr,w lV.1 ,M,jo 11.=1; stampBd ,an ~he steering heBd and on an i'm'OOTIaliDn d'.ecaJI ::It 'IDe sam a Il!Xl::lIIioo.

SBI3' lFigure 2-2., A.n abbrEl'i'isfedl \!'J.N_ is ~Bmped on tha ifroot ten s.i.de et '!:he Cifail'kCas e.

sot«

.s.E'e Figillie.' 2-3.. Jh\·.m3,VS grue' the' ~lN. fIII"' s\bb.ri3vi.s!red Ii!..I.N. wRE:IJl' ~parJ's or .rfiaI1i:ing inqumes ,crbr,iUl!' YiJiiI' B'rI(}II mDrilli"¥.'.ff.!,.

~ .

.------' Mamrfaolural': lBu8111M'o1!Jf'Cyde G;.ollirJ:t01riY -Type [ll!!stgnaliClF!·FiFCt)(t!JI' ,XB5IR

112 = WDlrl'd I

EngjDB --------;1 57 = C.allfQml;;.

HDIiSE!~ l:;od!3'

-'-- -'-- -'-- _'-

Mil: AX '1l'l J

S8JlTIple 'If_LN. BB i! appS8JI'B 00 ~hi3' s.1Si3mg IhBad - ~MZA.x:1:2J ~ 334I!11"iI01 Sample :=.ii:;lt;!lw.!.!'latf!i;I V_LN. as I! ;;Ivpeal'$ !l)!IiI 'Ihe, let!: i9lde C:lEnloi~ -, .1\')(1 ~I

2-6 ::2003 IBue111 lmgR= Ch8ssili!l;

WHEELS

\

\

2[.4

\IGENIEIRAL

600d lft<i1idli~ and IiIl{!lDnI.rnJ tiliB I age arc all"ee1fy relalsd to ihe CEi.ilE' oil: M8i3l's, ,and l.ir"(:S, Reguh;l1!<v ~: ",,\hsels ,;liM tires 1m ,datf!age and 'WEar. If hBDiillin91 pru'bleFfl!;l; r.c::UI"" see 1.:2 ~ TOOU:E!lLESHOOTI~ or Table 2-7.

Se.e , _7 1'1 ~E'S AlND 'WE-lIEEl..S lor ure ~~ureg;_ Ke8p' ti~e:; inElatad to e reeoMm~ded air pt"eiSSUffi_ Always. Ib~lance ltile wheel .af;jer replacing <II i[iI'Q.

-

AWARNfNG

- -

Do not Inflate amy tinli H:ton:d 11l5. maxl'mllm infl'aJtitlD prer;sulf8 ,;!iIt;, peelftled en "litrE< !li!io8IKall. O'I(.el'lnn!'Uoo may ~se 'dIrE! to· :s;url'dsol;)i' 'dI'l~!e· \'IIhlm CD:uld aoal5u[t in 'M itl "

IZIlIi _nO-tis In~urv- 'Ioj

Se.8 Fig)l(ra 2:-4. C~ ti~e [nfl~tloo pressure art !e<tst once ~ w~ellC- A~ ~he· same ~im8, in:spect, tire .read 'for punctu~E!s, eum, Ibreahi iilind lItl'lCr 'C1am~w-. lAepaat ~hBI inspection bef.l;Jre kJng "bitp$:,

OHECK IFUJiI' REJ.lIIrnY

ILooBtl, sileR T~ froo1: ,B)(la Mih LOCTITE ANTI-SE~ 'fa ;:;;9-4 ~ It-'JOS ~-5i;) Nm}, liig,htGfllB<ilr.:Klde wi!h ILOClITJiE ANirI-SEI2E to 4:8-52 ft-lbs ~66-7(lIN'ml_

lE:reasiive Eiid~ ,Dr r:adlial (u,p-aruihdawn) lRe~ !nheeJ bearings.

pifJy in Wheel IllfOO.

Rims- ,aM 'lfteS QuMr...lllUc SidCW~; Mfl;JUld R8p1';..tt;(;i ~if~, Sec, ,2,;9 TIRES,

not bl31 f1}[I f"Q 'Iha n to _os I) in _ (:2 _03 r.mm}.

~------------------------------+-------------------------------------------------

Rims and tiraa ou~-of,..rDfmd or eroen~rk: ReJ;fla~ rims. See :2 .. 8 TIRES. wilr! il'futr. s~lould nal bs, mDIiB Ihan O.®QO' in,

(2:..29 mm).

Rcprare as ~8SQ"11I)e{!l unoer ;2,5 FOOMT 'III.!1-IElEL" 2J6 REAR WHEEIL and :2.$ TIRES.

Infla,te' tires tn rorJ;B'ci: p~Ufl'e_ See '1_711l1~ES AND '!.I'iiHE~LS~

-------I

SIlilJ:l:: balaffee rn~ De Salisf.lcMry iI idy"ffamiC OO'lane.ingl rWf;ili'li~ ':Ha' fiij~ Si\!8 i I atiJe. H!JIHBlI.8J. ~riI:: b al3.'l:m g is B1rein g I ~ reDl!i1III11.Efi1d edL

Chedo; fur proper torque, and! ~ W1Jm or da~edl bt'!l!brln~., See 1_ t:J, STEERING HEAD IBEA.A[I''fGS.

'DDrT!3ct 'tirs' inflation_

Steering head iba8Jiings.

Chedt; klrilE!aks. Sl:iiEI2.16 FOOHT FORK,

Ch.ed!: ~rnlpingl ,action and firiiOun~s.. See. 11..'11 &USPEN...'UCiN NMPIJlJG; ADJU8lIlMBN,liS.,

Ghaek klr proper IOIiqUlEi ~ndl f13~ 'ilium or Garnilagad bearings.. See 2.'19 S'IIiJINtGAFiM AND BRACE.

QWARNING

To, Ipt"i:lvelil ,dtGilli'I ilU ,:swioos iIif.jllfJ'Y" lIfse 'Iha, klllewifillQl gul:delJineB w'Jil.enl In:!rta[JIn,g1 ,a Inew itlIlle, or' 1~:!dfl\lng ;!Ii 'nl:ll=

'~,. A~a, 1'cill::8te and ,elImInate. 'lhi!!' fiaU5i~ J!lI1' tl'fe @~i!ll[ffSiI

'Ore il't!!11fl[1"e,

2. Do lifot, IpstGIil or 'lIIulCBJiflze 8 tlI\E' easIng. The£e Jl"iJCE!-' ,dI1.1IeS 'weal<e.n the t3Si1if9 o1n:(l ilif~r'!t!B!5f:jI IIihlifi a'i~'k of .a b.l iIlfWDU.t.

@. Tlhe IUs:e of tiJ13iS! (fliifsl' 'lhaD Ulfl&B ,apaciliBd can ,adr.reraelllJ s.ffeel: Ihs~fftil'lng w;i1lf:h QOullell r.e~flIIt !J:! (I'eaU~ or 'S:Qtl!Ou~ ilifjury,

,4_ Tilrea, and whei!!~9 al,E' mtt lea II ~~15:_ $.Ino~ lllie' S>efl'!ll(}lIng! 0'1' IIihO$C OOm;p.;ofiiGlm:s ~uiiil$ ,:spaJciillluo'ls ,~n[l sKl:lla, Ei1!feJl I'Jeco.rnme:f'1cs llllal: you aee '!{Qu~ ,l1Ba&e~ ih?"lIlh~ $.el'¥iiOe:s.

AWAIFtNIRilG

IBusllllretlDJllm.iiffifds r,aplBcame.nt of any 'line IPlJm::mred or damaged. lIn ~' e;;!i~e$ ~m~[I 1~~elUr.e$ lIn ~l'Ie lI'eat:l af'Ca rrn~ Ibo r'Jt!paifiKll ffi1llfilll wLthln '1h8' d'amDiunl!ild itira, b!j!' your Bl!J'.E!ll d'e.al'e:r, s'peEid ~o.l!I'ld Inot ,e~ceeml ,50 mph (;SDI IrimJiM) 1,611' the 'Df"$e.1; ~'4 ~!'S a.ft.e~ lIe,proalr anti ithe rep:3I)fe-(iJ tiin1ll ,:slliooltll II'\IE.V~Ft lbe 1I.If:sed1 ollsr' :H;OI rnph ,~~:2.9 Ikrruh(t. lIn ~er.g~cy !;f;IW;:l.ti!@!!'Ii$" 11 a Jt.eImPonrry re,alr iI, mad'e\, ride ~iim!I¥ w~hi illflS, lilQhl: of 9 load BlBI J!Nl86iib!e until "hE!' iIlire iB permanenU~ re;p!li1r,edl ,o:r reJiillaoed, ~IU.lf'ti itO trotlow 'Hif~ Iffami;ng CD"uld r,asult in death Dr ,a!HKM!J8! i.njl![ry.,

AWAIFilNING

Rap.la.C!Ei eoocEai9hre,I!jI' wo:m 'dfN!!5:_ ~1:Ee"!f;51l1.i1ely M;!illffl ~n~ ,adV!:ItsGlI¥ a.fif8G!I: mm!J'J.J<:jd8' ~Jra'Clii'o.n. slearinl1l a 001 lhan:-dlln~ ,andl oof!.lld 1f'"e!j;f,J'lt Illi 'die~lh or ~M!@fllIS ~!IlJ\!In"~

.At ~f.Jlar !f'Llew:ilJs Qr 250U inllCs (40lJiJI ~ll) 01 whrii1ilEn.rr:lt ihand!ing irregwlan"";ii!3G, are notad .. IPI300rm 1ha Irerommendl3d ~Jce che~~ ,see rabie, ;2-7_

I~ tires ~' be replaced, !;:ame :;I::",:, L)1~ginal ,ei;JIJlvmerJt 1tre.s mtl!S~ ba ussd OTher tilBS may riIDt m IOOHScHy and ma~ bl3! hazaroous, to use.

\ REMOVAL

1. iPIIDB .8.~ ~ under lacking ~JTt a.rrl1lBiSiEl frOlIt ~ IiiIr @XIlIM. r.or I~ of jamtg ~rlU see FgI.mE':2-98..

NOTE

Do oo.r opsr:atE' fMtI lmJtJi;e lev,er ~ front whs8'l fCMrCved or cat~r pisJons may 00 ibf.CoElu ,[)[r.!', Re~tmg pisloos ~-s c;a/,pat disa..",,~

.2. R:ernDVEll [h81 I'i.IlIhm Side fenIlIer '~'EnBI":6..Sae 2.31 FeNDERS.

r"> :3.. See Figure 2-5. L.ooo.w I~on axle plIioc:h [aBi:8Ii1iBrS ~2')

(Metfl.::) (!In liunt tark.

4. Reroow 8."!;ls' (1).

_",.-..,

NOTE The fJrmf a:xJfJ is IrJfr rtrtnded ~fuaad.

!J<. See H"glJlrsl 2.-6. Ri:li_~e me wneel !.!p until the roter ~fS tl"!e call~l .andi rotate ~he furk leg ~~rrterdo.do;:wiaa aJlowiDg wt~1 cLOOfJ1!nce fOil" remD'o'al.

6, Rem01le wheel

'1. Ai xii e' I~ t!etI: Ihand ad threail)

:2. FKIfiIl.iU1Ie [pane!i!! hi<Stenera (2) (malrie)

IFigrll'Tc 2;-5, IFront WheeilMoum.ting

DIISASSEMB l Y

Beariing RlemC,V,SJI \

NC.ffE·

On ~ ~ ~IIG.~ arw~JfS '~moliF IIt6! .t'IrotkB' (Ji$C 'S'idt fimt.lflhe wh~Jha~ nm ~ke disc.."J, ~ml)l,if.' th~.I¢t·~~ ~~'.

1. Sw F(;IU('i;ll 2<7'_ Rer:Jil'lJ!fa 'l'ifi;eel bea!rings usi~ BUS8-lIINS AND BEAR!I~G IPUWER: (Part No.. BA.3993-·7) ami WH:E:E:L Bj[;$LRln[j IRwOVER: .A~D IMSTALL.E'fI ,[PM 1'irD. E-!I [li...4;.::J00{I'_

2'- ·Spallngl1}.r a~fJry lElill'Cllilr;:; I?r~u~ UJl)Fi~n! (J·2344l4=A} to Ihe threads of _ '~11: f!Jro'l!I:IgI screw ,t I) to pJ,nloog

sef'l!Ce IDe aM: ensure smoClth i!)j)ClroliOO.

1. SIiMJrt 1nni:i I!1.:QI :8!1:!'BW

2. lNul

:3_ lNice be8flng 4.. wa.mrar·

5. lE!lrI:dge

3. A:ssel!J;1bie Ihe ShOoft iQrclnQ screw (H, ~ ~2:)J I'll,llee Ibear~ (3). wash8I ~.~) and! brid'ga {5) from tbB Wh8!3~ tBaarEng Ilnsmllci1RcFl"lO~t (a-I[!·4W130~.

4. see P""ligIure· :2-f;!;. lnaert the' Front ~el Bearlngl JiiL'e1iOO'll.Ef GOif,;l:L ~B'-4J993-7) ir'l~o"1M ViM !!! I' b~ririg 1!JIiI~1 iI. rUlly 888lB agsinst ·th8,lbs81ingL

CoUet

~:

,5, 1!F!serrt ·the Il)alllbellfil"lQ iF!~ rtfie couet,

6. Se8 iFllgIur-a, 2-9'_ 'irihFead the PUlleJ8i3BEHiril'bJy ~ 1)1 into ~he cenet (:in,

7. HoI'd the rollBt {:2).. and! ~um the fo:rcing ,~ ~) to QJ;pantd 1M ,oollr!lt

0)

'1.. Pl!ill'e:r ,8i!18.eOilbl'y 2. Cc-Ilit!t

:t f.o:n!:iI!)§1 i3!1:ife!iY

8.. Sea lFigure :2-10. !P1IBD!:! thl;!' lMidg,eo (1) again$t the wheel hw..

9,. IHClICli rno roId~ :lero.W (2). ailId IM.tn II1Ic nut (3) c.locKl'iiSt;:: ul!I.1i1 the beBfil;fg is; has· o~ !he hub.

r-.

\ \ \

11. Br.'Jdge

2. FD:rt:i~1 SItftW' 3, Nun

UL :see' Figlill\C ,2-'111, Loos-en the nut (1). and baCk 'Oil ~he Dlid'g;9 (2)_ Hold tha r~ screw (~) w.hile holding Ihra; i!;JJ09"l ( } to "£!fIlIO'!lE!' the forcing scrawfrom trlY oolla.

11. RenL(!IVe the m.all bearing (.5) BDi:I I'iMCIlDearing (6} from t!he oolll2:l [4·).

C!)

1_ Iftu"t

a, Sfld\ge

3. IForcing s.~",Ii\1' 4·. (::(Jil'e1l

5,_ E3a 11 Ibeaii RIJ

'is'. Wheell !i)e:,rtl'l!!a

13_ IRep9.Bl! Steps· -12 !"or' Ihc tJearii""lg en the O1bar ada of me wheel.

L Ssa, F~ura 2-1IiB. Rcf'OOVe ::;i~ ~cem room llOCIurt.ing t;;Istt:mell"S m ..

:2_ R'e'.m.OVI3' and] iinspRCt bl1lke retor ~6) Ib.r 1NE!13J" and \\-\9rp-

lng-See 1_7' TIRES AND 'IM-IElELS_

,3. l\'e'IDmIE' -d we Ib u s'h i n 9)5, (.a) an dI eli S. ea re,

". ~!'i!lO'ile wasnarr: (9) a:1iId dia:ard.

5. RcIlllO'l.!'e roIjor !;iJ!ring (4) and diE-card.

CLEANIING AND INSPIECllON

Ns;wr 11lI.~ '~:Ol'iiipl\O:!;1edl ;ii!I[r tio ":'5lP,llln-l!hy" basJi'ngs. v,arij' I!!~ llIearl'ng spa!'ds CBIl1i damilgE! ur'lh.ib'ncl.l;edl tiemtl!l~s.. SpiliIlilll'i,gl Dearing$; '!MI1h CO'I1IIPI'1!!BBSD iIIfr !1:aJiI ,also eause',~ besrlng to '1Iy' a parit " wli'i~h oO!L!lJdI !'e$U!t tnl dea'" or SiEiI1i~ (IUS I n,f;!.I nt

1. In~ect sIll parts for dlamatle or excesstve "'ear.

I\'~

XB. ~ li~il'ntlgs ate;- d:.",,_~ed' ~ aea'led DFa"firJ.It' whJt::h .ii,t? nDf UJtsIlded to be dI'sa~b.licct ~~ or dsa.f'fed M 1f.I :s-0iW;:.r:r&-;..

AlIIli!I.y.III fSptaG!3I bmaik.e, l~d18 In I!XIIID'p.'IE!te i9le'I!s, llJll'" 'J;:!ilillFsct [br~ opera~a. Nell'-eI" rE!flnHca just IIilIilB. lit,an IIM,IiI .. IFaJlb ure to, IJiI~mm Drake [pad's 1116 !iI :i5Bt Mdilill'eSIlIIt 1111 death or '51 el'f:ous, ilil,iury.

2. Ins~' braks' rotlJl" <:i!nd PQtlS_ Soc '1',,15 BRAKE SYSTEM Wi. I TEMANCE_

ASSEMIBlV'

--------------- - - .

r, SM' Figul'13l ,2:-11:B. IJilE.1B11s;pB..OaF (5,).

:2. IlnataJll naw ....ne,el D2:=.iIlDi1!;: (:<!1' Ir'lOO !'IUD m;ilflg suif<llbl8' dr ~r_ P res S 00 o ui£ r f<l:'c6i oo'l].I:.

iWJTE

:Pfeas inf.!' ~ sJde ~rii'l'@$ iii! fifSI 6'.r~ i.l ~ 58ElrEM1 ,00 ,r~1'C ;S)i~' 01' the' whes~:, F.iJJJ\:lw:ed ~ ,plEss/ng tl:le. .~1"I'1Ij.re 5idI3 ~ti1 rt coolE'Cts i!t.Je.' spe.cer.

._

AWAIRNING

I!)c, In_ol: ;pllt;I!W bli'a~e' ~Iut(:jl. mean'iiillg 'gf9<l:S!3~ Rwbri1:i!lnt&i!, etc. :to.; '81t1i1't'tad lbr,ake Il'OOO~ 'D~ IrNul!:e;riIl i!:Iri~IdIilSI ,I:ltlllll:'t!l 'Wilill O!I:CUl", wh11!:h ~1c:!1 result iii'll detllih 'IJ(r ,5!3ri:o.u:s. ililjuTf'

IBealifillng Ilnos,teJllla,tion

NOTe

{)n.slnJfoJ (Ji$f; whBsf.5. ~ways";nstall iltJe' ,b,r5~ ,dis!; $Ide. ~ If i!tJe wtJeBl' fJ.Bs I'WO b"m-ke' (/is(;$, Ii'tSUl1Jl ,rh6 IBN be.af~' iITfst

The foIIo."MIitg lProoe~.IJ€ describes ifiElibEiaring instaHation for the ~rom wJ'lMI~ the' IProo!3d'l.1JtB fur the ll'E!er \meel ls '!he, ~.

'I. See figJ!lJ,e 2-1..'3. !I1IStaJ'l ~ i9ill:;f;iing lPlate ~B--4.3g00- ~ '1)

001'1.'0 IJiEl kingl fuming a!:IB'Il fIron1l ~ Wheeli Biewin!;l InBta'lIer/PI'e.rnmre-r ~1i;1I~D). 'i'Illh Iiita amaDar diarnacar !UlM:trd 'Ihe ...meal hub, lmert 1he 'klrrclng"~ and ~. in,g phte in.l0 ~ ~I il'!Ut)1

B"e~ngl Plalrii!' B43993-1~

Il.O ngi Iu rt6i n~ ,Eicrew

FISUn:II 2-'1:~. InSi'ta1] the lEl!a:ckilili!J 1P>late (B;..43993-11) ;plfl<dl F\otIetn&l :Sel\ew

2. See lFigure ;2·14. S~ring,ty apply E:drE'1iI8 PreSSl!IrE' W'bricanl' (J~A~ n:o '!be m~s 01' IItIa.J~ IiDrcing saew (1) to pll"(i{Jng' servk:e lIte ruW cmwe s.F.IiIOofri operation.

2:-12 ,~003 IBua111 ,XB9~= Chai3s'ls

a, Inseit.a liIew 'i'itieal Dearing ~2) .e;quare.Jy into 'the· hub" m1h tIit8 latIs!Blll a i de perirrtirn g i[J I.lt ~ ;iI.'Nay I rom i1ht:l I'll tl aa'l}.

4., Slide 1he. FrCftt Whool ~wJin~ Ililestc;;lllE'l Ti:mll {B·43l9.g:3~ '1{i~ (.3) oolb 1M IiDrDing .. :;aeii'i (1 ),l,!,Iith 'the i!;ll1'la~r ,(ilarn·, 6ilar tm'i'ard lhe bearing oore.

:5. In~ a 'wasncr 1'*). Nioe baam;g (5,~ @nd' nut {I$} flOt(!; tliJe "Eo rciIiIg se rs 'AI {'I} ..

6, Whill!i; ooldlliij]l the fuJeing ~rew' ~1 }., tighten Ihe oot (6) unlil1lile bBBrt~ 1$ 110m Witl1llMI huh.

7. R'~~ tM nut, ibearing'. 'UBaher" Fro.n! 'Wheel i9.eat1!'1,g 1~0l1l6'I (B-4..s9.00-~ I1)l3nd '~rcllilg $C~

11" Loog f(]"EI'mg 81::~' 2.. 'W~I be'llfln~

~:. F,rnm.t Wheel it1IeBro,lng Il!I!Btalle:r 1~~993-'51~

4.. 1iV:!Is he.~

S. Wi!l:9 Earing

Igc INl!.!t

;6. See, FIgU~ 2--15., H6IliI0'i'a 'the lBEioi;.i~ PIEite (8·43993~ 11} i'rnnil 'the 10Iiig ilnrclngl ~ Rcins.l?all me Baokiing Plate !!)1~t(J !be IJjrein,g scraw, with lh.e sr:nall'E!'r clametor tm\\3;rd 1liIe ~'·liLead.

9, fnstlr1 EM, IiDriojng :;cr,EM' 'thro.ugh 1lite wheeU llIuD 00 lfiIB DppDmte 8ide·.of ~he wheel

.-

IF'@rrelng ~rew

1 L 3sI3< FiglJ.ll'iB :2··11. InMtl a 1i'I!eW' w:hee~ IilEiBring (~l ~ref,y ImD the huh, with ths' iet!:siT6d ade· ~intjf!gl !l)1;I1: {a!l'iE.~1 fro'lIii the ~cl)-

12:. Slide the IFtOnt 'INfl.'C;e1 ~rI!'l~ IllL"I;'Ialler Tool (B....iI-S993:- 1<0) !l2) olilto fue fum:::ing SC~EIl.\, P.). 'i'tI11h me .sin!.:tl!er dl\3:me.ter l!JW.:!lrdl·1iite 1lIe~ tore,

13. Il!t3l£iIl;8. 'j'JB.:3h.e'I ~.~}, ~ Ce:liririg ~5} ~ tll!t ~a,) ente ilhe furci ng SOJ'ElYi' (Jl

NOTE

&BiOI' figure ~UJ.. Cei'1"lf!r I'h~ ~r'~ UlsJa'lMllg 1l:i6 'W}1'CoCJ il.iICarlflrg. Fa!Me. :ro oen1ef' i!hs' sp.!3a8.f coutal ,carn>E:I' fIlii:! bf!.a~ i!iO t· !D .puiJ,in :5'tr.I3(g.1ir1.

14. \I'i.I1iIile· hdlclin~ nhi:"!' forcing! ::;cr8~'!.1 &3~. 'lighten the mIl' ffi} until tlhe cEGiring is ifI!lIl!ih willi Ihe, hutl;.

15.. R.iaroove, ·lifte lIiIut;Matjng~ wash.c:I, IFronl WhC-C:1 ~FI~ 1R3l£illetl ~0:3QOO- ~ O'}.and kiriC.ingl:E-C1i€lJl\r.

1 ~ 1n:s~1I tJiJe 'IIifiIeell:Sea INSTALlLAnDN iri iIhl3. ·ElB01ioo a~iFlgl'M lhe: ~~l,Jre' ln the :f5.ervloe IM~:nI.J:;iL

(! .....

~, .••.

1.. 'lll!heel ~rlli\gl

2" Fronl:'WfiB61~ Beating Iinsta'!lev ~~~51i3;"'1Ql 3... IF·o.rnin~ 1!ICn3W

41._ 'IiI\~~her

!!II" Nics, liJe<llfii 091 16" NUIi

Fllron~ Roi@:1T' Ifillstallliatiol'1ll

1. See· Figure, :~-·'18. lm,laJ~ new spt'ing (4.)._ 2.. ,1nstalillil!3li'f WElslilsll5 {9r

;'3, Iinst-all dri¥e ~!J!j; (a) 1:ntD mIN.

.M:J'TE

Nata, me idsfflifyiny·l'i'.totfk (Jf,([)'/{;J,r is. up an(1~' en.d ¢ ~ ~shlng roJ lI'lr~rd ,cellt.B.r Df whSQ( 'SeB F.~ 2- t.~.

4. 8M F~Llrn' :2·16, AII~ raere~ ,ool' !D'Ii lront rotor 'I'IIi.'Ih lhe vaJllle Bt8'1i1I..

:5. 'IM~II new rotor IA¥)!J!FitIFl§ '~lene19; illl a erias-eresa pattern aro.tJndl hl3< wheal !JJ i'~ plfl:lt)CF litlifflg IbetweeF! Wi.'Ur, TastcFlef and ,bush!ng!- im!'lh~en to :25-27 ft-ilbB {:3<'11-· $llNm)_

--

ACAUnON

IR'tltor IJilliiljj1rlti~g! t.tS'I:enen mu~iI: be· !iI~i!I limn dii!i's! 1~t!liItn,s; ;~ndl d~~ b'1,J~lli1gB; I1I1USt be falteet ,i'rilbil· InMr.:r ~~rty: FBii'lull'e ito 'l:::olIJ]pl¥ may aflab't Il!ral([n(jl aDIJL~ 3M lead tn nllB'~s' iflaill!ll'!ili wtiitlh OD-wld II\8sui~ llil llileatl"ll !OIf selrtl'oos injlllli}!'.

b.. Sea R"IQUIi9 2 ... 5. With ~l~ mBtelilal"8 ,(rmetric) [100$:0" il!t32rt hreadsd[ 8M elf <:Ul1C (1) 1tuuu. left sida ifurll; •. whee'l hI~b and! !bread into rigfrt futk.,

II NSTALLATION

~abe frnnt ,rils!31 to allow clearance klr -he Cl3. !p!3F to ~~i'lg uncer he 'from rotor,

11::_ CIJIUI~, the. 1r(!r1'lt ~nE;lo.n ~]JI malB, ~lJ're I~ 1$ (ree. and not tHnding~

i:!l. AlJigr'l W11leell ~ Ihat rotor mounIing [asronCi'$ ~rad(Ja caE,per.

b. [Rm.8lc· Fight r~onJ' fed:: lJDullIi'll3rcl~ ~o ,allg:n Il703Iipar with rtADr.

4_ S6ii:I Figuro 2-5. lighten 1M frooi .81')]s[pir'leh rasteners ,(2) t;l) 20-~2 'i'!:-Ibs ~2:7-:3Qi 1'Itm}.

a, Apply LOCTliE AIIITI-$.E:IZIE UJBRJCA.NT to ~,

,

3

/

:2

/

~' ,~

.! :. oj ' ...

---.:;_-~ $''''''''

~ ---~

---- 7

'1.. IFroBI: aids,

2.. Whee.t 1bear:J!I\!;I[ 3.. IF'KlftI: wheel

.ilL [Fr.ool1b.'J'8'kia s[:iri:nttF (8~ 5.. [Frool'whallJ spacer

6. f,rom brise ItlkJr

7. Rotoc iJililllufit 'I'uteiller. ~)

8. Drillve bus'hlD!J!Ii (6)

9.. WaSlhE!1l!II (6)

REAR W'HIEEIL.

26""

-

II!!!.: I

1'. See ~igwre 2'-'1~. ~B1iIID1lI3' cafpar carriar i'rUIiI'l S1o'riI~garm ~:!' relilM!i6~ Caliper camer M_steflelf$" ;See, 2.115 IREAR:

BlRAKE CALIPER.

NOTE:'

,~ ,n(llt ~J''.I~ r-i?8I ,M-leo ,pecft,j' w-.ilh .l'8J3f' rwhI38J ~d (.IJ' caFJPBf piSlUi'J i'iTrJY biOI' ~ (;itt.!:. Rcsearmg ~1l' ~ (.'if(!JPe;r~~~

11,. Arie!'

2, P'iinelii bell 'fMfoner

3, ~e' ~1.Jre' :2'-20. ~emDve I'eIEIr a'da fl}.

-4. RI3IiFIO'i'EI lfiEiali WJ"iBal

C'ILEAN~INIG AN D mNS PECTlION

N'eVer U$e' oO'IlIiIIi)f'e!j;~ed air '00' "i!I\iJ'!n-<EI'ry'JI besr.;IIlIi!J_S_ 'VEir,y h:igliw lbeallin!31 ~p6ad:5. ,emil liIi:'itli'l;ll"re 'iJiillubrl:eltleti ~arl1l!g~:Splrmllilg lbe:liIll'ilngs wiith iIXImpr,s:s:&E!d air CElli <llso ~blM <i 1~lI'ilng 'to' ")I' 'iQiIMt 'Whte!"ll 'e'oul(!! l~utl: lin death ar 'serifOI!Ii!I; tnju"Y_

t, Inspecti all pal1s: :.or damage at" e~i!/a 'flea:I_

:2. Iln.speel! bliBka, rotor, SeE! 1_6; B~KE S1(STEM MAJrfl'ENAiNCE:_

DJISA':S:<S, EMB,'llv

l,', ',' I _1i..1i

1. IR 6f1i1 0'0'~E! :5prm:t.E! t

iiIJ. Filemow. ~oD.i:&Et mBte'IislfS and! 'w.sBh13ll"8. Discard f<liS_i8r.~r,s..

b.. Rem a..-e a p rodolert fro m rwIiI.e.a L

2. 1R6fF11Jfi\E1 ll\EltiE ru~OI'_

a, Sec FlglJre ,2-\2'3, 1=iI~~' ;;J1Tit;l ~Ild roter mOOJliltin g fa<stslIleJ -B (11).

~ Iffiemo:..-e afldll~: bll"Ske, Il'01rw lOr '!Near and 'Warpin~. See BAAKJE lROTOR fflIOI!:;N!;$$ In '1,.i;j. OOAKE SYSTEM MAINTENANCE.,

3, FlClfflev.'C rear whee! bearings lJ~g IBU<SH INO AND BEARING! lPULLER (PBJrt No.. 843993-:2l) and! 'WI-{EEL BEARING RBMOVER ANn) I N;f;I;i\lbEi~ {Part No. HO-' 44QIlDl

JiKJ'TE

ITolriI' ~"(j'[[((!' lOr I'M Jt!a,l'" IIIffiee_r ~~ J':P..l'l'J.I'lt..'};'j' £"1 ;rhe 8.!i.In9 aa Iro.nt wnsal beamg i!\5'molJVil~_ BlOIS' 8B<.I~' R'rMnLHtt1i D'l' 2.5' Ffq'ONT ~S:L

4_ RBi'nOW rear' ~cl ... eer (4~.

A.SSEJMSLY

1i:J;o; !not iIIIIDW b[a~_9' fluf!i::!~ ~?iIlIITi!J !Jli1!<IIa9, tubrican15, e:tc:. to ,f:r:!!l!litBi!lt IMake roh!r IIlirr li'edl!~l lblraklln!) ,abj]ity w'ill [1Je~1II1"" w~ld'b OO:I,JM IIEiY!Ih Ho dBaithi IIlirr SliWiO!I.!iS; tf'!IUflI'-

1_ Sse F~ur13[ g-.23.. Insta'll w.neeJ ~ring (3)[ on rotor :5idr::: or i ~l.r.},rcy(:le,

2. In..:;£all rear 'wheel apaear (4}.

3c IRSiiaJl wh9EI1 bearing (3~ 00 a~odIlBt We!J nocrtoreycle.

ReIilKl1/e1 rsar whE€l1 bsari~.

B IPflXGClUre ~or the reer lIMtBBI b6.'arin~ imst:lllarion Is: the same 8J3 . Illflt wheel baCl1iif'lgl ~a1lat!(IO. See Bi3a1- in!) Ins1.al1a1iml -R 2.5 IFRONT WNEEL

4_ lJ'1$1aJJ sproo~_t-

a, Po!!!1ioo :spm-;.ati (Sl 00 'Wneel (!5.} keE;ping lip !JI c.p:r·cdi.91 IJ ein €II the in:!:IDe.

b. ln54aJllli'IBW sprocket fastenei'8, (1) andl washerS IJgflt,enlng 0.$5-37 It-Ibs (-48-50 rim).

5. See IF! ~ !r,e :2 - 2 3.. I ru:rt.a.1I I1B ar rilIo ~ ~2).

a. f5.0sttron rear Ibm.1ola Klb!!ir (2) on ~I (:5,.

D.. 11iIl::<1aI1 tlilakC- ml:©1' '2') with 111 ew 1iD1IH' m oun1i~1i8 mstenors (~) ;and! tight:!n to 25-27 fl:·lbs r(3.4-37 NFfI).

2-Hj, 2003, BuElIl m9:1lI':: [Cttia55i$

INSTALLATION

1. SCe Figure 2:-23. InBta!l he IiS'a.r i3!J'de Ilrj,' 'lhrea~ par·, ~i ally into sW:in gill\ilIl.

131. GaD'deI" 'i'.!Deel In :swin~rm aM low-Br bCl;g[ lID i1ligFtJ :sMrng81!111J and tlua.

b_ Sea FlQure 2:-22. 0(1).1 ~ S!lde 'IlI1h A.NTI-SIIEZE LJUBRJCANT.

e, Slide.uJJe. Ihrough, Fignt ~ of swing BJ!1111 and wheel hut).

2. l~aJl (!FWe bell!. ~e IDRIVE BEll INSlfAllATilCJN in 1,9 . .....-..

DRNE BELT SYS1"EM.

J. Ins'IaIJ iccer DIJII~: ,See I[)'lER PULLE.Y IHHirALLATIOr-l in'S..o OOWE B.En SYBTE'M.

CAUTION

:5. Se:a fiQUr[B 2-:20. Trlght.en rear axle I(~) te ,4I~ ift·lbs {65· 7Il1lN!'fI} ..

6. Tig ten li'jnlil filSlGner (2} 00 rlgh' :!lIme of :3lidngarm to, 4(l!-.4S ft ·1Da. (54 -61 N rn).

7. Siee Figure 2· 19. nE-.iB.II tatip9 r earner aJ'I.d tlghte'l'l faamaner to :241·2:6 ft-iltlS ~2·35 Nm}.. See 2.1.5 EiEAJR I6!=tAK~ ,CJ!,L[I;'ER.

{VOTE

T.Me ,~~ pads maY' ~ ~ and wjlJl 1.100 B~ ;rhB ~a.WW slk1e Inri[! iIl'le·catipeJ: ,F'fess 00 h ~pOO:il'r'tWtl' ri~ ~}15Ide attire caliper to. s.frai~.!'iJ6it.I oor. Ult:!' pad.

AWARNING !

- ,

AlwlilY~ 1e5t Irfio.tof<eyde' b'l1l'lr,e!ll, at low .apeed .atmr se:l"'!tI'iic:tng ;~ b'leeod Ingl ay&tanJ' To, p;r8Y8nt Cilet.tn o:~ ~rlD'Ui!l; i:njl.lrry, IEh.llalII'9Qlilimm,enCils.1~ allillrosk.ea rl8~in;, lbe pSli'"' '1'01"Inecl b1l" a IEh,lell de:a~~ !D~ mDem qlll'iill'iIie.r:llMe~litls..

1" IFhi!l.e~ IUl(Jurrrtililg fal!iBillilt"' (JiI}

:2" tEl ,,:Ike fO..'tO r

3. WhaeJ lbeaniing 4! wnw spaCrii!t'

5, Wheel

!&. Sprodlet

1. Sproltlr81i f<i5tMrt!" a. A'de

.... -~ ..

,.)0

CHECKING CAST RIM RUNO~JrT

2.7

GJE,NERAL

Ched; whe@ tor 1ate:1'fd1 8M I"8.!JaI rutiIOu' betore mrtalling a if'j~llre·.

R:lm Late n a_~ IRunout:

1 . $e e· f I g:u r,a 2:-24. IIi15f iii II Ifl.iiIlg a d)n r I F1I wbaa I h.ub ilIl.Ii.1 plaCE! '1lhee! rn WHEEL TRU[NG ~V SALANCI NG Sf AND (lPs.1it NID. E1ID-~9!35!OCl"80).

2. Tighten arbor mils so 11Ub will turn em its bearings. •

.3. Cheek rim lateral runoet by pliMing <:I gau~ !'OO OJ diail im:[caJ:rm neat 'lJ'iC M1 head Replace, 'i'ffige1 -, lateral Fl!~1)t e~ceed8 specl'ic.Eroon ~ In Table 2-8.

'1. See FigUIie :2·.25.. Install '4Jl~ingJ Siroor in wheal iI'1!.JD and pl~ wileel In WlHEEL TAU ING ANIJ 8AUi,I\K:tlMG STANDI (Pan No. HO-OO5[]iJ-OO).

2, Ti@h1-en f.1mo.r nuts m h1.llb nil tum (to lls h!eEiri~

3. Cheek ra;diaJ rUi)l)U~ es shown. Replaoe' 'Wh~CI !I iIl,JnllUt ~reed$ ~cstio.n mIJlo'm in Tab!e 2:-6.

Tab:~e 2-8. Wheel RUI110U~

uoao

11'1.1

IMM

Ma:.:ll11Iurn la'teJaJ Runout

i,.oe

M;;v:lmum Radial Ruoout

'Wh~1 Tirui:ng.mdl Bilf.I.1ft"<:it.Jg Sbmdl (P.Sr1i No·. HD-9.9~

I

Meet TrI)J]ng a:md lEili91sJ11!1::i~QI Stand lPali'il: No. HIiJ'-99Sw-:eO,)

I

.-

--

2:.8

~GENIEAAL

Iinspsct firas i:Dr pum::tuI\E!:;_, ruts, Ibreak::; amd 'i'Iffilr at least w-ee'"1dy,

AWA,RNING

• ,AIW3If$ dht'dl!: bO!t1ili 'lIre sldleWl!!lJls 'for ,l:Jr,I"@W~, I'l1idl~-, [ng 'li!I,-~1I"d Kibtl!l!llll. ,Some ilill\ES I\Eql!lir€' iIliffe:re:n.t itirlal 1fOiE.'tiiijlllil d8pBntl:ing en W\hrathlilF 1iiTB ii5 U:!ietll 'QiJiI fJli'Onl' 'Oir ~r, 'whE!~L tl'l$ta[iln.gl ,iii tlr.~, w~h 'lbj!' wKln!!) lIata1!f:on '~"'II.I.ld ['~$un lin g9ilf1jjj Olf gnD"u$ iFljm)l'.

'.' !i)!;!I!I~' '!r.ont and! lrear, ~r.e~ 'fo.r suerl 11!I:Ql@r.cyilil'eo9i SIl"e not: lhB ~11i1i9" Th!3¥ ,ar,B' m:l!l iiilm:rn:him:~ilbl'8" IIJI~ ~Ii'@n!!' t!'fe' ONLY' _ ,!;!I 1: 11'(1 n1i, ~Ir.e'_ InJO NOT pU1!' S lrea~ 'dr.-e 0IiI tiihe fmnl!' 00: al '!IIBhiDla~ Faih,[!'B tD tollbH this w.i!lrlilIng iOO4.IItdlresul"t inl dettUiJ «~terl'ou$, l!nl!.lJ¥.

:SOirt!le' 'lilieS II1Mt-e ',UII'OW$. n1I;Qld'edl !11!!"t0! 'me' '1I1le $I'dewall. Theae tir.8B I!Ih~liJ"ld lbe moontsd (]fiItna lrim 'wilBi ~h.i9 i3rrGW IPCifi'tting lin tli'li9 c[;!lMielio]rJ ~I 'C'OfIm.'rcI Irol!!lUO'.nL The, '~reno'fl cr.rcP.e 0liI 'dla! aid!ewalll is, ,a' blillaooal mark and :1511001,:1 !be aUgme:d1l1:r;!i1if ;dBg:ree~ tl"llllll1:1l 'lI!Ie balaooE' liI'Iark (Mue do1i~lllIJn iifit;ld:e IOf Ii\ifi1i'l'.

REMOVAL

1. fil8rM'i'(;I lrilICcl ltorn fnl)!t)rc:yc1e- see ,2-5 FPiCliNfIf WHEEL IX 2~16 REAR ''i'iHEEIL

Do In£lt use eJro.Bai3!l'i!e rorce whan aiarlilillQl bead IilIljIBf rim, EJr«t;tavo fOIIee: ml:Jl.l' Jl!i~:e 'lIre. !O\I' r~rn ~nd ,aii;lvEfIliE!~ aIifed: Iha:n.d[log w'hil::n coukil Il'eall.lll ~n dsalh o.r 5'iillfiieilil5 iri~!IIIfy.

,4,_ II' ,il b~ Ib~j m'lachj"j;)C ii.ll; oot a .... ~i!1)JJfeJ a~:d'I fUM POOlECIDRS ~Pa.rfi Mo'. B-1IIJI-{!128"9,~ 10 1he nni. USin~ '1i'C tools tf;)i)t snarp Iflstrl]JI~Fit:s;l~ 51ifJrI' tipper baad i[f!i8'J edg:e ai' rim at '!i'ahia Re,pi3at 13111 around rim II.IInfillirsL Moo iiS D'i'Elr Ifim.

,5. See' ~urre 2'-27, !"'wh IOl.!.!er bea;:;l inla, rim Itfeln on one aide. and m..e-rt 'Iiral 'llXi1 Ulitdall1ilE!afh baM 'fwin ~Site Sl:cle, Ptry ooaCl ~ rom 'e~, Rem~ ~Ir.e from (lim.

7- _ lM.oont ~irre 00 TIRE. S!PREADlEIil (part No.. ll·m-211](M)} Tot ifile.pactilJO BJiid If\Elpail proorBilIures.

Pry bead ove:r r:\IlITIl e~:e and IlemovJ8I ti~f'ei tli\om rim

Ll!l.brl.cate rfm if.lsnge i!t.fId boon baa.ds, IIJe.fof\8 iifisli!llla~ieli1i

ClEANllNIG AND INSPlECllI10N

1_ IGlIeafli insid.a; ttl' lire witl'l d!"i ~.

2'_ If \im is. dilitJ or GJ:iflOth3({. ~F1 WJtn a stiff wire bl!ll3b..

3. 1~1)t 1Ir~ ror.1.I.I!:!ar al!l!!il !!iIa1l'l8.ge.. Rapface 'IIOIil1 or aamageiiillil"S\'!i. Se!3l ~ _7 TIIFIES ,i\NO WH~~.,

Oiil!"l IlliIstall (i<rt!;l;Ii\!!i~ ~.ulp:rnenll: 1~'arodQ lIlil'iB' '!I!aiv,ss ~d ''WJ'i'B CIII!)S .. ,A ' .... aJIl!31 IIlIr y,all!.i;e ,rulId eap ecrmbll'!tlrttOri 1lml: la, 'I~I!) ~g may Il!rteri'.e1l"e W:11b (str.iib) aD,jac!3I1Il OD]11iiJMMl!~ 'dal1ill3l.Q8 the '!I!i!liv,BI aiild 'C;~iJlfti I~d 1[te (!Ie1Is~h!!!nL RapJd 'll1i'e ci:e1iatholll !QO'l,Ild eBIIJ~' ~,of carnlr,nl. Tha:S1ili ~Ii'rls !OO u I'd 11'1!!81!1'11 in ,dBaDl OJ' 5Eilfii 0 illS i nj,\!I i)\.

,A flEt"ilitarke'li ",at'll rtIi caps iIIlI iI'L't ,!:Ire h e:aJi!r~ E!r 'Itii:;ln 'iii! e. al!DC Il;, ~I) m~' h~e e!e1lraflii!}1!!i a1!: ,alDW :apead:s;; but, ,ill: hllgh i9pBiIIidl ths 'iI8.l",~, wlil biI'lfiAoved OIi.LWLn:l1 by 'l!<eiIIlril'ugaJ '1'(!!1i'CI!_ ilihls !l!!u.tw8rd mc,\!Bmanil: IQ!1)"lild CIiIU:S9 "Ui!l!1 '!I'ilMeicap, to, ~tri'ilkeilJ!le' ,a"'J;!I~1!VI! 1lXim;~nema~ ,dameg9 thB 'M\iI'1'Il9 ;rna 1i:'8:"W_SlIII rap:id '1i1i8 ,d9:IWeoft. IFitGild! ~tre d~ls.tI!l!i1!'l 'll:o.l!.I'ld i!:i!tUBe II !!liaa: of !l::C nillro! I. Tih 9IiiE!' 113 ",en IS IIXM.J leIl fet!i.!l It iIr!l Clesl:h O~ sef1o:us In]lIIll'11.

3.. 11"tllJl'lJU{lhl)' IuIbricaM~ rim II~es IDld both ~dB of tire With 'tire· lubliicam.

4,_ See JF"«IUIfF} 2·28. Startlngl 3It iIhe ~ ~el'll.sta.rt fi~: be~ IIn.1'O' ~ IIBII well llC3iflql a !baad bllB3!kBi" rno'IDl'Iinr;:;. II no mathirlifii Vi; ~llablc,. W(Wlk: t:le;ao en as far as lPoae.1b'la by hand. lIsl3l a ~if!3i tool ~!J! !PI)' ilh.e rem~ingl Ibcfi~ (AA;!F rlm11'aFlge'-

5c St-2ilFil. 100') fro..n vaJ~c stem ~i)le <RJiiO ~ ,~ be::.-;d en rim_ Wari:: bea-D onto rim 'i'li h 'lire m'lS. ~ toward val'i'e Wi! oollil aired~ c.t}S;.

; AWARNING

Do IrI'Ot: 1!n11late· O-'i'-l!!I' 40 Ips'l (27,5, ki~,a] 'hi! :sem 'DIBI lH:Ia-as.

I fl "'. ~""'~ 1- I~" ,...'. ~·21!ii "'1l'!I.~" .. .".... 1he rr 113_,101) "I"", '11l1I! .,;.,., ........ ' ...... [pIiJ \ .': ' nil "".!' .:0 ~""""

beaiil S. oan CIt Iif;$'" ilih e '1I1i'e rim as:Je 1JIl)!y 't(j, lbu ll"8trw;i HI ro roB' !juffti!:lem, tD !C;81!l&E!' deErth or l!Ierioos i~ul'Jo n 1M, e:l.dJ$ 'fall ltg, ,ti-Mli Ilia; -40 pSI {ZiI'"!ij tl1pal" ~i'ate' ,l;mdlllElulbr[Cllts, 'lhB' be:;!~ ;!I'md rim aJild l\E!inllale fo ,l5am 'Iilal beati$, but (llO· inl!)t ,s\XCiElB!il 40 p:s~ (2Ji'5, IW'aJ).

6.. Apply air to stem to seal: b~~ em rim, [t mBlJ be n!3C!3SSial)!" ro use ;fJ TIRE BEAD E)DPANDER ~Part MD. HID· :2807(0). on the iire ulil.m beads ,~aJl 'Orli Fi~.

2:-2D iilD03IE1:uelll XSeR= (:"'~!i!$I!i:

l11li1=

.~.

- =--oJ iG;!I.\!Ige'

~
RU.rNOUrr I.NL 11M
-
Radial, 0.000 ~'!s2
~
Leterall 0..000 ;2.-03 ,"",

CIi1I;edkJing Tire, L:ateram [Run c'ut:

1_ ,see Fi'gurs' 2:-29. lium ~I on ~~1'e andl mea.:3!!J1'e a mo 1,1 I!I..l' a~' displacement from a 'fimd plJirl~ Ii\I ~jr.e ~Idewall.

\

2~

'~e~ nre tref.lo fur appr,cpriate r,unoo1 :speC1ir~all(ln, ~ Ta'b.lB 2:-9. tF ruoout lis IJOOI\Ei me.fil ~ca-fkin, remO'ilB 'lire I'r'tltlfl rim.

iJ. '~eO}:: rtm bead! aide runout, SaB' 2..7 GIHECKl~ ,CAST RIM R.l!JOOLJT_ Repra~ i!hs oot fFlae.ting spacilic;:_lIIiU(ls..

Chsokiing II re Rad:lal Ru nout

See FI{i!!JlIle' 2:-30. Tum wh.eell[]n. 1311:1'8 and measure t~ radial rumJ!lIt

'OhOOk !:1~e treao for appraprliBte run.out ~'pB!Jifij;<jJjOO, see Tatls 2:-9. II~ runout is liDUfo8 InCfil ~calian. Fef1i10'0'S 1j,fe ilf(!m rim,

'(;!heCk rim bead runoot. Sea ,2~'7' CHEOKING CAST ~IM RUlMOUf. FlI3~ 1'im-s.,'FI0' meetIDg s~iCBf1o.ns.

II~aJP JjrC' aM ,eheeJc: tlre ~ IlBdiall1!D[iu~ !3fIilin-

1.
r=
2~
3.
,""""'"
,~,- ADJUSTMENrT

'Wheel Balan~ifil,g

.r-·

Wh66llibalwiCDg is reoommended to impFG'iIB hBDllllin91 aM reI!ilooe vibra:tioo, 'Bsp8Gi<ily ,i:'l~ ~~h r'CIilCI s,j)e~

r.n I'iiMt ~ sta11'c ~i:;.nclng usingl WlHEEL mUJNGi #liNV BALANCING STANK) '(P'<Irt, N'il.. 1410.9!3500-8O') will produDa, sa~tI.r.lif!f ,results. t:loweveg. dynamiG. bal'al!il;irilg" IIJfliizii~ a whe~ oo-Inner. am be u:sed to prodwDe 'lifter ~I)I~ ifl:ir bettsr Ihig~d Ihi:lfL(]lingl dlIaracteri~. R:ill.atN tfu,e i'~JUctlens at!!pplied 'with ~he babnoEi mB.diiM '!lOO ere 1!!!'IIng.

NOfE

If the I'6'M wJJi::IB'I wl' I1Jc ,XllS'R ~l)I f!Iollr ffl; ,0flI 8 sredf. dY.!EIm.i"r.: spJn oaJa rICe' $J!its.~, us e ;rne Ga d8'OO ri!d1ee.1' ~rc(!, S'I't.ftit (P$ rt. NaAFt.:5i)_

WEIGt!lITS FOR ,CAST WH.EiE!ILS

The, rBFi~tlilUlTl W-Big,ht Iparmissible to ~lJliTlpliSh l:Ji.lIe;nce 19.:

.. .~ _o oz. {28 g) iotal .... ~h~ rlPPlir.Xd ~o, 'Ine iront wtiBeL

'. :2.0 CI.Z.. ~56 g) l.o~1 ~m aJ)pll~ ~Q' '!'he rear 'l'lfilBaL Whe:e1E. should loe, b<lf:::t;noeCi to 'I'iWl~ 1/4 (!12~ f1 g} 5.1 00 MPH ~ 91 KJl.1/IFI ~,

~ FIg,Jr,B :2-;3,1_ Uaa' o.n!':."' WIi-9EEL WEIGIiT$ fP;:Jrt f14D. ,4:}B9.2'94 "f) 'I'itlik:n have gpecial aeU-adIiIEtE.:We bae.kings, Apply WI{EEL \iViEliGHFS to Jlhe Eli!J~ ~uli'bw CiI' 'Ine w.i!teellrim.

1_ MAke sure that alBa of ap;plicafiOr"J is ~~ clean,

dr;y and hS9 'o~ @il <:t:fld :grease.

2~ Rsl1'lD1l8 P'3PS[ ba.dMi'lg 'I'i'OM weight for a(:Iditionai adha~ ~gfh" a~1y thrse dlqps 01: lOCll"IT~ S!!JPE:FI-, BOOOEFl 4.20 tID atlt1r;:si'o'e slCie m we.IQh~.

a. Locals l3! list EiurFa.-o:o 'Dr'i 'IllB IIilglM ~de' CIf ithe 'Wheel rim and ~,waigh! iifM1~r IIFllPlace'" holdingl fl~ilan :EalX(nds.

4.. ,AJ~ow eight hcUT;3, 'for adflB!:WEI' to wfG' oompletefy bekire using! '~VhBel.

NaTE

rllWI'teeJ ,;;<~~t;y is.out at sp9ciflCaucm p ,oz'~; 2 ()Z;;c.ad rolal'8 i!iri::r .§irrof ~tance ~IfrJi~ w.Me~ is M~9arTiCauoo_

:2,0!iK1; Busll ,XD.9R: Cha.s6is

:Z·:iii!:11

BRAIKE, IPEIDAL

2.9

REI¥OVAL

t, See· FigLJre~~32. iiiemlJlle oortel pm (7) aM dl~fd. 2. IRemO\!E devis pIn {2}-

;3. HOO1~~ peClhl ~~l!!rliD:f (5).

4. IR et1i1 iW B shift br~ ke pBIIIel slse!v.B. (·.:Il-

5. ~efi1ilcw.e pedal DlJshl~ (:l)t.

6. Retm[]l;,l!;i brake pedal (lel_

II NSTALLATIIOINI

'11" . 8M IFjg:u~e :g·3_2~ Iri.5tall pM'aI ~h~$ fl~.

2.. Instal shift brake'lPed'al $lee"i\B (4}. ..

3.. 1&.1B.II Drake pedal (6) using ILQGlilITlE 27.2: BJOO ~ ·~tener l5) to zg-\?4 tt~ ~:J,1!lI.;;3a N',m) ..

4.. Ing.laJ i .0'1 Ef!.iia·IP i n, C:±!l-

5.. l.malll Ii\ieW C011>cF pin {7).

1. IFiI:N~ I11tuter C:YlindIr b;Od~ :2. Cl8!i1i8'lptlil

3. 1~lll!:M.tIshtn!ls.; I(il)

Ai. S.h.:i ft D:raicB [pi3G8~ a 1'eBl,r.81

s, IE!lri!!iU ptdl!l~ ·fast'M~

6.. IEliniltre pedall

7.. Clii!'li1el" ll)ili'!l

r :

FR,ONT B,R:AIKlE MASTER CY1LIND'E,R AND H~ND LE,VER 2.'101

\IR:E,MOVAL

NOTE

Steps. 1 .\sI 001' re~d ti;Jr oFeI.!i1OWoIiIijr the' l'1lil~fCt r;yID:ider 8ssembJ'y ifrDm me hand,'..;oOOf.:>. Do not dl9iiJBEBmbSs JffiISJer 'Cylihttff{,Ui1'i'e$'.S'~' ar;a' ~'(J.

1. [l1i'aiilI L:i«I.1ce ftu'id into a ~ eentamer. Di3card usedl flui.i!I acoo~ ~:o 1!X211 1tll.'i'S.

131. InsLa I a lell1g1h ef plaB1ic tubing if)l;iCI' Cll!!'pEIf bl'eadSli

'iIEi.lve. Pbce IraQ Cf)(iIl.n a sultahle C®'IiI1la'inE!~,

b. Qpen bleeder vaLYE! r(JfJ'i9'ltiie) aoout '112:-rum. e, IP LJ i'IlIP D ra ke. Mn d II3l.i'el to d ra i Iii IJ I"<IilB t!U1d.

Q. TL~ IJreadBt 'iIOllve to 36-00 l'rn-lbs (4-'7 IN~J.

,

I CAUTION

Dsm~;e(;l1 liIl!lnj!O' boil I: 'Si3MlollJ ~1iJ1'fa.tliII:!i, Wlil leal!:: whsn lIe~$$elll'lbl'eclb PirBvenl liI,lu'i1'I;@iIe 'to seBd~1 l5ulff .. e.e$ by il3nrlun~ i'.mo.vI~1 t;trs.\e Iline COmpOMiittJ.

2. See flg,t re 2-S5'_ RSIi11O-'I'!B 1hQ- banto bolt (12) lmalriC} and '~'ro co;ppCl' 't,'i'&.~r50 (14) to disotrnneCl bra e' limB (11:3}. ifr.om 1Jila5'b3f ~dCf (4}. iDlacard COJ!l1Psr w~rs.

3. UnpilJlg ternninsJ (11) to uel.<:idl t)1ake lamp solli eli (110).

NotE

ThEl! .r't'td1vifJQ.lai pai'1$ (1f me ~~ Jamp ,SmlCll a.re.not BeIVicsa-D;le.. ~ awircJJ LlpOO ~.

4L Rem0'lr8 moun in91 cIOUflP' 'fastenem, ~51 (mBilric) to ~h ~er. ,cyU:nder reBSNoir ~4l 'from MfldlebBr..

D1SAS'S'EMIBlV

1,. SIili9 Figl.JFJe :2-~. iFlemO'llB piVDt boQ, fllI1' fa) '1i118~riC,) am;I pi\!01i 1be1t P 5} Irum IlIand lever piv.o.L

2. OcL\ae'tl 'W!I;Inl ibr,akEi h8Ji\fiil ~.E!1IifIf ~efFlb:l~ (i'} nJIiTl ha1fl!".:l I e;IB r IP iwt.

S. DalMh 'rmnl bmke llamp swirtft (Ull ~ I'EmO!ling thE! i3'Witc:h fastenE!ii' (Sf)..

Fron~ MaSite.1I" rCyIl nder

1_ See, Figure 2-,35_ ReIOO!.f8, master eytin.dar OO!.I!3i (2) !by

Irref'lilD1.rirng Cljlimler 1t000r fasrenel'iB (1~_

,2_ Discan:i C.».::e5.$ brBke '·Iuid.

:J. .see Figure. 2-3111., Re.FfIl)w robber boot ~1) ,arid dJs.card

4.. ,See Fl!!lurS 2·a3. Dept"e;tS pEl:DI'II ~9fIi1tlty f1J) and rsrllo...e intemall !Wi1'iiP' ring (2) aiiICI ~iscam.

5.. See IFigu~D 2-:Js. ReI'1ilClVe pistonr assclilltiJy W)irom fronm master C¥lIm:fe"J reaenroir (4) aoo d!sca_1!l'd.

CLEANIING AND INSPECTION

. -.

"WARINING

Clean Il:wsJre Bl'Sbim ecmtpo en.~ U~ ng deM1!1!lred ale..,.. IilliiIll. Do I!"IO~ 11,!15e 1'IJ11!lera'I-I:iJS58 'ct1iiill'iing $..(!Ii'l,r,em~, r!l:u'dh 8S gsmi'nrill or' paEnt ithIIltM.e;.r_ LIse' 0.1: m:'ine.rill~ le~nt~ eay,$e~ dete"riD:ratiolil af ruD:be:r pm$. iIlhat QD:ndnlJN 'lIflw' iIIISl!Ismi>lJ, lnfi'l:!i, Imi!l}" Jf'e$utl; In Impll'l!lp.E!~ bra'koe. operallol!i wlTtim (:O'utd 1I~!!1J,!1I1i In dSB.fh or ,15Srit:!U:!i, IliiJllllY.,

1. C[Mn a I part.' wllb demrtul'Eldi .:.loohOi or 0 . .0.. T_ .iii IBRAKlE IRbUIUi [io oot Clol!l.ramlnate with mineral oil or o1ner $olven 50. WiPs dry WI h ,ill. iClGan.. t fr.ee do1h.. 8few out drillsd! ~s.~ ;5!1'l4 ~re' with a. clean air :5yWly. 00 not U$!;! a wire or simiilaJi ~rurnern '0' cle-a d , !d IJS.Ssa-gBS in ootflJr'rfI Of reservoir.

,2._ Im;~ p'i:S'l.OO O:GI"e In master aylind'ai hoo.sDiJ ifQr ~t"ing.. pimng Of OOI,r(lSiioFI. Re~ hauailil9 if ~ny of ~ oonclltlons ars' fooJoci.,

3_ Impeo'l: tlll'lJel)Xlft IMI ~ with brake line lit'lir."Lg. As ~ e~ sea!ing E.1JIrfa.ce" r,splfOC900'LI I"Ig If {'..TrY scratches." dents oT;;rlI;@r a,lma!;w Is ~.

1. IPI:$'to;n ;t;!ste;r:TfjD'ly 2._ S MIDi rilil!IJ

,ASSEMBLY

Fmnltt MaS1t$,n' ICyli'nder

1. mrrain IPISTON ASSEMBLY' IKIT_

2, s.e.e Ftflul"Q 2-34 .. AssBliTlble 1IIEfW' piaton oomponentB ~ smali eftij ,oi ~ritl.g (5,) IlJehiJto1t:l pltirnary .::.Eii1I1 ~: pi~l\on (-41,,_

3.. u!JiniCErte '1nE!~:er e:yllnmer i;i~ ;ana PiSton sc<tl!S witn '~ee!aJ Ilubn:aaL 'fw.nd iin :IJiieo :saMo!3' part:;, Ikit

, AWAIRNING

Wi'_enllnmmn~1 ,SRi!!IjiiI ring to g.cllHlIi rmasf_!3f cyllmlB'F" lbe :EiIllI'1ll the :s:na;p ring SRBptEi Imoo, 1P'lsCl!- FaUI,lr,e it'Ot I!i!I!) ~o (O!!!nl Ire.!I;l!J'lt lin Impll'll)~V li)ntl!ie (Ope""IIOn W(hielfi QUIlII'd r'E!:&.\iI1t! inl 1d'N1l1ii ~n" MnO"U!5 imjul!Yo

4. Sea H=igulB :2-3&. InB:Eiril: pfat-nn aaBErnbly (~). :5:P-rlniJ iIl~~! intQ FfL:;'~' cy;I!M'ei ~~r (4),

5. Sea FlguFI3' ,~'-$3. S~rle 'C).1~oo aiSs8rMly (1~ 'I'iiIh a Inew snap ff~ (2'"

6.. SEE! F~ure :2-34.. 1'lil5<tall [Id~ on oeet (1 ~ IFUo, ~ en pI5ro:n f.j).

Br,aJke Hand Lev-eli

I.. SElB' Figl!Ne 2-35.. ILl!Jtl_rlcate IPM!)rt ~It (t5) wilh 1.0 ClI" ITE:, ANTI-SEll~!:.

:2. Mgn holB' i'n !hBnd 18!le'l (Tlllli~h htD1e in IitAndilever pIVOt and lnstall jJlW1t 1))011 (15) 'Ililrough Wp (lr iIlOln(llevar p:~:

BDrlliglirten to :811-1:00 inr-ilbB, (g-'14 rNJm} ..

~ • IlfI iii gEi!' (lfil IfU b'be_r IiJiocit

,:2'_ $1I\a1!). rl1!lg

::11. Gilt! iWIIB' iIJIiI llii :!Il'tG n

4. IPIllI~lary ~II Q)'ft-lPisi:Oii'i s, Spain~1

1_ IF.I'e!tel!'V~h il;lO~ i;:!lste:ne.il'$, ;2.. IRl~lIiK!i~ 1IXl'ilBt'

:3.. lFiI~II'I,i\OI~ C:C¥e.r !&1M~:al 4, ·Ma'&.tB~ CY:limrlee.r lreaeli'!i'(lo!r.

~. '.ij;~!_$iter. e¥~ln:Ger Ihousing fi:tsmners, '~'l1TletFi!i:'li

6, ~:sron iil!is!iIm'bIy

7_ BIl"8I!iE' Iiland lev-.er.

is. Pi1ilD'l! bell nul (roShli'c)

~ ar.alllle' swheiill Mste!nlr

~ 0.. B'rak>B' 8Wm:,E:1i1I

~ 11. 8:ra'K£i swilcJill 'lsnmlnBI 12.. Ban']!!!! 00[1 (melr,!'(;)

~ a. 1E!\i'akls li:niill

1.4. C(ippe~ 'W&SIi'l811tP 1.!iL IPi;vot bof1:

'1:2

. ,

~[NS,TAlLATION

11. Sea lFi~rlEi 2-3& rIFl~t.A1I froort bm!s, lamp switch '1 !iii).

a. 1'Jir::.1~ Drake lamp switch -(1 O~ wist) swltch iaE.tener '~I SJOO'lignlBFIi ttl 7~~ o Iln.(1)s (Jl.a~1.0 Mm).

b.. Co!'1~· DIake :swi tgFiflln '111) to bra.ts Ii1Im~

.::;m ,dh (10).

c, TMt swttoch aedon, TBJil@I 00 t;'WiIth IIlIU5il relaase' wheo Iir.a:nd IBv.'et' Is rnl.'li'iredL

:2_ Install 11iI3:;1Bj cylinoor to hem:IIe.bar bey fasref"lln~ clamp wilh ·rasteF!~· and! tightan to 83!90 1~lb\$ (g1...10 Nm)_

\

r"

-

, AWAJ1NINQ

Uae o:nJ!j' ~pe.r c::f\t!~h ba1ilJo 'WSl6in:e:rs lSe !Pgrit'!li Cstmllo;1iJ fer !P'3'1'it lr.:lo_l with O.D. T. 4· br.ake,nlll'ld_ EarJi'e.r siifYer 1b«l'Ilo WasMIi5 aiN!l Mt ICQmpatlbFe ·W.D lil.iOl"T. "'II "Ou'ld ,and wlil n01 seliE p.rnpelfil!j'· (War time. F1flluTe to oomp&y I11@V s.dve:rElBiI~· ri'ali:lt tllil1(Jlli!!l abllllJ' :lilooll8<ii:l 'b:II bl'op~e' failure wh.ien ~ldl reauli in daaltii or serl'@UBi InJury.

-

AWARNING

To 8;wid !allEge. v,eli'ili'y !;tiI~t banjo ¥lasli'lGrtS. i:I-a:n.lo bo.lt,. IhrdrauliQ t)tt.alk'e line and mllsmr Q}fItnder lbcre ,ara I!;lOm· IpI!etely ,elun .

.3 _ :s EI~' F~ U Fe .2·-:k'ii. ,Clo n n Ed i:ifr'illke I fiJle .0, rn!1I!!l1:el cyiocIe ~ 1IJC..mg two new ,oopper washe:rs ('1.4) and! D@njo 00l"i. (-41) ·(metr'lc) and lig tl3fT'l f.O 16-2'0 ·ft-lb:!I: (22-.::rli' Nln)'-

.

. 4., See Rigurre ,2-36. VM 'I bilI,t"e lamp S!4'itchl mr'M are' IghJ' ..

6, See Ftlgure :2-.S6. R~e IWO master oylind!:.W '001iE!:J screws (1} •. !X!!l9r (2) aoo (:OWer gaakBt >(:3)-

D_ See Figl!ll1B 2:-3]'. With Ih:e master cylin~ iJl a leve'J position, add IOv(!I.1; 4 BRAlKE Ft..lUlID. IBring i1uiCi I~I to within 1/8· k'I. (3..2 mrIil} of rnoldMI Doss, IMiIia lriJnm mastar cylinder IJ'eSi9r'tOlr~

-

AWARNING

Verify pFll)per (I~ra1!1loo ,m flil8 master qtillnoil!f" r.e.liaf po.r't .A pll!Ji!JJIDBdI or 1[X!\lWt.(!J lreile' part: CS'lilICa.lllS8 bliakle' dl"9l!!l m lockUp" whim CD'uld I'Bs-\!IIli lin J(!I~5I, n11 wliride oontJIo'l whl'cIIiJ c!lliw~d rawn lin d~h ·Dr amiOO5 i:ri,j!!lI'Y-

'7 _ V8iif)' proper Q[leration !Ji' the r'l'[1i.1Ste:r C)!lindar relfef port .Ar;:;'I:rJ.ra1B the. Iiuake lall'Cr with ~he ressr:vcir rove ~emove:d. A. sliglfrJ. spurt ;of fl'uidwill DllBak o suri&oe if .all interrial mmponarnts are 'W(i(ikfng priiJpeily.

et·- Bleeorl blake ~-ysl£m, $8e 1 .IJ, BRAKE 8YSll~M MAlNlEJlYi.NQE.

9.. Se:e F~ural ca5 •. Attach ma.6~Br cylinder ~ {:2~ 8Ii'tiiI ,~ gasket (3). Trglrrten two rover iBst.enars '1)0 to; 9.- 13 trt-ilba (1..0-1..5 Nm)-

AWARNINiGi

Always !teal: momrcyr:le ibr~ke"!;!i sI: IDW :s;_r:lafter !;!:E!nt-cII P g or Ibleed in I ~S'~'sJte'r'rlL il'l!l! [prla'il9iir t '!!tilth (fa' :a erilcu:5, [IntuIT.! BuBJl l'8eOmfflenDa: imlat :11[1 brake repl;lim lbe FJiill'f.lJlrlliietll by. aJ BI!IlI!!IJ duTer 'o.r !Mhr 'Civailllll'edl :Isd:rni.cia-n.

"_o"

Cooek: fOG" p:ro;pe:r bra'~ Ilamp o.parBti'on lbefoi'!' rl"!!dlng motorcycle_ VllIiIibiliIJ' is, :a mll(!lr. ej!)'ncelfn ror Ilil.GWrrcydii&1!s. FanUN ee hillve proper iI:JraJaI; IIam,p operallion ,~!l}lLI'ld fewh in dE!'$h I!U .ss:rirnlr:s. i'1:rj!![l7.

10 .. Tun'1 ignitiOFl Ke'.f :!M!itch ~[} ON_ Apply' bi'a'ire' hand l1E!.rer -0 tam D:r8i'ke laimp OJ;leffil1ao. Tum ignition ~ ~iitCh '~ OFF.

Fiig!llr1iJ 2:-37. BC~'ke 1IFIILI'Id 1JL.ey.a1 ~'Eloo'ard Br;ao RasW"WiiI'r S~n)

FIRONIT IBRAKE LIINIE

2.1'1

IRE,., OVA L

1_ Q.r8iin bra1s, 'Iluidl iIiIto a ,suitable tOD_rlt.!:Jinef., Oii~rd at rU~ ~IUiij a-.re(l~g I.c.o locaJIlaws..

,=" InstJJI ,01, lengllil of pl8s.IE lubing o.1IE(f ca1i,pBr ml:eredm 'ilB1'o'e. ~ 'lFee ,el!l.d i'n a suitEble' oor.rt:a;'lneJr.

!l. ()p.en IDlccoor ~laJ¥C ~1Ji'ii:} ,;;ili;;)uL 11.Null1l. e, P'u.mp limt'keo h~oo erer. to (!J";(!j!n brake fIlJ~,

Ii. Tigh .an ble6der vaLvB to ::l6-i!O ilil-Ibs ~4-1 !'!.1m}.

2. .Sea F~ufI3i 2-3£:.. lFIermooe p-clarnp ff1} ~rl1!ng b~J\;e 1!1fIe IFOffI rlg1i1l ~ of I(lw,er 'f(lu. mmp.

(;:,AUTlON

tJie!~@Sedl b!:!~J:O' DOll: seating $uffa-os:s 'will 19<ik 'wll!ilil Uili:'j_5Hmbl'9lll~ Pv~~QIiII: 'daliTlB."g1ilt 'ID :sE!81in~1 :81l11'tfBEl8S b!f '1!:I3l'efuUy r>Eirn.tI!i!il~ng Iblll3ke nne ,ecll'tlp1!l!llIe:nts_

3_ 889 RgUIi6l ,2,-35. RsIiOClll!3t rrnastGir 'cyind8r bBJnio IOOIt ~ 12) ,rlillellic} 8Jl1O 'f:!N1} 'oo.ppCf 'N_asl'le~ (~'4} 1:(1 idiSCl:ltllncct br:aka line from 1Iffi~'Br ~Iindar '4}. Iliscam oo,p;per 'i'ffl~h!'!\f\_~"

4, Sec, FiQiafC 2-38, Rl!!mow iCr.l:l(p811 ~njlJt Wil (5) (metric), IwD copper wam.e.rs and "nVe form (:3,) no ~ct brake li~ (2) frQlm tCa'lIpeJ'" lDf$carcli 'OO~pe1 waSflcrrs,

:5. CarefuJ-.v inspect '[hB' bra]i;e, linB' fat" dEn1E" cuts, chsiFjng Cf CiIh~r ~~ H8p1'r.l.Ce Ihe, IlfahI, liM if ,an:.- dama;g:e ~, noted.

IllNIS,TAlLATl'ON

CAUnONI

-':01 avoid! I'ealalge'. 'V<lll'iify thM '!jjlRsl«lt5" banjo ~1 .. IiI:tdu .. u,. l'ii<:: lbr:ake li'liI!3t !Imdl rn8j6ib8~ ~ind!34" bone Bf8t ifiDmpJetel:y 'E:I~Ii1!.

1. Se8' F~urB' 2-96.. Goonect bfah!. Iline (1~} te rmaet2r cylinocr ~4} IilIMg ~ Inn otlJIpai 'ffiI1;h6ils (14' and a hwiljo' oolt (1:2) {rF1e~ric)._ iLoo.!l!!'!tv ~all 1)011; into ~er cylln-, crer.

2, Houls tha braka line j'rotiIl the rm!Bter c1Jind'_E'J 10 the caliper. see ill. ~ IHOSE AND WllRE ROUliINB lOr' fl'i:itill b~ line rot!llDg.

U!;!:e' iO'!'IIJ' eopper ol1iih lbfUiijO! wuliliers ~ lP'arts Cilt~I'o!l fnr Part No..) wifih IltD.. T., 4. blr3li;e' 'fluld- ~rtl'e~ siltyer It.-fill!) 'wa!lihJitts ~1iIi m:i!l c(]~p8.tibl'e witlill Ililu!ll.,'1i: ;4 Uujd amll wi]! li'iiOl ,sIM'I lpr!~ 011'81' 'il:iiIUlB" IFeil't!lr,8' ro 'li:ompl;V I'EIB.¥ ,~iltv~l'SeL\l' a1Mc1: Ibrial'i:i~l'iil abili:ty anti! ~!BiiI1 tD IiII'i:i[hl8' fai~RlI'8 wh!'e'lil ,e@llLld rei!.!I.: lin Cleatn (O~ s.e:I1O'us InJUfi"!!!\.

:2-::26 :zoos: BUEll XIMR1:: Oha!li Si lSi,

CAJUTION

TiD BIIOidlleaI!;8gE!', ~Il\!fy ~M;p,t ~lI!S!(el$, bl!!n]1i:I Doll', h}'·dI'a'U· I:iQ! 1i1rali.19 ~i.ne ;md eai:ipBr bOTe BiB ,C!j)"mpIEf8~ deBJiI.

:3. lln:st.:all br:ake lEe iID ,~Iiper_

a. sea figure 2-:3Bc InataJi naw mp:per 'IA'B~erJ IbrF.ike line (~l .. new c~r wasMt .and] wife 'fd(rriil ~3} onto banjo bolt {$).

b" Filngei' il.!gnt:efllDiMli.O M" (5,). (lt1li.U I[rum GtiJiper D6CriI;Q i[l.:l!r<sEul n~: 1[1 pinch 'Wiffi nxm (3) while ttightetTling~ m.re fuli111 ,!;hal,ll\:;l ro,1are a.l'OllIDd oorllo bca: 1'reely,

e. iW1st b~ liM' 1[:2' ~I.U wire, fo1tiiii PJi :spjral and cl'tOC:k wira KlI1'F1 ;Eiga~ Ueed'F.l 'i'f.!h.ie (4),

,4.. TIghten D-~fI1Ij) wilh Iriits:l:CI~e~ (~) en llOm;ir 1.ri'FltB clamp to :36.-00 ilil"lb:s, (4-.'7 Mm).

1,. ~i;jl:ml!)

2, Bll\iIl!;sl'i08

3. Wr.r. 'l'O.m'II

4. Bleeder, 'vd¥e s.. Paojo,l!';i!oh

5.. &;-,£1 Figure 2-.35.. Tig':too master cytindef DaJija. 001t (12~ (nrt~rtt;::) to '1 ~:201 ft·lbs (:22-21 Nrn).

6. Sse ~ure 2-3·8·. ilgh EI'1I bra'ke calip£:r [banio oot~ {5) (mslliic) to '16-,20 'fl·IM, C~I,l:-27 Nm).

-

AWARNINGi

~ya tS8t mo.rorII:J!i:I!9I~1 ,Jt low ;liipead .1I1Im' :&eMS~ ilflg « [bt~I"'!!I sys.tEfrn.'llfu. prii'llltmt dnJlli ar ,8~:S trnjury, Ow'IJ rgeornme.f1~5 that .8111 brake IrtlpiIJlI'$ [!:Ie (;I!I!i1i"t~1 by l1li B.U8[lldealg~ or ,o.t!'1ier l!Iua'IHI'edI macliJ;an.l~:.

7'. InsIF.ill bleeder wtv.a iF milW'lle(l., Fie ill lliIIBSter cyliMCf and ilOged t:lfates. See 1.6 'BRAKE SYSTEM MA[NllEI"fANCif.

r-.

i _ A'l,I'~A.RNING

Che~,,": im- l(OO'D,per br'Ot'lte [Iwp IIl'IpI!l'81il'on 1bBf;g.... Il'Idin!!J roo'tOrq·e.!e. V~lblll1y ~B ill I1ilBjilll~ IQ~i'ialillll mr I1'lOloli"CJ"" dl'9t8. Fai'lUII1I! ~D ha'llltli PK!flIer'lbrab IIam;p Qp.aratBon ,e.ould

F..... fBS-\ilH in liiI_hi G~ s~e; tn,illlry.

$. Tum igniliDn k6y $-NltdlCl' ON. Apply bIBb haoo leVer tn

te$t b'rs:ke - 'opard.1ioo. TUm ilgnltlon. I!<sy SlNib;;h W

LOOK.

FRO NIT IBR:A.KIE CAlliPER

2.112:

IR:IE~OVA.L

1. Dt.a!n Ibrake ill.Jl~ IFi~i) 8J Sl,.ll~ble oorrtalner. LiisriEln::I Il.!lSEid filIi d a 00JIId i n 91 to 1iooa1 1'a'lfS.

a, lnstall a fengIh 01 plwstie iI.utlQrig ~r' caliper I!)!eerer wl¥B. IPlacs fIl'ee 8liId m Si aui;'able container,

lb. Open bl~i;!r '!.!'8hre. (metric) a'bDu~' 'i,i'2~1l!Un_ c, IPUri1,p br:akEi haridllawr (0' idrailfl btaM ·l'Itlid.

d. liigtdelii ~dl3t' 'i':.:Ii1!ie 10 :36-00 ilil-iM (4-7' Nlil) ..

CAl..mON·

!i)8ma.geQ Ii;J;pI'lJJI!;!I 1i;J!g11! !!!i1;!:;IJilI!)!:l1 I!W!IrlaceB wm IIei9lk Wlnelii re;a EiS I9JII b:l EMil. !fI1\EI .... 81i1: d'arfrila'g 8' to :&&a1! [fig ~!I[rfliIOe:!;, t:iI)!' ei1!i~ruUy 1i'II1~JlflilOO.l'l~g ibr,l!ike. 1111i~' ,f:l!l!mponsnta.

:2. See· Flg)!!l!P. .2-00. DlsmnFiecl! brske line at caip.Br. Sae 2:111 FOONT ElJRAJ<E LINE

;3. lRenncwe cafipE!~ .liOOun~in9l·fa6<~anElJ.!i. ~51'-

4. $iiQe' ca~er oown 'fb.e ~Ol' to ~r 'I'i!!!rk lower aDIlI thalli l'e1DDVl3' 'off ~or.

DIS.ASSE.MIB'LY

~. ~ ~l,.Ire· .~-41. ~eFlitove ~ hBng:e'I sel m, caliper padl :spmg (2' and! b~B pads.

2. SPlit caliper by' Ir'B~g mt.(p8~ ·f;.:llilleriatS. (!J.J.

3. SBElIFi'glUr!EI 2-42:. R.emim,ra, .<lriOi djf:;oar'dl {I·rin;gs ('6).

4.. See figJ,llre :2-;39'_ lReflilO'i!B pi&tCft3. uaing a IBRAKE P~STONI iilEMO.';I.EFl (P""I1INb.. B42BH7}_

.5.. IRen1OVB' and! disD:llr.o "bp and MtlJ:ltli .seal.

:Z·.:l!iSI 2ll1O~ B~I] X6'9Ii'1i~ O"@'sSiI~

'1 .. WiliO'fIi)rttiA 2.. BfB~ lilliE!'

3" BaJiljo b!J!ll: ([IJ!i!mriG.)' 4.. Pil n pllllgi

5" MCW'lIIii'i'!jji la:5tefi'ie~ (2)

11. Plnl Mn.g;e~ ~elt

:2:. 'cal]per pad sJ)'ling' :11. 'C;;illpEio" '~enE!t5

C,lEANllNiG AND INS'PEC110N

,aWARNUNG

CINt'ii brae SV.llem QflfIlJKJnents usi:ng ,dermiured !3le!l)hot [Ilo, nm' uS8IIITIIi:ne.TB.1·bilu ,r;I_li'lln~ $@~1rems, :&;u~h lal!i Uilsu[ine, il!Ir ~!nt 'IfrItnJller: nlaa, D1i milllSral-b.ase il1l.ltv.ent!il ~:ses datisrK;Jr,atio:iil of r~ P_BI!1iB,lhst ccntinue5.t1ter oa$SenilhlY'- This mq r'ssulli in rmprol'!'er b:ra_\e oparilltiDn wtJ i(: Iii ItiOU kli l1e!iullit Inl de ath i[]G' ss r i'iIl! us' injury;.

'1. Cls8J!l sll[ part; wi'lh cenat led ~lI;dhol or 0.0. T. 4 BRAlKE fLUJD- i!iIo, not iXlnh8min~B wifu IIMI'IcraJ 011 er oIih er ool!ie nts, 'Vii IiJEI dry. \III i mac I ean 1 lin" 'fIB;s cin'lh _ B 1IJtlI!' oiill (!FiIIe{1lp:=JsS9ges and[ bole. wilh a dean ali ~um [;IQ, not use i:I wire UI ~ilar lnstrurnant to clean dril[ed passage:;::-

2. Cl;irefu inapecl! ilJlI re.n'lptJMn1S. F"!'E!tIlaoe any panE that

appsar d'runagM 'lor ",,-orne [)o 11101 oons, calip - ~oon ~rie.

AJwa,ys I\Eplacsl b-.ra:'k!B [po1'd'fl; If'll C:otml1e-te aets ;for CmTiBliit [Ix am OPSii'MIIOIfI. Nle\i'.;:r IIEplace' just 'DrnJ brake, pad!. IF:~(Iu~e '00 111IB>ta'11 [twsb [lJ8Id:s as ;ji ~.' ,c(lIuld I'e!l;ult in dsa'tih Iln s!ilri(lu$ InJu,,"

3_ Insped brake ro.1Qr and pads_ SeE! 1.ri3, SRAKE: $,YSllBPi4I !MAINTENANCE.

4_ Chadk. rotor surfaM. Repb:e If wa:rped or badly ~t"Jt'OO.

Sec- Table :2-10..

JatJi a 2-10. Frofillt IRolor IRun,out,

RijNOtlllf' [IN. MM l
Radial i:)_D'~77 0.45
Lataral (t024B 0.63 a l...uIbriCBte Iil8W o-iings (6), ~(jng (5). and caJjpEir' piston 1OOFe$ 'i'hth n.OLT_" BRAlKE flU!.lIlD.

b, fn&1:afI1wO Inew Q-rt~ ffj.) m gri[i{]¥5iS 13:1' ,each plsten bare.

c. In!Jt;;l ~Qna (5). 'in each piStoo OO'r~.

a. Clt!;rnv caliper tCig~h8i ""'illl (:aJIp.er l'a1!'ene:1'.3. (11)< ar'lCi 1igbte'J1i -O! 15-19 it-Ibs (2'0",26 Nm).

INS,TAlLATION

1_ 800 figJl!Ie 2-42'_ Snstall brake pa'ds (10)-

2. 1'nE,'IBII !p i n han Qe r SB t (1 J aM iffg,:hten to 11 -14, ft-I ba (~:S- 19 film).

3.. Rotate fren" "'rk ~'ockmSe ,and Install (:;::1 . _ r on

calip . mourn. US!!'iQl LOCmlE 27,2, IIig.hten il'a6tenars (9~ to 35--:3:;1" 'ft-iltE ~41-:5.G Nm),_

4.. Rotate '~-j)nt 1'oc'Kf<:allper clockwise and slfuia caliper onto rn.1m.

AWAFINING

Usa onl)" '~I1JF$8r CII'<i.l~ Ht\lt,ii1 w,gI~her.!I; (See, P,art,a, Catalog ltor llii'tlill1 ND..] 'li!dIih I!).O. "If; 1\\ !br,an fJtllid~ [5arilier ~sl]ve-J' !b:!:!!nJ,o, w ... .:shers ,are nOit c:o.!'I!II!){!I1Ible, W:11h D.o. T., A, fluid 81iId 'Win 111011: sesl properly 'DY9F 'mi:filiie'. failure '~ QOm;~ ma!J" adMeI'$e'ly ;!!f~ IIl1i'a'l!;l'rn!a a'bUlty smllead '00' [!Jr:ilIu 'fi1IjtUA! whJdJ CDlilid riE!su[t inllilril'<t'l1I'1, er ,$.~r.ou~, I'mJLfI"jjI'.,

5, lfi!it I brake li'De D' mlips1i. Sss, 2_11 RHO . T BRAKE LlNE_

16. BlP-ed[ friDrr! braw.. See BLEED[NG BRAKi:$ in. 1 J~, BRAiKE SYSiTEM MAl NTlENANCE_

'CliJedi: ~Ii proper b~lc",e lamp, '~lBtiDn befDre mlIilil$ll mmnrcyc1sl. ViisiliJ'ilitv ir; ill mlajOr c:onoem ''o'r motEll"f:"ye I ill'S. IF;fI! tUlle' '!li1I i'l8'II'e' ,pm pe.r III 1l'.II ~cl3l I.a m p. '!JIjJ9mi!ill nl ~ kI[ res.l!I'll in d8aifi (Ii 5e1li!1!!1!I'<S Inj,lll'J-

'7 _ Turn igriiUon key ~Oh to o.NL Ap,ply brake nd I!3!tBr to teat biriIJKe lamp oj!l8nmun.

~. - ..

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