Jade's Collection .

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Jade's Collection .net Archives
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DATE MILES TYPE OF SERVICE
 Chapter One
1 General Information
Chapter Two
2 Troubleshooting
Chapter Three
3 Periodic Lubrication, Maintenance and Tune-up
Chapter Four
4 Engine
Chapter Five
5 Clutch, Primary Drive and Starter Drive
Chapter Six
6 Transmission
Chapter Seven
7 Fuel, Exhaust and Emission Control Systems
Chapter Eight
8 Electrical System
Chapter Nine
9 Wheels, Hubs and Tires
Chapter Ten
10 Front Suspension and Steering
Chapter Eleven
11 Rear Suspension
Chapter Twelve
12 Brakes
Supplement
13 1996-1998 Service Information

14 Index

15 Wiring Diagrams
 CONTENTS

QUICK REFERENCE DATA ........................................................................................................ IX

CHAPTER ONE
GENERAL INFORMATION ............................................................................................................1

Manual organization Expendable supplies

Notes, cautions and warnings Basic hand tools
Safety first Test equipment
Service hints Precision measuring tools
Serial numbers Other special tools
Parts replacement Mechanic's tips
Torque specifications Ball bearing replacement
Fasteners Oil seals
Lubricants Riding safety
Sealant, cements and cleaners

CHAPTER TWO
TROUBLESHOOTING....................................................................................................................36

Operating requirements Engine noises

Troubleshooting instruments Engine lubrication
Testing electrical components Clutch
Emergency troubleshooting Transmission
Engine performance Electrical problems
Electric starting system Excessive vibration
Charging system Front suspension and steering
Ignition system Brake problems
Fuel system

CHAPTER THREE
PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP ......................................................89

Routine safety checks Periodic maintenance

Maintenance intervals Tune-up
Cleaning your motorcycle Ignition service
Tires and wheels Idle speed adjustment
Periodic lubrication
CHAPTER FOUR
ENGINE .................................................................................................................................... 127

Service precautions Pushrods

Special tools Lifters and lifter guides
Servicing engine in frame Oil pump
Engine Oil filter mount (1992-on)
Rocker arm cover and cylinder head Gearcase cover and timing gears
Valves and valve components Crankcase and crankshaft
Cylinders Engine break-in
Pistons and piston rings

CHAPTER FIVE
CLUTCH AND PRIMARY DRIVE............................................................................................. 210

Outer primary cover Primary chain alignment

Clutch plates Compensating sprocket inspection
Clutch, compensating sprocket and primary Inner primary housing
drive chain removal and installation Starter jackshaft
Clutch overhaul Clutch cable replacement
Primary chain and guide inspection

CHAPTER SIX
TRANSMISSION....................................................................................................................... 238

Production gear changes Transmission shafts

Shifter adjustment Main drive gear
Transmission top cover Transmission case
Shifter cam Transmission side cover
Shift forks Oil tank
Transmission side door

CHAPTER SEVEN
FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS..................................................... 275

Air filter backplate (all 1991-1995 domestic Fuel tank

and 1991-1994 international models) Fuel valve
Air filter backplate (1995 international models) Exhaust system
Carburetor Evaporative emission control system
Throttle and idle cable replacement (California models)
Enrichener cable replacement Evaporative emission control system service
CHAPTER EIGHT
ELECTRICAL SYSTEM ........................................................................................................... 321

Battery Switches
Charging system Horn
Ignition system Turn signal module
Ignition coil Speedometer speed sensor (1995)
Vacuum operated electric switch Indicator lights
Starter Electric panel
Starter solenoid Starter relay switch replacement
Lighting system Circuit breakers

CHAPTER NINE
WHEELS, HUBS AND TIRES...................................................................................................376

Front wheel Wire spoke wheels

Front hub Cast wheels
Rear wheel Wheel balance
Rear hub Tires
Driven sprocket assembly Tire repairs (tube-type tires)
Secondary drive belt Tire repairs (tubeless type)
Drive sprocket Vehicle alignment

CHAPTER TEN
FRONT SUSPENSION AND STEERING ................................................................................ 409

Handlebar Steering head bearing race

Front forks Steering play adjustment
Steering head and stem

CHAPTER ELEVEN
REAR SUSPENSION............................................................................................................... 427

Shock absorbers Rear swing arm

CHAPTER TWELVE
BRAKES................................................................................................................................... 439

Front brake pads Rear master cylinder

Front brake caliper Brake hose and line replacement
Front master cylinder Brake disc (front and rear)
Rear brake pads Bleeding the system
Rear brake caliper
SUPPLEMENT
1996-1998 SERVICE INFORMATION....................................................................................478
Periodic lubrication Charging system
Periodic maintenance Ignition system
Ignition service Starter
Clutch plates (1998 models) Switches
Clutch overhaul Front master cylinder
Battery

INDEX .....................................................................................................................................506

WIRING DIAGRAMS ..............................................................................................................510

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