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2. 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

3. CONTENTS
QUICK REFERENCE DATA ........................................................................................................ IX
CHAPTER ONE
GENERAL INFORMATION ............................................................................................................1
Manual organization
Notes, cautions and warnings
Safety first
Service hints
Serial numbers
Parts replacement
Torque specifications
Fasteners
Lubricants
Sealant, cements and cleaners
Expendable supplies
Basic hand tools
Test equipment
Precision measuring tools
Other special tools
Mechanic's tips
Ball bearing replacement
Oil seals
Riding safety
CHAPTER TWO
TROUBLESHOOTING....................................................................................................................36
Operating requirements
Troubleshooting instruments
Testing electrical components
Emergency troubleshooting
Engine performance
Electric starting system
Charging system
Ignition system
Fuel system
Engine noises
Engine lubrication
Clutch
Transmission
Electrical problems
Excessive vibration
Front suspension and steering
Brake problems
CHAPTER THREE
PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP ......................................................89
Routine safety checks
Maintenance intervals
Cleaning your motorcycle
Tires and wheels
Periodic lubrication
Periodic maintenance
Tune-up
Ignition service
Idle speed adjustment

4. CHAPTER FOUR
ENGINE ....................................................................................................................................127
Service precautions
Special tools
Servicing engine in frame
Engine
Rocker arm cover and cylinder head
Valves and valve components
Cylinders
Pistons and piston rings
Pushrods
Lifters and lifter guides
Oil pump
Oil filter mount (1992-on)
Gearcase cover and timing gears
Crankcase and crankshaft
Engine break-in
CHAPTER FIVE
CLUTCH AND PRIMARY DRIVE............................................................................................. 210
Outer primary cover
Clutch plates
Clutch, compensating sprocket and primary
drive chain removal and installation
Clutch overhaul
Primary chain and guide inspection
Primary chain alignment
Compensating sprocket inspection
Inner primary housing
Starter jackshaft
Clutch cable replacement
CHAPTER SIX
TRANSMISSION....................................................................................................................... 238
Production gear changes
Shifter adjustment
Transmission top cover
Shifter cam
Shift forks
Transmission side door
Transmission shafts
Main drive gear
Transmission case
Transmission side cover
Oil tank
CHAPTER SEVEN
FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS.....................................................275
Air filter backplate (all 1991-1995 domestic
and 1991-1994 international models)
Air filter backplate (1995 international models)
Carburetor
Throttle and idle cable replacement
Enrichener cable replacement
Fuel tank
Fuel valve
Exhaust system
Evaporative emission control system
(California models)
Evaporative emission control system service

5. CHAPTER EIGHT
ELECTRICAL SYSTEM........................................................................................................... 321
Battery
Charging system
Ignition system
Ignition coil
Vacuum operated electric switch
Starter
Starter solenoid
Lighting system
Switches
Horn
Turn signal module
Speedometer speed sensor (1995)
Indicator lights
Electric panel
Starter relay switch replacement
Circuit breakers
CHAPTER NINE
WHEELS, HUBS AND TIRES...................................................................................................376
Front wheel
Front hub
Rear wheel
Rear hub
Driven sprocket assembly
Secondary drive belt
Drive sprocket
Wire spoke wheels
Cast wheels
Wheel balance
Tires
Tire repairs (tube-type tires)
Tire repairs (tubeless type)
Vehicle alignment
CHAPTER TEN
FRONT SUSPENSION AND STEERING ................................................................................ 409
Handlebar
Front forks
Steering head and stem
Steering head bearing race
Steering play adjustment
CHAPTER ELEVEN
REAR SUSPENSION............................................................................................................... 427
Shock absorbers Rear swing arm
CHAPTER TWELVE
BRAKES................................................................................................................................... 439
Front brake pads
Front brake caliper
Front master cylinder
Rear brake pads
Rear brake caliper
Rear master cylinder
Brake hose and line replacement
Brake disc (front and rear)
Bleeding the system

6. 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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