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Table of Contents
- 3. Table of Contents
- 4. General Specifications (400/400 TBX/400 ...
- 5. General Specifications (400 - Manual Tra...
- 6. General Specifications (500 - Manual Tra...
- 7. General Specifications (500/500 TBX/500 ...
- 8. General Specifications (650 H1)
- 9. General Specifications (650 V-Twin)
- 10. Break-In Procedure
- 11. Genuine Parts
- 12. Preparation After Storage
- 14. Periodic Maintenance Chart
- 15. Lubrication Points
- 16. Fuses
- 17. Air Cleaner/Filter
- 21. Valve/Tappet Clearance (Feeler Gauge Pro...
- 22. Valve/Tappet Clearance (Valve Adjuster P...
- 23. Valve/Tappet Clearance (650 V-Twin - Val...
- 24. Testing Engine Compression
- 25. Spark Plug
- 26. Gas/Vent Hoses
- 27. Engine/Transmission Oil - Filter - Strai...
- 29. Front Differential/Rear Drive Lubricant
- 30. Adjusting Clutch (400/500 Manual Transmi...
- 31. Tires
- 32. Suspension/Shock Absorbers/Bushings
- 33. Switches
- 34. Reverse Shift Lever
- 36. Frame/Welds/Racks
- 39. Burnishing Brake Pads
- 40. Checking/Replacing V-Belt (400/500/650 H...
- 41. Checking/Replacing V-Belt (650 V-Twin)
- 44. Adjusting Differential Lock Cable
- 46. Engine/Transmission
- 47. Specifications (400 - Automatic Transmis...
- 48. Specifications (400 - Manual Transmissio...
- 50. Specifications (500 - Automatic Transmis...
- 51. Specifications (500 - Manual Transmissio...
- 53. Specifications (650 H1)
- 54. Specifications (650 V-Twin)
- 58. Top-Side Components
- 59. Removing Top-Side Components
- 62. Left-Side Components
- 67. Right-Side Components
- 71. Center Crankcase Components
- 72. Disassembling Crankcase Half
- 74. Servicing Components
- 81. Cylinder/Cylinder Head Assembly
- 84. Servicing Left-Side Components
- 87. Measuring Shift Fork (Thickness)
- 88. Measuring Shift Fork Groove (Width)
- 91. Inspecting Oil Pump
- 93. Crankshaft Assembly
- 94. Driveshaft
- 100. Countershaft
- 103. Assembling Crankcase Half
- 105. Joining Crankcase Halves
- 106. Installing Right-Side Components
- 109. Installing Left-Side Components
- 113. Installing Top-Side Components
- 119. Installing Engine/Transmission
- 126. Top-Side Components
- 130. Left-Side Components
- 133. Right-Side Components
- 137. Center Crankcase Components
- 138. Disassembling Crankcase Half
- 140. Servicing Components
- 161. Assembling Crankcase Half
- 163. Joining Crankcase Halves
- 164. Installing Right-Side Components
- 168. Installing Left-Side Components
- 169. Installing Top-Side Components
- 175. Installing Engine/Transmission
- 183. Top-Side Components
- 187. Left-Side Components
- 189. Right-Side Components
- 190. Removing Right-Side Components
- 193. Center Crankcase Components
- 194. Disassembling Crankcase Half
- 196. Servicing Components
- 217. Assembling Crankcase Half
- 219. Joining Crankcase Halves
- 221. Installing Right-Side Components
- 224. Installing Left-Side Components
- 226. Installing Top-Side Components
- 232. Installing Engine/Transmission
- 240. Top-Side Components
- 244. Left-Side Components
- 249. Right-Side Components
- 254. Center Crankcase Components
- 255. Disassembling Crankcase Half
- 285. Assembling Crankcase Half
- 288. Joining Crankcase Halves
- 289. Installing Right-Side Components
- 293. Installing Left-Side Components
- 298. Installing Top-Side Components
- 305. Installing Engine/Transmission
- 367. Carburetor Specifications
- 369. Carburetor (650 V-Twin)
- 373. Troubleshooting
- 378. Cleaning and Inspecting Carburetor
- 379. Throttle Cable Free-Play
- 380. Gas Tank (400 VP)
- 381. Gas Tank (FIS Models)
- 382. Gas/Vent Hoses
- 383. Oil Flow Charts
- 384. Oil Filter/Oil Pump
- 386. Testing Oil Pump Pressure
- 387. Oil Cooler (400)
- 388. Liquid Cooling System (500/650 H1/650 V-...
- 389. Hoses/Thermostat (500/650 H1)
- 390. Hoses/Thermostat (650 V-Twin)
- 391. Fan
- 392. Servicing Water Pump (500/650 H1 - Autom...
- 394. Water Pump/Alternator Cover (650 V-Twin)
- 396. Testing Electric Fuel Pump (650 V-Twin)
- 398. Testing Vacuum Pulse Fuel Pump (400 FIS/...
- 400. Electrical system
- 401. Specifications
- 402. RPM Limiter
- 403. Brakelight Switch (Handlebar Control)
- 404. Oil Temperature and Cooling Fan Switches...
- 405. Fan Motor
- 407. Fuses
- 408. Indicator Lights (400 VP)
- 409. Electronic Speedometer Speed Sensor
- 410. Ignition Switch
- 411. Handlebar Control Switches
- 412. Front Drive Selector Switch (400 FIS/500...
- 413. Front Drive Selector Actuator (400 FIS/5...
- 414. Magneto Coils (400/500/650 H1)
- 415. Magneto Coils (650 V-Twin)
- 416. Starter Motor
- 421. Starter Relay
- 422. CDI Unit (400 FIS/TBX/500/650 H1/650 V-T...
- 423. Taillight - Brakelight
- 424. Ignition Timing (650 V-Twin)
- 425. 100-Hour Belt Inspection Mode Clearing (...
- 426. Controller-to-Engine Brake Actuator Volt...
- 427. Output-to-Actuator Voltage (650 V-Twin)
- 428. Tilt Sensor Voltage (650 V-Twin)
- 431. Drive System
- 432. Front Drive Actuator (400 FIS/500/650 H1...
- 433. Front Differential (FIS Models)
- 448. Drive Axles
- 453. VP - Rear Suspension
- 457. Rear Gear Case (FIS Models)
- 459. Hydraulic Brake Caliper
- 461. Front and Rear Suspension Assembly Schem...
- 462. Shock Absorbers
- 463. Swing Arms (VP - Rear Suspension)
- 466. Rear A-Arms (FIS - Rear Suspension)
- 468. Wheels and Tires
- 471. Steering Post/Tie Rods
- 476. Handlebar Grip
- 477. Steering Knuckles
- 479. Measuring/Adjusting Toe-In
- 480. Front Rack
- 481. Front Bumper Assembly
- 484. Front Body Panel/Side Panels (TBX/TRV/50...
- 488. Footrests
- 489. Belly Panel
- 490. Rear Body Panel/Rack (500/650 H1/650 V-T...
- 492. Side Storage Box (TBX Models)
- 493. Adjusting Headlight
- 494. Taillight Assembly
- 497. Hand Brake Lever/Master Cylinder Assembl...
- 499. Auxiliary Brake Assembly Schematic
- 501. Gearshift Pedal (Manual Transmission)
- 502. Reverse Shift Lever
- 503. Speedometer/Tachometer/LCD (400 FIS/500/...
- 509. Tightening torque
- 511. Troubleshooting
- 512. Engine
- 515. Drive
- 516. Fuel System
- 517. Electrical
- 519. Steering/Suspension
- 520. Brakes
Page 1 of 520
Table of Contents
- 3. Table of Contents
- 4. General Specifications (400/400 TBX/400 ...
- 5. General Specifications (400 - Manual Tra...
- 6. General Specifications (500 - Manual Tra...
- 7. General Specifications (500/500 TBX/500 ...
- 8. General Specifications (650 H1)
- 9. General Specifications (650 V-Twin)
- 10. Break-In Procedure
- 11. Genuine Parts
- 12. Preparation After Storage
- 14. Periodic Maintenance Chart
- 15. Lubrication Points
- 16. Fuses
- 17. Air Cleaner/Filter
- 21. Valve/Tappet Clearance (Feeler Gauge Pro...
- 22. Valve/Tappet Clearance (Valve Adjuster P...
- 23. Valve/Tappet Clearance (650 V-Twin - Val...
- 24. Testing Engine Compression
- 25. Spark Plug
- 26. Gas/Vent Hoses
- 27. Engine/Transmission Oil - Filter - Strai...
- 29. Front Differential/Rear Drive Lubricant
- 30. Adjusting Clutch (400/500 Manual Transmi...
- 31. Tires
- 32. Suspension/Shock Absorbers/Bushings
- 33. Switches
- 34. Reverse Shift Lever
- 36. Frame/Welds/Racks
- 39. Burnishing Brake Pads
- 40. Checking/Replacing V-Belt (400/500/650 H...
- 41. Checking/Replacing V-Belt (650 V-Twin)
- 44. Adjusting Differential Lock Cable
- 46. Engine/Transmission
- 47. Specifications (400 - Automatic Transmis...
- 48. Specifications (400 - Manual Transmissio...
- 50. Specifications (500 - Automatic Transmis...
- 51. Specifications (500 - Manual Transmissio...
- 53. Specifications (650 H1)
- 54. Specifications (650 V-Twin)
- 58. Top-Side Components
- 59. Removing Top-Side Components
- 62. Left-Side Components
- 67. Right-Side Components
- 71. Center Crankcase Components
- 72. Disassembling Crankcase Half
- 74. Servicing Components
- 81. Cylinder/Cylinder Head Assembly
- 84. Servicing Left-Side Components
- 87. Measuring Shift Fork (Thickness)
- 88. Measuring Shift Fork Groove (Width)
- 91. Inspecting Oil Pump
- 93. Crankshaft Assembly
- 94. Driveshaft
- 100. Countershaft
- 103. Assembling Crankcase Half
- 105. Joining Crankcase Halves
- 106. Installing Right-Side Components
- 109. Installing Left-Side Components
- 113. Installing Top-Side Components
- 119. Installing Engine/Transmission
- 126. Top-Side Components
- 130. Left-Side Components
- 133. Right-Side Components
- 137. Center Crankcase Components
- 138. Disassembling Crankcase Half
- 140. Servicing Components
- 161. Assembling Crankcase Half
- 163. Joining Crankcase Halves
- 164. Installing Right-Side Components
- 168. Installing Left-Side Components
- 169. Installing Top-Side Components
- 175. Installing Engine/Transmission
- 183. Top-Side Components
- 187. Left-Side Components
- 189. Right-Side Components
- 190. Removing Right-Side Components
- 193. Center Crankcase Components
- 194. Disassembling Crankcase Half
- 196. Servicing Components
- 217. Assembling Crankcase Half
- 219. Joining Crankcase Halves
- 221. Installing Right-Side Components
- 224. Installing Left-Side Components
- 226. Installing Top-Side Components
- 232. Installing Engine/Transmission
- 240. Top-Side Components
- 244. Left-Side Components
- 249. Right-Side Components
- 254. Center Crankcase Components
- 255. Disassembling Crankcase Half
- 285. Assembling Crankcase Half
- 288. Joining Crankcase Halves
- 289. Installing Right-Side Components
- 293. Installing Left-Side Components
- 298. Installing Top-Side Components
- 305. Installing Engine/Transmission
- 367. Carburetor Specifications
- 369. Carburetor (650 V-Twin)
- 373. Troubleshooting
- 378. Cleaning and Inspecting Carburetor
- 379. Throttle Cable Free-Play
- 380. Gas Tank (400 VP)
- 381. Gas Tank (FIS Models)
- 382. Gas/Vent Hoses
- 383. Oil Flow Charts
- 384. Oil Filter/Oil Pump
- 386. Testing Oil Pump Pressure
- 387. Oil Cooler (400)
- 388. Liquid Cooling System (500/650 H1/650 V-...
- 389. Hoses/Thermostat (500/650 H1)
- 390. Hoses/Thermostat (650 V-Twin)
- 391. Fan
- 392. Servicing Water Pump (500/650 H1 - Autom...
- 394. Water Pump/Alternator Cover (650 V-Twin)
- 396. Testing Electric Fuel Pump (650 V-Twin)
- 398. Testing Vacuum Pulse Fuel Pump (400 FIS/...
- 400. Electrical system
- 401. Specifications
- 402. RPM Limiter
- 403. Brakelight Switch (Handlebar Control)
- 404. Oil Temperature and Cooling Fan Switches...
- 405. Fan Motor
- 407. Fuses
- 408. Indicator Lights (400 VP)
- 409. Electronic Speedometer Speed Sensor
- 410. Ignition Switch
- 411. Handlebar Control Switches
- 412. Front Drive Selector Switch (400 FIS/500...
- 413. Front Drive Selector Actuator (400 FIS/5...
- 414. Magneto Coils (400/500/650 H1)
- 415. Magneto Coils (650 V-Twin)
- 416. Starter Motor
- 421. Starter Relay
- 422. CDI Unit (400 FIS/TBX/500/650 H1/650 V-T...
- 423. Taillight - Brakelight
- 424. Ignition Timing (650 V-Twin)
- 425. 100-Hour Belt Inspection Mode Clearing (...
- 426. Controller-to-Engine Brake Actuator Volt...
- 427. Output-to-Actuator Voltage (650 V-Twin)
- 428. Tilt Sensor Voltage (650 V-Twin)
- 431. Drive System
- 432. Front Drive Actuator (400 FIS/500/650 H1...
- 433. Front Differential (FIS Models)
- 448. Drive Axles
- 453. VP - Rear Suspension
- 457. Rear Gear Case (FIS Models)
- 459. Hydraulic Brake Caliper
- 461. Front and Rear Suspension Assembly Schem...
- 462. Shock Absorbers
- 463. Swing Arms (VP - Rear Suspension)
- 466. Rear A-Arms (FIS - Rear Suspension)
- 468. Wheels and Tires
- 471. Steering Post/Tie Rods
- 476. Handlebar Grip
- 477. Steering Knuckles
- 479. Measuring/Adjusting Toe-In
- 480. Front Rack
- 481. Front Bumper Assembly
- 484. Front Body Panel/Side Panels (TBX/TRV/50...
- 488. Footrests
- 489. Belly Panel
- 490. Rear Body Panel/Rack (500/650 H1/650 V-T...
- 492. Side Storage Box (TBX Models)
- 493. Adjusting Headlight
- 494. Taillight Assembly
- 497. Hand Brake Lever/Master Cylinder Assembl...
- 499. Auxiliary Brake Assembly Schematic
- 501. Gearshift Pedal (Manual Transmission)
- 502. Reverse Shift Lever
- 503. Speedometer/Tachometer/LCD (400 FIS/500/...
- 509. Tightening torque
- 511. Troubleshooting
- 512. Engine
- 515. Drive
- 516. Fuel System
- 517. Electrical
- 519. Steering/Suspension
- 520. Brakes
Also for: 400 TBX, 400 TRV
File size: 180.51 MB
Created: March 10, 2023
Last updated: March 30, 2023
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