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Table of Contents
- 2. A Few Words About Safety
- 3. How to use this manual
- 4. Symbols
- 5. General information
- 6. Service rules
- 7. Serial numbers
- 9. General specifications
- 10. Lubrication system specifications
- 11. Cylinder head/Valves specifications
- 12. Crankshaft/Piston/Cylinder specification...
- 13. Battery/Charging system specifications
- 14. Standard torque values
- 16. Lubrication & Seal points
- 18. Cable & Harness routing ('02 - '05 model...
- 29. Cable & harness routing (After '05 model...
- 40. Emission control systems
- 41. Exhaust emission control system ('02 - '...
- 42. Exhaust emission control system (After '...
- 43. Frame/Body panels/Exhaust systems
- 44. Body panel locations
- 45. General
- 46. Trim clips
- 47. Front fender
- 48. Luggage box
- 49. Body cover
- 50. Side cover
- 51. Step floor
- 52. Lower cover
- 53. Rear fender
- 54. Front meter cover
- 55. Muffler
- 57. Maintenance
- 59. Maintenance schedule
- 60. Fuel line
- 61. Air cleaner
- 62. Crankcase breather
- 64. Valve clearance
- 66. Engine oil
- 67. Engine oil strainer screen
- 68. Engine idle speed
- 69. Radiator coolant
- 70. Secondary air supply system: ('02 - '05 ...
- 71. Secondary air supply system: (After '05 ...
- 72. Brake system
- 74. Brake lock operation
- 75. Suspension
- 76. Nuts, bolts, fasteners
- 77. Lubrication system
- 78. Lubrication system diagram
- 80. Oil pump
- 87. Fuel system
- 88. Component location: ('02 - '05 model)
- 89. Component location: (After '05 model)
- 90. Fuel system
- 92. Air cleaner housing: ('02 - '05 model)
- 93. Air cleaner housing: (After '05 model)
- 94. Carburetor removal
- 96. Carburetor disassembly
- 97. Vacuum chamber
- 98. Float chamber
- 99. Carburetor assembly
- 102. Carburetor installation
- 104. Pilot screw adjustment: ('02 - '05 model...
- 105. Pilot screw adjustment: (After '05 model...
- 106. High altitude adjustment (After '05 mode...
- 109. Pair control valve removal/installation ...
- 110. PCV control solenoid valve/PCV reed valv...
- 115. Cooling system
- 116. System flow pattern
- 119. Coolant system testing
- 120. Coolant replacement
- 123. Water pump/Thermostat
- 124. Thermostat inspection
- 125. Installation
- 127. Radiator
- 129. Radiator reserve tank
- 131. Engine removal/Installation
- 132. Component location: ('02-'05 model)
- 133. Component location: (After '05 model)
- 135. Engine removal
- 138. Engine installation
- 141. Cylinder head/Valves
- 142. Component location
- 144. Tools
- 146. Cylinder compression test
- 147. Camshaft/Rocker arm removal
- 150. Cylinder head removal
- 151. Cylinder head disassembly
- 153. Valve guide replacement
- 154. Valve seat inspection/Refacing
- 155. Valve seat refacing
- 157. Cylinder head assembly
- 158. Cylinder head installation
- 159. Camshaft/Rocker arm installation
- 162. Cylinder head cover installation
- 163. Kickstarter/Drive pulley/Driven pulley/C...
- 167. Belt case cover
- 168. Kickstarter
- 171. Drive pulley
- 174. Clutch/Driven pulley
- 183. Final reduction
- 187. Final reduction oil
- 188. Driveshaft removal
- 190. Bearing replacement
- 191. Final reduction assembly
- 195. Alternator/Starter
- 201. Crankshaft/Piston/Cylinder
- 205. Crankcase separation
- 206. Crankshaft inspection
- 208. Piston/Cylinder inspection
- 210. Piston installation
- 211. Crankcase assembly
- 213. Front wheel/Brake/Suspension/Steering
- 218. Front wheel
- 221. Front brake
- 229. Handlebar
- 232. Equalizer
- 233. Steering stem
- 234. Bearing replacement
- 239. Rear wheel/Brake/Suspension
- 242. Rear wheel
- 243. Rear brake
- 246. Rear shock absorber
- 249. Battery/Charging system
- 250. System diagram
- 254. Battery
- 255. Charging system inspection
- 256. Alternator charging coil
- 257. Engine control module (ECM)
- 258. Ignition switch circuit inspection
- 259. Main relay
- 263. Ignition system
- 267. Ignition system inspection
- 268. Ignition pulse generator peak voltage
- 269. Ignition coil
- 270. Ignition timing
- 272. Data reset
- 273. Electric starter
- 278. Starter relay
- 279. Engine control module (ECM)
- 281. Lights/Meters/Switches
- 284. Headlight
- 285. Turn signal light
- 287. Brake/Tail light
- 288. License light
- 289. Turn signal indicator
- 292. Fuel gauge/Fuel level sensor
- 293. Fuel level sensor inspection
- 294. Coolant temperature indicator/ECT sensor
- 296. Fuel pump
- 299. Ignition switch
- 300. Left handlebar switch
- 301. Horn
- 303. Wiring diagrams
- 304. Standard ('02 - '05 model)
- 305. P-type ('02 - '05 model)
- 306. Aftr '05 model
- 308. Technical features
- 309. Magnetic-coupling water pump
- 310. Brushless alternator/Starter
- 312. Troubleshooting
- 313. Engine does not start or is hard to star...
- 314. Engine lacks power
- 316. Poor performance at low and idle speed
- 317. Poor performance at high speed
- 318. Poor handling
Page 1 of 319
Table of Contents
- 2. A Few Words About Safety
- 3. How to use this manual
- 4. Symbols
- 5. General information
- 6. Service rules
- 7. Serial numbers
- 9. General specifications
- 10. Lubrication system specifications
- 11. Cylinder head/Valves specifications
- 12. Crankshaft/Piston/Cylinder specification...
- 13. Battery/Charging system specifications
- 14. Standard torque values
- 16. Lubrication & Seal points
- 18. Cable & Harness routing ('02 - '05 model...
- 29. Cable & harness routing (After '05 model...
- 40. Emission control systems
- 41. Exhaust emission control system ('02 - '...
- 42. Exhaust emission control system (After '...
- 43. Frame/Body panels/Exhaust systems
- 44. Body panel locations
- 45. General
- 46. Trim clips
- 47. Front fender
- 48. Luggage box
- 49. Body cover
- 50. Side cover
- 51. Step floor
- 52. Lower cover
- 53. Rear fender
- 54. Front meter cover
- 55. Muffler
- 57. Maintenance
- 59. Maintenance schedule
- 60. Fuel line
- 61. Air cleaner
- 62. Crankcase breather
- 64. Valve clearance
- 66. Engine oil
- 67. Engine oil strainer screen
- 68. Engine idle speed
- 69. Radiator coolant
- 70. Secondary air supply system: ('02 - '05 ...
- 71. Secondary air supply system: (After '05 ...
- 72. Brake system
- 74. Brake lock operation
- 75. Suspension
- 76. Nuts, bolts, fasteners
- 77. Lubrication system
- 78. Lubrication system diagram
- 80. Oil pump
- 87. Fuel system
- 88. Component location: ('02 - '05 model)
- 89. Component location: (After '05 model)
- 90. Fuel system
- 92. Air cleaner housing: ('02 - '05 model)
- 93. Air cleaner housing: (After '05 model)
- 94. Carburetor removal
- 96. Carburetor disassembly
- 97. Vacuum chamber
- 98. Float chamber
- 99. Carburetor assembly
- 102. Carburetor installation
- 104. Pilot screw adjustment: ('02 - '05 model...
- 105. Pilot screw adjustment: (After '05 model...
- 106. High altitude adjustment (After '05 mode...
- 109. Pair control valve removal/installation ...
- 110. PCV control solenoid valve/PCV reed valv...
- 115. Cooling system
- 116. System flow pattern
- 119. Coolant system testing
- 120. Coolant replacement
- 123. Water pump/Thermostat
- 124. Thermostat inspection
- 125. Installation
- 127. Radiator
- 129. Radiator reserve tank
- 131. Engine removal/Installation
- 132. Component location: ('02-'05 model)
- 133. Component location: (After '05 model)
- 135. Engine removal
- 138. Engine installation
- 141. Cylinder head/Valves
- 142. Component location
- 144. Tools
- 146. Cylinder compression test
- 147. Camshaft/Rocker arm removal
- 150. Cylinder head removal
- 151. Cylinder head disassembly
- 153. Valve guide replacement
- 154. Valve seat inspection/Refacing
- 155. Valve seat refacing
- 157. Cylinder head assembly
- 158. Cylinder head installation
- 159. Camshaft/Rocker arm installation
- 162. Cylinder head cover installation
- 163. Kickstarter/Drive pulley/Driven pulley/C...
- 167. Belt case cover
- 168. Kickstarter
- 171. Drive pulley
- 174. Clutch/Driven pulley
- 183. Final reduction
- 187. Final reduction oil
- 188. Driveshaft removal
- 190. Bearing replacement
- 191. Final reduction assembly
- 195. Alternator/Starter
- 201. Crankshaft/Piston/Cylinder
- 205. Crankcase separation
- 206. Crankshaft inspection
- 208. Piston/Cylinder inspection
- 210. Piston installation
- 211. Crankcase assembly
- 213. Front wheel/Brake/Suspension/Steering
- 218. Front wheel
- 221. Front brake
- 229. Handlebar
- 232. Equalizer
- 233. Steering stem
- 234. Bearing replacement
- 239. Rear wheel/Brake/Suspension
- 242. Rear wheel
- 243. Rear brake
- 246. Rear shock absorber
- 249. Battery/Charging system
- 250. System diagram
- 254. Battery
- 255. Charging system inspection
- 256. Alternator charging coil
- 257. Engine control module (ECM)
- 258. Ignition switch circuit inspection
- 259. Main relay
- 263. Ignition system
- 267. Ignition system inspection
- 268. Ignition pulse generator peak voltage
- 269. Ignition coil
- 270. Ignition timing
- 272. Data reset
- 273. Electric starter
- 278. Starter relay
- 279. Engine control module (ECM)
- 281. Lights/Meters/Switches
- 284. Headlight
- 285. Turn signal light
- 287. Brake/Tail light
- 288. License light
- 289. Turn signal indicator
- 292. Fuel gauge/Fuel level sensor
- 293. Fuel level sensor inspection
- 294. Coolant temperature indicator/ECT sensor
- 296. Fuel pump
- 299. Ignition switch
- 300. Left handlebar switch
- 301. Horn
- 303. Wiring diagrams
- 304. Standard ('02 - '05 model)
- 305. P-type ('02 - '05 model)
- 306. Aftr '05 model
- 308. Technical features
- 309. Magnetic-coupling water pump
- 310. Brushless alternator/Starter
- 312. Troubleshooting
- 313. Engine does not start or is hard to star...
- 314. Engine lacks power
- 316. Poor performance at low and idle speed
- 317. Poor performance at high speed
- 318. Poor handling
Also for: Metropolitan CHF50P, Metropolitan CHF50S
File size: 43.36 MB
Created: March 11, 2023
Last updated: April 09, 2023
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