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Table of Contents
- 2. How To Use This Manual
- 3. Symbols
- 4. General Information
- 5. Service Rules
- 6. Model Identification
- 7. Specifications
- 9. Lubrication Item
- 10. Cylinder Head/Valves Item
- 11. Piston/Cylinder Item
- 12. Clutch/Kickstarter/Gearshift Linkage Ite...
- 13. Crankshaft/Transmission Item
- 14. Front Wheel/Suspension/Steering Item
- 15. Brake System Item
- 16. Electrical System Item
- 17. Torque Values
- 18. Frame
- 22. Lubrication & Seal Points
- 23. Frame (Cont'd)
- 24. Cable & Harness Routing
- 26. After '97/California type
- 27. Emission Control System (After '97/Calif...
- 28. Vehicle Emission Control Information Lab...
- 29. Frame/Body Panels/Exhaust System
- 30. Front Fender
- 31. Rear Fender
- 33. Installation
- 34. Maintenance
- 36. Maintenance Schedule
- 37. After '97
- 38. Competition Maintenance Schedule
- 39. Fuel Tank
- 40. Air Cleaner
- 41. Spark Plug
- 42. Replacing A Spark Plug
- 43. Engine Oil
- 44. Oil Change
- 45. Engine Oil Filter
- 46. Decompressor System
- 47. Engine Idle Speed
- 49. Drive Chain Slider
- 50. Brake Pad Wear
- 51. Brake Redal Height
- 52. Side Stand
- 53. Front Suspension
- 54. Cleaning
- 55. Steering Head Bearings
- 57. Lubrication View
- 58. Lubrication
- 59. Oil Strainer Screen Cleaning
- 60. Oil Pump
- 63. Assembly
- 65. Oil Pass Pipe
- 66. Oil Pipes
- 69. Fuel System View
- 70. Fuel System
- 72. Fuel Tank Removal/Installation
- 74. Crankcase Breather
- 77. Carburetor Assembly/Installation
- 79. Float level inspection
- 80. Pilot Screw Adjustment
- 81. Idle Drop Procedure (After '97)
- 82. Temperature And Altitude Adjustment
- 83. Engine Removal/Installation View
- 84. Engine Removal/Installation
- 85. Drive Sprocket Removal
- 86. Engine Removal
- 88. Engine Installation
- 89. Drive Sprocket Installation
- 90. Cylinder Head/Valves View
- 91. Cylinder Head/Valves
- 93. Cylinder Head Cover Removal
- 95. Rocker Arm And Sub-rocker Arm Inspection
- 96. Camshaft Inspection
- 97. Cylinder Head Removal
- 98. Cylinder Head Disassembly
- 99. Cylinder Head Inspection
- 100. Valve Guide Inspection
- 101. Valve Seat Inspection And Refacing
- 104. Cylinder Head Assembly
- 105. Cylinder Head Installation
- 106. Camshaft Installation
- 108. Cylinder Head Cover Assembly
- 110. Cylinder Head Cover Installation
- 112. Cylinder/Piston View
- 113. Cylinder/Piston
- 115. Cylinder Removal
- 116. Piston Removal
- 117. Connecting Rod Small End Inspection
- 118. Piston Ring Installation
- 119. Cylinder Installation
- 121. Clutch/Kickstarter/Gearshift Linkage Vie...
- 122. Clutch/Kickstarter/Gearshift Linkage
- 124. Right Crankcase Cover Removal
- 125. Right Crankcase Cover Inspection
- 126. Clutch Removal
- 127. Lifter plate bearing inspection
- 128. Clutch spring inspection
- 129. Clutch outer and outer guide inspection
- 131. Clutch Installation
- 133. Kickstarter Removal/Disassembly
- 134. Kickstarter Inspection
- 135. Kickstarter Assembly/Installation
- 137. Gearshift Cam
- 138. Right Crankcase Cover Installation
- 140. Alternator View
- 141. Alternator
- 142. Left Crankcase Cover Removal
- 143. Flywheel Removal
- 144. Left Crankcase Cover Installation
- 146. Crankcase/Crankshaft/Balancer View
- 147. Crankcase/Crankshaft/Balancer
- 149. Crankcase Separation
- 150. Balancer/Crankshaft Removal
- 151. Balancer Gear Inspection
- 152. Crankcase Bearing Replacement
- 154. Right crankcase bearings
- 155. Balancer/Crankshaft Installation
- 157. Crankcase Assembly
- 159. Transmission View
- 160. Transmission
- 162. Transmission Removal/Disassembly
- 164. Gearshift Spindle Inspection
- 165. Transmission Assembly/Installation
- 168. Front Wheel/Suspension/Steering View
- 169. Front Wheel/Suspension/Steering
- 171. Front Wheel
- 172. Wheel bearing
- 173. Wheel Assembly
- 175. Fork
- 181. Fork damper/Piston rod/Spring
- 187. Tripmeter
- 188. Steering
- 189. Handlebar Installation
- 191. Steering Stem Removal
- 192. Steering Stem Bearing Replacement
- 193. Steering Stem Installation
- 195. Rear Wheel/Suspension View
- 196. Rear Wheel/Suspension
- 198. Rear Wheel
- 199. Axle
- 204. Shock Absorber
- 205. Bladder Replacement
- 208. Damper Disassembly
- 209. Piston Ring Replacement
- 210. Damper Rod Disassembly
- 211. Rod Guide Case Inspection
- 212. Damper Assembly
- 217. Spherical Bearing Replacement
- 219. Shock Linkage
- 220. Shock arm
- 221. Needle Bearing Replacement
- 223. Swingarm
- 230. Brake System View
- 231. Brake System
- 233. Brake Fluid Replacement
- 234. Air Bleeding
- 235. Brake Pad Replacement
- 237. Brake Disc Inspection
- 242. Front Master Cylinder
- 246. Rear Brake Caliper
- 251. Rear Master Cylinder
- 255. Brake Lever
- 256. Brake Pedal
- 258. Electrical System View
- 259. Electrical System
- 261. Ignition System
- 262. Lighting System
- 263. Ignition System Inspection
- 264. Exciter Coil Peak Voltage
- 265. Ignition Pulse Generator Peak Voltage
- 266. Ignition Coil Removal/Installation
- 267. Alternator Lighting Coil
- 268. Headlight
- 269. Taillight
- 271. Wiring Diagram 0030Z-KCE-0000
- 272. Troubleshooting
- 273. Engine Lacks Power
- 274. Poor Performance At Low And Idle Speed
- 275. Poor Performance At High Speed
- 276. Index
Page 1 of 280
Table of Contents
- 2. How To Use This Manual
- 3. Symbols
- 4. General Information
- 5. Service Rules
- 6. Model Identification
- 7. Specifications
- 9. Lubrication Item
- 10. Cylinder Head/Valves Item
- 11. Piston/Cylinder Item
- 12. Clutch/Kickstarter/Gearshift Linkage Ite...
- 13. Crankshaft/Transmission Item
- 14. Front Wheel/Suspension/Steering Item
- 15. Brake System Item
- 16. Electrical System Item
- 17. Torque Values
- 18. Frame
- 22. Lubrication & Seal Points
- 23. Frame (Cont'd)
- 24. Cable & Harness Routing
- 26. After '97/California type
- 27. Emission Control System (After '97/Calif...
- 28. Vehicle Emission Control Information Lab...
- 29. Frame/Body Panels/Exhaust System
- 30. Front Fender
- 31. Rear Fender
- 33. Installation
- 34. Maintenance
- 36. Maintenance Schedule
- 37. After '97
- 38. Competition Maintenance Schedule
- 39. Fuel Tank
- 40. Air Cleaner
- 41. Spark Plug
- 42. Replacing A Spark Plug
- 43. Engine Oil
- 44. Oil Change
- 45. Engine Oil Filter
- 46. Decompressor System
- 47. Engine Idle Speed
- 49. Drive Chain Slider
- 50. Brake Pad Wear
- 51. Brake Redal Height
- 52. Side Stand
- 53. Front Suspension
- 54. Cleaning
- 55. Steering Head Bearings
- 57. Lubrication View
- 58. Lubrication
- 59. Oil Strainer Screen Cleaning
- 60. Oil Pump
- 63. Assembly
- 65. Oil Pass Pipe
- 66. Oil Pipes
- 69. Fuel System View
- 70. Fuel System
- 72. Fuel Tank Removal/Installation
- 74. Crankcase Breather
- 77. Carburetor Assembly/Installation
- 79. Float level inspection
- 80. Pilot Screw Adjustment
- 81. Idle Drop Procedure (After '97)
- 82. Temperature And Altitude Adjustment
- 83. Engine Removal/Installation View
- 84. Engine Removal/Installation
- 85. Drive Sprocket Removal
- 86. Engine Removal
- 88. Engine Installation
- 89. Drive Sprocket Installation
- 90. Cylinder Head/Valves View
- 91. Cylinder Head/Valves
- 93. Cylinder Head Cover Removal
- 95. Rocker Arm And Sub-rocker Arm Inspection
- 96. Camshaft Inspection
- 97. Cylinder Head Removal
- 98. Cylinder Head Disassembly
- 99. Cylinder Head Inspection
- 100. Valve Guide Inspection
- 101. Valve Seat Inspection And Refacing
- 104. Cylinder Head Assembly
- 105. Cylinder Head Installation
- 106. Camshaft Installation
- 108. Cylinder Head Cover Assembly
- 110. Cylinder Head Cover Installation
- 112. Cylinder/Piston View
- 113. Cylinder/Piston
- 115. Cylinder Removal
- 116. Piston Removal
- 117. Connecting Rod Small End Inspection
- 118. Piston Ring Installation
- 119. Cylinder Installation
- 121. Clutch/Kickstarter/Gearshift Linkage Vie...
- 122. Clutch/Kickstarter/Gearshift Linkage
- 124. Right Crankcase Cover Removal
- 125. Right Crankcase Cover Inspection
- 126. Clutch Removal
- 127. Lifter plate bearing inspection
- 128. Clutch spring inspection
- 129. Clutch outer and outer guide inspection
- 131. Clutch Installation
- 133. Kickstarter Removal/Disassembly
- 134. Kickstarter Inspection
- 135. Kickstarter Assembly/Installation
- 137. Gearshift Cam
- 138. Right Crankcase Cover Installation
- 140. Alternator View
- 141. Alternator
- 142. Left Crankcase Cover Removal
- 143. Flywheel Removal
- 144. Left Crankcase Cover Installation
- 146. Crankcase/Crankshaft/Balancer View
- 147. Crankcase/Crankshaft/Balancer
- 149. Crankcase Separation
- 150. Balancer/Crankshaft Removal
- 151. Balancer Gear Inspection
- 152. Crankcase Bearing Replacement
- 154. Right crankcase bearings
- 155. Balancer/Crankshaft Installation
- 157. Crankcase Assembly
- 159. Transmission View
- 160. Transmission
- 162. Transmission Removal/Disassembly
- 164. Gearshift Spindle Inspection
- 165. Transmission Assembly/Installation
- 168. Front Wheel/Suspension/Steering View
- 169. Front Wheel/Suspension/Steering
- 171. Front Wheel
- 172. Wheel bearing
- 173. Wheel Assembly
- 175. Fork
- 181. Fork damper/Piston rod/Spring
- 187. Tripmeter
- 188. Steering
- 189. Handlebar Installation
- 191. Steering Stem Removal
- 192. Steering Stem Bearing Replacement
- 193. Steering Stem Installation
- 195. Rear Wheel/Suspension View
- 196. Rear Wheel/Suspension
- 198. Rear Wheel
- 199. Axle
- 204. Shock Absorber
- 205. Bladder Replacement
- 208. Damper Disassembly
- 209. Piston Ring Replacement
- 210. Damper Rod Disassembly
- 211. Rod Guide Case Inspection
- 212. Damper Assembly
- 217. Spherical Bearing Replacement
- 219. Shock Linkage
- 220. Shock arm
- 221. Needle Bearing Replacement
- 223. Swingarm
- 230. Brake System View
- 231. Brake System
- 233. Brake Fluid Replacement
- 234. Air Bleeding
- 235. Brake Pad Replacement
- 237. Brake Disc Inspection
- 242. Front Master Cylinder
- 246. Rear Brake Caliper
- 251. Rear Master Cylinder
- 255. Brake Lever
- 256. Brake Pedal
- 258. Electrical System View
- 259. Electrical System
- 261. Ignition System
- 262. Lighting System
- 263. Ignition System Inspection
- 264. Exciter Coil Peak Voltage
- 265. Ignition Pulse Generator Peak Voltage
- 266. Ignition Coil Removal/Installation
- 267. Alternator Lighting Coil
- 268. Headlight
- 269. Taillight
- 271. Wiring Diagram 0030Z-KCE-0000
- 272. Troubleshooting
- 273. Engine Lacks Power
- 274. Poor Performance At Low And Idle Speed
- 275. Poor Performance At High Speed
- 276. Index
File size: 102.80 MB
Created: March 10, 2023
Last updated: March 27, 2023
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