QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Excessive vibration / Fuel system (carbureted models) / Fuel system (fuel injection models) / Front suspension and steering / Brake system / Electrical testing / Starting system / Charging system / Ignition system / Lighting system / Electronic diagnostic system / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Tires and wheels / Oil tank inspection / Engine oil and filter / Transmission oil / Primary chaincase oil / Front fork oil change / Control cable lubrication / Throttle control grip lubrication / Control lever lubrication / Steering head lubrication / Jiffy stand lubrication / Primary chain adjustment / Drive belt deflection / Motorcycle alignment / Brake system service / Clutch service / Throttle cable adjustment / Starting enrichment valve (choke) cable adjustment / Fuel line inspection / Steering play / Rocker arm bearing inspection and adjustment / Swing arm pivot shaft inspection / Shock absorber inspection / Fasteners / Electrical equipment and switch inspection / Tune-up / Air filter element / Compression test / Spark plugs / Ignition timing / Idle speed adjustment / Specifications

CHAPTER FOUR / ENGINE TOP END AND EXHAUST SYSTEM
Engine rebuild precautions / Servicing engine in frame / Rocker arms, pushrods and valve lifters / Cylinder head / Valves and valve components / Cylinder / Pistons and piston rings / Exhaust system / Exhaust system inspection / Specifications

CHAPTER FIVE / ENGINE LOWER END
Engine / Valve lifters / Oil pump / Oil tank and oil lines / Camshaft support plate / Crankcase and crankshaft / Counterbalancer assembly / Engine break-in / Specifications

CHAPTER SIX / CLUTCH AND PRIMARY DRIVE
Primary chaincase cover / Primary chaincase housing / Clutch assembly / Clutch pushrod and release plate / inspection / Primary drive assembly / Primary chain alignment / Clutch shell, hub and sprocket / Primary chain and tensioner inspection / Compensating sprocket inspection / Starter jackshaft / Clutch cable replacement / Clutch lever assembly / Clutch release cover / Hydraulic clutch service / Specifications

CHAPTER SEVEN / TRANSMISSION AND SHIFT MECHANISM
Shifter assembly / External shift mechanism / Transmission top cover / Shift cam / Shift arm assembly / Shift forks / Transmission side-door assembly / Transmission shafts / Main drive gear / Transmission drive sprocket / Transmission case / Specifications

CHAPTER EIGHT / AIR/FUEL AND EMISSIONS CONTROL SYSTEMS (CARBURETED MODELS)
Carburetor / Intake manifold / Manifold asbolute pressure (MAP) sensor / Throttle and idle control cables / Starter enrichment cable replacement / Fuel hose and clamps / Fuel tank / Fuel valve / Fuel gauge and fuel level sender / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM
Electrical component replacement / Fuses / Maxi-fuse / Circuit breaker / Battery / Charging system / Front electrical caddy / Alternator / Voltage regulator / Ignition system / Ignition coil / Ignition control module / Electronic control module / Manifold absolute pressure (MAP) sensor / Crank position (CKP) sensor / Starting system / Starter / Lighting system / Headlight / Auxiliary light / Turn signals / Rear signal module / License plate module / Tail/brake light assembly / Front fender tip light / Instrument console / Speedometer / Indicator lamp assembly / Ignition switch / Tachometer / Automatic compression release solenoid / Switches / Horn / Electrical panel / Turn signal and security modules / Vehicle speed sensor (VSS) / Relays / Electrical connector service / Specifications

CHAPTER TEN / WHEELS, HUBS AND TIRES
Motorcycle stands / Brake rotor protection / Front wheel / Rear wheel / Front and rear hubs / Belt guard and debris deflector / Driven sprocket / Drive sprocket / Drive belt / Wheel runout / Rim and laced wheel service / Disc and cast wheels / Wheel balance / Tires / Tire changing / Tire repairs / Tire runout / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING (TELESCOPIC FORK MODELS)
Handlebar / Front fork / Steering head and stem / Steering head bearing race replacement / Steering play adjustment / Specifications

CHAPTER TWELVE / FRONT SUSPENSION AND STEERING (SPRINGER FORK MODELS)
Service precautions / Handlebar and risers / Front shock absorber / Fork rockers / Spring fork / Rigid fork / Steering stem / Steering play adjustment / Specifications

CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorbers / Swing arm / Specifications

CHAPTER FOURTEEN / BRAKES
Brake service / Brake system bleeding / Front brake pad replacement / Front brake caliper (Springer fork models) / Brake reaction link / Front brake caliper (all telescopic fork models) / Front master cylinder / Rear brake pad replacement / Rear brake caliper / Rear master cylinder / Brake hose and line replacement / Brake disc / Rear brake pedal / Specifications

CHAPTER FIFTEEN / BODY AND FRAME
Seat / Seat base / Passenger seat support / Seat post / Splash guard / Front fender / Sissy bar / Luggage rack / Rear fender / Footboards and footrests / Jiffy stand / Windshield / Saddlebags / Specifications

INDEX

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