They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Distorted clutch plates, d rive and drive n. Loosen the cylinder head cover bolts in the ascending ord er numbers and remove the cylinder head cover. If a ny signs of crackin g or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. I nspect each piston f o r d a m a g e and wear.
I nstal l the d owel pins. Tightening torque : 40 - 60 N ' m 4. Pour fork oil to the inner tube. Remove the caliper by removing the caliper mou nting bolts. Hose guide When tighten the brake hose clamp, align the bottom ® of the thick hose tube with bottom of the clamp. I nsta l l t h e brackets , spacers, bo lts and n u t properly a s shown i n t h e i l l u stration. Remove the spark pl u g.
Float h eight 1 4. Using a caliper g a u g e , measure the conrod s m a l l e n d insdie d i ameter. They bear the following identification n u m be rs. If the camsh aft journal oil clearance measured exceeds the limit, measure the outside dia meter of camshaft. Remove the rear brake h o s e with c a l i p e r from the hose guides. These service manuals are your number one source for repair and service information.
Check the continuity and measure the resistance values with a pocket tester. Remove the odometer bracket with the odometer a n d c a b l e. Not enough pressure in tires. If any abnormality is found, replace the respective switch assemblies with new ones. Po sition 0 provides the maximum spring pre-load a n d position Position 6 5 provides the m i n i m u m spring pre-load. Using this service manual is an inexpensive way to keep your equipment working properly. Clutch cable eel bearing Side stand pivot.
Separate the jet need le and th rottle valve. If the battery voltages is lower than the spe cifi. Tig hten each bolt to the specified torq u e. The valve sea t con tact area must be inspected after each cut. Not enough brake fluid in the reservoir. Remove the cran kcase breather pipe. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycl e.
If a la rge resistance is felt to rotatio n , in s pect the pinion and rack for damage or wear. Remove t h e upper bearing race and lower beari n g race with the s pecial tool s. Similarly oil the lip of the stem sea l. Rotate each bearing s pacer to i nspect for abnormal noise and smooth rotation. Inspect the piston surface for scratches or other d a m ag e.
Fit it to the side where the thrust is as shown in figure. Detailed substeps expand on repair procedure information. Remove the piston pin circ l i ps with long-nose pliers. Shorted, grounded or open generator coils. Remove the circlip with the special too l. Major lubrication points are indicated belo w.
From that position , turn back and find out first click that is 1 -position then turn back and count the specified position as follows. Production model years 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000. Enlarged inset helps you identify and examine parts in detail. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper. Place a cloth u n derneath t h e u nion bolt on the master cylinder to catch spilled d rops of brake fluid. Simply print out the pages you need or print the entire manual as a whole!!! Bold figure number help you quickly match illustrations with instructions. The valve must be replaced if the runout exceeds the limit.
Rotate the inner ring by hand to inspect i f any abnormal noise occurs or rotating smoothly. Disconnect the crankc a se breather hose. If the seat and needle are worn beyond the permissi ble l imits, similar trouble will occur. Numbered instructions guide you through every repair procedure step by step. Ca is for p u l l i n g and cable is for retu rning.