Product Details

Clymer repair manuals are written specifically for the do-it-yourselfer.

For routine maintenance or more extensive repairs involving engine and transmission disassembly, it has all the information you need.

Step-by-step procedures, detailed photography and extensive use of exploded views based on the complete disassembly of the machine.

Clymer shop manuals are perfect for everyone, from the first-time user to the seasoned professional.

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Front rear final drive gear case oil change / Control cable lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Reverse cable adjustment / Tune-up / Valve clearance / Compression test check / Spark plug / Air filter / Ignition timing / Pilot screw adjustment / Idle Speed Adjustment / Storage / Specifications

CHAPTER FOUR / ENGINE TOP END

Engine principles / Rocker case / Rocker arm / Camshaft / Cam chain tensioner / Cylinder head / Cam chain / Chain guides / Cylinder / Valves and components / Piston and rings / Specifications

CHAPTER FIVE / ENGINE LOWER END

Removal installation / Oil screen / Oil pump / Oil pipes / Primary gear and oil pump drive gear / Stator coil and alternator cover / Alternator cover and stator clutch / Kick starter mechanism / Kick starter idler gears / Crankcase and crankshaft / Break-in / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM

Clutch cover / Clutch release mechanism / Clutch / One-way clutch check / External shift mechanism / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM

Transmission troubleshooting overhaul inspection / Internal shift mechanism / Reverse stopper assembly / Neutral reverse switch / Reverse cable / Reverse lever / Reverse lever shaft / Specifications

CHAPTER EIGHT / FUEL AND EXHAUST SYSTEMS

Carburetor adjustments / Throttle cable / Choke cable replacement / Fuel tank / Fuel level gauge / Fuel valve / Air box / Exhaust system / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM

Basic information / Charging system / Regulator/rectifier / Capacitor discharge ignition / IC igniter / Ignition coil / Pickup coil / Starting system / Lighting system / Cooling fan circuit / Carburetor heater circuit (1995-on UK models) / Switches / Fuse / Specifications

CHAPTER TEN / COOLING SYSTEM

Cooling system inspection / Coolant tank / Radiator and cooling fan / Cooling fan / Thermostat / Thermostatic fan switch / Water temperature switch / Water pump / Specifications

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING

Wheel alignment / Front wheel / Front hub / Handlebar / Steering shaft / Tie rod / Steering knuckle / Control arms / Steering stopper adjustment / Shock absorber / Tires and wheels / Specifications

CHAPTER TWELVE / FRONT DRIVE MECHANISM

Front drive shaft / Front axles / Front differential / Output bevel gear case / Output bevel gear / Specifications

CHAPTER THIRTEEN / REAR AXLE, SUSPENSION AND FINAL DRIVE

Rear wheel / Rear suspension arms / Rear shock absorbers / Left rear hub / Rear differential unit / Drive shaft / Rear axle / Specifications

CHAPTER FOURTEEN / BRAKES

Disc brake / Front caliper / Brake hose replacement / Front master cylinder / Brake disc / Brake hose replacement / Rear drum brake / Brake pedal / Rear brake cable / Parking brake cable / Bleeding the system / Specifications

CHAPTER FIFTEEN / BODY AND FRAME

Seat / Front carrier / Front guard / Rear carrier / Fuel tank cover / Front cover / Front fender / Rear fender / Mud flap / Front skid plate / Engine skip plate / Footrests / Frame / Specifications

INDEX

WIRING DIAGRAMS