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.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

Service intervals / Tune-up / Pre-ride inspection / Engine lubrication / Transmission oil / Air filter / Spark plug / Carburetor / Exhaust system / Cooling system / Engine compression test / Ignition timing / Control cable lubrication / Throttle cable adjustment / Clutch / Engine top end inspection / Kick pedal and shift pedal / Brakes / Drive chain and sprockets / Tires and wheels / Wheel bearings / Steering / Front fork / Rear shock absorber / Rear swing arm and linkage / General lubrication / Nuts, bolts and other fasteners / Storage / Specifications

CHAPTER FOUR / ENGINE UPPER END

Engine operating principles / Cleanliness / Exhaust system / Cylinder head / Cylinder / KIPS exhaust valve / KIPS service / Exhaust valve cleaning and decarbonizing / Piston, piston pin and piston ring / Reed valve assembly / Engine break-in / Specifications

CHAPTER FIVE / ENGINE LOWER END

Servicing engine in frame / Engine / Countershaft seal replacement / Left side main bearing seal replacement / Crankcase and crankshaft / Transmission shifting check / Specifications

CHAPTER SIX / CLUTCH AND PRIMARY GEAR

Clutch cover / Clutch release lever / Right crankcase cover / Exhaust valve governor / Clutch / Clutch service and inspection / Primary drive gear / Kick starter and idle gear / External shift mechanism / Clutch cable replacement / Specifications

CHAPTER SEVEN / TRANSMISSION AND GEARSHIFT MECHANISMS

Transmission overhaul and inspection / Internal shift mechanism / Specifications

CHAPTER EIGHT / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS

Float height adjustment / Carburetor fuel level adjustment / Carburetor rejetting / Fuel tank / Fuel shutoff valve / Throttle cable / Air box / Specifications

CHAPTER NINE / ELECTRICAL SYSTEM

Capacitor discharge ignition / Flywheel / Stator coils / Igniter / Ignition coil / Engine stop switch / Ignition timing / Power jet assembly /

WIRING DIAGRAMS/ Specifications

CHAPTER TEN / FRONT SUSPENSION AND STEERING

Safety precautions / Cooling system check / Radiators / Water pump / Hoses / Specifications

CHAPTER ELEVEN / REAR SUSPENSION

Front wheel / Rear wheel / Front and rear hubs / Rim and spoke service / Tire changing / Drive chain / Sprocket / Specifications

CHAPTER TWELVE / BRAKES

Handlebar / Steering head / Front fork / Front fork service / Front fork adjustment / Specifications

CHAPTER THIRTEEN / FRAME

One-track rear suspension system / Shock absorber / Shock linkage / Swing arm / Rear suspension adjustment / Specifications

CHAPTER FOURTEEN / BRAKES

Brake pads / Caliper / Master cylinder / Brake hose / Brake disc / Brake bleeding and draining / Rear brake pedal / Specifications

CHAPTER FIFTEEN / BODY

Seat / Side covers / Radiator covers / Sub frame / Specifications

SUPPLEMENT / 1999-2000 SERVICE INFORMATION

INDEX

WIRING DIAGRAMS