Table Of Contents - Buell XB9R 2003 Service Manual

Table of Contents

Tools3
Amp Multilock Electrical Connectors9
Removing Socket/Pin Terminals9
Installing Socket/Pin Terminals9
Release Tang And Back Out Terminals10
Multilock Connector Cutaway View10
Secondary Locks Open (Socket Housings Shown)11
Stamped Numbers On Secondary Locks Indicate Wire Color Locations11
Crimping Instructions12
Amp Multilock Crimping Procedure12
Deutsch Electrical Connectors13
Removing/Disassembling13
Removing/Installing Sockets13
Removing/Installing Pins14
12-Pin Deutsch Connector (Exploded View)14
Depress Terminal Latches/Back Out Pins14
Deutsch Connector Pick Tool15
Attachment Clip Installation15
Deutsch Crimping Procedure16
2-Pin, 3-Pin And 4-Pin Deutsch Connectors17
Packard Electrical Connectors18
Pull-To-Seat Terminals19
Removing External Latch Type19
Installing External Latch Type19
Removing Push-To-Seat Terminals20
Installing Push-To-Seat Terminals20
Packard Terminal Crimp Tools21
Inspect Core And Insulation/Seal Crimps21
Electrical Connectors22
Electrical Connector And Location Table22
Index To Wiring Diagrams24
Xb9R Wiring Diagrams24
Table Of Contents24
Main Harness25
Engine Management Circuit26
Lighting Circuit27
Horn And Instruments Circuit28
Starting Circuit29
Starting And Charging Circuits30
Component Circuits31
Metric Conversions32
Fastener Torque Values33
English Torque Values33
Metric Torque Values33
Hose And Wire Routing34
Front And Rear Brake Systems, Right Side View34
Rear Brake Systems, Top View35
Rear Brake Systems, Left Side View36
Evaporative Emissions Control, California Models, Top View37
Evaporative Emissions Control, California And 49 State Models38
Wiring Harness, Left Side View39
Wiring Harness, Top View40
Wiring Harness, Right Side View41
Oil Lines, Right Side View42
Oil Lines, Bottom View43
Clutch And Throttle Cables, Right Side View44
Clutch, Throttle And Seat Release Cables, Left Side View45
Clutch, Throttle And Seat Release Cables, Top View46
Maintenance48
Servicing A New Motorcycle50
Safe Operating Maintenance50
Xb9R Tool Set50
Inspecting50
General50
Fluid Requirements51
Primary Drive/Transmission Fluid51
Front Fork Oil51
Brake Fluid51
Regular Service Intervals52
Care Of Molded-In-Color Body Panels53
Recommended Products53
Care And Maintenance53
Cleaning Between Washings53
Battery Maintenance54
Battery Testing54
Battery Electrolyte Antidotes54
Voltmeter Test54
Battery Disconnection And Removal55
Cleaning And Inspection55
Storage55
Battery Self-Discharge Rate55
Battery Installation And Connection56
Engine Lubrication System57
Checking Engine Oil Level57
Changing Engine Oil And Filter58
Draining Oil58
Changing Filter58
Replacing Oil58
Recommended Oil Grades59
Oil Tank Drain Plug59
Dipstick Location/Engine Oil Level59
Oil Filter59
Brake System Maintenance60
Bleeding Brakes60
Brake Troubleshooting61
Bleeding Front Brake62
Front Caliper Bleeder Valve62
Front Master Cylinder Reservoir62
Bleeding Rear Brake63
Rear Caliper Bleeder Valve63
Rear Master Cylinder Reservoir63
Brake Pedal Adjustment64
Pushrod Adjustment64
Brake Pad Thickness65
Brake Rotor Thickness65
Front Brake Rotor65
Brake Pad Replacement66
Front Pad Removal66
Front Pad Installation66
Rear Pad Removal67
Rear Pad Installation67
Tires And Wheels68
Tire Inflation68
Tire Replacement68
Wheel Bearings68
Clutch69
Transmission Fluid69
Clutch Inspection Cover69
Primary Drain Plug69
Adjustment70
Clutch Cable Adjuster Mechanism70
Clutch Adjustment70
Adjusting Clutch Free Play71
Drive Belt System72
Rear Sprocket72
Idler Pulley72
Drive Belt Removal73
Drive Belt Installation73
Rear Wheel Mounting, Right Side73
Belt Guard Assembly74
Idler Pulley Removal75
Idler Pulley Installation75
Idler Pulley Assembly75
Drive Belt Wear Patterns76
Primary Chain78
Primary Chain Inspection Cover78
Measuring Primary Chain Tension78
Primary Chain Tension78
Chain Tension Adjusting Fastener79
Suspension Damping Adjustments80
Setting Rear Shock Preload80
Setting Front Fork Preload80
Recommended Suspension Settings81
Rear Shock Preload Adjuster81
Front Fork Preload And Rebound Adjuster81
Adjusting Suspension Damping82
Setting Front Fork Rebound Damping82
Setting Front Fork Compression Damping82
Setting Rear Shock Rebound Damping82
Recommended Suspension Damping Settings83
Front Fork Oil Change84
Fork Tube Holder (Hd-41177)84
Fork Spring Compressing Tool84
Drain And Replace Oil85
Measuring Fork Oil Level85
Front Fork Assembly86
Steering Head Bearings87
Measuring Steering Head Bearing Resistance87
Spark Plugs88
Typical Spark Plug Deposits88
Rear Spark Plug Access89
Air Cleaner Filter Element90
Air Box, Fuel Vent Tube And Fuel Vapor Valve90
Installed Air Cleaner Filter Element90
Airbox Baseplate91
Throttle Cable Adjusters92
Idle Adjuster (Behind Left Fork)92
Throttle Cable And Idle Speed Adjustment92
Ignition Timing93
Checking Static Timing93
Timing Plug93
Correct Timing93
Adjust Timing94
Timer Cover94
Cam Position Sensor94
Advanced Timing94
Headlights95
Checking Headlight Alignment95
Headlamp Switch95
Headlamp Height Adjustment96
Throttle Position Sensor (Tps)97
Removal From Storage98
Troubleshooting99
Starter Motor Does Not Operate Or Does Not Turn Engine Over99
Engine Turns Over But Does Not Start99
Starts Hard99
Electrical System100
Spark Plug Fouls Repeatedly100
Pre-Ignition Or Detonation100
Oil Does Not Return To Oil Tank100
Fuel System100
Shifts Hard101
Jumps Out Of Gear101
Drags Or Does Not Release101
Handling Irregularities101
Suspension102
General Suspension Problems102
Rear Suspension Problems102
Front Suspension Problems102
Chassis104
Specifications106
Dimensions106
Weight Specifications106
Capacities106
Torque Values107
Tire Specifications110
Tire Fitment-Tubeless Cast Wheels110
Rim Markings110
Vehicle Identification Number111
Abbreviated V.i.n. Location111
Vehicle Identification Number (V.i.n.)111
Wheels112
Checking Tire Inflation Pressure112
Wheel Service113
Front Wheel114
Front Wheel Mounting114
Front Wheel Removal And Installation114
Bearing Removal115
Assemble Puller115
Install Collet And Ball Bearing115
Expand The Collet115
Front Rotor Removal116
Remove The Bearing116
Remove The Spacer116
Removing Bearing From Puller116
Bearing Installation117
Install The Backing Plate (B-43993-11) And Forcing Screw117
Install Bearing117
Front Rotor Installation118
Insert Forcing Screw And Backing Plate118
Install The Spacer118
Install The Bearing118
Front Wheel Assembly119
Rear Wheel120
Rear Brake Caliper Carrier Fasteners120
Removing Wheel Bearing121
Anti-Seize Lubricant Location121
Rear Wheel Assembly122
Checking Cast Rim Runout123
Rim Lateral Runout123
Rim Radial Runout123
Wheel Runout123
Tires124
Loosening Beads From Rim Flange124
Starting Tire Off Rim124
Starting Bead On Rim124
Checking Tire Lateral Runout125
Checking Tire Radial Runout125
Tire Runout125
Wheel Balancing126
Weights For Cast Wheels126
Wheel Weights126
Brake Pedal127
Front Brake Master Cylinder And Hand Lever 2.10128
Brake Hand Lever128
Front Master Cylinder128
Piston Assembly In Master Cylinder128
Front Brake Hand Lever Assembly129
Front Brake Master Cylinder129
Brake Lamp Switch Connectors130
Brake Fluid Level130
Front Brake Line131
Front Brake Caliper Mounts133
Pad Spring (Typical)133
Removing Pistons (B-42887)133
Front Rotor Runout134
Front Caliper Assembly135
Rear Brake Master Cylinder136
Rear Master Cylinder Mounting136
Brake Line Switch Connector136
Remote Reservoir136
Master Cylinder Internal137
Rear Master Cylinder Assembly138
Rear Brake Line139
Rear Brake Line Switch/Banjo Bolt139
Rear Brake Caliper141
Caliper Mount Clip141
Brake Pads142
Removing Rear Brake Caliper Piston142
Rear Rotor Runout142
Rear Reservoir143
Front Fork144
Stopper Ring144
Fork Cap Assembly145
Holding Damper Rod Assembly145
Damper Rod Disassembly146
Fork Assembly146
Damper Rod Assembly146
Rebound Assembly And Fork Cap Assembly146
Fork Seal Driver147
Fork Clamps, Upper And Lower150
Cable Straps On Upper Fork Clamp150
Steering Stem Assembly151
Steering Head Bearings Installation Tools152
Steering Head Bearing Lip152
Install Bearings153
Lower Bearing153
Swingarm And Brace154
Swingarm155
Oil Line Fittings155
Final Swingarm Inspection156
Swingarm Assembly157
Front And Rear Isolators158
Rear Isolator158
Clutch Cable P-Clamp158
Front Isolator158
Frame159
Lift Frame Off Motorcycle159
Rear Shock Absorber160
Adjuster Screw Alignment160
Cable Strap160
Rear Shock Absorber Assembly161
Throttle Control162
Throttle Control Cables162
Cable Connections162
Clutch Hand Lever163
Clutch Hand Control Assembly163
Headlight Support Bracket164
Headlight Connector164
Headlight Support Bracket Assembly165
Headlamp Pivot Groove166
Fairing Support Bracket167
Fairing Support Bracket Assembly168
Handlebars169
Right Clip-On169
Left Clip-On169
Handlebar Clip-On Mounting Fasteners169
Handlebar Clip-On Assembly (Left Clip-On Shown)170
Exhaust System171
Muffler171
Rear Muffler Mounting Block171
Exhaust Header171
Front Muffler Mounting Block172
Muffler And Straps172
Footpeg, Heel Guard And Mount173
Rider173
Remove Footpeg173
Remove Heel Guard173
Passenger174
Remove Mount174
Install Footpeg174
Install Heel Guard174
Sprocket Cover175
Chin Fairing Assembly175
Front Fender176
Rear Fender176
Belt Guards177
Chin Fairing179
Intake Cover Assembly180
Air Scoops181
Engine Shroud Air Scoop181
Ram Air Scoop181
Oil Cooler Air Scoop181
Tail Frame And Body Work182
Left Side Tail Frame Hose And Wire Routing182
Inside Tail Frame Hose And Wire Routing182
Remote Reservoir Clamp Nut183
Tail Frame And Body Work Assembly184
Front Fairing, Windshield, And Mirrors185
Seat186
Rider Seat186
Pillion Seat186
Accessing Rider Seat Screws186
Passenger Seat Lock187
Seat Lock And Cable Assembly187
Sidestand Switch Removal188
Sidestand Removal188
Sidestand Switch With Cable Strap188
Sidestand Disassembly189
Sidestand Assembly189
Sidestand Switch Installation189
Sidestand Installation189
Engine190
General Information192
Engine Ignition Specifications192
Valve And Valve Seat Specifications192
Valve Spring Specifications192
Rocker Arm Specifications193
Piston Ring And Piston Pin Specifications193
Cylinder Head Specifications193
Cylinder Specifications193
Hydraulic Lifter Specifications194
Oil Pump Specifications194
Gearcase Specifications194
Flywheel Specifications194
Pinion Shaft Bearing Specifications195
Electrical Items For Engine Removal And Replacement196
Fuel197
Adjustment/Testing197
Gasoline/Alcohol Blends197
Lubrication197
Compression Test Procedure198
Compression Test Results198
Air Leakage Test198
Cylinder Leakage Test198
Diagnosing Smoking Engine Or High Oil Consumption198
Engine Rotation For Service199
Fuel Line And Ddfi Electrical Connections199
Electrical Connections And Throttle Cables200
Muffler And Mounting System201
Oil Line Connections At Oil Cooler202
Clutch Cable Retaining Clamps202
Engine Mounting System203
Rear Isolator Bolt And Rear Tie Bar204
Front Isolator And Tie Bar Assemblies204
Lubrication Points On Front Isolator Bolt205
Oil Cooler Feed And Return Oil Line Orientation And Clearances206
Stripping Motorcycle For Engine Service210
Electrical Connections216
Supporting Vehicle For Disassembly217
Supporting The Swingarm217
Transmission Vent Line217
Rear Isolator Bolt And Swingarm Pivot Shaft217
Center Tie Bar Mount218
Front Exhaust Mount Bushings (2 Piece)218
Removing Threaded Insert218
Rear Isolator And Mounting Hardware219
Rolling Chassis219
Securing Vehicle For Relocation219
Engine Installation220
Engine Prep For Re-Installation220
Installing Engine In Frame221
Supporting Vehicle For Assembly221
Installing Rear Isolator Bolt221
Muffler Mounting System224
Oil Lines And Connections225
Oil Line Clearances And Torques226
Clamp Orientation And Oil Line Spacing228
Oil Cooler Oil Lines230
Oil Cooler Feed And Return Oil Lines Location And Orientation230
Correct Routing Of Wiring Harnesses231
Cylinder Head236
Rocker Arm And Pushrod Cover Assemblies236
Rocker Box Assemblies237
Lower Rocker Box Fasteners237
Removing Rocker Arm Shafts237
Cylinder Head Assemblies238
Head Screw Loosening/Tightening Sequence238
Valve Spring Compressor238
Cylinder Head, Cylinder And Piston Assembly239
Cylinder Heads240
Checking Gasket Surface240
Rocker Arm Assemblies241
Measuring Rocker Arm Shaft Diameter241
Measuring Rocker Arm Shaft Bore Diameter In Lower Rocker Cover241
Valve Seats242
Valve Guides242
Valve Springs242
Replacing Rocker Arm Bushings243
Replacing Valve Guides244
Valve Stem Clearances And Service Wear Limits244
Installing Shoulderless Valve Guide244
Cleaning Valve Guides244
Procedure For Using The Neway Valve Seat Cutter245
Neway Valve Seat Cutter245
Intake & Exhaust Valve And Seat246
Valve And Seat Dimensions246
Valve Guide Seal Protector Sleeve248
Valve Seal And Lower Collar Assembly248
Push Rod Cover Installation250
Push Rod Locations250
Push Rod Selection250
Push Rods And Push Rod Cover Assembly250
Cylinder Head Installation251
Tightening Head Screws251
Lower Rocker Box Hardware253
Cylinder And Piston254
Removing Piston Pin Circlip255
Piston Pin And Piston Identification255
Removing Piston Rings255
Measuring Cylinder Bore257
Deglazing Cylinder257
Fitting Piston Rings258
Piston Rings258
Measuring Ring End Gap258
Measuring Ring Clearance In Groove259
Ring End Gap Position259
Connecting Rod Bushing260
Connecting Rod Clamping Tool260
Removing Wrist Pin Bushing260
Installing New Wrist Pin Bushing260
Piston Support Plate261
Installing Piston Pin Circlip261
Compressing Piston Rings262
Lubrication System264
Checking And Adding Oil264
Changing Oil And Filter264
Winter Lubrication264
Oil Hose Routing And Oil Reservoir265
Oil Pressure Indicator Switch266
Oil Pressure Signal Light266
Troubleshooting Oil Pressure Signal Light266
Crankcase Breathing System267
Reed Valve Replacement268
Reed Valve Assembly268
Reed Valve Stop And Reed Valve268
Oiling System269
Oil Pump270
Oil Pump Hardware271
Gerotor Wear Limits272
Separator Plate Slots272
Oil Filter Mount273
Oil Filter Mount Assembly273
Hydraulic Lifters274
Lifter Assembly (Typical)274
Base Circle275
Valve Lifter Service275
Gearcase Cover And Cam Gears276
Gearcase Cover & Cam Assembly276
Cam And Pinion Gear Location And Timing Mark Indexing277
Cam And Pinion Gear Identification,278
Bushing Inspection278
Gear Shaft Specifications278
Aligning Pinion Gear279
Crankshaft Locking Tool279
Gearcase Cover Mounting Screw Torque Sequence280
Checking Cam Gear End Play280
Crankcase281
Crankcase Halves281
Rear Isolator Assembly281
Piston Jets282
Crankcase Fasteners282
Piston Oil Jet Assemblies282
Removing Flywheels From Left Crankcase283
Crankcase And Flywheel Assembly283
Removing Sprocket Shaft Inner Bearing Race284
Removing Left Main Bearing Retaining Ring284
Removing Left Main Bearing From Crankcase284
Fitting Pinion Bearings285
Removing Pinion Bearing Inner Race285
Factory Inner Race Sizes285
Paint Dot Specifications285
Stamp Specifications286
Factory Outer Race Sizes286
Roller Specifications286
Bearing Selection287
Pinion Shaft Bearing Selection287
Outer Pinion Race Service Wear Limits288
New Component Specifications288
Pinion Shaft Bearing Tools288
Pinion Inner Race Fitment Specifications289
Inner Race Location289
Lapping Engine Right Main Bearing Race290
Checking Connecting Rod Side Play290
Left Main Bearing Assembly291
Left Main Bearing Installation292
Pinion Shaft Bearing292
Sprocket Shaft Seal/Spacer Installer294
Cylinder Studs295
Fuel System Specifications298
Fuel Tank Specifications298
Idle Speed Specifications298
Dynamic Digital Fuel Injection (Ddfi)300
Buell Dynamic Digital Fuel Injection301
Diagnostic Introduction302
System Problems302
Resolving Problems302
Check Engine Lamp302
Checking For Trouble Codes303
Ignition Key Switch303
Engine Stop Switch303
Code Types304
Retrieving Trouble Codes304
Multiple Trouble Codes304
Check Engine Lamp Blinks304
Check Engine Lamp Diagnostics305
Diagnostic Test Wire305
Installing Diagnostic Test Wire305
Clearing Codes306
Breakout Box307
Installed Breakout Box307
Wiggle Test308
Fluke 78 Multimeter (Dvom)308
Initial Diagnostic Check309
Diagnostic Notes309
Engine Starts Hard309
Engine Performance Problems309
Engine Exhaust Emits Black Smoke Or Fouls Plugs310
Trouble Codes And Fault Conditions310
Check Engine Lamp Not Illuminated At Key On 4.9314
Electronic Control Module314
Check Engine Lamp Circuit315
Check Engine Lamp On Continuously317
Engine Cranks But Will Not Start320
Spark Plug Tester (Part No. Hd-26792)320
Test Lamp320
Ignition Circuit321
No Ecm Power325
Sidestand Switch325
Neutral Switch325
Clutch Switch325
Ecm Power Circuit326
Fuel Pressure Test328
Fuel Pump Connector328
Fuel Line328
Fuel Pressure Gauge Adapter329
Fuel Pressure Gauge (Part No. Hd-41182)329
Fuel Pump Circuit330
Idle Speed Control333
Engine Idle Speeds333
Idle Adjustment Cable333
Misfire334
Misfire At Idle Or Under Load334
Spark Plug Cables334
Ignition Coil Circuit335
Trouble Code 11338
Throttle Position Sensor338
Tp Sensor Assembly338
Tp Sensor Terminals [88A]338
Throttle Position Sensor Circuit339
Trouble Code 13342
Oxygen (O2) Sensor342
Oxygen Sensor342
Oxygen Sensor (Shock Absorber Removed)342
Oxygen Sensor Circuit343
Trouble Code 14347
Engine Temperature Sensor347
Engine Temperature Sensor Specifications347
Engine Temperature Sensor Circuit348
Trouble Code 15351
Intake Air Temperature Sensor351
Intake Air Temperature Sensor Specifications351
Intake Air Temperature Sensor Circuit352
Trouble Code 16355
Battery Voltage355
Electrical Relays355
Fuse Block355
Battery Voltage Circuit356
Trouble Codes 23 And 32359
Front Fuel Injector (Code 23)359
And Rear Fuel Injector (Code 32)359
Fuel Injectors359
Fuel Injector Circuit360
Trouble Codes 24 And 25363
Front Ignition Coil (Code 24)363
And Rear Ignition Coil (Code 25)363
Trouble Code 33366
Fuel Pump366
Fuel Pump Assembly366
Trouble Code 35369
Instrument Module Connector [39]369
Tachometer Circuit370
Code 35 Test371
Trouble Code 36372
Cooling Fan High Voltage372
Cooling Fan Specifications372
Cooling Fan Low Voltage372
Cooling Fan Circuit373
Code 36 Test (Part 1 Of 2-Fan Runs Continuously)374
Code 36 Test (Part 2 Of 2-Fan Does Not Run)375
Trouble Code 44376
Bank Angle Sensor Operation376
Bank Angle Sensor376
Bank Angle Sensor Circuit377
Trouble Codes 52, 53, 54 And 55380
Ecm Failure380
Trouble Code 56381
Cam Sync Failure381
Cam Position Sensor Circuit382
Cam Position Sensor And Rotor388
Marking Ignition Timing388
Ignition Components389
Ignition System Circuit390
Connecting Sensor Wires391
Ignition Coil392
Ignition Coil Primary Circuit Test392
Ignition Coil Secondary Circuit Test392
Ignition Coil Substitution392
Ignition Coil Location393
Installed Oxygen Sensor394
Oxygen Sensor Connector394
Intake Air Temperature Sensor Installed398
Cooling Fan400
Draining Fuel Tank401
Fuel Pump Puller402
Fuel Pump Removal402
Fuel Pressure Regulator Replacement403
Low Fuel Level Sensor Replacement403
Fuel Filter Replacement403
Fuel Screen Replacement404
Fuel Pump Specifications404
Fuel Pump Clips404
Regulator Housing O-Rings404
Fuel Pump Wire Harness Replacement405
Fuel Pump Connector Disassembly405
Wire Harness Removal Direction406
Fuel Pump Installation406
Fuel Tank Vent Valve407
Fuel Pump Drain Screw407
Fuel Cap Retaining Ring408
Throttle Body409
Throttle Body/Intake Manifold Assembly410
Repair411
Intake Manifold411
Throttle Cable Bracket (Typical)411
Intake Manifold Fasteners412
Intake Flanges413
Intake Leak Test414
Leak Tester414
Nozzle414
Airbox416
Airbox Cover416
Baseplate416
Evaporative Emissions Control-Ca Models418
Carbon Canister Installation418
Vent Valve419
Canister419
Carbon Canister Mounting419
Hose Routing420
Emissions Hose Attachment420
Electric Starter422
Starter Specifications424
Service Wear Specifications424
Electric Starter System425
Wiring Diagrams425
Starter Relay425
Starting System Diagnosis427
Starter Terminals427
Solenoid Clicks428
Relay Clicks428
Nothing Clicks429
Starter Spins, But Does Not Engage430
Starter Stalls Or Spins Too Slowly430
Starter Activation Circuits431
Typical Circuity431
Diagnostics/Troubleshooting432
Voltage Drops432
Electric Starting System Circuit433
Starter System Testing434
"On-Motorcycle" Tests434
Starter Relay Test434
Starter Current Draw Test434
Starter435
Starter Mounting435
Starter Wires (Protective Boot Not Shown)435
Testing Assembled Starter436
Free Running Current Draw Test436
Starter Solenoid436
Solenoid Pull-In Test436
Solenoid Hold-In Test437
Solenoid Return Test437
Hold-In Test437
Return Test437
Disassembly, Inspection And Repair438
Field Wire438
Removing The Thru-Bolts438
Starter Components438
Undercutting Mica Separators439
Shorted Armature Test Using Growler440
Grounded Armature Test440
Open Armature Test440
Grounded Field Test441
Open Field Test441
Brush Holder Insulation Test441
Starter Drive Assembly442
Starter Assembly443
Drive/Transmission 6446
Primary Cover, Primary Chain Adjuster And Shifter Assembly450
Primary Cover451
Removing Primary Cover451
Clutch Release Mechanism451
Primary Chain Adjuster Inspection & Replacement452
Measuring Chain Adjuster Shoe452
Primary Drive/Clutch456
Clutch Assembly457
Clutch Pack458
Compressing Clutch Diagram Spring458
Pressure Plate Assembly458
Primary Chain/Drive459
Sprocket Locking Link Tool459
Mainshaft Nut And Washer459
Adjusting Screw Assembly459
Aligning Tabs460
Compensating Spring Set461
Measuring Friction Plates462
Checking Clutch Shell462
New Needle Bearing In Clutch Shell463
Clutch Hub Bearing Race463
Replacing Clutch Shell Bearing464
Clutch Shell Bearing Remover/Installer464
Bearing Installer464
Removing Clutch Shell Needle Bearing464
Clutch Hub And Shell Assembly465
Clutch Pack Stack-Up (Cut-Away View)465
Friction Plates465
Spring Seat Installation466
Adjusting Screw Assembly Aligning Tabs467
Sprocket Locking Link467
Transmission470
Transmission Power Flow470
Case Disassembly For Transmission Removal471
Right Crankcase Removal471
Shifter Drum Neutral Detent471
Countershaft Retainer471
Removing Shifter Shaft Assembly472
Shifter Shaft Assembly472
Scribed Line on Shifter Drum at 6 O'clock472
Separating Crankcase Halves473
Removing Flywheels From Left Case Half473
Transmission Disassembly474
Transmission Removal From Left Crankcase474
Removing Shifter Fork Shafts474
Shifter Forks, Drum And Shafts474
Shifter Mechanism475
Removing Transmission Assembly From Left Case Half476
Mainshaft/Countershaft477
Transmission Parts Identification477
Transmission Assembly-Right Crankcase Half477
Transmission Assembly-Left Crankcase Half478
Mainshaft Disassembly479
Countershaft Disassembly480
Transmission Assembly481
Mainshaft Assembly481
Countershaft Assembly482
Transmission Countershaft Assembly/Reassembly482
Main Drive Gear483
Main Drive Gear Assembly483
Removing Main Drive Gear483
Bearing Remover Cross Plate Mounting483
Needle Bearing Installation Tool484
Main Drive Gear Installation484
Transmission Assembly Right Crankcase Half485
Transmission Right Case Bearings486
Countershaft Needle Bearing486
Mainshaft 5Th Gear Ball Bearing486
Shifter Drum Bushing486
Transmission Assembly Left Crankcase Half487
Transmission Left Case Bearings488
Mainshaft And Countershaft Bearings488
Shift Drum Bushing Assembly488
Transmission Installation489
Transmission Assembly In Fixture489
Installing Transmission In Left Case Half489
Shifter Forks And Drum Assembly490
Installing Shift Fork Shafts490
Installing Right Crankcase492
Gear Detent Assembly Aid492
Shifter Shaft Installation493
Shifter Shaft Return Spring493
Installing Shifter Shaft Assembly493
Transmission Sprocket494
Transmission Sprocket Tightening495
Aligning Transmission Sprocket496
Battery Specifications500
Regulator Specifications500
Spark Plug Specifications500
Ignition Coil Specifications500
Ignition System502
Ignition System Components503
Ignition/Headlight Key Switch504
Ignition Key Switch Positions504
Indicator Markers504
Upper Fork Clamp505
Ignition Switch Assembly506
Ignition Switch Connector (Viewed From Underneath Fairing)506
Ignition Key Switch Wiring507
Spark Plug Cable Location508
Testing Resistance509
Starter Interlock510
Starter Interlock Troubleshooting510
Starter Circuit510
Diode Polarity511
Ohmmeter Diode Test511
Diode Wiring511
Ignition Test512
Starter Test512
Interlock Circuit514
Testing/Replacement515
Ignition Relay516
Key Switch Relay516
Main Fuse516
Diodes517
Fuse Block (Contains Diodes)517
Fuses And Diodes517
Charging System518
Alternator518
Voltage Regulator518
Battery518
Symptom: Battery Becomes Discharged519
Voltage Regulator Bleed Test522
Milliampere Draw Test522
Total Current Draw Test522
Current And Voltage Output Test523
Voltage Output Test523
Positive Regulator Cable (Red Wire)523
Test For Grounded Stator523
Ac Output Check524
Check For Stator Resistance524
Check Stator Ac Voltage Output524
Rotor525
Stator525
Rotor Assembly525
Removing Rotor From Sprocket525
Pressing Rotor Onto Sprocket526
Voltage Regulator Connector [77]527
Battery Cables528
Negative Battery Cable528
Positive Battery Cable529
Maintenance-Free Battery (Typical)530
Battery Warning Label530
Load Test531
Battery Load Test531
Disconnection And Removal532
Battery Charging533
Charging Battery533
Safety Precautions533
Battery Charging Rates/Times534
Battery Cable Routing534
Headlight Bulbs536
Tail Lamp538
Tail Lamp Assembly538
Turn Signals539
Bulbs539
Front Turn Signal Connections539
Front Turn Signals539
Rear Turn Signals540
Rear Turn Signal Connections541
Turn Signal Flasher542
Turn Signal Controls542
Handlebar Switches543
Right Side543
Left Side543
Right Handlebar Switch Connection543
Left Handlebar Switch Connection544
Vehicle Speed Sensor545
Speedometer Sensor545
Vehicle Speed Sensor Wiring545
Instrument Module546
Speedometer Performance Check547
Speedometer Operation Test547
Speedometer Tester547
Vehicle Speed Sensor Connector547
Speedometer Sensor Test548
Test Harness548
Odometer, Trip Odometer And Reset Switch Testing549
Inoperative, Inaccurate Or Erratic Speedometer550
Tachometer Performance Check552
Tachometer Accuracy Tolerances And Conversions552
Sweep Test553
Testing Tachometer553
Horn554
Horn Assembly554
Horn Wiring554
Horn Switch555
Neutral Indicator Switch556
Neutral Indicator Switch Location556
Main Fuse And Fuses557
A Main Fuse Location557
Main Wire Harness558
Tail Harness Connector558
Battery Tray Wiring558
Sidestand Switch Connector559
Wire Harness Clip560
Corner Mounting Tab560
Cable Straps561
Fairing Wiring (Viewed From Underneath Fairing)562
Sprocket Cover Wiring563
Cam Position Sensor Wiring563
Neutral Switch Connector564
Neutral Switch Wiring564
Assembled Wiring564