Table of Contents
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General Information........................................................... 2
General Specifications............................................................ 2
Torque Specifications ............................................................. 3
Torque Conversions (ft-lb/N-m)............................................... 4
Break-In Procedure ................................................................ 4
Gasoline - Oil - Lubricant........................................................ 4
Genuine Parts......................................................................... 5
Preparation For Storage ......................................................... 5
Preparation After Storage ....................................................... 6
Periodic Maintenance ........................................................ 7
Periodic Maintenance Chart ................................................... 7
Lubrication Points ................................................................... 8
Air Filter .................................................................................. 8
Valve/Tappet Clearance.......................................................... 9
Testing Engine Compression................................................ 10
Spark Plug ............................................................................ 10
Liquid Cooling System.......................................................... 11
Muffler/Spark Arrester .......................................................... 11
Adjusting Throttle Cable ....................................................... 12
Adjusting Engine RPM (Idle) ................................................ 12
Engine/Transmission Oil - Filter ........................................... 12
Front Differential/Rear Drive Lubricant ................................. 13
Tires...................................................................................... 14
Driveshaft/Coupling .............................................................. 14
Nuts/Bolts/Cap Screws ......................................................... 14
Ignition Timing ...................................................................... 14
Lights .................................................................................... 14
Shift Lever............................................................................. 16
Frame/Welds/Racks.............................................................. 17
Hydraulic Brake Systems...................................................... 17
Burnishing Brake Pads ......................................................... 18
Checking/Replacing V-Belt .................................................. 19
Steering/Frame/Controls ................................................. 22
Front Body Panel/Fender...................................................... 22
Rear Body Panel/Rack ......................................................... 23
Steering Post/Tie Rods......................................................... 24
LCD Gauge........................................................................... 26
Handlebar Grip ..................................................................... 26
Throttle Control..................................................................... 27
Steering Knuckles................................................................. 28
Measuring/Adjusting Toe-Out ............................................... 29
Front Rack ............................................................................ 30
Front Bumper Assembly ....................................................... 30
Exhaust System.................................................................... 30
Seat ...................................................................................... 31
Troubleshooting .................................................................... 31
Engine/Transmission....................................................... 32
Troubleshooting .................................................................... 33
Removing Engine/Transmission ........................................... 36
Top-Side Components .......................................................... 38
Removing Top-Side Components ......................................... 38
Servicing Top-Side Components .......................................... 41
Installing Top-Side Components ........................................... 48
Left-Side Components.......................................................... 52
Removing Left-Side Components......................................... 52
Servicing Left-Side Components .......................................... 54
Installing Left-Side Components........................................... 57
Right-Side Components ....................................................... 58
Removing Right-Side Components ...................................... 58
Servicing Right-Side Components........................................ 61
TABLE OF CONTENTS
Installing Right-Side Components.........................................62
Center Crankcase Components............................................65
Separating Crankcase Halves...............................................65
Disassembling Crankcase Half .............................................66
Servicing Center Crankcase Components ............................67
Assembling Crankcase Half ..................................................72
Joining Crankcase Halves.....................................................74
Installing Engine/Transmission..............................................75
Fuel/Lubrication/Cooling .................................................77
Electronic Fuel Injection ........................................................77
Throttle Body.........................................................................77
Throttle Cable Free-Play .......................................................78
Gas Tank ...............................................................................78
Oil Filter/Oil Pump .................................................................79
Testing Oil Pump Pressure....................................................79
Liquid Cooling System ..........................................................80
Electric Fuel Pump/Fuel Level Sensor ..................................81
Troubleshooting .....................................................................84
Electrical System..............................................................85
Battery...................................................................................85
RPM Limiter ..........................................................................86
Accessory Receptacle/Connector .........................................86
Brakelight Switch (Pressure) .................................................86
Fan Motor ..............................................................................87
Fuse Block/Power Distribution Module..................................88
Ignition Coil ...........................................................................89
EFI Sensors ..........................................................................89
Speed Sensor .......................................................................90
Ignition Switch .......................................................................90
Handlebar Control Switches..................................................91
Front Drive Selector Switch...................................................91
Front Drive Selector Actuator ................................................92
Gear Position Switch .............................................................92
Stator Coil .............................................................................92
Starter Relay .........................................................................93
Starter Motor .........................................................................93
Electronic Control Module (ECM)..........................................94
Regulator/Rectifier ................................................................94
Lights.....................................................................................94
Ignition Timing.......................................................................96
Tilt Sensor .............................................................................96
Throttle Position Sensor (TPS)..............................................97
EFI Diagnostic System..........................................................98
Troubleshooting ...................................................................103
Drive System...................................................................105
Front Drive Actuator ............................................................105
Front Differential..................................................................106
Drive Axles ..........................................................................116
Rear Gear Case ..................................................................117
Hub......................................................................................118
Hand Brake Lever/Master Cylinder Assembly.....................118
Hydraulic Brake Caliper.......................................................119
Troubleshooting Drive System.............................................122
Troubleshooting Drive System.............................................122
Suspension .....................................................................123
Shock Absorbers.................................................................123
Front A-Arms.......................................................................123
Rear A-Arms .......................................................................124
Wheels and Tires ................................................................125
Troubleshooting ...................................................................126
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Table of Contents
Troubleshooting
