Honda ATV Manuals

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Honda ATV Service Manual

Honda ATV Service Manual (443 pages)

HONDA motorcycles and motor scooters and ATVs Common Service Manual

Brand: Honda | Category: Motorcycle | Size: 12 MB

Table of Contents

Table of Contents
3
How to Use this Manual
3
Symbols
4
Abbreviations
5
Carbon Monoxide
7
Gasoline
7
General Information Contents
7
General Safety
7
Hot Components
8
Nitrogen Pressure
8
Used Engine/Transmission Oil
8
Service Rules
9
Fasteners
12
Thread Sizes
12
Types of Threads
12
Hex-Head Bolt Strength Markings
13
Width Across Flats
13
"Torx" Bolt
14
CT Bolt
15
Torque Values (Tightening Force)
16
Fastener Loosening
18
Locking
19
Ball Bearing Replacement
22
Removing Ball Bearings
22
Installing Ball Bearings
23
Bearing Remover Compatibility for Wheel Bearing
24
Bearing Remover Compatibility Table
24
Bearing Size
24
Tool Compatibility Chart for Standard Bearings
24
Tool Compatibility Chart
25
Maintenance Contents
27
Fuel Line
28
Fuel Strainer Screen
28
Throttle Operation
29
- Oil Pump and Oil Line
  30
- Oil Strainer
  30
- Carburetor Choke
  31
  - Manual Choke
    31
  - Starting Enrichment Valve
    31
- Air Cleaner
  32
- Oiled Urethane Foam Element
  32
- AIRCLEANER HOUSING DRAIN TUBE (Off-Road Motorcycles and Atvs)
  33
- Crankcase Breather
  33
  - Paper Element
    33
  - Replacing a Spark Plug
    34
  - Reusing a Spark Plug
    34
  - Spark Plug Inspection
    34
- Valve Clearance
  35
- 4-Stroke, Wet Sump Engines
  37
- Engine Oil 2-1
  37
  - 4-Stroke, Dry Sump Engines
    38
  - Leak Inspection
    38
  - Oil Change
    38
- Engine Oil Filter 2-1
  39
- DECARBONIZING (2-Stroke Engine)
  41
- Carburetor Synchronization
  42
- Carburetor Idle Speed
  43
- Radiator Coolant
  43
- Cooling System
  44
- Level Check
  44
- Evaporative Emission Control System
  45
- Pulse Secondary Air Supply (Pair) System
  45
- TRANSMISSION OIL (2-Stroke Engine)
  46
- Transmission Oil Change
  46
- Drive Chain Adjustment
  47
- Adjustment of Pro-Arm Type
  48
- Cleaning, Inspection and Lubrication
  49
- Inspection of Chain Replacement Period
  49
- O-Ring Chains
  49
- Non O-Ring Chain
  50
Refer T O the Model Specific Service Manual
50
- Replacement of Endless Chain
  50
- Sprockets
  50
- Drive Belt
  53
- Drive Chain Slider, Chain Guide, Guide Slider and Rollers
  53
- Belt Case Air Cleaner
  54
- Final Drive Oil Level
  54
- Battery
  55
- Fluid Level
  55
- Specific Gravity of Fluid
  55
- Brake Fluid
  56
- Condition of Terminal Connections
  56
- Brake Pad Wear
  57
- Brake Shoe Wear
  57
- Brake System
  58
- Free Play Adjustment
  58
- Inspection for Air in System
  58
- Brake Pedal Height Adjustment
  59
- Hydraulic Brake Type
  59
- Date of Issue: March, 1995 HONDA MOTOR CO
  60
- Drum Brake Type
  60
- Brake Light Switches
  61
- Headlight Aim
  61
- Clutch System
  62
- On Centrifugal Clutch
  62
- Clutch Fluid Level
  63
- Conventional Type
  63
- Side Stand
  63
- Dual Motion Type
  64
- Inspection for Side Stand with Ignition Cut-Off Switch
  64
- Suspension
  64
- Nuts, Bolts, Fasteners
  66
- Spark Arrester
  66
- Wheels/Tires
  67
- Steering Head Bearings
  69
- Toe-In
  69
- Wheel Alignment
  69
- Camber/Caster
  70
- Engine Testing Contents
  71
- Service Information
  71
- Troubleshooting
  71
- Compression Testing
  72
- 4-Stroke Leak-Down Test Information
  73
- Leak-Down Twsting
  73
- 2-Stroke Pressure/Vacuum Leak-Down Test Information
  74
- Lubrication Contents
  75
- Lubrication Service Data
  75
- Lubrication Service Information
  75
- Lubrication Troubleshooting
  76
- 4-Stroke Systems
  77
- System Description
  77
- Typical Oil Flow Pattern
  77
- Dry-Sump Type
  78
- Four-Stroke Engines
  78
- General
  78
- Wet-Sump Type
  78
- Separate Oil Systems
  79
- Two-Stroke Lubrication Systems
  79
- Premixed (Oil in Fuel) Systems
  80
- Oil Pump Descriptions
  81
- Trochoid Type
  81
- Oil Pump Operating Principle
  82
- Plunger Type
  82
- Oil Pressure Check
  83
- Oil Pump Inspection
  83
- In-Set Type Oil Pump
  84
- Pressure Relief Valve
  84
- Oil Pump/Oil Line Bleeding
  85
- Outlet Line Bleeding
  85
- Suction Line, Oil Pump Bleeding
  85
- Oil Cooler Inspection
  86
- Cooling System Contents
  87
- Cooling System Service Information
  87
- Cooling System Troubleshooting
  87
- Cooling System Descriptions
  88
- System Flow Patterns
  88
- Cooling Fan
  89
- Cooling Fan Switch
  89
- Radiator
  89
- Radiator Cap
  90
- Reserve Tank
  91
- Thermostat
  91
- Water Pump
  91
- Coolant Preparation
  92
- Coolant Replacement
  92
- Air Bleeding
  93
- Coolant Gravity Chart
  93
- Coolant System Testing
  93
- Hydrometer Test
  93
- Mechanical Seal Inspection
  94
- Radiator Cap Test
  94
- System Pressure Test
  94
- Water Pump Replacement
  95
- Exhaust System Contents
  97
- Exhaust System Service Information
  97
- Exhaust System Troubleshooting
  97
- Exhaust Pulse Scavenge Effect
  98
- Exhaust System Descriptions
  98
- Common Exhaust Pipe
  99
- Emission Control System Contents
  101
- Emission Control System Service Information
  101
- Emission Control System Troubleshooting
  101
- Crankcase Emission Control System
  102
- Emission Control System Descriptions
  102
- Source of Emissions
  102
- Exhaust Emissio Control System (Pulse Secondary Air Supply System)
  103
- Evaporative Emission (EVAP) Control System
  104
- Noise Emission Control System
  104
- Evaporative Emission Purge Control Valve (EVAP Purge Control Valve)
  105
- System Inspection
  105
- Evaporative Emmission Carburetor Air Vent Control Valve (EVAP Cav Control Valve)
  106
- Emission Control Information Labels
  109
- Pulse Secondary Air Injection Check Valve (Pair Check Valve)
  109
- Fuel Freshness and Troubleshooting
  111
- Fuel System Contets
  111
- Fuel System Service Information
  111
- Fuel System Troubleshooting
  112
- Carburetor
  113
- Fuel System Description
  113
- Principle of the Vacuum Piston Operated CV Type
  113
- Types of Carburetor
  113
- Float System
  114
- Operation of Systems
  114
- Starting System
  114
HONDA MOTOR Co.,Ltd
115
Slow System (Low Degree of Opening)
115
Date of Issue: March, 1995
116
- Accelerator Pump
  117
- Air Cut-Off Valve
  117
- Main System (Fully Open)
  116
- Main System (Medium Throttle Opening)
  116
Fuel System
117
- Reed Valve Inspection
  117
- Fuel Auto Valve
  118
- Fuel Auto Valve Inspection
  118
- Fuel Line
  118
  - Carburetor Disassembly/Inspection
    119
  - Throttle Valve Inspection (CV Type)
    119
  - Throttle Valve/Starting Enrichment Valve Inspection
    119
  - Starting Enrichment Thermal Valve
    120
  - Starting Enrichment Thermal Valve Removal
    121
  - Starting Enrichment Valve (Manual)
    121
  - Throttle Valve (Piston Valve Type)
    121
  - Vacuum Piston (CV Type)
    122
  - Float/Jets
    123
- Carburetor Assembly
  124
  - Carburetor Cleaning
    124
  - Float/Jets Assembly
    125
  - Float Level Inspection
    126
  - Carburetor Separation/Assembly/Installation
    128
  - Pilot (or Air) Screw Adjustment
    128
  - Pilot (or Air) Screw Removal
    128
  - Limiter Cap Type
    129
  - Plug Type
    129
  - Idle Drop Procedure
    130
- Pilot (or Air) Screw Adjustment 8-1
  130
  - Pilot (or Air) Screw Installation
    130
  - Air Screw or Pilot Adjustment
    132
  - Best Idle Procedure
    132
  - Limiter Cap (or Plug) Installation
    133
- Accelerator Pump Adjustment
  134
- High Altitude Adjustment
  134
  - Cylinder Head Contents
    135
  - Cylinder Head Service Information
    135
  - Cylinder Head Troubleshooting
    135
  - Cylinder Head Construction
    136
  - Cylinder Head System Description
    136
  - Valve Train
    137
  - Example of DOHC with Valve Bucket Type
    138
  - Example of SOHC-4 Valve System
    138
  - Valve Lifter Mechanism /Arrangement
    138
  - Hydraulic Tappets
    139
  - Hydraulic Tappets Operation
    139
  - Construction
    141
  - Decompressor System
    141
  - Description
    141
  - Function of Decompressor System
    141
  - Reverse Decompressor Cam
    142
  - Camshaft Bearing Inspection
    143
  - Camshaft Inspection
    143
  - Camshaft Oil Clearance Inspection
    143
  - Rocker Arm, Rocker Arm Shaft
    144
  - Cylinder Head Inspection
    145
  - Solvent Test
    145
  - Warpage Inspection
    145
  - Cylinder Head Disassembly
    146
  - Valve Springs
    146
  - Valves
    146
  - Stem-To-Guide Clearance
    147
  - Valve Guides Inspection
    147
  - Valve Guides Replacement
    147
  - When Using a Dial Indicator
    147
  - Flangeless Type Guides
    148
  - Valve Guide Reaming
    149
  - Valve Seats Inspection
    149
  - Inspect the Valve Seat Face
    150
  - Valve Seat Refacing
    150
  - Cylinder Head Assembly
    152
  - Initial Camshaft Lubrication
    153
  - Cylinder/Piston Contents
    155
  - Cylinder/Piston Service Information
    155
  - Cylinder/Piston Troubleshooting
    155
  - Cylinder/Piston System Description
    156
  - Piston
    157
  - Piston Ring
    157
  - Cylinder
    159
  - Wear Inspection
    159
  - Piston/Piston Ring Inspection
    160
  - Piston/Piston Ring Removal
    160
  - Piston Pin Inspection
    162
  - Piston/Piston Ring Installation
    162
  - Small End Bearing Surface Inspection
    162
  - Piston Installation
    163
  - Cylinder Installation
    164
  - Clutch Contents
    165
  - Clutch Service Information
    165
  - Clutch Troubleshooting
    165
  - Clutch System Descriptions
    166
  - Wet Multiplate Manual Clutch (Type A: Outer Push Type)
    166
  - Damper Spring Purpose
    167
  - Judder Spring Purpose
    167
  - Type B (Inner Push Type)
    167
  - One-Way Clutch System (Type C: Inner Push Type with Back Torque Limiter Mechanism)
    168
  - Operation
    169
  - Power Flow Diagram
    169
  - Type D (Crankshaft Mounted)
    170
  - Type A: Shift Clitch Combined
    171
  - Wet Multiplate Centrifugal Clutch
    171
  - Gear Shift Lifter
    172
  - Operation Principals
    173
  - Type B: Separated Shift Clutch
    173
  - Clutch Inspection
    174
  - Clutch Lifter Disassembly/Inspection
    174
  - Clutch Removal/Disassembly
    175
  - Clutch Outer
    179
  - Clutch Outer Guide, Needle Bearing
    179
  - Lifter Plate Bearing
    179
  - Clutch Disc
    180
  - Lifter Push Rod
    180
  - Lutch Center
    180
  - Lutch Plate
    180
  - Clutch Spring
    181
  - Mainshaft
    181
  - Udder Spring, Spring Seat
    181
  - One-Way Clutch
    182
  - Primary Drive Gear
    182
  - Clutch Center Guide, Collar
    183
  - Clutch Reassembly
    183
  - Crankshaft
    183
  - Clutch Lifter Reassembly
    190
  - Fluid Replacement
    191
  - Hydraulic Clutch System Service
    191
  - Clatch Master Cylinder Removal/Disassembly
    192
  - Clatch Master Cylinder Inspection
    193
  - Clatch Master Cylinder Assembly/Installation
    194
  - Clutch Slave Cylinder
    195
  - Clutch Slave Cylinder Assembly
    195
  - V-Matic Belt Drive System Service Information
    197
  - V-Matic Belt Drive System Description
    198
  - Drive Pulley Operation
    199
  - Driven Pulley/Centrifugal Dry Clutch
    200
  - Drive Belt Inspection
    201
  - Drive Belt Installation
    201
  - Drive Belt Removal
    201
  - Drive Pulley Removal
    202
  - Drive Pulley Disassembly
    203
  - Drive Pulley Inspection
    203
  - Dry Type
    203
  - Wet Type
    203
  - Drive Pulley Assembly/Installation
    204
  - Drive Pulley Face Installation
    205
  - Clutch/Driven Pulley Disassembly
    206
  - Clutch Outer Inspection
    207
  - Clutch Shoe Inspection
    207
  - Driven Pulley Inspection
    207
  - Driven Pulley Spring Inspection
    207
  - Clutch Shoe Replacement
    208
  - Driven Face Bearing Inspection
    208
  - Driven Face Bearing Replacement
    209
  - Clutch/Driven Pulley Assembly
    210
  - Transmission Contents
    213
  - Transmission Service Information
    213
  - Transmission Troubleshooting
    213
  - Gearshift Mechanism
    214
  - Transmission System Description
    214
  - Planetary Gear Type
    215
  - Shift Finish
    216
  - Shift Return
    216
  - Shift Start
    216
  - Constant Mesh Transmission
    217
  - Bushings Cheking
    218
  - Gears Checking
    218
  - Transmission Disassembly
    218
  - Transmission Inspection
    218
  - Shift Drum Checking
    219
  - Shift Fork Checking
    219
  - Shift Fork Shaft Checking
    219
  - Transmission Assembly
    219
  - Crankcase/Crankshaft Contents
    221
  - Crankcase/Crankshaft Service Information
    221
  - Crankcase/Crankshaft Troubleshooting
    221
  - Crankcase/Crankshaft System Descriptions
    222
- Crankshaft Inspection
  223
- Crankshaft Main Bearing
  223
- Radial Clearance (Assembly-Type Crankshaft Only)
  223
- Side Clearance
  223
Crankcaseicrankshaft
224
- Main Bearing Selection
  225
- Crankcase/Crankshaft Removal
  226
- Main Beraing Installation
  227
- Connecting Rod Bearings
  228
- Oil Clearance Inspection
  228
- 4-Stroke Big End Bearing Selection
  229
- Bearing Replacement
  230
- Connecting Rod Installation
  230
- Connecting Rod Selection (Multi Cylinder Engine)
  230
- Final Drive/Output Shaft Contents
  233
- Final Drive/Output Shaft Service Information
  233
- Final Drive/Output Shaft Troubleshooting
  233
Nal Driveioutput Shaft
233
- Final Drive/Output Shaft System Description
  234
- Output Shaft Removal
  234
- Backlash Inspection
  235
- Output Shaft Inspection
  235
- Gear Tooth Contact Pattern Check
  236
- Drive Shaft Removal
  237
- Final Drive Removal
  237
- Output Installation
  237
- Drive Shaft/Damper Disassembly
  238
- Damper Case Assembly
  239
- Drive Shaft Inspection
  239
- Drive Shaft Installation
  240
- Universal Joint Inspection
  241
- Final Drive Inspection
  242
- Ring Gear Removal/Shim Replacement
  243
- Pinion Gear Removal/Shim Replacement
  247
- Pinion Gear Installation
  249
- Case Bearing Replacement
  250
- Breather Hole Cleaning
  251
- Gear Case Assembly/Installation
  251
- Wheels/Tires Contents
  253
- Wheels/Tires Service Information
  253
- Wheels/Tires Troubleshooting
  253
- Axle Nut Type Installation
  254
- Axle Nut Type Removal
  254
- Front Wheel
  254
- Wheel Removal/Installation
  254
- Double Holder Type Disassembly
  255
- Double Holder Type Removal
  255
- Single Holder Type Installation
  255
- Single Holder Type Removal
  255
- Double Holder Type Installation
  256
- Pinch Bolt Type Installation
  256
- Pinch Bolt Type Removal
  256
Wheelsitires
256
- Chain Driven Type Installation
  257
- Chain Driven Type Removal
  257
- Rear Wheel
  257
- Shaft Driven Type Installation
  258
- Shaft Driven Type Removal
  258
- Unit Swing Type Installation
  259
- Unit Swing Type Removal
  259
- Pro-Arm Type (Center Lock Type) Installation
  260
- Pro-Arm Type (Center Lock Type) Removal
  260
- Axle Inspection
  261
- Wheel Bearing Installation
  262
- Wheel Bearing Removal
  262
- Wheel Bearing Replacement
  262
- Basic Tire Information
  263
- Tire Code
  263
- Tubeless Tire
  263
- Tire Storage
  264
- Tire Removal
  265
- Tube-Type Tire Only
  266
- Rim Valve Replacement (Tubeless Tire Only)
  267
- Wheel Center Adjustment (Spoke Wheel Only)
  267
- Tire Installation
  268
- Tubed Tires Only
  269
- ATV Wheel/Tire Removal/Installation
  271
- Wheel Balancing
  271
- Tire Removal (USA Only)
  272
- Tire Removal (Except USA)
  273
- Tire Repair
  274
- Tire Assembly
  276
- Brakes Contents
  277
- Brakes Troubleshooting
  277
- Brake System Descriptions
  278
- Dual Leading Shoe Type
  278
- Mechanical Drum Brake
  278
- Single Leading Shoe Type (Or, Leading-Trailing Shoe Type)
  278
- Hydraulic Brakes
  279
- General Information for Service
  282
- Eyelet-Type Line and Hose Joints
  283
- Hose Joints Removal
  283
- Brake Fluid Replacement
  284
- Hose Joints Installation
  284
- Hydraulic Disc Brakes
  284
- Metal Brake Lines Removal
  284
- Brake Pad Removal
  286
- Brake Pad Replacement
  286
- Brake Pad Intsllation
  287
- Brake Caliper Disassembly
  288
- Brake Caliper Removal
  288
- Brake Caliper Assembly
  289
- Caliper Cylinder Inspection
  289
- Caliper Piston Lnspection
  289
- Brake Disc Inspection
  290
- Master Cylinder Disassembly
  290
- Master Cylinder Assembly
  291
- Master Cylinder Inspection
  291
- Master Cylinder Piston Lnspection
  291
- Brake Drum ID
  292
- Mechanical Drum Brakes
  292
- Mechanical Drum Brakes Inspection
  292
- Brake Lining Thickness
  293
- Coil Spring Type
  293
- Mechanical Drum Brakes Disassembly
  293
- U-Spring Type
  293
- Mechanical Drum Brakes Assembly
  294
- Front Suspension Contents
  297
- Front Suspension Service Innformation
  297
- Front Suspension Troubleshooting
  297
- Basic Damper Operation
  298
- Friction Damper Operating Principles
  298
- Front Suspension System Descriptions
  298
- Oil Damper Operating Principles
  299
- Fork Disassembly
  301
- Fork Removal
  301
- Fork Inspection
  303
- Fork Assembly
  304
- Fork Installation
  306
- Handlebar(S)
  307
- Handlebars Installation
  307
- One-Piece, Tubular Type
  307
- Handlebars Removal
  308
- Two-Piece, Clamp-On Type
  308
- Handle Grip Installation
  310
- Handlebar Weight Replacement
  310
- Steering Stem Removal
  311
- Steering Stem Inspection
  312
- Race Replacement
  313
- Top Race Removal
  313
- Bottom Race Lnstallation
  314
- Bottom Race Removal
  314
- Steering Stem Bottom Race Replacement
  314
- Top Race Installation
  314
- Loose-Ball Type
  315
- Steering Stem Installation
  315
- Retainer-Type Ball Bearings
  316
- Tapered Roller Bearing Type
  317
- Steering Head Bearing Preload Measurement
  318
- Measurement
  319
- Rear Suspension Contents
  321
- Rear Suspension Service Information
  321
- Rear Suspension Troubleshooting
  321
- Conventional, Dual Spring/Damper Type
  322
- Pro-Link. Progressive Link Type
  322
- Rear Suspension System Descriptions
  322
- Damper Design and Operation
  323
- Pro-Arm Type
  323
- Cam Type
  325
- Rear Damper Springs
  325
- Spring Preload Adjuster Designs
  325
- Damping Adjuster
  326
- Remote Control Type
  326
- Threaded Type
  326
- Shock Absorber Compressor Use
  327
- Shock Absorber Disassembly
  327
- Shock Absorber Installation
  327
- Shock Absorber Removal
  327
- Damper Unit Inspection
  328
- Lock Nut Removal
  328
- Spring Inspection
  328
- Stop Ring Removal
  328
- Compression Force
  329
- Shock Absorber Disposal Procedure
  329
- Hydraulic Press Use
  330
- Joint Installation
  330
- Shock Absorber Assembly
  330
- Pro-Link Suspension Linkage Inspection
  331
- Pro-Link Suspension Linkage Removal
  331
- Swingarm
  331
- Swingarm Inspection
  331
- Pro-Link Suspension Linkage Installation
  332
- Frame/Body Panels Contents
  333
- Frame/Body Panels Service Information
  333
- Frame/Body Panels Troubleshooting
  333
Frameibody Panels
333
- Frame/Body Panels Description
  334
- Back-Bone
  335
- Diamond Frame
  335
- Double Cradle Frame
  335
- Single Cradle Frame
  335
- Frame/Body Panels Inspection
  336
- Sub Frames
  336
- Electrical Fundamentals Contents
  337
- Electrical Service Information
  337
Electrical Fundamentals
338
- Basic Electronic Knowledge
  342
- Current Flow
  342
- Alternating Current and Direct Current
  343
- Resistance
  344
- Voltage
  344
- Electrical Circuit
  345
- Ohm's Law
  345
- Power
  345
- Diode
  346
- Parallel Circuit
  346
- Semiconductor
  346
- Series Circuit
  346
- Thyristor (SCR)
  347
- Transistor
  347
- Thermistor
  348
- Electrical Symbols
  349
- Basic Electrical Diagnostic Methods
  350
- How to Measure Voltage Using a Voltmeter
  350
- Voltage Measurement
  350
- Howt Omeasure Resistance Using an Ohmmeter
  352
- Measuring Resistance
  352
- How to Measure Current Using Ammeter
  354
- Measuring Current
  354
- Battery/Charging/Lighting System Contents
  355
- Battery/Charging/Lighting System Service Information
  355
- Battery/Charging/Lighting System Troubleshooting
  357
- Battery Descriptions
  360
- The Structure of a Conventional Battery
  360
- Mainteance-Free Battery
  362
- DC Voltage Unit
  363
- Motorcycles Without Batteries
  363
- Voltage Regulator
  363
- Battery Removal/Installation
  364
- Battery Testing
  365
- Battery Testing/Charging
  365
- Before Using the Tester
  365
- Battery Charging
  367
- Before Operating the Charger
  367
- Alternator Types
  368
- Charging System Description
  368
- Permanent Magnet Type
  368
- Alternator Function
  369
- Brushless Excited Field Coil Type
  369
- Excited Field Coil Type with Brushes
  369
- Single Phase Output Type
  369
- Regulator/Rectifier
  370
- Triple Phase Output Type
  370
- Type of Regulator/Rectifier
  370
- Diode Rectification Method
  371
- Internal Voltage Regulation Method
  371
- Single Phase, Half-Wave Rectifier
  371
- SCR Switching Regulation/Ac Regulator Built in Type
  372
- AC Regulator Function
  373
- Single Phase, Full-Wave Rectifier
  373
- AC Regulator
  374
- Triple Phase Full-Wave Rectifier
  374
- Triple Phase Full-Wave Rectifiers with Field Coils
  374
- Charging System Inspection
  375
- Charging Voltage Inspection
  375
- Leak Test
  376
- Regulator/Rectifier Inspection
  376
- Headlight Voltage Inspection
  378
- Regulator/Rectifier with Built-In AC Regulator
  378
- Resistor Inspection
  378
- AC Regulator Type
  379
- AC Regulator Inspection
  380
- Alternator
  381
- Charging (Charging/Lighting) Coil Inspection
  381
- Stator Removal
  381
- Rotor Installation
  383
- Stator Installation
  383
23. Ignition Systems
385
- Ignition Systems Connection
  385
- Ignition Systems Service Information
  385
- Ignition Systems Troubleshooting
  385
- Ignitions Systems Descriptions
  388
- Operating Principles
  388
- Principle of Ignition Timing Advance
  389
- DC-CDI
  391
- Transostorized Ignition System
  391
- Digitally Controlled Transistorized Ignition System
  392
- Spark Plug
  393
- Spark Plug Heat Range
  393
- Construction and Usage
  394
- Description of Peak Voltage Adaptor
  394
- Operating Precautions
  394
- Spark Test
  395
- Ignition Timing
  396
  - Ignition Coil Primary Voltage Inspection
    397
  - Ignition System Inspection (Peak Voltage Measurement Method)
    397
  - Exciter Coil
    399
  - Ignition Pulse Generator
    400
  - Ignition Coil
    401
  - Peak Voltage Adaptor Inspection
    401
  - Primary Coil Inspection
    401
  - Secondary Coil Ispection
    401
  - Operating Principle
    403
  - Side Stand Ignition Cut-Off Switch Description
    403
  - Typical Component Locations
    403
  - Component Function
    404
  - Indicator Operation
    405
  - Side Stand Switch Operation
    405
  - Model with Centrifugal Clutch
    406
  - Model with Manual Clutch
    406
  - Starting Systen (Starter Motor) Operation
    406
  - CDI System Integrated with Side Stand Switch And/Or Neutral Switch
    407
  - Ignition System Operation
    407
  - DC-CDI Systems Integrated with Side Stand Switch And/Or Neutral Switch
    408
- Ignition Coil
  408
- Transistorized Lgnition System Integrated with Side Stand Switch and Neutral Switch
  409
- Electric Starter/Starter Clutch Contents
  411
- Electric Starter/Starter Clutch Service Information
  411
- Electric Starter/Starter Clutch Troubleshooting
  411
Electric Starteristarter Clutch
412
- Starter Motor Disassembly
  413
- Starter Motor Inspection
  413
- Starter Motor Assembly
  414
- Starter Relay Switch
  416
- Starter Relay Switch Inspection
  416
- Starter Relay Voltage
  416
- Operation Check
  417
- Starter Relay Switch Ground Line
  417
- Clutch Switch Diode Inspection
  418
- Disassemble the Housing
  418
- Starter Clutch Inspection
  418
- Starter Pinion Inspection
  419
- Light/Meters/Switches Contents
  421
- Light/Meters/Switches Service Information
  421
- (4-Stroke Engine)
  422
- Oil Level Indicator
  422
- Oil Pressure Warning Light
  422
- Fan Motor Switch
  424
- Timer Type Indicator Inspection
  424
- Coolant Temperature Gauge
  425
  - Fan Motor Switch Inspection
    425
  - Coolant Temperature Gauge Inspection
    426
  - Thermo Sensor Inspection
    426
- Fuel Gauge
  427
  - Fuel Gauge Inspection
    427
  - Fuel Unit Inspection
    427
- Low Fuel Indicator
  428
  - Low Fuel Indicator Inspection
    428
  - Fuel Pump Description
    429
  - Fuel Cut-Off Relay
    430
  - Fuel Pump Inspection
    430
  - Discharge Volume Inspection
    431
  - Headlight Bulb
    431
  - Contact Base Replacement
    432
- Switches 25-1
  432
  - Switches Inspection
    432
  - When the Contact Base Is Mounted with Screws
    432
  - When the Contact Base Is Secured with Tabs
    433
  - Neutral Switch
    434
  - Neutral Switch Inspection
    434
  - Brake Light Switch
    435
  - Brake Light Switch Inspection
    435
- Turn Signal Lights 25-1
  436
- Clutch Switch
  435
- Clutch Switch Inspection
  435
- Horn
  437
- Side Stand Switch Inspection
  438
- Side Stand Switch Replacement
  438
- Side Stand Indicator Description
  439
- Side Stand Indicator Inspection
  439
- Index
  441

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