Maintenance • Troubleshooting • Repair

Clymer Maintenance Troubleshooting Repair Service Manual Book General Information Manual organization Warnings cautions and notes Safety Serial numbers and information labels Fasteners Shop supplies Snap On Craftsman tools Measuring tools Micrometer Torque wrench Electrical system fundamentals volts ohms amperage amps Service methods Storage Specifications Troubleshooting Starting the engine Engine will not start Poor engine performance Fuel system Engine Engine lubrication Cylinder leakdown leak down test Clutch transmission linkage Trans Electrical testing Final drive Front suspension and steering Brake system lube Lubrication Maintenance and Tune-Up Valve adjustment and measurement Cylinder identification Pre-ride inspection MoDiTec diagnosis and integral ABS bleed test Throttle cable operation and adjustment Engine oil and filter Transmission Final drive Clutch Brake system Cooling system Battery service Front suspension inspection manual Rear wheel mounting bolts inspection Swing arm bearing inspection Speedometer sensor cleaning Tune-up Compression test Air filter replacement Fuel filter replacement Valve clearance measurement measuring Slide rail tensioner rail lining and thrust piece replacement Spark plugs Lights and horn inspection Non-scheduled inspection and maintenance schedule pre-ride inspection Rear shock adjustment Specifications Cylinder numbering and firing order Maintenance intervals Tune-up Air filter replacement Compression test Ignition timing Valve clearance Spark plugs Engine oil and filter Engine oil pressure test Throttle cable adjustment Idle speed adjustment Fast idle speed adjustment Throttle valve synchronization Fuel line inspection Emission control system inspection Clutch adjustment Shift pedal height adjustment Cooling system Tires and wheels Front suspension Rear suspension Drive chain Brake system General lubrication Fastener inspection Specifications Engine service Engine removal installation Engine block Crankshaft cover Cylinder head cover Timing cover cam chain tensioner and crankshaft oil seal Timing chain chain guides and camshaft sprockets Crankshaft rotor flange and sprocket Camshafts Cylinder head Valves and valve components  Intermediate housing and driver Auxiliary shaft starter clutch and starter idler gear Auxiliary shaft and starter clutch overhaul Auxiliary shaft front bearing and oil seal replacement Main oil seal replacement Pistons and connecting rods Crankshaft Oil pan lower crankcase half and output shaft Output shaft overhaul Break-in procedure Specifications Cylinder head cover Camshaft Cam chain tensioner Cam chain chain guides and timing rotor Cylinder head Valve lifter and shims Valves and valve components Specifications Starter idler cover Starter clutch and gears Alternator cover Flywheel Oil pump Oil cooler Oil pan and strainer Crankcase Crankshaft Connecting rod Piston and piston rings Engine break-in Two-stroke operating principles Engine lubrication Preparation for engine disassembly Engine removal Cylinder and cylinder head Piston pin and rings Reed valve Flywheel magneto and starter generator Engine sprocket Right crankcase cover Clutch Primary drive gear Kickstarter Tachometer drive gear Shifter Crankcase Transmission Crankshaft Clutch Clutch master cylinder Clutch slave cylinder Clutch system draining Clutch system bleeding Specifications Transmission and shift mechanism Transmission rubber bushings Transmission seal replacement assembled transmission Transmission disassembly Transmission housing and front cover inspection bushing and seal replacement Shift mechanism Transmission shaft overhaul Transmission reassembly Reverse system Specifications Sprocket cover Neutral switch Engine sprocket External shift mechanism Shift detent Transmission gears Fuel and Exhaust Systems Fuel injection system Fuel tank Fuel filter replacement Fuel pump replacement Fuel tank vent and float Fuel lever sensor Roll-over valve Air box Air intake guide Fuel pressure check Fuel rail fuel injectors and pressure regulator Throttle body Fuel hose replacement Motronic control unit Air temperature sensor Coolant temperature sensor Oxygen sensor Exhaust system Carbon canister Throttle and cruise control cables Cruise control unit Specifications Carburetor Fuel level Fuel tank Fuel valve Fuel level sensor Air suction system Emission control Exhaust system Electrical System Engine Battery Charging system Alternator Starting system Starter Starter relay Ignition coil Hall-effect sensors Ignition timing SpecificationsAlternator Transistorized ignition Electric starter Lighting system Switches Wiring and connectors Instrument cluster Thermostatic fan switch Water temperature sensor Horn Junction box and fuses Wiring diagrams Flywheel magneto operation Magneto troubleshooting Capacitor discharge ignition CDI Starter generator Lights Horn Main switch Electrical system Body Bulbs Headlight housing Headlight head light left right turn signals signal taillight tail light brake light adjuster cable replacement Turn signal bulb holder Instrument panel Electronic equipment box Relays Flasher unit Fuses Switches Stop switch starter switch horn button cruise control Electrical components On-board computer  Power socket Horn Audio speakers speaker tweeter woofer cd player radio antenna CB assembly Wiring diagrams Specifications Cooling and Lubrication Systems Temperature warning system Cooling system inspection Hoses Coolant reserve tank Radiators Cooling fans Thermostat Coolant pipe Water-oil pump Oil cooler housing and thermostat Oil cooler  Specifications Cooling system inspection Coolant reservoir Radiator and fan Thermostat Water pump Hoses Thermostatic fan switch and water temperature sensor Wheels and Tires Motorcycle workstands Front wheel Front wheel bearings Rear wheel Wheels Wire Cast spokes rims spoke rim Tires Specifications Front Suspension and Steering Handlebars grips and controls Upper fork bridge Lower fork bridge and ball joint Front fork Front strut Steering damper Suspension A-arm Specifications Front wheel Front hub Wheel balance Tubeless tires Tubeless tire changing Handlebars Steering head Brake plunger and anti-dive Rear Suspension and Final Drive Shock absorber Final drive unit Final drive unit overhaul Ring and pinion gear adjustments Swing arm and front drive shaft Specifications Rear wheel Rear hub Rear sprocket and coupling Drive chain Wheel balancing Tire changing and repair Rear shock absorber Rear swing arm Brake System ABS II Brake service ABS II  Brake pads Brake calipers Brake fluid adapter Front master cylinder Rear master cylinder Brake disc and sensor wheel ABS sensor ABS control unit ABS relay Rear brake pedal Brake bleeding  Specifications Brake System Integral ABS Brake service Integral ABS Brake pads Brake calipers Specifications Disc brakes Brake pads Brake calipers Front master cylinder Rear master cylinder Brake hose Brake disc Bleeding the system Body and Frame  Saddlebags and holder Seat Front fender Windshield wind shield wind screen and holder assembly Hand guard front turn signal housing models Upper fairing Instrument panel trim  Fairing side panels Engine spoiler Side covers Grab handle and luggage rack Lock carrier Rear section Rear fender assembly Left front foot peg pegs footpeg and holder Left rear footpeg and holder Right front footpeg and holder Right rear footpeg and holder Sidestand side stand Centerstand center stand Cross-tube Raising the frame Specifications  Windshield Front fender Mirrors Wind deflector Front turn signal indicator Bottom fuel tank cover Bumper strip Fairing side panels Radio compartment cover Fuel tank cover Engien spoiler assembly Handlebar cover Upper fork bridge cover Outer instrument cover Upper fairing Inner instrument cover Footrest assemblies Crash bar assembly Sidestand Engine guard and manual centerstand Engine guard and electro-hydraulic centerstand EHCS Seats Battery covers License plate holder Trunk Rear trunk trim Saddlebags Cross-tube Raising the frame Specifications Index Color Wiring Diagrams Schematic 1948 1949 1950 1951 1952 1953 1954 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2008 2006 2007 2008 2009 BMW Harley Davidson HD H-D Honda Kawasaki Suzuki Yamaha Allstate Benelli Bridgestone Broncco BSA Bultaco CZ Ducati Garelli Gilera Hodaka Husqvarna Maico Montesa Moto Beta Moto Guzzi Norton Ossa Puch Rex Royal Enfield Sachs Triumph Velocette Villiers White Antique Classic Vintage Late model Modern Cruiser Sport tourer touring Sport bike Sportbike Motorcycle Bike Motorbike Dirt track tracker Chopper Bobber Café Racer Dual Sport Motocross MX Freestyle Motocross FMX Enduro Baja Thumper Smoker 2 stroke 4 stroke Two Stroke Four Stroke not a crash not a free download pdf no wheelies endos or stoppies Supermoto Sumo GP GPZ v twin inline 4 6 four six rat rod single