CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers and information labels / Shop supplies / Tools / Measuring tools /Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Final drive / Front suspension and steering / Brake system
CHAPTER THREE / MAINTENANCE, LUBRICATION and TUNE-UP
Tune-up / Air filter / Engine compression test / Spark plugs / Ignition timing / Valve clearance / Idle speed adjustment / Fuel system hose inspection / Fuel filter / Throttle cable / Clutch cable and clutch lever / Engine oil and filter / Engine oil pressure check / Cooling system / Front fork oil change / Specifications
CHAPTER FOUR and FIVE / ENGINE
Removal installation / Cylinder head covers and rocker arms / Camshafts / Cam chain tensioner and cam chain / Cylinder head / Valves and valve components / Cylinder / Piston and piston rings / Cylinder stud / Crankcase / Crankcase seal and bearing / Crankshaft / Connecting rods / Balancer shafts / Oil pump / Output gear / Specifications
CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Right crankcase cover / Clutch release assembly / Primary drive and driven gears and oil pump chain and sprockets / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Specifications
CHAPTER EIGHT / FUEL AND EMISSION CONTROL SYSTEMS
Fuel system differences / Fuel tank / Fuel valve / Air filter housing / Carburetor / Intake manifold / Pilot screw adjustment idle drop procedure / High altitude adjustment / Throttle cable replacement / Choke cable replacement / Fuel pump and fuel filter / Crankcase breather system / Pulse secondary air supply system / Evaporative emission control system / (California models) / Specifications
CHAPTER NINE / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Battery box / Charging system / Stator coil, ignition pulse generator and left crankcase cover / Flywheel, starter clutch and starter drive gears / Ignition system testing / Ignition coils / Ignition pulse generator / Ignition control module ICM / Ignition timing / Throttle position sensor / Starter / Starter relay switch / Clutch diode / Lighting system / Vehicle speed sensor VSS / Coolant temperature indicator and engine coolant temperature ECT sensor / Fan switch / Oil pressure switch and oil pressure indicator / Neutral switch / Sidestand / Clutch switch / Brake light switch / Ignition switch / Handlebar switch / Turn signal relay / Fuel cutoff relay / Horn / Fuses / Specifications
CHAPTER TEN / COOLING SYSTEM
Temperature warning system / Cooling system inspection / Radiator / Cooling fan / Coolant reserve tank / Thermostat / Thermostat housing / Coolant pipe / Water pump / Specifications
CHAPTER ELEVEN / WHEELS AND TIRES
Motorcycle lift / Front wheel / Rear wheel / Front and rear hubs / Driven flange / Wheel service (cast wheels) / Wheel service (lace wheels) / Tire safety / Tire changing / Wheel balance / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Handlebar / Handlebar grips / Front fork / Steering assembly / Steering head and stem / Steering bearing preload check / Steering bearing replacement / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber / swing arm / Final drive unit and drive shaft / Ring and pinion gear measurements / Specifications
CHAPTER FOURTEEN / BRAKES
Linked braking system LBS / Brake service / Brake bleeding / Brake fluid draining / Brake pads / Brake caliper removal and installation / Brake caliper overhaul / Front master cylinder / Rear master cylinder / Proportional control valve / Brake hose and brake line replacement / Brake disc / Rear brake pedal / Specifications
CHAPTER FIFTEEN / BODY AND EXHAUST SYSTEM
Seat / Side covers / Left crankcase rear cover / Front fender / Rear fender / Rider footrests / Sidestand / Windshield / Backrest and saddlebags / Exhaust system / Specifications
INDEX
COLOR WIRING DIAGRAMS
Materials
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Shopping Safely
At our Shopify store, we prioritize your safety and security. Here's how we ensure a secure shopping experience:
1. Secure Transactions: We use advanced encryption to protect your personal and payment information, ensuring it is safely transmitted and safeguarded.
2. Trusted Payment Gateways: Our store integrates with trusted payment gateways, ensuring your transactions are processed securely and efficiently.
3. Data Privacy: Your privacy is our top priority. We follow strict data protection policies to keep your personal information confidential and secure.
4. Secure Platform: Shopify provides robust security features and continuous monitoring against vulnerabilities, ensuring a safe shopping environment.
5. Verified Merchants: We are a verified merchant on Shopify, committed to providing authentic and high-quality products.
6. Transparent Policies: Our clear return, refund, and shipping policies provide peace of mind, knowing we stand behind our products.
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Shop confidently at our Shopify store, where your safety and satisfaction are our top priorities.
Built for everyday use, the product features carefully chosen components that balance durability with visual appeal.
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Featuring a streamlined and compact design, the product is crafted to fit seamlessly into a variety of spaces and lifestyles.
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We offer a hassle-free returns policy to ensure your complete satisfaction. If you're not happy, simply return it within 30 days for a full refund.
Any questions?
Text us anytime at 519-872-9088 with any questions and we will be happy to help!
Does it come with a warranty?
most items in store come with a manufacture defect warranty to give you peace of mind. we always strive to keep our customers happy with any issues on fitment or quality.
What happens if what i ordered does not fit?
If what you ordered does not fit, we will do a quick check for fitment via pictures of the item and your machine to verify. if the fitment widget was wrong-return cost is on us and a refund or instore credit will apply. Any other return is subject to a re-stocking fee and customer pays for return freight.
How fast is shipping?
most products leave same day if orderd before 11am. or next day if after that. delivery is anywhere from 2-7 days depending location in canada.
What's the returns policy?
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