Scouting For Boys. A Handbook for Instruction in Good. Citizenship Through Woodcraft. LORD BADEN-POWELL OF GILWELL. Founder of the Boy Scout.
- 1Table of Contents
- 6Features
- 6Product Overview
- 8Component and System Descriptions
- 8Chassis
- 8Engine and Related Systems
- 9Engine Component Locations
- 9Transmission and Drive
- 10Motorcycle Identification
- 10Chassis VIN
- 11Maintenance Service, Repairs and Safety
- 11Engine, Transmission Serial Number
- 12Maintenance
- 12Primary/Interval Service
- 13Renewal Service
- 14Chassis Troubleshooting
- 14Brakes Weak or Do Not Hold Normally
- 14Handling Irregulations
- 15Engine Troubleshooting
- 16Basic Engine Tests
- 16Lubrication System Troubleshooting
- 16Engine Compression Test
- 16Cylinder Leakage Test
- 17Emission Control System Troubleshooting
- 17Ignition System Troubleshooting
- 17Evaporative System Checks
- 17Spark Plug Condition, Electrical Ignition Diagnostics
- 18Ignition Cover (Trigger Plate), Speed Sensor Check
- 18Ignition Coil, Wires and Sprak Plugs Operational Check
- 19Ignition Module Operational Check
- 21Carburetor Troubleshooting
- 21Overflow or Flooding
- 21Poor Fuel Economy
- 22Poor Idle
- 22Poor Part Throttle Performance
- 23Poor Full Throttle Performance
- 23Carburetor and Exhaust Backfire
- 24Transmission and Drive Troubleshooting
- 24Shifts Hard
- 24Jumps Out of Gear
- 24Clutch Chatters
- 25Clutch Drags or Does Not Release
- 25Clutch Slips
- 26Electrical Troubleshooting Charts
- 26Alternator Does Not Charge/Alternator Charge Rate Below Normal
- 26Starter Motor Does Not Operate or Does Not Turn Engine Over
- 27Battery Charging
- 27Battery Voltmeter/Load Testing
- 28Using Battery Charging
- 28Battery Charging Rate
- 28Ground Path Tests
- 28Battery Ground Cable
- 29Current Draw/Leak Test
- 29Battery to Starter
- 30Rectifier/Regulator Current Leak Test
- 30Charging System Tests
- 30System Output Test
- 30Measuring Current Output at Specified Voltage
- 31Stator Resistance Test
- 31Alternator Output Test
- 31Short-To-Ground Check
- 32Starting System Tests
- 32Starter Current-Draw Test
- 33Wiring Circuit Tests
- 33Electrical Harness Controller
- 33Diagnostic Strip
- 33Coil
- 34Horn
- 34Resistance Tests
- 34Power-Side Voltage Drop Test
- 35Voltage Drop Test for Slow Cranking Starter
- 36Starter Solenoid Test (Starter Removed)
- 37Front Suspension Service
- 37Fork Oil Replacement
- 37Fork Tube Procedures, Removal
- 39Fork Tube Disassembly
- 40Fork Tube Cleaning and Inspection/Assembly
- 41Fork Tube Installation
- 42Fork Seating
- 43Steering Component Service
- 43Steering Stem Inspection and Adjustment
- 43Inspection and Fall-Away Test
- 44Bearing Preload Adjustment
- 46Steering Stem Disassembly and Assembly
- 46Triple Clamp Removal
- 48Stem Bearing Replacement
- 48Bearing Race Removal/Installation
- 48Triple Clamp Installation
- 49Handlebar Replacement/Removal
- 51Handlebar Installation
- 52Rear Suspension Service
- 52Shock Absorbers Removal, Assembly
- 53Shock Absorber Installation
- 53Swingarm Removal
- 54Swingarm Pivot Bearing Replacement
- 54Swingarm Cleaning and Inspection
- 55Swingarm Installation
- 56Wheel and Tire Service
- 56Front Wheel Removal and Installation
- 58Checking and Adjusting Wheel Bearing End Play
- 58Installing Front Axle
- 59Rear Wheel Removal and Installation
- 59Dial Indicator Setup
- 59Removing Caliper
- 60Axle Nut Removal
- 61Hub Bearing Cleaning and Inspection
- 61Seal and Bearing Removal
- 61Installing Caliper
- 61Removing Seal
- 62Bearing and Seal Installation
- 62Repacking Wheel Bearing
- 63Wheel Sprocket and Brake Rotor Removal and Installation
- 63Front/Rear Wheel Brake Rotor
- 64Wheel Rim, Hub and Spokes Inspection
- 64Rear Wheel Sprocket
- 64Tightening Loose Spokes (Front and Rear Wheels)
- 65Tire Inspection and Pressure Check
- 66Tire Inspection
- 67Tire and Tube Replacement
- 67Tire Removal/Installation
- 68Wheel Lacing Procedure
- 68Lacing 19-Inch, 40-Spoke Wheel
- 69Measuring Wheel Rim Offset
- 69Wheel Lacing Setup
- 70Lacing 16-Inch 40-Spoke Wheels
- 70Cup-Shaped Hub Flange
- 70Staggered Offset Rim Hole Arrangement
- 73Lacing 16-Inch, 60-Spoke Wheels
- 74Proper Cross of Inner-To-Outer Spokes
- 75Aligning the Hub and Rim (Truing)
- 75Checking and Adjusting Lateral Alignment
- 76Checking and Adjusting Radial Alignment
- 76Adjusting Lateral Alignment
- 76Spoke Group Centers
- 77Wheel Alignment Check
- 78Brake System Service
- 78Brake Fluid Level and Condition
- 78Front/Rear Brake Master Cylinders
- 79Brake Pad Replacement
- 79Checking Brake Pad Thickness
- 79Brake Pad Comparison
- 80Front and Rear Brake Pad Removal and Installation
- 81Brake Caliper Service
- 81Front Caliper Removal and Installation
- 81Disconnecting Caliper Brake Line
- 82Front Brake Caliper Assembly
- 83Front Brake Caliper Installation
- 83Rear Caliper Removal and Installation
- 83Rear Caliper Brake Line Removal at Bonjo Fitting
- 84Rear Brake Caliper Assembly
- 85Brake Caliper Shimming Inspection
- 85Rear Brake Caliper Installation
- 85Shim Placement On Mounting Screws Between Caliper and Mounting Bracket
- 86Brake Rotor Service
- 86Rotor Inspection
- 86Master Cylinder Service
- 86Front Master Cylinder Removal and Installation
- 87Front Master Cylinder Assembly
- 88Rear Master Cylinder Removal and Installation
- 88Rear Master Cylinder Location
- 89Rear Master Cylinder Pushrod Free Play
- 89Front and Rear Master Cylinder Disassembly and Assembly
- 89Front Master Cylinder Cleaning and Inspection
- 90Hydraulic Brake Line Replacement
- 90Front Brake Line Removal and Installation
- 90Opening Brake Bleeder Screw
- 91Rear Brake Line Removal and Installation
- 91Disconnecting Brake Line
- 92Disconnecting Brake Line at Rear Caliper/Junction Block
- 93Replacing Brake Fluid and Bleeding the Hydraulic System
- 95Frame and Accessories Service
- 95Seat Removal and Installation
- 95Seat Front Retainer Bracket
- 95Removing Seat Mounting Screw
- 96Fender Removal and Installation
- 96Unplugging Fender Light Connector
- 97Tightening Retainer Clip
- 97Removing Rear Fender Bracket Mounting Screws
- 97Unplugging Rear Fender Light Harness
- 98Dash Removal and Installation
- 98Front Turn Signal and Headlight Procedures
- 98Removing Dash Rear Retaining Screw
- 98Removing Lens
- 99Headlight Assembly/Bulb Replacement
- 99Housing Removal and Installation
- 99Removing Damp and Light Assembly
- 99Removing Headlight Turn Rug Screws
- 100Headlight Housing Replacement
- 100Front Fender Light
- 100Fender-Mounted Light Procedures
- 100Bulb Replacement
- 101Floorboard and Buddy Peg Removal and Installation
- 101Integral Taillight and Turn Signal Assembly
- 101Floorboard Overview
- 102Kickstarter Removal and Installation
- 102Mirror Assembly Removal, Installation and Adjustment
- 102Buddy Ped Procedure
- 102Removing Kickstand Assembly
- 103Chassis Frame Inspection and Repair
- 105Air Cleaner and Filter Element Service
- 105Air Filter Replacement
- 105Removing Air Cleaner Cover
- 105Filter Element Seated Over Web and against Base
- 106Air Cleaner Assembly Removal and Installation
- 107Installing Base-To-Cylinder Head Breather Rent Fitting Screws
- 107Filter Element Seated Over Base and against Base
- 107Installing Air Cleaner Cover
- 108Fuel System Service
- 108Fuel Filtration Maintenance
- 108Cleaning the Petcock Filter Screen
- 109Cleaning the In-Line Fuel Filter
- 110Fuel Line Inspection and Replacement
- 110Throttle Control Inspection and Maintenance
- 110Throttle Cable Lubrication
- 110Removing Mounting Screws, Removing Front Brake Control
- 111Removing Throttle/Switch Housing Screws
- 111Installing Front Brake Control
- 111Lubricating Throttle Cable
- 112Throttle Cable Adjustment
- 112Fuel Tank Removal and Installation
- 112Installing Clamp Screws
- 112Adjusting Front Cable Jam Nut
- 113Tank Removal
- 113Fuel Crossover Lube
- 113Removing Dash Panel
- 114Center Mounting Screws
- 114Removing Left Fuel Tank
- 115Installing Upper Mounting Screws
- 115Installing Left Fuel Tank
- 116Speedometer and Warning Light Wiring Connections
- 116Installing Dash Panel Rear Retaining Screw
- 116Installing Seat/Dash Panel
- 117Carburetor Service
- 117S&S Type E Carburetor
- 117Air Leaks
- 118Carburetor Removal and Installation
- 118Removing Air Cleaner Base/Cover
- 118Disconnecting Throttle-Control Cables
- 119Carburetor Maintenance
- 119Idle Speed and Mixture Adjustment
- 120Accelerator Pump Adjustment
- 120Idle Mixture Adjustment Screw
- 121Carburetor Rebuild
- 121Carburetor Disassembly and Assembly
- 121Accelerator Pump
- 121Directing Compressed Air Through Accelerator Pump Discharge Tube
- 122Diaphragm Removed From Accelerator Pump Cap
- 122Float Brass Needle/Float Pin Retaining Screw
- 122Accelerator Pump Discharge Tube With O-Ring
- 123Setting Float Height
- 123Low Speed Port/Main Jet Port
- 123Bleed Hole and Port Check
- 124Main Jet Discharge Tube
- 124Enrichener/Fast Idle Port
- 125Throttle Shaft/Spool
- 125Accelerator Pump Actuator Assembly
- 126Idle Mixture, Idle Stop and Accelerator Pump Adjustment Screws
- 126Bowl Gasket, Drain Plug and Body O-Rings
- 127Cabruretor Installation, Exploded View
- 128Cabruretor Exploded View Legend
- 129Ignition System Service
- 129Spark Plug Replacement
- 129Ignition Coil and Spark Plug Wire Replacement
- 129Coil Removal and Installation
- 130Ignition Trigger Plate/Rotor Removal and Installation
- 130Spark Plug Wire Removal and Installation
- 131Ignition Module Replacement
- 131Installing Ignition Rotor
- 131Access to Ignition Module
- 132Ignition Timing Check and Adjustment
- 132Static Timing Procedure
- 132Timing Mark Inspection Plug
- 133Dynamic Timing
- 133T:F Mark Centered in Inspection Hole
- 133Trigger Plate and Screws
- 134Flywheel With Indicated Timing Marks Shown
- 135Lubrication System Service
- 135Engine Oil and Oil Filter Replacement
- 135Opening the Oil Drain Tube
- 135Proper Engine Oil Level
- 136Cleaning the Tappet Screen
- 136Oil Line Inspection and Replacement
- 136Inspection at Oil Tank
- 136Removing the Tappet Screen
- 137Oil Pump Removal and Installation
- 137Inspection at the Oil Filter Adapter
- 137Oil Line Connections at Tank
- 138Removing Oil Pump Cover/Tappet Screw
- 139Oil Tank Removal and Installation
- 139Oil Pump Gear Arrangement
- 139Installing Tappet Screen
- 140Oil Tank Assembly
- 141Removing Retaining Nut at Rear Isolator Mount
- 141Removing Oil Tank/Rear Mounting Bracket
- 142Installing Seat
- 143Emission Control System Service
- 143Evaporative System
- 144Carbon Canister Removal and Installation
- 144Air Valve Removal and Installation
- 145Removing Air Valve and Diaphragm
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