This manual includes a Quick Reference Data section with frequently used
specifications and the following chapters.
Manual organization / Warnings, cautions and notes / Safety / Serial numbers
/ Fasteners / Shop supplies / Basic tools / Precision measuring tools /
Electrical system fundamentals / Special tools / Basic service methods /
Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Starting the engine / Engine performance / Electric
starting system / Charging system / Ignition system / Fuel system / Engine
noises / Engine lubrication / Clutch / Transmission / Lighting system /
Excessive vibration / Front suspension and steering / Brake problems
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine safety checks / Maintenance intervals / Tires and wheels / Periodic
lubrication / Engine oil and filter change / Transmission oil change /
Primary chaincase oil change / Front fork oil change / Periodic maintenance
/ Primary chain adjustment / Final drive belt deflection and alignment /
Rear brake adjustment / Clutch adjustment / Throttle cable adjustment /
Starting enrichment valve (choke) cable adjustment / Air filter service /
Tune-up / Compression test / Spark plugs / Ignition timing / Idle speed
adjustment / Specifications
CHAPTER FOUR / ENGINE
Removal installation / Rocker arm and pushrods / Cylinder / Valves and
components / Pistons and piston rings / Pushrods / Valve lifters / Oil pump
/ Oil filter mount / Camshaft support plate / Crankcase and crankshaft /
Break-in / Specifications
CHAPTER FIVE / CLUTCH AND PRIMARY DRIVE
Primary chaincase outer cover / Clutch plates and friction discs / Clutch
shell, compensating sprocket and primary drive chain / Clutch shell, clutch
hub and sprocket / Primary chain and guide inspection / Primary chain
alignment / Compensating sprocket inspection / Primary chaincase inner
housing / Starter jackshaft / Clutch cable / Specifications
CHAPTER SIX / TRANSMISSION
Shifter adjustment / Transmission top cover / Shifter cam / Shift forks /
Transmission side door and transmission shaft assemblies / Transmission
shafts / Main drive gear / External shift mechanism / Transmission side
cover and clutch release mechanism / Transmission drive sprocket /
Transmission case / Oil pan / Specifications
CHAPTER SEVEN / FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
Carburetor / Air filter backplate / Intake manifold / Throttle and idle
cable / Starting enrichment valve choke cable / Fuel tank / Fuel shutoff
valve / Fuel tank gauge / Exhaust system / Evaporative emission control
system / Evaporative control system service / Specifications
CHAPTER EIGHT / ELECTRICAL SYSTEM
Battery / Charging system / Alternator / Voltage regulator / Ignition system
/ Starting system / Lighting / Switches / Horn / Electric panel /Turn signal
module / Turn signal module and turn signal / Security module / Speedometer
speed sensor / Starter relay switch replacement / Instruments / Fuses /
Circuit breaker /Diagnostic trouble codes / Specifications
CHAPTER NINE / WHEELS, HUBS AND TIRES
Motorcycle stands / Front wheel / Rear wheel / Front and rear hubs (1999) /
Front and rear wheel bearing end play check / Driven sprocket assembly /
Drive sprocket / Drive belt / Wheel runout / Rim and laced wheel service /
Cast wheels / Wheel balance / Tires / Tubeless tire changing / Tire repairs
/ Vehicle alignment / Specifications
CHAPTER TEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Front suspension adjustment / Steering head and
stem / Steering head bearing race replacement / Steering play adjustment /
Specifications
CHAPTER ELEVEN / REAR SUSPENSION
Shock absorbers / Shock absorber adjustments / Rear swing arm /
Specifications
CHAPTER TWELVE / BRAKES
Brake service / Front brake pad replacement / Front brake caliper / Front
master cylinder / Rear brake pad replacement / Rear brake caliper / Rear
master cylinder / Brake hose and line replacement / Brake disc / Bleeding
the system / Rear brake pedal / Specifications
CHAPTER THIRTEEN / BODY
Seat / Windshield / Saddlebags / Specifications
SUPPLEMENT / 2002-2005 SERVICE INFORMATION
Tires and wheels / Periodic lubrication / Periodic maintenance / Engine /
Rocker arm and pushrods / Cylinder head / Valve and valve components (2005
models) / Pistons and piston rings / Camshaft support plate / Crankcase and
crankshaft / Clutch assembly (2005 models) / Transmission case (2003-on
models) / Shifter adjustment (2003-on models) / Air filter backplate /
Electronic fuel injection (EFI) / Depressurizing the fuel system (fuel
injected models) / Induction module (fuel injected models) / Throttle and
idle cables (fuel injected models) / Fuel tank console / Fuel tank (2004-on
carbureted models) / Fuel tank (2004-on fuel injected models) / Fuel tank
top plate and fuel gauge / sending unit (2004-on all models) / Fuel pump and
fuel filter (2004-on fuel injected models) / Alternator / Voltage regulator
/ Ignition system (2004-on models) / Starting system / Lighting system /
Switches / Electrical panel (2004-on models) / Turn signal module (TSM) and
turn signal module/security module (TSSM) (2004-on models) / Starter relay
replacement (2004-on models) / System relay replacement (2004-on fuel
injected models) / Instruments / Fuses and maxi-fuse (2004-on models) /
Front fork / Steering head and stem / Shock absorbers / Front brake pad
replacement / Rear brake pad replacement / Rear brake pedal (2003-on FXDWG
models)
INDEX
WIRING DIAGRAMS
Publisher: Clymer Publications
Softcover: Approx. 489
Dimensions: 8.5 x 11.0 x 1.2 inches
Part number: CM4253
ISBN-13: 9780892879861