ENGINE
Starter Motor Does Not Operate or Does
Not Turn Engine Over
1. Ignition switch not in ON position.
2. Engine run switch in OFF position.
3. Discharged battery, loose or corroded connections (solenoid
chatters).
4. Starter control circuit, relay, or solenoid faulty.
5. Electric starter shaft pinion gear not engaging or overrunning
clutch slipping.
6. Bank Angle Sensor tripped and ignition switch not cycled
OFF then ON.
Engine Turns Over But Does Not Start
1. Fuel tank empty or fuel supply valve turned off.
2. Fouled spark plugs.
3. Engine flooded with gasoline as a result of over use of
enrichener.
4. Vacuum hose to automatic fuel supply valve disconnected,
leaking, or pinched.
5. Discharged battery, loose or broken battery terminal connections.
6. Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
7. Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylinders.
8. Loose wire connection at coil, battery, or ignition module
connector.
9. Ignition timing incorrect due to faulty coil, ignition module
or sensors (MAP and/or CKP).
Starts Hard
1. Spark plugs in bad condition or have improper gap or are
partially fouled.
2. Spark plug cables in bad condition.
3. Battery nearly discharged.
4. Loose wire connection at one of the battery terminals,
coil, or ignition module connector.
5. Carburetor controls not adjusted correctly.
6. Water or dirt in fuel system and carburetor.
7. Intake air leak.
8. Fuel tank vent hose and vapor valve plugged, or carburetor
fuel line closed off, restricting fuel flow.
9. Enrichener valve inoperative.
10. Engine lubricant too heavy (winter operation).
NOTE
For cold weather starts, always disengage clutch.
11. Ignition not functioning properly (possible sensor failure).
12. Faulty ignition coil.
13. Valves sticking.
Starts But Runs Irregularly or Misses
1. Spark plugs in bad condition or partially fouled.
2. Spark plug cables in bad condition and leaking.
3. Spark plug gap too close or too wide.
4. Faulty ignition coil, module, or sensor.
5. Battery nearly discharged.
6. Damaged wire or loose connection at battery terminals,
coil, or ignition module connector.
7. Intermittent short circuit due to damaged wire insulation.
8. Water or dirt in fuel system, carburetor or filter.
9. Fuel tank vent system plugged or carburetor vent line
closed off.
10. Carburetor controls misadjusted.
11. Air leak at intake manifold or air cleaner.
12. Damaged carburetor.
Maintenance 1-53
HOME
13. Loose or dirty ignition module connector at crankcase.
14. Faulty Sensor(s): Manifold Absolute Pressure (MAP)
and/or Crank Position (CKP).
15. Incorrect valve timing.
16. Weak or broken valve springs.
17. Damaged intake or exhaust valve.
A Spark Plug Fouls Repeatedly
1. Fuel mixture too rich or enrichener left on too long.
2. Incorrect spark plug for the kind of service.
3. Piston rings badly worn or broken.
4. Valve guides or seals badly worn.
Pre-Ignition or Detonation (Knocks or
Pings)
1. Fuel octane rating too low.
2. Faulty spark plugs.
3. Incorrect spark plug for the kind of service.
4. Excessive carbon deposit on piston head or in combustion
chamber.
5. Ignition timing advanced due to faulty sensor inputs
(MAP and/or CKP).
Overheating
1. Insufficient oil supply or oil not circulating.
2. Insufficient air flow over engine.
3. Heavy carbon deposit.
4. Ignition timing retarded due to faulty sensor(s): Manifold
Absolute Pressure (MAP) and/or Crank Position (CKP).
5. Leaking valve.
Valve Train Noise
1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.
2. Faulty hydraulic lifters.
3. Bent push rod.
4. Incorrect push rod length.
5. Rocker arm binding on shaft.
6. Valve sticking in guide.
7. Chain tensioning spring or shoe worn.
Excessive Vibration
1. Wheels and/or tires worn or damaged.
2. Engine/transmission/rear wheel not aligned properly.
3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4. Engine to transmission mounting bolts loose.
5. Upper engine mounting bracket loose.
6. Ignition timing advanced due to faulty sensor inputs
(MAP and/or CKP)/poorly tuned engine.
7. Internal engine problem.
8. Broken frame.
Check Engine Light Illuminates During
Operation
1. Fault detected. See CHECKING FOR TROUBLE
CODES in Electrical Diagnostic Manual (Part No.
99495-01) for more information.
LUBRICATION SYSTEM
Oil Does Not Return To Oil Tank
1. Oil tank empty.
2. Oil pump not functioning.
3. Restricted oil lines or fittings.
4. Restricted oil filter.
5. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
Engine Uses Too Much Oil Or Smokes
Excessively
1. Oil tank overfilled.
2. Restricted oil return line to tank.
3. Restricted breather operation.
4. Restricted oil filter.
5. Piston rings badly worn or broken.
6. Valve guides or seals worn.
7. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
8. Plugged crankcase scavenge port.
Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.
1. Loose parts.
2. Imperfect seal at gaskets, push rod cover, washers, etc.
3. Restricted breather hose to air cleaner.
4. Restricted oil filter.
5. Oil tank overfilled.
6. Lower rocker housing gasket installed incorrectly (upside
down).
7. Restricted oil return line to tank.
1-54 Maintenance
HOME
Low Oil Pressure
1. Oil tank underfilled.
2. Faulty low oil pressure switch.
3. Oil pump O-ring damaged or missing.
4. Bypass valve stuck in open position.
5. Ball missing or leaking in cam support plate.
6. O-ring missing from cam support plate.
High Oil Pressure
1. Oil tank overfilled.
2. Bypass valve stuck in closed position.
ELECTRICAL SYSTEM
Alternator Does Not Charge
1. Voltage regulator/rectifier module not grounded.
2. Engine ground wire loose or broken.
3. Faulty regulator-rectifier module.
4. Loose or broken wires in charging circuit.
5. Faulty stator and/or rotor.
Alternator Charge Rate Is Below Normal
1. Weak or damaged battery.
2. Loose connections.
3. Faulty regulator-rectifier module.
4. Faulty stator and/or rotor.
Speedometer Operates Erratically
1. Contaminated speedometer sensor (remove sensor and
clean off metal particles).
2. Loose connections.
CARBURETOR
Floods
1. Dirt or other foreign matter between valve and its seat.
2. Inlet valve sticking.
3. Inlet valve and/or valve seat worn or damaged.
4. Float misadjusted.
5. Leaky or damaged float.
6. Excessive “pumping” of hand throttle grip.
7. See 4.2 FUEL SYSTEM TROUBLESHOOTING.
TRANSMISSION
Shifts Hard
1. Primary chaincase overfilled with lubricant.
2. Clutch dragging slightly.
3. Transmission lubrication too heavy (winter operation).
4. Shifter return spring (inside transmission) bent or broken.
5. Bent shifter rod.
6. Shifter forks (inside transmission) sprung.
7. Corners worn off shifter clutch dogs (inside transmission).
Jumps Out Of Gear
1. Shifter rod improperly adjusted.
2. Shifter drum (inside transmission) improperly adjusted or
damaged.
3. Shifter engaging parts (inside transmission) badly worn
and rounded.
4. Shifter forks bent.
5. Damaged gears.
Clutch Slips
1. Clutch controls improperly adjusted.
2. Insufficient clutch spring tension.
3. Worn friction discs.
Clutch Drags Or Does Not Release
1. Lubricant level too high in primary chaincase.
2. Clutch controls improperly adjusted.
3. Primary chain badly misaligned.
4. Clutch spring tension.
5. Clutch discs warped.
Clutch Chatters
1. Friction discs or steel discs worn

ENERAL DATA
Number of cylinders 2
Type
4-cycle, 45 degree,
air cooled V-twin
Torque
(with shorty, dual exhaust)
82 ft-lbs @ 3500 RPM
111 Nm @ 3500 RPM
Bore
3.75 in.
95.25 mm
Stroke
4.00 in.
101.6 mm
Piston displacement (approx.)
88 cubic in.
1450 cc
Maximum sustained
engine speed
5600 RPM
Idle speed 1000 RPM +/- 50
Powertrain weight
165 lbs
74.8 kg
OIL PUMP DATA
Type Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
dry sump
Pressure 30-38 PSI (207-262 kN/m2) at 2000 RPM
and normal operating temperature of
230°F (110°C)
Filtration 10 micron media, filtered between pump
and engine
ROCKER ARMS IN. MM
Shaft fit in bushing
(loose)
0.0005-0.0020 0.013-0.051
End clearance 0.003-0.013 0.08-0.033
Bushing fit in rocker
arm (tight)
0.002-0.004 0.051-0.102
ROCKER ARM
SHAFTS
IN. MM
Shaft fit in rocker arm
support plate (loose)
0.0007-0.0022 0.018-0.056
HYDRAULIC LIFTERS IN. MM
Fit in crankcase (loose) 0.0008-0.0020 0.02-0.05
CYLINDER HEADS IN. MM
Valve guide in head
(tight)
0.0020-0.0033 0.051-0.084
Valve seat in head
(tight)
0.003-0.0045 0.076-0.114
Head gasket surface
(flatness)
0.006 0.0152

VALVES IN. MM
Exhaust: fit in guide 0.0015-0.0033 0.038-0.084
Intake: fit in guide 0.0008-0.0026 0.20-0.066
Seat width 0.040-0.062 1.02-1.58
Stem protrusion from
cylinder head boss
1.990-2.024 50.55-51.41
VALVE SPRINGS OUTER INNER
Closed
72-92 lbs
@ 1.751-1.848 in.
38-49 lbs
@ 1.577-1.683 in.
33-42 kg
@ 44.45-46.9 mm
17-22 kg
@ 40.1-42.8 mm
Open
183-207 lbs
@ 1.282-1.378 in.
98-112 lbs
@ 1.107-1.213 in.
83-94 kg
@ 32.6-35.0 mm
44-51 kg
@ 28.1-30.8 mm
Free length
2.105-2.177 in. 1.926-1.996 in.
53.47-55.3 mm 48.9-50.7 mm
3-2 Engine
HOME
PISTONS IN. MM
Fit in cylinder 0.0006-0.0016 0.15-0.041
Compression ring gap 0.007-0.020 0.178-0.508
Oil control ring gap
(stock ring)
0.009-0.052 0.23-1.32
Compression ring side
clearance: top ring
0.002-0.0045 0.051-0.114
Compression ring side
clearance: 2nd ring
0.0016-0.0041 0.041-0.104
Oil control ring side
clearance
0.0016-0.0076 0.041-0.193
Piston pin fit (loose) 0.0001-0.0004 0.003-0.010
CONNECTING RODS IN. MM
Piston pin fit (loose) 0.0003-0.0007 0.008-0.018
Side play between
flywheels
0.005-0.015 0.13-0.38
Connecting rod to
crankpin (loose)
0.0004-0.0012 0.0102-0.0305
FLYWHEELS IN. MM
Runout
(flywheels at rim)
0.000-0.010 0.0-0.25
Runout
(shaft at flywheel)
0.000-0.002 0.0-0.05
End play 0.001-0.005 0.03-0.13
SPROCKET SHAFT
(TIMKEN) BEARING
IN. MM
Cup fit in crankcase
(tight)
0.003-0.005 0.08-0.13
Cone fit on shaft (tight) 0.005-0.0015 0.013-0.038
CRANKSHAFT
(ROLLER) BEARING
IN. MM
Roller bearing fit
(loose)
0.0002-0.0015 0.005-0.038
Pinion shaft runout 0.0-0.003 0.0-0.076
Bearing fit in
crankcase (tight)
0.0018-0.0021 0.046-0.053
Bearing inner race on
crankshaft (tight)
0.0009-0.0012 0.023-0.031
Engine 3-3
HOME
ENGINE TORQUE VALUES 3.2
ITEM TORQUE NOTES
Bearing retainer plate screws 20-30 in-lbs 2.3-3.4 Nm Page 3-92
Breather cover bolts 90-120 in-lbs 10.2-13.6 Nm Page 3-41
Cam cover screws 90-120 in-lbs 10.2-13.6 Nm Special pattern to tighten, page 3-53
Cam support plate screws 90-120 in-lbs 10.2-13.6 Nm Special pattern to tighten, page 3-48
CKP sensor mounting screw 90-120 in-lbs 10.2-13.6 Nm Page 3-53
Crank sprocket bolt See NOTES See NOTES
Special method to tighten, replace if possible. Apply
several drops of LOCTITE® thread locker 262 (red) to
last few threads. Page 3-52
Crankcase bolts 15-19 ft-lbs 20.3-25.8 Nm Special pattern to tighten, see page 3-46
Cylinder head bolts See NOTES See NOTES Special method to tighten, page 3-37
Cylinder head bracket bolts 28-35 ft-lbs 38.0-47.5 Nm Page 3-24, page 3-26
Cylinder stud 10-20 ft-lbs 13.6-27.1 Nm Page 3-109
Engine oil drain plug w/O-ring 14-21 ft-lbs 19.0-28.5 Nm Clean plug before installation, page 3-113
Front isolator mounting bolts 21-27 ft-lbs 28.5-36.6 Nm Page 3-26
Left footpeg bracket screws 25-30 ft-lbs 33.9-40.7 Nm Page 3-26
Lifter cover screws 90-120 in-lbs 10.2-13.6 Nm Crosswise pattern to tighten, page 3-39
Oil filter mount screws 90-120 in-lbs 10.2-13.6 Nm
Apply several drops of LOCTITE® thread locker 243
(blue) to last few threads. Bend locktabs, page 3-26
Oil fitting 120-144 in-lbs 13.6-16.3 Nm
Apply LOCTITE PIPE SEALANT 565 to last few
threads, page 3-109
Oil line cover screws 84-108 in-lbs 9.5-12.2 Nm Page 3-27
Oil pump screws/alignment
tools, initial torque
40-45 in-lbs 4.5-5.1 Nm Special tools and pattern to tighten, page 3-49
Oil pump screws, final torque 90-120 in-lbs 10.2-13.6 Nm Special tools and pattern to tighten, page 3-49
Pipe plug 120-144 in-lbs 13.6-16.3 Nm
Apply LOCTITE PIPE SEALANT 565 to last few
threads, page 3-109
Piston jet screws 20-30 in-lbs 2.3-3.4 Nm
Replace if possible. Apply several drops of LOCTITE
THREADLOCKER 222 (purple) to last few threads;
Otherwise-page 3-102
Rear cam sprocket bolt See NOTES See NOTES
Special method to tighten. Replace if possible. Apply
several drops of LOCTITE® thread locker 262 (red) to
last few threads; Otherwise-page 3-52
Right footpeg bracket screws 25-30 ft-lbs 33.9-40.7 Nm Page 3-24, page 3-27
3-4 Engine
HOME
Rocker arm support plate bolts 18-22 ft-lbs 24.4-29.8 Nm 2 sizes, 1/4 turn sequence, page 3-40
Rocker cover bolts 15-18 ft-lbs 20.3-24.4 Nm
Apply several drops of LOCTITE® thread locker 243
(blue) to last few threads. Special pattern to tighten,
page 3-41
Shifter foot lever pinch bolt 18-22 ft-lbs 24.4-29.8 Nm Page 3-26
Sprocket shaft nut 150-165 ft-lbs 203-224 Nm Page 3-108
Stabilizer link bolt 18-22 ft-lbs 24.4-29.8 Nm Page 3-24, page 3-26
Transmission drain plug w/Oring
14-21 ft-lbs 19.0-28.5 Nm Clean plug before installation, page 3-113
Transmission mounting bolts 30-35 ft-lbs 40.7-47.5 Nm Criss-cross pattern, page 3-26
ITEM TORQUE NOTES
Engine 3-5
HOME
SERVICE WEAR LIMITS 3.3
GENERAL
Wear limits are given here as a guideline for measuring used
engine components. Replace components when they exceed
values listed here.
ROCKER ARMS
REPLACE IF WEAR EXCEEDS
IN. MM
Shaft fit in bushing
(loose)
0.0035 0.089
End clearance 0.025 0.635
ROCKER ARM
SHAFTS
REPLACE IF WEAR EXCEEDS
IN. MM
Shaft fit in rocker
support (loose)
0.0035 0.089
HYDRAULIC
LIFTERS
REPLACE IF WEAR EXCEEDS
IN. MM
Fit in crankcase 0.003 0.076
Roller fit 0.0015 0.038
Roller end clearance 0.026 0.660
CAM SUPPORT
PLATE
REPLACE IF WEAR EXCEEDS
IN. MM
Cam chain
tensioner shoe
0.080-0.090 2.03-2.29
1/2 thickness of shoe
Cam support plate
warpage
0.010 0.25
Crankshaft bushing fit 0.0008-0.001 0.0203-0.0254
CYLINDER HEADS
REPLACE IF
IN. MM
Valve guide in head
(tight)
Less than
0.002
Less than
0.051
Valve seat in head
(tight)
Less than
0.002
Less than
0.0051
Head warpage
More than
0.006
More than
0.15
CYLINDERS
REPLACE IF WEAR EXCEEDS
IN. MM
Taper 0.002 0.05
Out of round 0.003 0.08
Warpage of gasket or
O-ring surfaces: top
0.006 0.15
Warpage of gasket or
O-ring surfaces: base
0.008 0.20
CYLINDER
BORES
REPLACE IF WEAR EXCEEDS
IN. MM
Standard 3.753 95.326
0.005 in. oversize 3.758 95.453
0.010 in. oversize 3.763 95.580
0.020 in. oversize 3.773 95.834
0.030 in. oversize 3.783 96.088
3-6 Engine
HOME
PISTONS
REPLACE IF WEAR
EXCEEDS
IN. MM
Fit in cylinder (loose) 0.0053 0.135
Piston pin fit (loose) 0.001 0.025
Ring
end gap
Top compression 0.020 0.51
2nd compression 0.024 0.61
Oil control rails 0.050 1.27
Ring
side
clearance
Top compression 0.0037 0.09
2nd compression 0.0037 0.09
Oil control rails 0.0072 0.18
CONNECTING RODS
REPLACE IF WEAR EXCEEDS
IN. MM
Piston pin fit (loose) 0.001 0.025
Side play between
flywheels
0.020 0.51
Fit on crankpin (loose) 0.002 0.05
FLYWHEELS
REPLACE IF WEAR EXCEEDS
IN. MM
Runout
(flywheels at rim)
0.015 0.38
Runout
(shaft at flywheel)
0.003 0.08
End play 0.006 0.15

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