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2016 90 Service Manual
Table Of Contents
General Information/Foreword.......................................... 2
Specifications ............................................................... 2
Torque Specifications.................................................... 3
Torque Conversions (ft-lb/N-m)..................................... 4
Gasoline-Oil-Lubricant.................................................. 4
Preparation For Storage ............................................... 4
Preparation After Storage ............................................. 5
Periodic Maintenance/Tune-Up......................................... 6
Air Filter ........................................................................ 6
Valve/Tappet Clearance................................................ 6
Testing Engine Compression........................................ 7
Spark Plug .................................................................... 8
Muffler/Spark Arrester .................................................. 8
Transmission Lubricant ................................................. 9
Engine Oil ..................................................................... 9
Brake Systems............................................................ 10
Replacing Drive Belt ................................................... 12
Adjusting Shift Linkage ............................................... 14
Steering/Body/Controls................................................... 15
Body ........................................................................... 15
Steering Post/Handlebar/Tie Rods ............................. 17
Handlebar Grip ........................................................... 20
Handlebar Switch ....................................................... 21
Hand Brake Lever Assemblies.................................... 21
Headlights................................................................... 24
Brakelight/Taillight....................................................... 24
Troubleshooting .......................................................... 25
Engine/Transmission....................................................... 26
Removing Engine/Transmission ................................. 26
Top-Side Components ................................................ 27
Removing Top-Side Components ............................... 28
Servicing Top-Side Components ................................ 30
Installing Top-Side Components ................................. 34
Left-Side Components................................................ 37
Removing Left-Side Components............................... 37
Installing Left-Side Components................................. 38
Right-Side Components ............................................. 40
Removing Right-Side Components ............................ 40
Servicing Right-Side Components.............................. 44
Installing Right-Side Components .............................. 45
Center Crankcase Components ................................. 47
Disassembling Crankcase Halves .............................. 47
Servicing Crankcase Components ............................. 48
Assembling Crankcase Half........................................ 49
Installing Engine/Transmission ................................... 50
Troubleshooting .......................................................... 52
Fuel/Lubrication................................................................54
Carburetor ...................................................................54
Throttle Cable Free-Play .............................................58
Engine RPM (Idle).......................................................58
Gas Tank .....................................................................58
Gas Tank Valve ...........................................................59
Troubleshooting ...........................................................60
Electrical System..............................................................61
Battery.........................................................................61
Ignition Switch .............................................................62
Ignition Coil .................................................................62
Ignition Timing.............................................................63
Handlebar Control Switches........................................63
Brakelight Switches .....................................................63
Headlights ...................................................................64
Stator Coil ...................................................................64
Regulator/Rectifier ......................................................64
Timing Sensor .............................................................64
Starter Motor ...............................................................64
Choke Circuit...............................................................64
Fuse ............................................................................65
Troubleshooting ...........................................................65
Drive System.....................................................................67
Drive Chain/Sprockets.................................................67
Rear Hub/Drive Axle....................................................69
Front Hub ....................................................................72
Brake Systems ............................................................73
Troubleshooting Drive System.....................................74
Troubleshooting Brake System....................................74
Suspension .......................................................................75
Shock Absorbers.........................................................75
A-Arm ..........................................................................76
Swing Arm...................................................................78
Wheels and Tires ........................................................80
Troubleshooting ...........................................................81
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