A download of the complete manual is here (44M PDF).
Instructions for use are simple. Look up the subject, click on the page and the page will download to your browser. You must have Adobe Acrobat Reader (or full version) to be able to view these files. They are large...some are close to 400K. The Index is copied directly from the manual, so if information continues on the next page and the page is not listed in the subject, just change the file number in your location bar and hit enter. The files are named for the page number in the manual...page 34 is 34.pdf. Someday I may attempt to make this a better looking page, but for now, it is straightforward and functional. I will accept full responsibility for typographical errors on this page, but not in the manual...I caught a couple of typos in the book, but probably made a few of my own. If any of the links here don't work, email me at Jeff and I'll get it fixed as soon as I can.
Here is the table of contents in .pdf format. Find what you need and then click on the page number link below to take you to that page. If you open it in a new window, then you can just flip back and forth to find what you need.
i , ii , iii , iv , 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 , 52 , 53 , 54 , 55 , 56 , 57 , 58 , 59 , 60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 , 68 , 69 , 70 , 71 , 72 , 73 , 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 , 82 , 83 , 84 , 85 , 86 , 87 , 88 , 89 , 90 , 91 , 92 , 93 , 94 , 95 , 96 , 97 , 98 , 99 , 100 , 101 , 102 , 103 , 104 , 105 , 106 , 107 , 108 , 109 , 110 , 111 , 112 , 113 , 114 , 115 , 116 , 117 , 118 , 119 , 120 , 121 , 122 , 123 , 124 , 125 , 126 , 127 , 128 , 129 , 130 , 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 , 139 , 140 , 141 , 142 , 143 , 144 , 145 , 146 , 147 , 148 , 149 , 150 , 151 , 152 , 153 , 154 , 155 , 156 , 157 , 158 , 159 , 160 161 , Conversions page 1 , Conversions page 2 , Cover page
Actual Index of the manual.
AC generator.........................................
22 ,
23 ,
101 ,
130 ,
120
Adjustment
Air screw..........................................
10 ,
52
Brake
Front.............................................
67 ,
68 ,
78
Rear..............................................
67
Brake lamp switch
Front.............................................
68 ,
78
Rear..............................................
67
Carburetor.........................................
9 ,
10 ,
52
Chain.................................................
62 ,
94
Clutch................................................
12
Float..................................................
52
Fuel level...........................................
52
Idle...................................................
9 ,
10 ,
11
Ignition Timing
H1 CDI.........................................
107
Contact breaker ignition.................
109
Magneto CDI................................
118
Jet Needle.........................................
48 ,
49
Oil Pump...........................................
11 ,
12
Pilot screw.........................................
49
Point gap...........................................
107 ,
109
Shock absorber.................................
91 ,
92
Signal generator.................................
109 ,
118
Starter lever.......................................
11
Steering.............................................
90 ,
91
Throttle
Cable............................................
9 ,
10
Grip..............................................
11 ,
83
Stop screw....................................
10
Air cleaner............................................
13 ,
14
Air pressure, tire...................................
57
Alignment, wheel...................................
55 ,
61
94
Arm, swing............................................
54 ,
55 ,
56
Axle
Runout...............................................
60
Torque..............................................
61
Baffle tube.............................................
99 ,
100
Balance, wheel......................................
57 ,
61
Bead protector......................................
57
Bearings
Clutch................................................
30
Connecting rod small end...................
20
Main.................................................
38
Steering stem.....................................
89
Big end, connecting rod..........................
37 ,
38 ,
43
Boring...................................................
17 ,
18
Brake lamp switch.................................
67 ,
68 ,
74 ,
78
Brake lining thickness............................
65
Brakes
Disc...................................................
69 ,
70 ,
71 ,
72 ,
73 ,
74 ,
75 ,
76 ,
77 ,
78 ,
79 ,
80
Expansion..........................................
61 ,
62 ,
63 ,
64 ,
65 ,
66 ,
67 ,
68
Bushing clearance, swing arm.................
55
Carburetors...........................................
9 ,
10 ,
11 ,
46 ,
47 ,
48 ,
49 ,
50 ,
51 ,
52
CDI
H1.....................................................
108 ,
109 ,
110 ,
111 ,
112
Magneto CDI....................................
113 ,
115 ,
116 ,
117 ,
118 ,
119
Chain, drive...........................................
23 ,
61 ,
94 ,
95
Check valves.........................................
45 ,
46 ,
71
Cleaner, air............................................
13 ,
14
Clearance
Clutch housing/plate...........................
30
Connecting rod, big end.....................
37 ,
38
Cylinder/piston...................................
17 ,
20
Main bearings....................................
38
Selector fork......................................
41
Swing arm bushing/sleeve...................
55
Transmission gears.............................
41
Clutch....................................................
12 ,
27 ,
28 ,
29 ,
30 ,
31
Compression, cylinder............................
17 ,
18
Connecting rods.....................................
20 ,
37 ,
38 ,
43
Conversion tables...................................
129 ,
130
Crankcase.............................................
34 ,
35 ,
36
Crankshaft.............................................
36 ,
37 ,
38
Cutaway, throttle valve...........................
48 ,
52
Cylinder.................................................
15 ,
16 ,
17 ,
18
Cylinder head.........................................
15 ,
16 ,
17 ,
18
Cylinder port
Measurements...................................
15
timing................................................
15
Damper, steering...................................
85 ,
93
Diameter
Brake drum.......................................
65
bushing, swing arm............................
55
Cylinder............................................
17
Needle jet.........................................
49
Piston...............................................
17
Sleeve, swing arm.............................
55
Sprocket
Engine..........................................
23
Rear............................................
66
Disc brake...........................................
69 ,
70 ,
71 ,
72 ,
73 ,
74 ,
75 ,
76 ,
77 ,
78 ,
79 ,
80
Distributor...........................................
24 ,
25 ,
26 ,
108
Drive chain..........................................
23 ,
61 ,
94 ,
95
Drum, brake........................................
61 ,
62 ,
63 ,
64 ,
65 ,
66 ,
67 ,
68
Drum, shift...........................................
32 ,
33 ,
34 ,
39 ,
40
Engine
Adjustments.....................................
9 ,
10 ,
11 ,
12
Components....................................
5
Left side...........................................
22 ,
23 ,
24
Minor disassembly............................
5 ,
6
Mounting..........................................
9
Removal...........................................
6 ,
7 ,
8 ,
9
Right side.........................................
24 ,
25 ,
26 ,
27
Sprocket..........................................
22 ,
23 ,
24
Exhaust pipes.......................................
99 ,
100
Expander ring.......................................
20 ,
21 ,
22
Float level............................................
47 ,
48 ,
51 ,
52
Float mechanism..................................
47 ,
48 ,
51 ,
52
Foot rests............................................
98
Fork, front...........................................
83 ,
84 ,
85 ,
86 ,
87 ,
88 ,
89 ,
90 ,
91
Frame..................................................
53
Friction plates.......................................
27 ,
28 ,
29 ,
30 ,
31
Fuel tank..............................................
95 ,
96 ,
97
Fuel Tap..............................................
95 ,
96 ,
97 ,
98
Gap, spark plugs.................................
107 ,
118
Gasoline tank......................................
95 ,
96 ,
97
Gasoline tap........................................
95 ,
96 ,
97 ,
98
Gear, primary.....................................
31 ,
32
Gear shift mechanism..........................
32 ,
33 ,
34 ,
39 ,
41
Generator
AC................................................
22 ,
23 ,
101 ,
103 ,
120
Signal.............................................
23 ,
108 ,
109 ,
110 ,
115 ,
116 ,
117 ,
118 ,
120
Handlebars.........................................
81 ,
82 ,
83
Head, cylinder....................................
15 ,
16 ,
17 ,
18
Honing...............................................
17 ,
18
Hubs..................................................
61 ,
62 ,
63 ,
64 ,
65 ,
66 ,
67 ,
69
Idle adjustment...................................
9 ,
10 ,
11
Ignition
H1 CDI..........................................
108 ,
109 ,
110 ,
111 ,
112
Contact breaker..............................
105 ,
106 ,
107
Magneto CDI.................................
113 ,
115 ,
116 ,
117 ,
118 ,
119
Injectolube.........................................
43 ,
44 ,
45 ,
46
Jet
Main..............................................
48 ,
50 ,
51 ,
52
Needle...........................................
48 ,
49 ,
50 ,
51 ,
52
Pilot...............................................
48 ,
49 ,
50 ,
51 ,
52
Jet needle...........................................
48 ,
49 ,
50 ,
51 ,
52
Kick stand.........................................
98
Kick starter.......................................
24 ,
25 ,
26 ,
42 ,
43
Length, spring
Brake shoe....................................
65
Clutch...........................................
30
Front fork.....................................
89
Master cylinder.............................
79
Level, float chamber fuel....................
47 ,
48 ,
51 ,
52
Lining thickness, brake......................
65
Lubrication........................................
43 ,
44 ,
45 ,
46
Needle, jet........................................
48 ,
49 ,
50 ,
51 ,
52
Needle jet........................................
49 ,
50 ,
51 ,
52
Main jet...........................................
48 ,
50 ,
51 ,
52
Mufflers...........................................
99 ,
100
Oil, front fork...................................
89
Oil pump..........................................
11 ,
12 ,
24 ,
26 ,
43 ,
44 ,
45 ,
46
Oil tank............................................
95 ,
96 ,
97
Overheating......................................
15 ,
80 ,
124
Oversize pistons...............................
18
Performance curves..........................
3 ,
4
Pin, piston........................................
18 ,
19 ,
20
Pinion gears......................................
24
Piston...............................................
18 ,
19 ,
20
Piston pin.........................................
18 ,
19 ,
20
Piston rings.......................................
18 ,
19 ,
20 ,
21 ,
22
Pivot shaft
Nut torque....................................
56
runout...........................................
55
Plates, clutch....................................
27 ,
28 ,
29 ,
30 ,
31
Play, connecting rod small end..........
20
Plug torque
Spark plug...................................
18
Oil drain plug...............................
27
Plug, spark......................................
1 ,
18 ,
107 ,
118
Port, cylinder
Measurements.............................
15
Timing.........................................
15
Pressure, tire air..............................
57
Primary gear....................................
31 ,
32
Pump, oil.........................................
11 ,
12 ,
24 ,
26 ,
43 ,
44 ,
45 ,
46
Rectifier...........................................
101 ,
102 ,
103 ,
104 ,
113 ,
114 ,
120
Regulator.........................................
103 ,
104 ,
105 ,
113 ,
114 ,
120
Rim, tire...........................................
57 ,
60
Rings, piston....................................
18 ,
19 ,
20 ,
21 ,
22
Runout
Axle.............................................
60
Crankshaft...................................
38
Disc.............................................
80
Pivot shaft....................................
55
Rim..............................................
60
Schematic diagrams..........................
129 ,
131 ,
133 ,
153 ,
154 ,
155 ,
156 ,
157 ,
158
Seat..................................................
99
Seizure, piston..................................
19
Selector fork clearance.....................
41
Semiconductors................................
102 ,
103
Shift mechanism................................
12 ,
32 ,
33 ,
34 ,
39 ,
41
Shock absorbers
Front............................................
83 ,
84 ,
85 ,
86 ,
87 ,
88 ,
89 ,
90 ,
91
Rear.............................................
91 ,
92 ,
93
Signal generator................................
23 ,
108 ,
109 ,
110 ,
115 ,
116 ,
117 ,
118 ,
120
Small end, connecting rod.................
20
Spark plugs......................................
1 ,
18 ,
107 ,
118
Specifications...................................
1 ,
2
Spoke size.......................................
57
Spring length
Brake shoe..................................
65
Clutch..........................................
30
Front fork....................................
89
Master cylinder............................
79
Sprocket
Engine..........................................
22 ,
23 ,
24
Rear.............................................
62 ,
65 ,
66
Stands..............................................
98
Starter, kick......................................
24 ,
25 ,
26 ,
41 ,
42 ,
43
Steering damper.................................
85 ,
93
Steering stem.....................................
83 ,
84 ,
85 ,
86 ,
87 ,
88 ,
89 ,
90 ,
91
Swing arm.........................................
54 ,
55 ,
56
Switch, brake lamp............................
67 ,
68 ,
74 ,
78
Tanks....................................................
95 ,
96 ,
97
Thickness
Brake Lining......................................
65
Friction Plates....................................
30
Disc...................................................
80
Throttle valve.........................................
50
Thyristor................................................
94 ,
96 ,
103
Timing
Distributor..........................................
26
Ignition
H1 CDI.........................................
107
Contact breaker.............................
109
Magneto CDI.................................
118
Port Valve..........................................
15
Tires.......................................................
56 ,
57 ,
59 ,
60
Torque
Axle....................................................
61
Cylinder Head.....................................
17
Crankcase...........................................
36
Disc Brake Parts.................................
72
Swing arm shaft nut.............................
56
Spark plug..........................................
18
Transmission oil drain plug...................
27
Torque Table..........................................
128
Transmission...........................................
39 ,
40 ,
41
Tube, baffle.............................................
99 ,
100 ,
101
Tube (bead) protector.............................
57
Tube, tire................................................
59 ,
60
Valves, check.........................................
45 ,
46 ,
71
Valve timing............................................
15
Ventilator................................................
64 ,
66
Voltage regulator.....................................
103 ,
104 ,
105 ,
113 ,
114 ,
120
Warp
Connecting rod....................................
37
Rim.....................................................
60
Swing arm...........................................
55
Disc....................................................
80
Weights, wheel........................................
61
Wheel balance.........................................
57 ,
61
Wheels....................................................
56 ,
57 ,
58 ,
59 ,
60 ,
61
Wiring Diagrams......................................
129 ,
131 ,
133 ,
153 ,
154 ,
155 ,
156 ,
157 ,
158
Supplement
Electrical System (H1-E)
CDI unit test........................................
151 ,
152
Distributor test.....................................
150 ,
151
Dynamo test........................................
149 ,
150
Ignition circuit......................................
146 ,
147
Rectifier/regulator................................
147 ,
148 ,
149
Regulator test......................................
152
Engine: Detailed Maintenance
Ignition timing adjustment (H1-E).........
137 ,
138
Lubrication system (H2-B)..................
138 ,
139 ,
140 ,
141
Frame (H1-E, H2-B)
Front fork tubes..................................
141 ,
142 ,
143 ,
144 ,
145 ,
146
Wiring diagram........................................153 , 154 , 155 , 156 , 157 , 158