Service manual

CHASSIS .............................................................................................. 2-21

LUBRICATION SYSTEM CHART AND DIAGRAMS .................................2-23

ENGINE OIL LUBRICATION CHART ...................................................2-23

LUBRICATION DIAGRAMS ..................................................................2-25

COOLING SYSTEM DIAGRAMS ...............................................................2-35

CABLE ROUTING ......................................................................................2-39

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENT

PERIODIC MAINTENANCE .........................................................................3-1

INTRODUCTION .................................................................................... 3-1

ENGINE.........................................................................................................3-4

ADJUSTING THE VALVE CLEARANCE ................................................3-4

SYNCHRONIZING THE THROTTLE BODIES .......................................3-6

ADJUSTING THE ENGINE IDLING SPEED ..........................................3-8

ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-8

CHECKING THE SPARK PLUGS...........................................................3-9

MEASURING THE COMPRESSION PRESSURE .................................3-9

CHECKING THE ENGINE OIL LEVEL.................................................3-10

CHANGING THE ENGINE OIL.............................................................3-11

MEASURING THE ENGINE OIL PRESSURE .....................................3-12

ADJUSTING THE CLUTCH CABLE FREE PLAY ................................3-13

REPLACING THE AIR FILTER ELEMENT ...........................................3-14

CHECKING THE THROTTLE BODY JOINTS ...................................... 3-15

CHECKING THE FUEL LINE ...............................................................3-15

CHECKING THE CRANKCASE BREATHER HOSE............................3-15

CHECKING THE EXHAUST SYSTEM ................................................. 3-16

ADJUSTING THE EXUP CABLES .......................................................3-16

CHECKING THE EXUP SERVO MOTOR ............................................3-17

CHECKING THE COOLANT LEVEL ....................................................3-17

CHECKING THE COOLING SYSTEM .................................................3-18

CHANGING THE COOLANT................................................................3-18

CHASSIS ....................................................................................................3-21

ADJUSTING THE FRONT DISC BRAKE .............................................3-21

ADJUSTING THE REAR DISC BRAKE ...............................................3-21

CHECKING THE BRAKE FLUID LEVEL..............................................3-22

CHECKING THE FRONT BRAKE PADS..............................................3-22

CHECKING THE REAR BRAKE PADS ................................................3-22

CHECKING THE FRONT BRAKE HOSES...........................................3-23

CHECKING THE REAR BRAKE HOSE ...............................................3-23

ADJUSTING THE REAR BRAKE LIGHT SWITCH ..............................3-23