Service manual

CHASSIS ....................................................................................................3-36

ADJUSTING THE REAR BRAKE ........................................................3-36

CHECKING THE BRAKE FLUID LEVEL .............................................3-38

CHECKING THE FRONT BRAKE PAD ..............................................3-39

CHECKING THE REAR BRAKE PAD .................................................3-39

CHECKING THE BRAKE HOSE .........................................................3-40

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...............................3-41

ADJUSTING THE SELECT LEVER CONTROL CABLE

AND SHIFT ROD .............................................................................3-42

ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................3-43

CHECKING THE FINAL GEAR OIL LEVEL ........................................3-44

CHANGING THE FINAL GEAR OIL ....................................................3-45

CHECKING THE DIFFERENTIAL GEAR OIL .....................................3-46

CHANGING THE DIFFERENTIAL GEAR OIL ....................................3-46

CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT ........3-47

CHECKING THE STEERING SYSTEM ..............................................3-48

ADJUSTING THE TOE-IN ...................................................................3-48

ADJUSTING THE FRONT SHOCK ABSORBER ................................3-50

ADJUSTING THE REAR SHOCK ABSORBER ..................................3-50

CHECKING THE TIRE ........................................................................3-50

CHECKING THE WHEEL ....................................................................3-53

CHECKING AND LUBRICATING THE CABLE ...................................3-53

LUBRICATING THE LEVERS, PEDAL, ETC. .....................................3-54

ELECTRICAL ..............................................................................................3-55

CHECKING THE BATTERY ................................................................3-55

CHECKING THE FUSE .......................................................................3-60

ADJUSTING THE HEADLIGHT BEAM ...............................................3-62

CHANGING THE HEADLIGHT BULB .................................................3-62

CHAPTER 4.

ENGINE

ENGINE REMOVAL ......................................................................................4-1

AIR DUCTS, MUFFLER AND EXHAUST PIPE ....................................4-1

SELECT LEVER UNIT AND COOLANT RESERVOIR .........................4-3

HOSES AND LEADS .............................................................................4-4

ENGINE MOUNTING BOLTS ...............................................................4-5

INSTALLING THE ENGINE ...................................................................4-7

CYLINDER HEAD .........................................................................................4-8

REMOVING THE CYLINDER HEAD ...................................................4-10

CHECKING THE TAPPET COVER .....................................................4-11

CHECKING THE TIMING CHAIN TENSIONER ..................................4-11

CHECKING THE CAMSHAFT SPROCKET ........................................4-11

CHECKING THE CYLINDER HEAD ...................................................4-12

INSTALLING THE CYLINDER HEAD .................................................4-13

Not For Resale