Service manual

CHK
ADJ
3-2
N
O
TE:
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
NO. ITEM ROUTINE
After
break-in
Every
race
Every
third race
Every
fifth race
As
required
16 * Cooling system
• Check coolant level and for leakage. √√
• Check hoses for cracks or damage. √
• Check radiator cap spring operation. √
• Change coolant. Every 2 years √
17 * Chassis fasteners
• Check all chassis fitting and fasteners.
• Correct or tighten if necessary.
√√
18 * Air filter element
• Clean. √√
• Replace. √
19 * Frame • Clean and check for damage. √√
20 * Fuel line • Clean and check for leakage. √√
21 * Brakes
• Adjust lever position and pedal height.
• Lubricate pivot points.
• Check brake disk surface.
• Check fluid level and for leakage.
• Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts.
√√
• Replace brake pads. √
• Replace brake fluid. Every year √
22 * Front fork
• Check operation and for oil leakage.
• Adjust if necessary.
• Clean dust seal and lubricate with lithium-soap-based
grease.
√√
• Replace fork oil. √√
• Replace oil seals. √
23 *
Shock absorber
assembly
• Check operation and adjust.
• Tighten if necessary.
√√
• Lubricate with molybdenum disulfide grease. √
√
(After
washing
the vehicle
or riding in
the rain)
24 *
Drive chain roller and
support guide
• Check for wear or damage.
• Replace if necessary.
√
25 * Rear suspension
• Check operation and tighten if necessary. √√
• Lubricate with molybdenum disulfide grease. √√
26 * Steering head
• Check operation, free play, and tighten if necessary. √√
• Clean and lubricate with lithium-soap-based grease. √
• Replace bearings. √
27 * Tires and wheels
• Check tire air pressure, wheel runout, spokes for loose-
ness, and tires for wear.
√√
• Tighten sprocket bolts if necessary. √√
• Check wheel bearings for looseness. √
• Lubricate wheel bearings with lithium-soap-based
grease.
√
• Replace wheel bearings. √
28 *
Moving parts and
cables
• Lubricate. √√
29 *
Throttle grip housing
and cable
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
√√
PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS