3
Parts – Plastic & Seat ............................................................................................... 38
Parts – Rear Brake ................................................................................................... 39
Parts – Rear Wheel .................................................................................................. 40
Parts – Shock ........................................................................................................... 41
Parts – Shock - Inside ............................................................................................... 42
Parts – Swingarm Assembly ..................................................................................... 43
Service ......................................................................................................................... 44
Engine Service ......................................................................................................... 44
Base Gasket Selection .......................................................................................... 45
Engine Removal ................................................................................................... 47
Complete Engine Disassembly Procedure ............................................................ 47
Top End Disassembly Procedure .......................................................................... 48
Splitting the Cases ................................................................................................ 49
Engine Assembly .................................................................................................. 49
Clutch ....................................................................................................................... 51
CLUTCH ASSEMBLY: .......................................................................................... 55
Ignition ...................................................................................................................... 56
Cooling System ........................................................................................................ 57
Radiator fluid removal: .......................................................................................... 57
Fuel & Air System ..................................................................................................... 60
Carburetor ............................................................................................................ 60
Reeds ................................................................................................................... 62
Exhaust .................................................................................................................... 62
Rear wheel pullers ................................................................................................ 63
Brakes ...................................................................................................................... 63
Rear Shock ............................................................................................................... 65
Tuning .......................................................................................................................... 66
Suspension ............................................................................................................... 70
Adjustment ............................................................................................................ 70
Front Fork Operation ............................................................................................. 71
Fork Damping Adjustments ................................................................................... 71
Rear Shock Adjustments ...................................................................................... 72
Carburetion ............................................................................................................... 73
Troubleshooting ............................................................................................................ 76
Index ............................................................................................................................ 78
