TABLE OF CONTENTS
3
11 SERVICE WORK ON THE CHASSIS .............................. 44
Raising the motorcycle with a lift stand ..... 44
Removing the motorcycle from the lift
stand ............................................................ 44
Bleeding the fork legs.................................. 45
Cleaning the dust boots of the fork legs..... 45
Removing the fork protector ...................... 46
Installing the fork protector........................ 46
........................... 46
Installing the fork legs ............................. 47
Removing the lower triple clamp ............ 48
Installing the lower triple clamp ............. 49
Checking the steering head bearing play ... 51
Adjusting the steering head bearing
play .......................................................... 51
Lubricating the steering head bearing .... 52
Removing the start number plate............... 52
Installing the start number plate ................ 52
Removing front fender................................ 53
Installing front fender ................................. 53
Removing the shock absorber ................ 54
Installing the shock absorber .................. 55
Removing the seat....................................... 56
Mounting the seat....................................... 57
Removing the air filter box cover................ 57
Installing the air filter box cover ................. 58
............................ 59
Cleaning the air filter and air filter
box ........................................................... 60
Installing the air filter .............................. 61
Preparing air filter box cover for
securing ................................................... 61
Removing the main silencer........................ 61
Installing the main silencer ......................... 62
Changing the glass fiber yarn filling of
the main silencer ..................................... 62
Removing the fuel tank ........................... 63
Installing the fuel tank ............................. 65
Checking for chain dirt accumulation ......... 67
Cleaning the chain....................................... 67
Checking the chain tension......................... 68
Adjusting the chain tension ........................ 69
Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 70
Checking the frame ................................. 72
Checking the link fork .............................. 72
Checking the throttle cable routing............ 72
Checking the rubber grips........................... 73
Adjusting the basic position of the clutch
lever ............................................................. 74
Checking/correcting the fluid level of the
hydraulic clutch ........................................... 74
Changing the hydraulic clutch fluid ........ 75
12 BRAKE SYSTEM........................................................... 77
Checking the free travel of the hand
brake lever................................................... 77
Adjusting the basic position of the hand
brake lever................................................... 77
Checking the brake discs............................. 77
Checking the front brake fluid level............ 78
Adding front brake fluid .......................... 78
Checking the front brake linings ................. 80
Changing the brake linings of the front
brake ........................................................ 80
Checking the free travel of foot brake
lever ............................................................. 82
Adjusting the basic position of the foot
brake lever ............................................... 83
Checking the rear brake fluid level ............. 83
........................... 84
Checking the brake linings of the rear
brake............................................................ 85
Changing the rear brake linings .............. 85
13 WHEELS, TIRES........................................................... 88
Removing the front wheel ...................... 88
Installing the front wheel ........................ 89
Removing the rear wheel ........................ 89
Checking the tire condition......................... 92
Checking tire pressure................................. 92
Checking the spoke tension ........................ 93
14 ELECTRICAL SYSTEM .................................................. 94
Removing the 12-V battery ..................... 94
Charging the 12-V battery ....................... 95
Changing main fuse..................................... 96
Diagnostics connector................................. 97
15 COOLING SYSTEM...................................................... 98
Cooling system ............................................ 98
Checking the antifreeze and coolant
level.............................................................. 98
Checking the coolant level .......................... 99
Draining the coolant ................................ 99
Refilling with coolant ............................ 100
Changing the coolant ............................... 101
16 TUNING THE ENGINE.............................................. 102
Checking the play in the throttle cable.... 102
Adjusting the play in the throttle
..................................................... 102
Adjusting the characteristic map of the
................................. 103
Adjusting the idle speed ....................... 104
Programming the throttle valve
position..................................................... 105
Checking the basic position of the shift
lever .......................................................... 106
Adjusting the basic position of the shift
lever ...................................................... 106