TABLE OF CONTENTS
3
11 SERVICE WORK ON THE CHASSIS .............................. 38
Raising the motorcycle with a lift stand ..... 38
Removing the motorcycle from the lift
stand ............................................................ 38
Cleaning the dust boots of the fork legs..... 38
........................... 39
Installing the fork legs ............................. 39
Removing the lower triple clamp ............ 40
Installing the lower triple clamp ............. 42
Checking the steering head bearing play ... 43
Adjusting the steering head bearing
play .......................................................... 43
Lubricating the steering head bearing .... 45
Removing the headlight mask..................... 45
Installing the headlight mask ...................... 46
Removing the front fender ......................... 46
Installing the front fender ........................... 46
Removing the shock absorber ................ 47
Installing the shock absorber .................. 47
Installing the air filter box ....................... 48
Removing the air filter box cover................ 49
Installing the air filter box cover ................. 49
............................ 49
Installing the air filter .................................. 50
Cleaning the air filter and air filter box....... 50
Removing the main silencer........................ 51
Installing the main silencer ......................... 52
Removing the fuel tank ........................... 52
Installing the fuel tank................................. 53
Checking the chain for dirt.......................... 54
Cleaning the chain....................................... 54
Checking the chain tension......................... 55
Adjusting the chain tension ........................ 56
Checking the frame ................................. 57
Checking the link fork .............................. 57
Checking the rubber grip ............................ 57
Checking the free travel of the clutch
lever ............................................................. 57
Adjusting the free travel of the clutch
lever ......................................................... 58
Adjusting the basic position of the clutch
lever ......................................................... 58
Checking/correcting the fluid level of
hydraulic clutch ........................................... 58
Changing the hydraulic clutch fluid ........ 59
12 BRAKE SYSTEM........................................................... 61
Checking the free travel of the hand
brake lever................................................... 61
Adjusting the free travel of the hand
brake lever ............................................... 61
Adjusting the basic position of the hand
brake lever ............................................... 61
Removing front brake disc guard ............ 62
Installing the front brake disc guard ....... 62
Installing the front brake caliper ............. 62
Checking the front brake fluid level............ 63
Adding front brake fluid .......................... 63
Checking the front brake linings ................. 65
Changing the brake linings of the front
brake ........................................................ 65
Checking brake discs ................................... 67
Checking the free travel of the foot
brake lever................................................... 68
Adjusting the basic position of the foot
brake lever ............................................... 68
Checking the rear brake fluid level ............. 69
........................... 69
Checking the brake linings of the rear
brake............................................................ 71
Changing the rear brake linings .............. 71
13 WHEELS, TIRES........................................................... 75
Removing the front wheel ...................... 75
Installing the front wheel ........................ 75
Removing the rear wheel ........................ 76
Checking the tire condition......................... 78
Checking tire pressure................................. 79
Checking the spoke tension ........................ 79
14 ELECTRICAL SYSTEM .................................................. 81
Diagnostics connector................................. 81
15 COOLING SYSTEM...................................................... 82
Cooling system ............................................ 82
Checking the antifreeze and coolant
level.............................................................. 82
Draining the coolant ................................ 83
Refilling with coolant................................... 84
Changing the coolant .............................. 84
16 TUNING THE ENGINE................................................. 86
Checking the throttle cable play ................. 86
Adjusting the throttle cable play
Carburetor tuning........................................ 87
idle speed ............................. 89
adjusting the idle speed .... 89
Checking the basic position of the shift
lever ............................................................. 90
Adjusting the basic position of the shift
lever ......................................................... 90
17 SERVICE WORK ON THE ENGINE ............................... 91
.................................................. 91
Checking the gear oil level .......................... 92
Adding the gear oil ...................................... 92
Changing the gear oil .............................. 92
18 CLEANING, CARE........................................................ 94