TABLE OF CONTENTS
3
Bleeding the fork legs.................................. 42
Cleaning the dust boots of the fork legs..... 43
........................... 43
Installing the fork legs ............................. 44
Removing the fork protector ...................... 45
Installing the fork protector........................ 45
Removing the lower triple clamp ............ 45
Installing the lower triple clamp ............. 46
Checking steering head bearing play.......... 48
Adjusting steering head bearing play ..... 48
Lubricating the steering head bearing .... 49
Removing the start number plate............... 49
Installing the start number plate ................ 49
Removing front fender................................ 50
Installing front fender ................................. 50
Removing the shock absorber ................ 50
Installing the shock absorber .................. 52
Removing the seat....................................... 53
Mounting the seat....................................... 54
Removing the air filter box cover................ 54
Installing the air filter box cover ................. 55
............................ 56
Cleaning the air filter and air filter
box ........................................................... 56
Installing the air filter .............................. 57
Preparing air filter box cover for
securing ................................................... 57
Removing the main silencer........................ 58
Installing the main silencer ......................... 58
Changing the glass fiber yarn filling in
the main silencer ..................................... 58
Removing the fuel tank ........................... 59
Installing the fuel tank ............................. 60
Checking the chain for dirt.......................... 61
Cleaning the chain....................................... 62
Checking the chain tension......................... 62
Adjusting the chain tension ........................ 63
Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 64
Checking the frame ................................. 66
Checking the link fork .............................. 66
Checking throttle cable routing .................. 66
Checking the rubber grip ............................ 67
Adjusting the basic position of the clutch
lever ............................................................. 68
Checking/correcting the fluid level of the
hydraulic clutch ........................................... 68
Changing the hydraulic clutch fluid ........ 69
12 BRAKE SYSTEM........................................................... 71
Checking the free travel of the hand
brake lever................................................... 71
Adjusting the basic position of the hand
brake lever................................................... 71
Checking the brake discs............................. 71
Checking the front brake fluid level............ 72
Adding front brake fluid .......................... 72
Checking the front brake linings ................. 74
Changing the brake linings of the front
brake ........................................................ 74
Checking the free travel of foot brake
lever ............................................................. 76
Adjusting the basic position of the foot
brake lever ............................................... 77
Checking the rear brake fluid level ............. 77
........................... 78
Checking the brake linings of the rear
brake............................................................ 79
Changing the rear brake linings .............. 79
13 WHEELS, TIRES........................................................... 82
Removing the front wheel ...................... 82
Installing the front wheel ........................ 83
Removing the rear wheel ........................ 83
Checking the tire condition......................... 86
Checking tire pressure................................. 86
Checking spoke tension............................... 87
14 COOLING SYSTEM...................................................... 88
Cooling system ............................................ 88
Radiator cover ............................................. 88
Installing the radiator cover........................ 88
Removing the radiator cover ...................... 89
Checking the antifreeze and coolant
level.............................................................. 89
Checking the coolant level .......................... 90
Draining the coolant ................................ 91
Refilling with coolant ............................... 92
Changing the coolant .............................. 93
15 TUNING THE ENGINE................................................. 95
Checking the play in the throttle cable....... 95
Adjusting throttle cable play ................... 95
Carburetor tuning........................................ 96
idle setting ............................. 98
Carburetor - adjusting the idle speed ..... 99
Plug-in connector of ignition timing
map adjustment ....................................... 100
Changing the ignition timing map............ 100
Checking the basic position of the shift
lever .......................................................... 100
Adjusting the basic position of the shift
lever ...................................................... 100
16 SERVICE WORK ON THE ENGINE ............................ 102
............................................... 102
Checking the gear oil level ....................... 103
Changing the gear oil ........................... 103
Adding the gear oil ............................... 104
17 CLEANING, CARE..................................................... 106