1
1. OPERATING INSTRUCTIONS ............................
2
Fuel ..................................................................
2
Basic Operation ..............................................
2
•
Starting The Engine ................................
2
•
Stopping The Engine ..............................
3
•
Break-In Procedure .................................
3
Contotls ...........................................................
4
Control Adjustment .......................................
5
•
Clutch Lever Free Play ............................
5
•
Clutch Lever Position ..............................
5
•
Hot Start ..................................................
6
•
Throttle Grip ............................................
6
•
Front Brake Lever ....................................
7
•
Brake Pedal Height .................................
7
Adjustment For Personal Fit .........................
8
•
Control Positioning .................................
8
•
Handlebar Position, Width & Shape .....
8
•
Additional Individualized
Adjustments ............................................
8
2. SPECIFICATIONS ................................................
9
3. OPTIONAL PARTS .............................................. 10
Optional Parts List .......................................... 10
4. SERVICE AND MAINTENANCE ......................... 11
Pre-ride Inspection Check List ....................... 11
Maintenance Schedule .................................. 11
General Service Information ......................... 12
Between Moto/Between Practice And Moto
Maintenance ................................................... 12
After Race Maintenance ................................ 13
•
After Race Lubrication ............................ 13
•
Routine Cleaning .................................... 13
•
Pressurized Spray Washers ................... 13
•
Condensation Control ............................ 13
•
After Cleaning Lubrication ..................... 13
General Maintenance .................................... 14
Maintenance Preparations ............................ 17
•
Seat .......................................................... 17
•
Fuel Tank .................................................. 17
•
Subframe ................................................. 19
Maintenance Procedures ............................... 21
•
Engine Oil ................................................ 21
•
Transmission Oil ..................................... 23
•
Coolant .................................................... 24
•
Spark Plug ............................................... 25
•
Ignition ..................................................... 26
•
Engine Idle Speed ................................... 26
CONTENTS
•
Crankcase Breather ................................. 27
•
Air Cleaner ............................................... 27
•
Clutch ....................................................... 28
•
Valve ........................................................ 30
•
Piston/Piston Rings/Piston Pin ............... 39
•
Handlebar And Steering Head
Bearings .................................................. 47
•
Throttle Grip ............................................ 47
•
Fuel Line .................................................. 48
•
Front And Rear Wheels And Tires ......... 49
•
Front Suspension .................................... 49
•
Rear Suspension ..................................... 50
•
Brakes ...................................................... 51
•
Drive Chain .............................................. 52
•
Drive Chain Sliders ................................. 54
•
Drive Chain Rollers ................................. 54
•
Driven Sprocket ...................................... 55
•
Exhaust Pipe/Muffler .............................. 55
•
Control Cables ......................................... 57
•
Nuts, Bolts, Fasterers ............................. 58
5. CARBURETOR ADJUSTMENT .......................... 61
•
Carburetor ............................................... 61
•
Tuning For Special Conditions ............... 70
•
Spark Plug Coloring Indications ............ 70
6. SUSPENTION ADJUSTMENT ........................... 71
•
Race Sag .................................................. 71
•
Rear Suspension ..................................... 72
•
Front Suspension .................................... 74
•
Suspension Adjustments Relating To
Specific Track Conditions ....................... 90
•
Suspension Adjustment Guidelines ...... 91
7. CHASSIS ADJUSTMENTS FOR TRACK
CONDITIONS ...................................................... 94
•
Rear End .................................................. 94
•
Fork Height/Angle ................................... 94
•
Wheelbase ............................................... 94
8. GEARING SELECTION ....................................... 94
9. TIRE SELECTION ................................................ 95
10. MAINTENANCE, TUNING & RACING
LOGBOOK ........................................................... 96
11. SPARE PARTS & EQUIPMENT ........................... 98
12. TROUBLESHOOTING ......................................... 99
•
Poor Performance At Low And
Unstable Idle Speeds ............................. 99
•
Poor Performance At High Speed ......... 99
13. CLEANING ........................................................... 100
14. STORAGE ............................................................ 101
•
To Prepare The Motorcycle For
Storage .................................................... 101
•
Removal From Storage .......................... 101
15. WIRING DIAGRAM ............................................. 102
16. INDEX .................................................................. 103
17. AUTHORIZED MANUALS .................................. 105
