CONTENTS
2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES ............................................................ 6
MOTORCYCLE..................................................................... 7
01/FORK, TRIPLE CLAMP.................................................... 8
Adjusting the compression damping of the fork .................. 8
Adjusting the rebound damping of the fork......................... 8
Bleeding fork legs............................................................ 8
Cleaning the dust boots of the fork legs ............................. 9
Removing the fork protector.............................................. 9
Installing the fork protector .............................................. 9
Removing the fork legs................................................... 10
Installing the fork legs ................................................... 10
Adjusting the fork overhang ............................................ 11
Removing the lower triple clamp ..................................... 12
Installing the lower triple clamp...................................... 12
Greasing the steering head bearing.................................. 13
Checking play of steering head bearing............................ 13
Adjusting play of steering head bearing............................ 13
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 15
Adjusting basic position of clutch lever............................ 15
Checking play in gas Bowden cable ................................. 15
Adjusting play in gas Bowden cable................................. 15
Handlebar position ........................................................ 15
Adjusting handlebar position .......................................... 16
04/SHOCK ABSORBER, SWINGARM................................... 17
Adjusting the compression damping of the shock
absorber ....................................................................... 17
Adjusting the rebound damping of the shock absorber....... 17
Measuring rear wheel sag unloaded ................................. 17
Checking the static sag of the shock absorber .................. 18
Checking the riding sag of the shock absorber .................. 18
Adjusting the spring preload of the shock absorber ........... 18
Adjusting the riding sag ................................................. 19
Removing the shock absorber ......................................... 19
Installing shock absorber................................................ 20
05/EXHAUST .................................................................... 21
Removing the exhaust manifold ...................................... 21
Installing the exhaust manifold ....................................... 21
Removing main silencer ................................................. 22
Installing the main silencer ............................................ 22
Changing the glass fiber yarn filling of the main silencer ... 23
Removing the glass fiber yarn filling of the main
silencer ........................................................................ 23
Installing the glass fiber yarn filling of the main silencer ... 23
06/AIR FILTER.................................................................. 24
07/FUEL TANK, SEAT, TRIM.............................................. 25
Removing the seat ......................................................... 25
Mounting the seat ......................................................... 25
Dismounting the fuel tank .............................................. 25
Installing the fuel tank................................................... 26
08/MASK, FENDER ........................................................... 28
09/FRONT WHEEL ............................................................ 30
Removing the front wheel............................................... 30
Installing the front wheel................................................ 30
Checking the tire condition............................................. 31
Checking tire air pressure............................................... 31
Checking brake discs ..................................................... 31
Checking spoke tension.................................................. 32
10/REAR WHEEL .............................................................. 33
Removing the rear wheel ................................................ 33
Installing the rear wheel................................................. 33
Checking chain dirt ....................................................... 34
Cleaning the chain......................................................... 34
Checking the chain tension ............................................ 34
Checking the chain tension - installing rear wheel............. 35
Checking rear sprocket / engine sprocket for wear ............. 35
Adjusting the chain tension ............................................ 35
Adjusting chain tension - after checking .......................... 36
Adjusting chain tension - installing rear wheel.................. 36
Adjusting the chain guide............................................... 36
13/BRAKE SYSTEM........................................................... 37
Checking free play of hand brake lever............................. 37
Adjusting basic position of handbrake lever...................... 37
Checking the front brake fluid level ................................. 37
Adding front brake fluid ................................................. 38
Checking the front brake linings...................................... 39
Removing front brake linings .......................................... 39
Installing the front brake linings ..................................... 39
Changing the front brake linings ..................................... 40
Checking the free travel of the foot brake lever ................. 41
Adjusting the free travel of the foot brake pedal................ 41
Adjusting the basic position of the foot brake pedal .......... 41
Checking rear brake fluid level........................................ 42
Adding rear brake fluid .................................................. 42
Checking rear brake linings ............................................ 43
Removing rear brake linings............................................ 43
Installing the rear brake linings....................................... 44
Changing the rear brake linings....................................... 44
30/ENGINE....................................................................... 46
Removing the engine ..................................................... 46
Installing the engine ...................................................... 47
30/DISASSEMBLING THE ENGINE..................................... 50
Clamping the engine into the engine work stand ............... 50
Removing the clutch pressure piece ................................ 50
Removing the oil drain plug............................................ 50
Removing the spark plug ................................................ 50
Removing the exhaust control ......................................... 50
Removing the cylinder head............................................ 51
Removing the exhaust control valve ................................. 52
Removing the cylinder ................................................... 52
Removing the piston ...................................................... 52
Removing the engine sprocket ........................................ 52
Removing the distance bushing ...................................... 53
Removing the generator cover ......................................... 53
Removing the rotor ........................................................ 53
Removing the stator....................................................... 54
Removing the kickstarter................................................ 54
Removing the water pump cover ..................................... 54
Removing the clutch cover ............................................. 54
Removing the outer clutch hub ....................................... 54
Removing the primary gear ............................................. 55
Removing the kickstarter shaft........................................ 56
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