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4. Coolant
Filling cooling system
- When engine is cool, unscrew radiator cap slowly to release any pressure safely.
Do not open when warm
or hot!
Fill the radiator until liquid reaches opening. Wait a few minutes for the coolant to reach all the internal cavities, top off
coolant as needed. Coolant must be visible over internal fins, but does not have to reach all the way to filler neck. Screw radiator cap
back on. Start engine and run for a few minutes, making sure to engage clutch and spin rear wheel. After engine cools, remove cap
and recheck coolant level. Add coolant if required. Screw cap back on. Coolant level must always be checked when engine is cool.
Check each day before riding, and after every race. If the radiators were just filled, some coolant will initially escape as the motor
warms up. If coolant suddenly begins to discharge from the vent tube, look for a combustion chamber leak, improper timing, or lean
jetting. Use motorcycle coolant only, automotive antifreeze contains abrasive silica and may damage water pump seals. Read con-
tainer before use to determine if antifreeze needs to be diluted before use. Use antifreeze if freezing is possible to prevent engine
damage. Engine Ice
®
motorcycle coolant is recommended as it will lower operating temperatures and is non-toxic. Keep ALL
antifreeze away from children and pets!
Note:
Water pump does not turn unless motorcycle is moving. Do not idle motorcycle for extended periods to prevent overheating.
5. Air filter cleaning
It is crucial to performance and engine life that the air filter be clean and properly oiled at all times. Proper cleaning is necessary to
remove dirt which could severely damage the engine, dirt buildup will also cause the motorcycle to run very rich and lose power rapid-
ly. The filter should be cleaned and re-oiled approximately every two hours of use under normal conditions, much more often during
dusty or wet conditions. Cleaning filter or using a freshly oiled air filter before every race is advisable. If water is used to clean the fil-
ter, the filter MUST be completely dry before re-oiling, or the water will evaporate leaving un-oiled portions of the filter which will
allow dirt and dust to pass directly into the motor. If the air filter gets soaked in water during use, it must be cleaned as soon as possible
because the water can displace the filter oil.
Performance wise, having a clean air filter is the single most important item on the
motorcycle and requires the most maintenance.
Purchasing one or more extra filters is a very good investment.
UNDER NO CONDITIONS USE GASOLINE OR OTHER FLAMMABLE LIQUIDS TO CLEAN FILTER.
In addition to creating an extreme fire hazard, these liquids will damage the filter foam over time, making it brittle and dissolving
the glue used to make the filter.
1. Clean your filter with Maxima, Twin Air air filter cleaner, or kerosene to remove all the oil residue.
2. Next, wash your filter twice with dish soap and hot water. Rinse a third time. Do not stretch or twist the filter. Be careful not to dam-
age or crush the seams at the corners of the filter.
3. Let filter dry
completely,
or else water will prevent oil from properly coating filter and will allow engine to suck dust through filter.
Use a hair dryer or leave filter in the sun to dry it more quickly.
4. Now that filter is totally dry, hit the filter on your hand to get all the dirt out. If you do this over a piece of paper or cardboard you
can see & hear the dirt falling onto it.
5. Now apply the filter oil, Maxima FFT Foam Filter Treatment is preferred as it is not prone to dripping into the carburetor and is
resistant to washing out by water or gas vapors. Using a plastic bag, put your filter into it and pour in some filter oil. Totally saturate
the filter with oil, making sure there are no dry spots. Squeeze out excess oil. Grease the groove on the aircleaner where it presses
onto the airbox to prevent air leaks. Make sure to use extra grease in the corners. Install filter with arrow to front
,
making sure groove
in air cleaner fits over sides of air box. Press filter cover over filter with arrow pointing to front to secure filter in place. Note that
spray air filter lubes must also be liberally applied, then squeezed, then the excess removed to insure full coverage. For racing use, a
long zip tie, or several attached together can be wrapped completely around air box and filter cover to insure positive retention.
6. Changing transmission oil
Change transmission oil often to remove clutch wear particles and other contaminants from transmission. Changing oil fre-
quently will greatly reduce the amount of clutch adjustment and cleaning required as well as reducing wear in the transmis-
sion.
Change oil after every race or at end of each riding day. Note that the Maxima MTL 75 transmission fluid is specifically for-
mulated to extend clutch life
and is strongly recommended!
To change the transmission oil, support motorcycle in a level position. Unscrew drain bolt on bottom of transmission cases using a
6mm allen wrench and remove drain screw from clutch side cover to fully drain oil. Drain oil while it is hot from riding to facilitate
draining of oil and wear debris. Dispose of used oil properly. Replace the transmission drain bolt and torque to 15 ft/lbs, install and
snug the transmission cover screw. Refill transmission using 10 oz. of recommended gear oil (Maxima MTL 75) through the upper
level checking screw. The vent hose fitting can also be removed and oil added there. (vent hose fitting is behind the coolant hose at
rear of cylinder) A ketchup squeeze bottle with a pointy tip is useful for injecting oil into screw hole. Mark the proper level on the
container so the right amount can be dispensed in the future without measuring. Check oil level after filling.
To check oil level, support bike in a level position and remove oil level check screw from side of case (screw is below kickstarter).
Oil should flow from hole. Add oil or allow excess oil to drain as required.
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