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7. Seat removal
To remove seat, loosen large screw at rear of seat using a coin, or a wide, flat screwdriver. When screw is loose, lift up slightly on
rear of seat and slide seat to rear to remove.
To install seat, note slot underneath seat at front. This slot must engage the bolt head on top of the fuel tank. Also note hook
underneath seat. This hook will engage rear of fuel tank. Place seat on motorcycle with slot slightly to rear of bolt on tank. Slide seat
forward, making sure slot engages bolt, and hook engages rear of tank. Push seat forward firmly, then snug screw at rear of seat. Do
not overtighten. Make sure front of seat is properly installed by attempting to lift upwards.
8. Tank removal, checking, gas filter
To remove tank, first remove seat. Use phillips screwdriver to remove tank mounting screw. Disconnect vent hose from fuel cap.
Check to make sure fuel valve is off, then remove fuel line from fuel valve. Lift tank upwards to remove. Make sure rubber pads
located at front and rear of tank in recess that fits over frame do not get lost. A little weatherstrip cement can be used to secure the
pads permanently to the bottom of the tank.
Use care in setting fuel tank down so that the fuel valve does not stick into dirt or
debris and get clogged
. Make sure tank does not spill gas or vent fumes near flame or sparks.
To install tank, make sure fuel valve is not clogged with debris, run a little fuel into a container if there is any question and clean
as required. Make sure two rubber pads are in place inside fuel tank frame recess. Line slots in tank up with two rubber cylinders on
frame and lower tank onto frame. Install phillips bolt into grommet located to the rear and top of the fuel tank. Snug screw but do
not overtighten. Reattach vent hose. Attach carburetor fuel line to fuel valve, making sure end of line is free of dirt or debris.
To check fuel filter, drain fuel and remove tank. Remove two screws attaching fuel valve to bottom of tank using an 8mm socket.
Pull valve out of tank. Clean fuel filter carefully, do not attempt to remove filter from valve. Insert valve into fuel tank making sure
o-ring is in place and not damaged. Install 2 screws and gently snug against valve. Do not overtighten screws or they will strip the
threads in the tank. They only need to be snug for the o-ring to seal effectively. For racing use, you may wish to turn the fuel valve
around so the lever faces inwards. It may be necessary to file the bump on the end of the lever for clearance.
9. Braking system
The motorcycle uses cable operated mechanical disc brakes.
Proper brake function is crucial for safe operation of motorcycle.
For proper operation, they must be kept clean and lubricated and adjusted to specifications
. If brake pads are allowed to wear
out, they may damage the discs, requiring costly replacement. Muddy conditions and improper servicing will lead to rapid brake pad
wear and possible loss of braking. Calipers will need to be disassembled, cleaned and lubricated after riding in muddy or wet condi-
tions.
Front and rear calipers are the same except for the mounting bracket. The foot activated rear brake can only be adjusted at the
caliper, using the adjusting screw on the caliper and cable position adjustment. Replace brake pads when friction material is less than
1mm thick or if the pad surface is badly scored or damaged. Use grease cautiously when lubricating caliper assembly so that grease
does not come out and contaminate the pads or disc.
Check brake rotors for damage, wear and wobble. If wear is noticeable check thickness of rotor several times across face, replace
rotors if they measure less than 2.5mm (.098˝). Use threadlocker on brake rotor bolts, and torque to
XX ft/lbs.
shaft
pad
retaining
bolts
caliper lever
hold hex nut with
wrench, use allen
wrench to loosen
set screw & adjust
cable
nut
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.1
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.2
.2
4 - 5
mm
Front caliper components, rear similar.
Adjust front brake lever play to 4-5mm as shown.
