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with masking tape, and notice where any curves and creas-
es might occur. The curves and areas where the plastic
tapers in 2 directions will be the most difficult areas to
apply. When you’ve determined the best fit, tape one edge
of the decal securely in place, and remove the tape from
the opposite edge. Lift the decal up and spray a light mist
of water from a squirt bottle onto the entire plastic panel.
This will allow you to dampen the adhesive so it won’t
stick as well during the application of the decal and allow
repositioning if necessary without losing the the final bond.
Carefully align the decal and lay it on the plastic. If the
graphic is not fitting the panel correctly, you can peel it
back up and start over. Start pressing down near the center
of the graphic to ‘work’ the water and any air away from
the center and toward the edges of the decal. Pay extra
attention to creases and irregular areas where the graphic
needs to conform to the plastic in unusual ways. Take your
time and work from the middle of the decal to the edges
pushing out any water and air as you go. The water will
weep out the side of the decal as you reach the edges.
If you’re having trouble with an irregular area, use a blow dryer or heat gun to lightly warm up the decal in order to make it con-
form. The heat will soften the material, so that you can stretch or compress it as needed to make it fit. Use just enough heat to make
the material pliable without melting it.
3. Pre-ride checks
Initial startup
- When motorcycle is at operating temperature, adjust idle speed to the lowest speed at which the motorcycle will run
smoothly by using idle adjustment screw. See photo II-6. Then adjust fuel metering screw. Roll on the throttle rapidly. If the engine
bogs or hesitates, try rotating screw clockwise (leaner) in
1
⁄
4
turn increments until hesitation ceases. If the engine surges or misfires,
rotate screw counterclockwise (richer) in
1
⁄
4
turn increments until bike accelerate smoothly. If the fuel metering screw has to be less
than 1
1
⁄
2
for proper running, consider using a leaner pilot jet. If fuel metering screw is more than 2
1
⁄
2
-3 turns out, install a leaner pilot
jet. The fuel metering screw is normally set from 1
1
⁄
2
to 2
1
⁄
2
turns out from fully seated. Never tighten fuel metering screw, just gently
turn in until it stops, then back out counting the turns to the desired setting. The fuel metering screw can cause overall jetting to be
too rich if it is turned out too far. Note that the fuel metering screw only affects the initial throttle response in conjunction with the
pilot jet until the needle jet takes over at
1
⁄
4
throttle and above.
Regular pre-ride checklist
- Check chain tension and make sure chain is well lubricated and not worn. Check tire pressure, spokes,
all nuts & bolts, steering stem for binding or play, swingarm bolt, engine mounting bolts, oil & coolant levels and condition, lever
and throttle adjustment, & air cleaner. Look for broken or worn parts, leaking fluids, etc. Check brake calipers for proper freeplay
and accumulations of dirt. Clean and adjust as needed to provide proper function.
4. Basic operation & control functions
Engine startup -
Make sure motorcycle has premix fuel, transmission oil and coolant. Make sure air cleaner is installed and proper-
ly oiled. Note that arrow on air cleaner and filter cover must point to front of motorcycle.
Turn fuel valve to ON position (vertical position). See photo II-3.
If engine is cold, lift the choke knob on carburetor and rotate about
1
⁄
8
turn so it stays in the up position. See photo II-4.
Squeeze brake lever to prevent sudden movement upon starting.
Motorcycle is always in gear and may move suddenly when started or whenever throttle is applied.
Push kickstarter down until slack is taken up, then kick briskly with throttle closed. If necessary, open throttle slightly and hold
while kicking. Motor should start readily.
If adult is starting bike, use restraint not to damage kickstarter gears with excessive
force! If bike will not start, find and fix problems rather than just kicking harder!
As engine warms, turn choke knob to return
it to the closed position and apply throttle slightly until bike idles without stalling.
To stop motor, depress kill switch until motor stops. If motorcycle will not start and there is a strong smell of fuel, the engine is
flooded. Turn off choke, open throttle fully and hold open, and kick motor approximately 10 times to clear engine of excess fuel.
Release throttle and try starting again. If engine still won’t start, remove sparkplug and inspect. If plug is wet with fuel, replace plug.
If plug seems to be dry, check fuel valve position and carburetor float and needle valve assembly for proper function.
Remove rubber cap, install vent tube onto vent fitting.
remove &
discard cap
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