INTRODUCTION Hams _INSP py PERIODIC MAINTENANCE/LUBRICATION 914848 / 333 _ ADJ PERIODIC INSPECTION AND ADJUSTMENT 2X16 Rin INTRODUCTION {Th chapler cdo alcermation necessary to perform recorenendod inspactons and adjsments,Thate preventive maintenance procedures. ¢ totoued wil ensure more relabe vehicle operation ard a lnge service He The need tr cst overhaul work wil be ieahy ened re Pion pple veticls area in senicw as well as now vehicles ta! ae beng prepared or sale. Al sand ecnlans hose Os tanta anes Chapter Fa Fe cens SRETATOMM AMOR ROSHAN. NUMHKOD SENNA RRET a TORORRGURAERTR OHMEDTEER-ENLRA MEMTNAN ABRONTAMTCARNENA TIGERS CHOATREMELOARSORS PERIODIC MAINTENANCE/LUBRICATION Unik ites) [ EVERY ‘BREAIGIN | &000%m | 12000Km mem REMARKS mam | 000) | e000)” a0 an 1,000 600) | oF month |or 12 month mame an seam ‘Spank pug A (Check conten. Cean or replace necessary WARNE WREEREN > 0 ‘Ar for 048 Clean Reiace necessary. MER IGE FH ‘Check de spesdstaner opranon Aust t necessary. MSIE HE: AIR ‘Chock uo Rose for cracks er damage Fusline wane | agen weTomasR > Replace #naceesay, RI CCaburote eat ‘Check ol evel leakage, Coreet fcessaly Replace every 24,000 16.000 a 24 meth Transmission of” auaGNGTad-aREN AEA Repuace atans ‘su 2cco0 abe 12 wae = (Warm engine bear cainng (188-4 :884 8) 7 (Check operation Corec f nacessay. Ar bleeding, ‘Autouive pump’ amen | Gace gowaton. Corea ns usual (Check operation eakage’See NOTE. BART [aa ONT = Conectt necessary. sR BaP a Orr Check operation. Acjustf necessary. WERT WR ‘Check swingarm assembly fr eosoness, Correct i necessary Moseratoly rack every 24000 (16,000) or 2¢ mons “= MERHMTHRAO MIRE UR BAL 5M 2400028 2418 8 AR (Chock balancaldanagenanout Ropar # necessary a : mT m RN mae eR Re a Shock bearings assem or losenessicamage, Replace ¥daraged MMM ee Wein (Soech bearings assembly for loosoness. Corect# nacoasan - Meratey repack every 26009 (16,000) or 28 months "= ‘Stee0g bearing oe aguaeeRe angi i SM2ACOORBAt2Sm 2 A 4 ‘Gheck operational leakage. Repair necessary, 2 reid - Fear shock absorber” | Check operational leakage. Repair nacoscary ane SEAT aRKA am BI ¢ ‘Ghack coolant wakage. Ropar ¥ necessary Replace Golan every 24,000 (18000) 0” 24 mans Ma tmms smn. mazes : Swingarm pv tig RAN Wrens ee Wel bearing” mabe Fronts” 2.0 Cooling system ak 2areeswa ; ‘Check chan Sacallgnment. Adis W necessary. rie chan 9a a erremuuns-aapan EVERY 500 200) Cesnarc ube ARS MEH ‘was002 ‘Check al chasss Hs an fastners | FringsFasteno ASH | me mnaR Hae teem) c ¢ Covet necessary, ARB BEER ‘hack speci rau. Check breather pipe for proper eperaton Baten” 5: SUCKALS NeaRE TREE Consett recoseay. REM FEL tis tecommended that these items be serviced by a Vamaha dealer “AAA EReMMNnRE Mecium weight wheel bearing grease. Seanunnas “*: Lithium soap base grease. “REAR 23[INSP I¢ 5 PERIODIC MAINTENANCE/LUBRICATION £mit#t/ Mit | ADJ _ NOTE: — Brake id replacement: 1 When dsassembing he master cyinder or caliper cylinder, replace the brake fis, Normally check the bake fid level and add the fluid as required, 2, On the inner pars othe master cylinder and caliper cylinder, replace the ol seals every two years 53, Replace the brake hoses every your years, orf cracked or damaged, ae: eeMnn eR 1 SRPMS ARMA KRM Me ONAER VRREIMMERATRREDE MADER 2 WATRRME FORMA ORR REER 3 SBROSERUBNE MRMHMRE HIE Ce O iam 24— a 7 COWLINGS Bata | AD. PY | COwLINes aaa Q Rearview miner @) Side coo! et) Qums Qn 2) Wind sereen © Side cow! ght) @aza Oana S) nner para © Front cow Drax Oun dover com 7 OrsSEATS, FUEL TANK AND SIDE COVER aa. tatsimingt | AD, SEATS, FUEL TANK AND SIDE COVER ae aOR Q seat Ore @aabbar @ue @ tateover es @ sie cover Oun G3 side pane 5) sui Fuel tank Onan 26YPVS CABLES ADJUSTMENT YPVS saan iene LADJ INSP ENGINE 318 YPVS CABLES ADJUSTMENT There 7 = Puey cover (poe vat) @) 2. Tune main sea oe YPVS san en ene et Prana erm® 2 amuse "nasa wore: 1 des ro opr ho YPVS mtr ort SYSTEM nthe GHAPYENS au SRSWMARAYEVSHe-AMZeEHAR "YPvSE, aT. "YPVS 8. Check + Alignment mark) Not akgned ~+ Adust the YPVS cables. 4 Adjust +“YPVS cables 3 8m ems foxwi 5 fate YPVs sue» 4 ae + Yevs aie Austen tps *Pulback We adustr covers + Loosen both eckrts CS) and um in both adjusters + rset a pin (4 fo4 me (00.16in] trough tha eons sere inthe pulley ard into re hole + Tum bot adjusters, counterclockwise so that fhe cable tee play becomes Zara mm (Zero in) wih gers + Tum bth aghster 1a tun cecowae + Tighten he eck Rhee Diam a ahanaves @ romsamnanan @. + RAAB LONI RE MM ARTO aesEn [0.16 %t)) AT ERM ORMROREEN eRROKTERE- NN ss MALARIA 14 + agmneEs ‘and check that the alignment marks Llocknuts: 10 Nm (1.0 m = kg) ‘838A E10 Nm (1.0 mg) + Romove th pin + Tumon the main ewitch aaned + If no, repeat the above steps. Push in the adjuster covers + Boas + REMMREM EAC + Oe Moe + aomaRORG- enneauescune. IDELE SPEED ADJUSTMENT 1. Start the engine and lt it warm up for several minutes 2. Attach: ‘+ Inductive tachometer (@) tothe spark plog load, samme 1 ERS coca mamm 2 - BATES 2 aiamwan() 2IDLE SPEED ADJUSTMENT/ THROTTLE CABLE FREE PLAY ADJUSTMENT |INSP | gy REVMKMMERAMMBaATEMMe | ADJ |= 28 3. Check + Engin idle spect Outof specification + Adjust. 3. en + cieeean- OR RATE — wm - Engine idle speed: 1200 ~ 1300 rmin yey] Siem wou eto sro 4, Adjust: + Engine idle speed 4 me ery Adsiment stops Turmithe tar sew C) unt ts ght sated {Tum out th plot ar scrow forthe spocted numb of uns. Rese “ievanman@menn o- + SMTOMNERERO ARMM Pilot air sorew: 1a tums out 2mm ie 48 + Tumtnemrcte stop srew (@) no out ntl specs Speed btained + itnenmananed © smemecneenase “Tum in ke speed becomes higher. sna eee Tum out ~ kde speed becomes lower akan seem ‘THROTTLE CABLE FREE PLAY ADJUSTMENT AMR ae TRO NOTE: Belore adjusting the thotle cable tre play the engine ide speed should be adlustes. a HERRReReTABAMaMO ETE 1 hex Pe onsen ny @ Out! spection Adee Lae nawesce® eee Throttie cable fr play: 3 ~ 5 mm ] AM MMA BE: 3-5 Ex |AUTOLUBE PUMP CABLE ADJUSTMENT &BbM# 29 [INSP ummm | ADJ | 2. Adjust: + Throttle cable tee play 2 ae sara nestor ‘Adjustment steps * Loosen the lockrut @) + Tum he acuster (2) in or et unt th conect re pay is obtained magn: + anaes @. + RRGERMMH OQreermeeeRy- [Turning n= Free pays inoreaced as eiHem at ee Tuming 0 i Fae la 6 dorased mo ‘+ Tighten the locknut (1) uxasis )- LA WARNING After aqjusting th fre play, turn the handle-bar to right and let and make sure that the engine idling does not run faster wa: Bae amemE ae MEE ESI Bee eR. ‘AUTOLUBE PUMP CABLE ADJUSTMENT AbARARmeM Nore: a Belore adjusting Avtolube pump cable, throttle cable hee pl ‘and YPVS cables should be adjusted au SWARM RAR aM sIRA HR YPVS Bem nemAUTOLUBE PUMP STROKE ADJUSTMENT A RR aR (THe 20 INSP. ADJ 1. Adjust: + Auolube pump cable 1 me Rpm Adjustment ene octnut Cs leosoned at wre adusing potion of tec pump cable «+ Fhe tte ori is opened uly. {im me orp tty pene, the ol pump cade achuster @)is turned soa to align he mark (8) orl pulley opening wh the aignment mark (a) on the Unit + The oeinut forthe ol pump cable i tightonee nese: cig aan nomen Dt 2 aneeem: 2 Shaeeny oemaarmannan@*@Oeunne PEG) HeRane mMcRT moe + Smee one LSM) - NoTE: Inthe corwantonal pump, this adjustments made by aligning the ‘Quide pin with the abgrment mark me: AROAAAT SRRMARY MER MTA MET AUTOLUBE PUMP STROKE ADJUSTMENT Disconnect Ol dover hose ol tank ol pump) @) 1 Oi deter hse {of pump —carouror ny @) anAtaRianme oa | Raewene canemmes) 2 Rhamame(anescaitay@ om Pg to al se goa lil tun ou oe tank a SGnaeneusaaane: 2. Remove «sea cin roca) scone ® autlae pump cable @) 2. hae SiLsamo maser) 3. © “aomansma® Note: aa eee ‘Tur the pump puley dlockwise by inger to make the pump cable loose enough for its end tobe rertoved from the pulley. mi: AFROSHFOMNARAG SEMA BTR CG RE LERAUTOLUBE PUMP STROKE ADJUSTMENT AnmARARiBmMe | ADJ an LINSP | 5. Adjust * Autolube pump minimum stoke 5 ate + AbR RARE Miriam pump stoke: 0:28 ~ 0.27 mm “| Ama M TH 020-027 Bx pee tee Aajucten sepa, “ferowe be te pg @D) + hatte gl nie + Werte sar ga penton tee (heath ate Sly ages hb kgaert nan Srcun + Trepumo ive gear is turesby ner so ae most Durga enchsigi dane Bate anetes tN Sie ove mu + Thommen are, 5 Lowen ect * Tum in ade) 1 ut nt conec inimum ste is obtained. © + ReANEOT ARK K URRMMLO “O° MUNEEE teneng) + Areaweremen ©). saneen mtmescie HaRe rita + aes seeame + akaRen @)- + omaoMeNNEN @-eNarmMEH y- Tum in -> Pump stroke is increased, FPR aes aetm ‘Turn out-» Pump stroke is decreased. AaSM ama & tan ae POting *Oua + ole @ tae Bots (Awolube pump: 5 Nm (0.5m = Ka (88 NIAE) BIH 5 Nm Osmo) 7, connec + Autolube pump cable 2) iret +, Steppe" lp (pump cable) @) ©. Comet + Ol dover hose ol tak i pup) + Oleivay hose (ol pump ~carbureta fn (@) 10. Air blood * Aol pup + elorto the “AUTOLUBE PUMP AIR BLEEDING" secon aa © + eames 8 ee eo) a S Raewene (eae anas + ZAaweneacencaas © todas Tpenpan Bsa "heasasnonws, aAUTOLUBE PUMP AIR BLEEDING AND SPARK PLUG INSPECTION INSP | BnARaRneaMeA eRe | ADS 22 AUTOLUBE PUMP AIR BLEEDING 4. Air bleed: ‘Pump case andor ol pipe ANARARATENeH 1. oReam + ae N/E Airbleeing steps: Spomove te Bleed screw meKnEnee *simzeinis G) ores POEs a vag undo the autolobe pup to catch he of mE: ATARARAR Tie eeHwOR Koop the oll running out untl air bubbles disappear 1 When airbubbles are expelled completely, ighton the bleed . ERS BRERL ETHERMABLL- L Rama oie eNO ae Check the blead sorew gasket, and if damaged, replaced wih a ae Aawitemnasese oR HeINR RL AIH 2 Aibloed Mpump dstibutor andor delivery pipe 2. ame Snes Tine MAE Air bleeding steps: Mpomewe he cp (). Disconnect the devery pipe + Stat the engine + Purthe pump eable 2) allthe way out ose the pump stoke amanmum renames oars 2 xm Diane Qneanrmanncs Nore: —_ Ths cficul to blood the dtibutor complately with the puro Stoke al @ minimum, and therefore the pump stoke should be sett a maximum. ae BF AR Tm MAMMA aS RMA MEET BA Mane RA ALTE 7"Reep te aoe unring at abut 2,00 rin for wo minutos Coe a bus and dong pp canbe completely fea «fst ne op ©. + aayeiie ptcome mee ME sO HEH Sieenpeastnwee = mae) ‘SPARK PLUG INSPECTION 1 Inspect ‘+ Spark plug type Incorrect ~» Replace, re 1 ae eR BU TLE ‘Standard spark plug: BR9ES (NGK) PiFRIBSEC TEM BROES (UGK) aENGINE OIL LEVEL INSPECTION 313i (sim) 888 | ADJ INSP 2. Inspec: + Erecrode (D) WearDamage — Replace. = + Ineuator 2) — ‘Abrormal colar» Replace ——— Normal color is a medium-to-ight tan color. 3 2 wie: — + eH ay eee Sms + emmnsie@ 2 REE Fie PROAM BOE TAMRE 3. Clean the sparkplug witha sparkplug cleanor or wie brush 4 Measure "Pug gap @ Use a wire Gauge or feeler gauge. — ‘Out of specification -> Regap. = 7 ——> —7 enaenmarres ® = moran ser ‘Spark pug gap: 0.7 ~ 0.8 mm FRM 07-00%% sew | ENGINE OIL LEVEL INSPECTION 1. Check + Oillovel Cillovel low -+ Add suticient oi Sema TNA 1 a make WexKTEE FRM Recommended ol: Aircooled 2 stroke engine of Oil tank capacity: 12 AGA aes RI wamem 122% | ® wrindeaterignn — © rman, wae [ outevetinaeter cicon once Santenemoa ‘i evel iar igh oes it come on mene ———} Peter to heSIGNAL SYSTEM" inthe CHAPTERS MeeW a ORR, aT ee an onic OF Gear in NEUTRAL” ‘aaamEy wegen baron ue [ Grieve nicator tht comes or ort ‘Shiki gear amas yo eee ‘Oi level ete light comes on | Engin al ovelandeeccal crcuf are OK Go aneee win ing nome Raa mone Le 33 PaceTRANSMISSION OIL LEVEL INSPECTION AND [Rep] TRANSMISSION OIL REPLACEMENT _INSP | ADURMRAKTHERROmEM Ame | ADJ @ Yims conan ty Shot Fu Ltrs Yona Fine Snel wae Ree 34 ‘TRANSMISSION OIL LEVEL INSPECTION WnERAR ARTO NoTE. Cee ee eee Positon the motorcycle straight up when inspecing the ol eval a: Raumexts TEeARN 4. tnspec: #Ollevet Ot ove should be between ep of the ol evel inspection window (1) and minimum (2) mark Oitevel ow =» Add oto proper level 1 ae aaxy arien seen taws Onnnxeaa®2n- Max FR SAS RAE Recommended oi: SAE 10W30 type SE motor oi femmia- SAETOW30 SE mnt gine and let it warm up for several minutes, ngine and inspect the ol evel once aga. EMSs KRM OEMAHZA ROTA TRBM EXE: 2 a 2 3 NOTE: SesESECEESSEESEESEENEEEEnEEGEEES ‘Wait afew minutos until the oll seties before inspeding the ol lovel me: ARM IEA MULE BIKE ‘TRANSMISSION OIL REPLACEMENT aneR AER + Do:not add any chemical adtives. Engine ol aso lubreates the clutch and additives could cause clutch slippage. + Do not allow foreign material o enter the crankease, aE: RRAMEGMUNLMEON- WARRANT A SONSRBBMS OTR RRMA PEAR ‘Star the engine and let it warm up for several minutos ‘Stop the engine and place an ol pan undat the engine ese eK mMRRIMZ A» Mese-HN—MaARes RET. 3. rareve: Oren @ + brain pag 2) Oran fe trafemssion case ots insat ran ou 8 mais Thee Seamus Seenana@annms- suuaee saatine eee Drain plug: 20 Nm (2.0m + kg) Stata NFO ° 20 Nem Omg)LINSP CLUTCH ADJUSTMENT maemo | ADJ 5, Fit + Transmission case Recommended oi SAE 10W30 typo SE motorai | Total amount: 0.8 L Periodic ol change: 0.75 L AE MARRY « SAETOWS0 SE RUMI 08 1 TREAM AEM: 0.75 2% CLUTCH ADJUSTMENT naBRy Cable Free Play Adjustment hack + itch cable ree pay 2) Outo specication > Adjust. 1 fw sedan eancina@ Banat Free play: 30~ 15mm ‘At Clutch lever and 8210-15 2. Adjust: * Clutch abe tree play 2 me oeegmeneae Adjustment steps: Frat stp: Face he ocknut @) + Tumthe jst nut ino out unt especie hee plays obtained meon 2 hiss G + ANGANIMANEH OxwaRenAeimaBE Tum in Free play is increased. Poe RantTeea Tum out > Free pay is decreased. FSH ameTIRR + Totton te locknt eonexan © 35AIR FILTER CLEANING AND COOLANT LEVEL INSPECTION SRAREORRE A MOK OR 36 AIR FILTER CLEANING 4. Remove Airiter case cover ) eaaanons 1 nie + omenaae 2. Remove PA ment @) LaF + emaaz@® Ui ‘Never operate the engine with the ir fit eloment removed. Untitred air wil cause rapid wear of engine paris and possible engine damage. Adcitonaly, operation without the fitar element wil affct carburetor tuning with subsequent poor performance and possibo engine overheating aE ARLIMMASHART YSMNIe- Engine (to spected level ona Maw 2 etewex O)38 Recommended coolant High qualiy ethylene glycol ant-reeze containing corrosion inhibitors for akuminum engine inhstors ape BRemame—m AS RANA) Royse Coolant and wator (sot water) Mixed ratio: 50%50% Total amount: 0.8 L Reservoir tank capacity: 0.429 AMARA KIRK) MEHOMIEM : SomSO wanmso8 ar aRAWER | 0.42907 Handling notes of coolant ‘The coulis harmful so shouts be hancled wit special care, anawase ADAGE AM: Mvmt: Nid * Hard water or salt water is harmful tothe engine pars, Use boiled or cistited water it you cant got sof water + Do not use water containing impurties or ol * Tako care so that coolant does not splash on painted surfaces. ‘Wit eplashes, wash it away with water. + Do not mix more than one ype of ethylene glycol antirooze ‘containing corrosion inhiptors for aluminum engines aa: + PAROS RAMI TOR mK ICH + UNEREBRMARO x. + SE*ERTAAAT SRAM BEWERS-ABAEARS + BRRSINMH 2HRRMMHA-HZ NAM TEES ene 7. Insta + Radiator cap + Radiator cap stopper 7 eR cord + MRE NE Bo adit cap stoppe) 5 Nm (0.5 m+, 38B) RM ONAL) eR DHE SN Se 8. Connect + Hose reservoir tank) 9. Ft * Reson tak (tomaximum evel G) 8 wie oe can) za A onan taney @) @ Lower evel @nexrFRONT BRAKE ADJUSTMENT AND REAR BRAKE ADJUSTMENT |_INSP_| nRRaRenHeMe | ADJ CHASSIS BR FRONT BRAKE ADJUSTMENT Thee * Brake lever tree play (@) Outot specication Adu big me me Minenanae@ aera mihe | Free play: 2 ~ 5 mm At brake lever end DTW: RRR TER 2-5 wx 2. Adust Brake lever tee play 2. me “Sime manice Adjustment stops + Loosen the leeknat @) + Tum the aust 2) in o out unt the spect replay is obtained. ® neon Sneakan © { + AACANEMRRENOZKaREDIATHM- “Turning in Froe pay e decreased mise BT ERD Turing out -> Free play is increased. nee naman Teen te oc + nemeen REAR BRAKE ADJUSTMENT Oheck + brake paca ght @) Outet specication > Aust anomme aM “Seances @ aS | Brake pada: 4 rm Blow topo otost | UBEKRR WERRLT RBS | 2. Adust Brake pada neg 2 an Shewems + Turmthe adjuster 2) ino ou unti the specie pedal eight is obtained | ArManieawan Oxaancoum sine Turning in| Pedal height is increased ruse | maa Turing out | Pedal eights decreased ease | wemras 39Abs | a BRAKE FLUID LEVEL INSPECTION simmxPiniee | ADJ |B + Tiphten the locknut @) + examen © 3. Adjust + Brake light switch Reler tothe "BRAKE LIGHT SWITCH ADJUSTMENT" section, 3. me une Bee MUMAMERAE mE BRAKE FLUID LEVEL INSPECTION 1. Ingpect: + Fluid lovel Fluid levels under “LOWER level ine 1) Fillo proper level. wnaxtoen a aR om TET er, a) ame EDT. 7) For tront brake For rear brake @ owan (5) aman Recommended ud Front: DOT # 4 or DOT #3 Rear: DOT # 4 or DOT # 3 EAR I~ ietGaRIE DOT 84 007 #3 Nore; \When inspecting the fuid level ofthe reservoir at he handlebars, make sure the mastor cylinder top is horizontally level me: SRMMACUNASE BATT LORE RT OM CU ‘Tho fluid may corrode painted surtaces or plastic pans, Always ‘lean up spilled fuid immediately, t MMAR ARATE BEER MMM oAMERS f ee Oana 40INSP. ae AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) _!T eeza(aewmxe) | ADJ Fa AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 1 Bioed 1 Brake tus BEDE (ANMDRE) 2 2. Add broper bre hid othe servo ©: Intl he aphvegm Be carl nto spl any tide alow tho reson overon 6. Connect the cea plac tube G7) tit tothe caper bed LB For rot bake For rear brake 4. Pace the ote end a the ube nto a container © Sowtyappy the brake lover or pedal over nes 1 Bale leer imor posh dow onthe pode othe eve or oda poston 9. Loosen the bleed screw and alow the over or pedal ravel toward ts it nh. Tighton the Bleed screw when the lever or pent nas been reached hen rise the ever ot pea siesem:/aaRpem a staaeawa rar > ROMA Rigma Row aea- c maemeamenmR (Da tmenenan > aie amin 4. eH A — wae. © Hien ramanaemat Pao i neumaman tam waKm 6 GheRan-aemanmoat A eRe ermH mmm o RH fenmamasee Bleed scrow: 6 Nr (0.6 m+ kg, 4.3 fb) EME aEMED NB | 6 Nm (0.6 mag) |. Repeat steps (e) to (n) until the air bubbles have been removed ftom the system. | SMM 0) F()- FR eMRMREABOORAL. Note: pe '¥ bleeding is cific, may be necessary to let the Brake Rud ‘stom stabil for a few hours. Repeat the bleoding procedure ‘hen te ty bubbles in the system have disappeared. | aE ARTO ARON oH AD RAMBERRAT TER 2A: SENDA TRAM MAT RS |. Add brake fui to proper level i Sma same Recommended fuid Front: DOT #4 or DOT #3 Fear: DOT: #4 or DOT #3 atenonaRD 18 COT 8s Dora PNT Check the operation ofthe brake after bleeding the brake system, wa: AMAR ay a aBLAR a Rl aNaRENRA RN « aBRAKE PAD INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT/ DRIVE CHAIN SLACK ADJUSTMENT |INSP | Ea SAM MMe (INR) COREE / SMR Om Fe | ADS | BRAKE PAD INSPECTION 1. Activate the brake lever or brake pedal 2. Inspect + Brake pad Wear indicator brake pads as a set onasean Mannesencns 2 ae Minas nates Qonnamon communes arly contacting brake disc + Replace Wear lit Front: 0.8 mm Roar: 0.8 mm mnam mee i Reet to the “BRAKE PAD REPLACEMENT section in the CHAPTER 7. [A] Front Rear Se TMS IIN, RE BRAKE LIGHT SWITCH ADJUSTMENT + Ste tot operating ting sngunmvome Unmemme nan [Adjustment stepe: + Hold the main body 7) of he switch with your hand 0 that 008 not oat, an um te agustrn or out (2) un the operating ting coree, maT) TEMES sno OE DRIVE CHAIN SLACK ADJUSTMENT Anas SCOR rm Belore checking andior adjusting, rolae the rear wheel several revolutons and check slack at several points to find the tightest point, Check andior adjust the chain slack with the rear wheel In this "ightest positon a FEORMEAE TOM RERMMMER LENORE GNRPRSARH—O- REG RAS, BORE T ER 1. Check 7 2 Bive chain lack Out et specitcabon > Adjust + “aeaaras@ mnnane oi “bie chan alas 20 = 3 rm wi lovato roar wha antes UceSIAT -40~50 8x a2 (LINSP | DRIVE CHAIN SLACK ADJUSTMENT ‘#RDE4/a Fa mecha es CADJ | 2. Adust * Drive chain slack 2 ae ‘ahearee Adjustment steps: * Loosen the rea brake caliper bracket bot (7) + Reeve he cater pin 2) an ose he ae nut 3) + Loosen the locknuts) Ce + Tun te adjusters) Yin or ot unt the pected sack isovalned neon ‘etatesimemicean@ er rorrrirt to) + staan + GhmoARHiNE @)- SaRE THERE Turning in Slack doreased. saw tas Turing out ~+ Slack is increased. Toe ae > Fame Nore: __ pee eee = ‘Tum each adjuster exactly the came amount fo maintain covet ‘ale alignment. (There aro marks on each side of swingarm sea on each chain puller. Use them to check for proper algnmmont). aE EHRUORREMRAMRIEH CRORE METER SHORE LEAL ANE MRR MT ES) * Tighten the axle nut to specication while pushing up or down ‘onthe chain to 2er0 slack + ERMINE SH ReneS EE ML } | | ‘Axle nut: 80 Nm (9.0 m+ kg) ‘eS: SER NHE 90 Nm (9.0 meg) + Tighton te locknuts), Tighten the rear brake caliper bracket bot cemmanss © Ne eN Im kore Bolt rear brake caliper bracket 48 Nm (4.8 m= ka) aeuncnnea S89E 038-48 Nm (4.8 kg) 2 Insta "Cater pin @) 2 ee + Roa@ Always use a new cotter pin wa: saa Ame—smoe 4344 DRIVE CHAIN LUBRICATION/STEERING HEAD ADJUSTMENT LINsP | SbAHMR/ BamHme | ADJ | © DRIVE CHAIN LUBRICATION ‘The chain consists of mary parts that work with each other. he hain is not maintained property, itwill wear out rapidly, ‘Therefore, form the habit of peroccally servicing the Ghai, This Service is especially necessary whan ning in dusty condions {This motoreycle has a drive chain with small rubbet O-rings between the chain plates. Steam cleaning, high preseure, washes, and certain solvents can damage these O-rings Use fel kerosene to clean the dive chain. Wipe it dy and thorough lubricate it with SAE 20 = 50W motor oll Go not ube any othe |Ubricants on the ove chain. They may contain solvents that ‘ould damage the O-rings anaRO RR ADERERNOS ERAS RRO A aK RM BN SHeRURE FORGE samenMnaRiT te # CORR ROR AUEMSTR UN REMBERA hE) SRNOPS-GHANNS- RRR AORC AMAR JARED MAH Mem anATaRaROEM AAA Ane HSU » EER SAE 20 ~ SOW RMA FILA MAR at ANDOOMCMAIN- COS ADAMTERE Of Qo Oona ‘SAE 30 ~ 50W Motor Oi or chain lubricants suitable for“O-ring” chains. a eROTIAM SAE 30 ~ SOW maim SiO Waa eR me ‘STEERING HEAD ADJUSTMENT samme CRUSE Securely support the motoreyce so there is no danger ot faling wa: FHMaR RMB EMBRAER 1. Elovate the front wnee by placing a sutable Sand under the enaine. 2. Check: * Steering assembly bearings Grasp the bottom ofthe forks and gently rock the fork assembly back and for, Looseness > Agst steering head 1. eminwmen ssi sna a8 + domme town SGRe AEMNeREH IER oRROMR smeAanZ Recommended iubricant, ] 2. Remove + Handlebar cover ) + Hanaiebar @) we whe + ae@®STEERING HEAD ADJUSTMENT wammme | ADJ 45 INSP 4, Loosen + Pinch bots (upper bracket) 5. Remove: e 2 Crown ut 5 Upper bracket @) 4 Searerecie) @) mx + tae 6. Adjust 6 ae + Stooring head San Adjustment steps: ‘Remove tne lock washer (7) + Remove the ng nat opp loosen the ring nut ower) (a) + Thien ne sing rt fower arg Png nt wrench nase: whrasee@: + mrawane@nxmee@- sms mE (Tm) + HaSRMAnaiReRs @ ween. nove; Setthe torave wench to The Ping na fang 1h 80 that thoy form 2 RR A Ring nut wrench: PN. 90890-01403 BMOME eH 90890-01409 Fing nutower (nial tightening): 46 Nm (4.6 m ka) FR (7882) NHB: Nem (4.6 mg) + Loosen the ring nut (ower) one turn + Retghten the ring nut (ower) using the Ring nut wrench, + GEReRE (Ta) a ee Ring nutlower (final tghtoning): 16 Nm (1.6 m+ ka) “FRR ARES ARR) HIE 1G Nm (1.6 kg) LA WARNING ‘Avid over tohtening we: Reamanwe + Check the stering stem by turing itlck to lock ther ie any binding, romove he storing stem atseriby and napect the stoorns bearnes instal te damper colar an ing ut (pee) (2) Finger hten tg ni per (2) then align He sls of Beth ring mite iot signed hols ing ut (ome) C9 as {atten he other uri ty aie once AAROSROMAMLEROMR- wae R A SA TMAH MRM RENOIR eR amemnanas(sa)® EAT RRMMEEES Ua) @)-HeRWE MEEEN 2M smansay emma (ra) @emaneALFRONT FORK INSPECTION/REAR SHOCK ABSORBER ADJUSTMENT | INSP | HRHaReRaRBoMs | ADS + Instat te lok washer @) + exazem/aa@ Nore: —_ Make sir he lock washer tab pled nthe wots an S2hemawnom Amn a FRONT FORK INSPECTION wee PNG Securely support the motorcycle so there is no danger of it faling wa: ACA aR 1. Hold the motorcycle in upright position and apply the front brake, 2 Chock: * Operation Pump the front fork up and down several times. Unsmooth operation > Repai FRter tothe “FRONT FORK" section in CHAPTER 7. 1 FMeRERMR LORD 2 oe eas amNY FMS Sere nee weERce my, RE REAR SHOCK ABSORBER ADJUSTMENT Tague + Spring prtoad Tums aduser 3) to drecton (@) or @ eunRsoms Mae + Samim #@2@7onwana@ ‘Turing toward) Spring preload is nereased. 8Oeeaanamean Turing toward(@) Spring preload is decreased #@ eam ‘Adjuster postion. ] ‘Standard 2 Minimum 3 Maximum 4 mec 92 nen wens | 46TYRE INSPECTION muthite | ADJ | cd LINSP | ggera FRONTS: Warutacure ze Type xa Ri a FANE soso-17465 | ree ean Maniacs Sie Type ua rat oe FKRUIRC vioeo-17575 | nrae | TYRE INSPECTION @ measure tyre pressure ito spcteaton + Adjust mene oe tearm Stake mez Cold tyre pressure: | Front Rear Siar = ‘ Upto 90g eae ona | co0aPa sasanee | (7oKm | @owem 91 kg (180 kg) 200 kPa 225 kPa | sranieoan) | Boker | @26igeme) * Load isthe total weight of cargo, rier, passenger, and accessories “RAW B I a Reema 2. Inspect + Tyre sutaces WeariDamege -» Replace, 2 we mame ies erry Minimum tyro tread depth (ron and rear: 0.8 mm (0.03 in) Mme: (RRA) 08 BH @ Tread depin @ See wal @ Wear indcator Quaresze @uz Oxnme CNG _ * Its dangerous to ride with a woen — out tyre, When a tye tread ‘begins to show lines, replace the tyre immediately. + Dornot use tubeless tyres on a wheel designed for tube type tyre only. Tyre failure and personal injury may recul fom sudden deflation wa: + AIRm sear eoeaRe MOTT PATE - RTCA BR Rae Fim + cma ACA Kamo RPM A aN MH ABER RRA Hae PTE RAM Tube type wheel Tube type tyreonly PNET AAPM MMC Tubeless type wiieel Tube type or tubeless iyre ANGIE IM PNAS MPO MRL + Be sure to instal the corect tube when using tube type tres + RAPIER MER LCAMB PIGWHEEL INSPECTIONICABLE INSPECTION AND Lusrication _INSP Eeoae ManamEmMe | ADJ 48 nore: Fo the tres wth ROTATION’ mark @) * Install he whoo wih the "ROTATION" markt the rotting rection z Rig the ght point mark yetlow) (3) with the vale instalation pint an: {O44 18m ROTATION . #4 ©) + i882 ROTATION , FeSO + HememE He) @uTRARAD PNG Z ‘After mounting a tire, ride conservatively to allow proper tee to tim seating. Falure to do so may cause an accident resulting in motoreycle damage and possible operation iny PRNMM IE ENO RA TTA LLIREIR NL ASEM ET AAR TURD TERE TET AR Raanhes WHEEL INSPECTION ray 1. inspect 1 ai 2 Wheels or Damage/Bends -+ Replace. Bik iam ae Nort ‘Always balance the wheel when a tire or wheel has been changed or replaced, ate FRE AMREMME CARRE T ARTE LA WARNING ana Nvor ttompt to make any repairs tothe whee ae UnEkenn amenity CABLE INSPECTION AND LUBRICATION RAORERAR FRUIT _ amaged cable sheath may cause corrosion and intorfeo with the cable movement Replaced damaged cabios as soon a3, possibe. we: Amie a PAN RED sae miee 1. Inspect 1. tie "Cable sheath > sun 29 Damage -» Replace. es ER 2. Checks 2 6s ‘Cable operation + aL ie Unsmooth operation be = Lubveate sReRAL ty Recommended lubricant: SAE 10W30 motor ol HEP ORAERIRM : SAE 10190 mh NOTE: _ Hold cable end upward and apply several ops of Wbicant iio the cable me: BAR RET EMAM ERASLINSP | gerry BATTERY INSPECTION #R@iéhiee | ADJ 49 ELECTRICAL BATTERY INSPECTION Inepect Fuld level shouldbe between upper 3) and ower (3) lve marks ineorect + Rett Rae aRenes ae teaxrants@-e@xrevom BRxITE Aa E OER Fell wth cstiled water only; tap water contains minerals harmful to a battery aE: AAAMB AN RRM RK 2. Inspect ‘Battery terminal Direty terminal + Clean with wire brush Poor connection -» Correct. 2 ae + Beeman RAAB RRM emeMAs ‘SHEMET MEM RO See ‘Atercieaning the terminals, apply grease lightly tothe terminal WGP AeNie Helem a Lo mie #m Ree 3. Disconnect 3 * Battery leads EU Disconnect the negative lead (7) frst and then disconnect he positive lad 2) ae: FRRARGID -eETAMERECIA - 4. Remove: 445 = Batery owes 5. Check © Specie gravity ess than 1.280 + Recharge battery 5 me RR LMF 1200 on Re ‘Charging Current 0.3 amps/i0 hrs Specific Gravity: 1.280 at 20°C (68°F) #RRE:03.21/10185 Hem: FM 20 mF se 9.200 LSS Ten COS -Hms280 6. Connect + Breather hose Be sure the hose is properly attached and routed. 6 2 aoe TIER ERMA ATORINSP | FUSE INSPECTION smaatiia® | ADJ FUSE INSPECTION sma CAUTION ‘Always turn off the main switch when checking or replacing @ fuse. Otherwise, shor-creuting may occur ae FETE is a BAalTeR 45am « nw, 1 Remove: aT Mam tuse @) + resmn@ * Spare tse 2) amsnn @) 2. Inspect Fuse 2 am ote Inspection steps: * Connect the Pocket tester tothe fuse and check tor continuity. axon = SRraAnIe ene Lam ANE NOTE: seo Sel the fester selocior o "XT positon a: MRRWME OX, Mo Pocket tester. PIN. 80890-03112 ‘AUR SH 90890-03112 * Ht the testers indicates at = . Replace the fuse, + ORAL RMR RI RIE IG = Blown fuse 3. ae + Beamicomraas + Tum of the ignton, + Install a new fuse of proper amperage + Tum on the switches to very operation of the effected electical device. + Ifthe fuse immediately blows again, check the electrical circuit Ceara) | azaam armies: + MERE S RON MMM RO RMNT HER LAWARNING Never uso 2 fuse with a rating other then spectiod. Never use ‘other material in place oa fuse. An improper fuse may cause ‘damage tothe electrical systom, to possibly cause a ite, the ligating andior ignition ia UNEP ARERR AT ATR RRM Tae Mae MM ER BPA RMNT RARER EA Sek e MES SREB 50[INSP HEADLIGHT BEAM ADJUSTMENT/HEADLIGHT BULB REPLACEMENT MAGtROMS / MARBAMR® | ADJ | 51 HEADLIGHT BEAM ADJUSTMENT To Adust + Heaaignt beam jertca) Tarte aster 3) nor ot nxaeROmE ae Shame (aaseme) Ps MRNA (3) [Turning in = Headight beam moves to lower BME mee Turning out = Headlight beam moves to raiso AME RARER AR 2 Aust +H beam (hoizont Ture ter 2) nor ot 2am Mbxwxeccrsame Srv mmme 2) Turing in Headlight beam moves to lft. SAM > mM RA Turing out» Headight beam moves to right. BNE MAREE RE HEADLIGHT BULB REPLACEMENT eOrcatanEs 1. Disconnect: 1m + Headight eas (2) + mAs Ns + Auli hattiesd@) + sivas asian 2) 2, Remove = Cover @) 2 is “27@ 3. Umock 2 uo +"Bu poker @) + Beene 4 Remove aor Bub @ Keep flammable products and your hands away trom the bulb ‘while itis on it will be hot. Do not touch the bulb unt f cool ‘own, we: MENTS RLASAEOMTOTRRAE- CARH. TEAAAT RT OSMEME 5 ae + An ioe) PRMARE \emeD “22® 5 instar + Bub (new) Secure the new bulb withthe bulb holder Avoid touching glass par of bulb and keep it ree from ol Otherwise, transparency of glass, bulb ie and ilumines fx will be adversely affected. loll gets on the bub. clean t wih a ceth moistened with alcohol of lacquer thinner. aa: ARomnoeercm ae RRS em THE oy TRAM Aa le Baw a ——