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    13 views40 pages

    Contenido Modulo - Biblioteca 39 MANTENIMIENTOPERIODICO PDF

    Uploaded by

    Jorge Antonio Alvarado Vanegas

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 40

    PERIODIC MAINTENANCE

    PERIODIC MAINTENANCE

    For a trouble free performance of the vehicle and its longer life, the vehicle should be periodically inspected for a wear of
    component, carbon deposits, stretched cables, etc. The worn-out components to be replaced or repaired and necessary
    adjustment to be made for certain items for better performance of the vehicle as indicated in the table.

    Note:
    More frequent maintenance checks may be performed on vehicles that are used in severe conditions like
    dusty environment, dense traffic conditions, sustained full throttle operation and un-metalled roads.

    PERIODIC MAINTENANCE SCHEDULE - FREE SERVICES


    2
    Period 1 month 3 months 6 months 9 months 12 months
    ITEM km 500 - 600 2000 - 2500 4500 - 5000 7500 - 8000 11500 - 12000
    Engine cum transmission oil R R R R R
    Oil filter R R R R R
    Oil sump filter I&C I&C I&C I&C I&C
    Spark plug I&C I&C I&C R I&C
    Compression pressure – – I – I
    Air cleaner elements2 I&C I&C I&C I&C I&C
    Engine pipe breather – C C C C
    Carburettor assembly3 – C&A C&A C&A C&A
    3
    Tappet clearance I&A I&A I&A I&A I&A
    Fuel cock sediment bowl C C C C C
    Clutch cable I&A I&A I&A I&A I&A
    Throttle cable – I&A I&A I&A I&A
    Steering play & smooth operation I&A I&A I&A I&A I&A
    3
    All fasteners I&A I&A I&A I&A I&A
    3
    Drive chain C, L & A C, L & A C, L & A C, L & A C, L & A
    All bulbs and horn I I I I I
    Head lamp beam I&A I&A I&A I&A I&A
    Battery electrolyte level I&T I&T I&T I&T I&T
    4
    Specific gravity and voltage I I I I I
    Brakes I&A I&A I&A I&A I&A
    Tyres (air pressure) I&A I&A I&A I&A I&A
    Idling CO% I&S I&S I&S I&S I&S

    R - Replace, C - Clean, I - Inspect, T - Top up, A - Adjust, TI - Tighten, T - Top up, S - Set
    2 3 4
    Replace parts if necessary If necessary Recharge if necessary (..........contd.)

    Periodic maintenance 2-1


    PERIODIC MAINTENANCE

    PERIODIC MAINTENANCE SCHEDULE - PAY SERVICES

    Period 15 months 18 months 21 months 24 months 27 months 30 months


    ITEM km 14500-15000 17500-18000 20500-21000 23500-24000 26500-27000 19500-30000

    Engine cum transmission oil R R R R R R


    Oil filter R R R R R R
    Oil sump filter I&C I&C I&C I&C I&C I&C
    Spark plug R I&C I&C R I&C R
    Compression pressure – I I I I I
    Air cleaner elements2 I&C I&C I&C I&C I&C I&C
    Engine breather pipe C C C C C C
    Carburettor assembly3 C&A C&A C&A C&A C&A C&A
    3
    Tappet clearance I&A I&A I&A I&A I&A I&A
    Head cylinder / piston – D – – – –
    Fuel cock sediment bowl C C C C C C
    Clutch cable I&A I&A I&A I&A I&A I&A
    Throttle cable I&A I&A I&A I&A I&A I&A
    Steering play & smooth operation I&A I&A I&A I&A I&A I&A
    Front fork oil – R – – – –
    3
    All fasteners I&A I&A I&A I&A I&A I&A
    3
    Drive chain I&A I&A I&A I&A I&A I&A
    All bulbs and horn I&A I&A I&A I&A I&A I&A
    Head lamp beam I&A I&A I&A I&A I&A I&A
    Battery electrolyte level I&T I&T I&T I&T I&T I&T
    4
    Specific gravity and voltage I I I I I I
    Brakes I&A I&A I&A I&A I&A I&A
    Tyres (air pressure) I&T I&T I&T I&T I&T I&T
    Idling CO% I&S I&S I&S I&S I&S I&S

    R - Replace, C - Clean,I - Inspect,T - Top up, A - Adjust, D - Decarbonise, TI - Tighten, S - Set

    2 3 4
    Replace parts if necessary If necessary Recharge if necessary

    Periodic maintenance 2-2


    PERIODIC MAINTENANCE

    LUBRICATION SCHEDULE
    Running parts must be lubricated periodically. Insufficient lubrication will cause rapid wear and severe damages to the
    components. Lubricate following parts as per the schedule:

    Period INITIAL EVERY EVERY EVERY


    ITEM KM 500 - 600 2000 - 2500 4500 - 5000 9500 - 10000

    Throttle grip

    Brake cam
    –

    –
    –

    –
    –

    Grease
    Grease

    Grease
    2
    Kick starter pedal pivot SAE 20W40 SAE 20W40 SAE 20W40 SAE 20W40

    Brake pedal shaft Grease Grease Grease Grease

    Throttle cable & clutch cable 4T oil 4T oil 4T oil 4T oil

    Drive chain Recommended chain spray

    Steering stem races Clean and lubricate with fresh Grease at every 12000 km

    Swing arm races Clean and lubricate with fresh Grease every year

    Warning:
    Do not apply more grease on cam brakes. The grease may get on to the brake shoe linings resulting in brake
    slippage.

    Note:
    Before lubricating each part, clean them thoroughly, remove rusty spots if any. Lubricate exposed parts which
    are subjected to rust with either engine oil or grease whenever the vehicle is used / operated under wet or
    rainy conditions.

    Periodic maintenance 2-3


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    21 FREE SERVICE CHECK POINTS .....................................................................................................................................................................................................
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    l Check o eve on he gauge make sure ha o .....................................................................................................................................................................................................
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    eve s be ween m n mum and max mum eve .....................................................................................................................................................................................................
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    l Wh e chang ng eng ne o nspec s ra ner or .....................................................................................................................................................................................................
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    l Change o er a every serv ce F g 2 2 Re er .....................................................................................................................................................................................................
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    l Check er e emen or any damage a every .....................................................................................................................................................................................................
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    so ven Kerosene and wash horough y F g 2 3 .....................................................................................................................................................................................................
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    l nspec carbure or ven ur or any b ack carbon .....................................................................................................................................................................................................
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    depos on c ean horough y F g 2 4B Re er .....................................................................................................................................................................................................
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    chap er 4 - Fue ubr ca on and exhaus sys em .....................................................................................................................................................................................................
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    l Check d e RPM ad us necessary F g 2 4B .....................................................................................................................................................................................................
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    Re er page no 2-12 or d e rpm ad us men .....................................................................................................................................................................................................
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    5 Spark p ug c ean ng .....................................................................................................................................................................................................
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    l Check he co our o spark p ug and c ean a every .....................................................................................................................................................................................................
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    serv ce F g 2 5 Re er page no 2-19 or ur her .....................................................................................................................................................................................................
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    Rep ace spark p ug w h a new one a every .....................................................................................................................................................................................................
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    8000 kms .....................................................................................................................................................................................................
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    2
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    Do not ad ust the spark p ug e ectrode gap. t .....................................................................................................................................................................................................
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    6 Va ve and tappet c earance .....................................................................................................................................................................................................
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    l Check and rese appe c earance necessary .....................................................................................................................................................................................................
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    7 Steer ng ad ustment and hand e bar freeness .....................................................................................................................................................................................................
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    l Check hand e bar reeness ad us necessary .....................................................................................................................................................................................................
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    l nspec ue hose or any damage A so c ean ue .....................................................................................................................................................................................................
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    l nspec dr ve cha n or s ackness ad us he .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    s ackness ound more or ess han spec ed m .....................................................................................................................................................................................................
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    F g 2 9 Re er page no 2-34 or cha n ad us men .....................................................................................................................................................................................................
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    procedure .....................................................................................................................................................................................................
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    S ackness 20 - 30 mm .....................................................................................................................................................................................................
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    l Lubr ca e dr ve cha n per od ca y or be er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    per ormance .....................................................................................................................................................................................................
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    Fg 2 9
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    10 Brake f u d eve check .....................................................................................................................................................................................................
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    l Check ron brake u d eve ound be ow he .....................................................................................................................................................................................................
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    ower eve op up w h resh brake u d F g 2 10 .....................................................................................................................................................................................................
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    Re er page no 2-23 or ur her de a s .....................................................................................................................................................................................................
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    F g 2 10
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    l A so check rear brake u d eve n Apache RTR .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    DD ensure ha brake u d s be ween m n mum .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    and max mum eve F g 2 11 Re er page no .....................................................................................................................................................................................................
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    2-28 or ur her de a s .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    M MAX MUM LEVEL
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Rep ace he brake u d once n a year or every M M N MUM LEVEL
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    20000kms .....................................................................................................................................................................................................
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    F g 2 11
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    11 Rear brake ad ustment .....................................................................................................................................................................................................
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    l Check rear brake ree p ay n case o rear drum .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    brake mode ad us necessary F g 2 12 .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Re er page no 2-27 or brake ad us ng .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    procedure .....................................................................................................................................................................................................
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    Free p ay 15 - 25 mm .....................................................................................................................................................................................................
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    F g 2 12
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    ...............................................................................................................................................................
    Periodic maintenance 2-6
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    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    12 Brake sw tches .....................................................................................................................................................................................................
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    l Check proper work ng o brake sw ches and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us he rear brake sw ch necessary .....................................................................................................................................................................................................
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    F g 2 13 .....................................................................................................................................................................................................
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    2
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    F g 2 13
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    13 Thrott e free p ay ad ustment .....................................................................................................................................................................................................
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    l Check hro e ree p ay and se he p ay requ red .....................................................................................................................................................................................................
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    F g 2 14 Re er page no 2-22 or hro e ree .....................................................................................................................................................................................................
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    p ay ad us men procedure .....................................................................................................................................................................................................
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    l Check smoo h opera on o gr p comp hro e .....................................................................................................................................................................................................
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    ubr ca e nner cab e necessary .....................................................................................................................................................................................................
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    F g 2 14
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    14 C utch ever p ay ad ustment .....................................................................................................................................................................................................
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    l Measure ree p ay a ever end p ay ound more .....................................................................................................................................................................................................
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    or ess ad us o spec ed eve F g 2 15 Re er .....................................................................................................................................................................................................
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    page no 2-22 or c u ch ree p ay ad us men .....................................................................................................................................................................................................
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    procedure .....................................................................................................................................................................................................
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    Free p ay 5 - 10 mm .....................................................................................................................................................................................................
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    F g 2 15
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    15 Check a sw tches and bu bs .....................................................................................................................................................................................................
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    l Check proper unc on ng o a sw ches and .....................................................................................................................................................................................................
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    bu bs F g 2 16 .....................................................................................................................................................................................................
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    F g 2 16
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    Periodic maintenance 2-7
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    16 Check a bo ts and nuts .....................................................................................................................................................................................................
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    l Check gh ness o bo s and nu s espec a y .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    eng ne moun ng ron and rear whee ax e nu s .....................................................................................................................................................................................................
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    and sw ng arm moun ng F g 2 17 .....................................................................................................................................................................................................
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    F g 2 17
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    17 Head amp beam ad ustment .....................................................................................................................................................................................................
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    l Check head amp beam pos on and ad us R DER WE GHT
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    requ red F g 2 18 Re er page no 2-21 or head H m
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................

    mm
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    amp beam ad us men procedure .....................................................................................................................................................................................................
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    H m
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    m
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    F g 2 18
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    18 Battery top up and vo tage check .....................................................................................................................................................................................................
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    l Check ba ery e ec ro y e eve shou d be .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    be ween m n mum and max mum eve no op .....................................................................................................................................................................................................
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    up w h d s ed wa er on y .....................................................................................................................................................................................................
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    l Check ba ery vo age vo age s esser han 12V .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    charge he ba ery F g 2 19 Re er page no 2-20 .....................................................................................................................................................................................................
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    or ur her de a s .....................................................................................................................................................................................................
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    F g 2 19
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    19 Tyre pressure check .....................................................................................................................................................................................................
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    l Check yre pressure and ma n a n spec ed yre .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    pressure or good road s ab y and onger yre e .....................................................................................................................................................................................................
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    n a e yres o he pressure as g ven be ow .....................................................................................................................................................................................................
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    F g 2 20 .....................................................................................................................................................................................................
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    Tyre pressure Front Rear .....................................................................................................................................................................................................
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    Kg/cm² ps Kg/cm² ps .....................................................................................................................................................................................................
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    So o r d ng 1 75 25 2 00 28 .....................................................................................................................................................................................................
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    Dua r d ng 1 75 25 2 25 32 .....................................................................................................................................................................................................
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    F g 2 20
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    Periodic maintenance 2-8
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    20 Em ss on check .....................................................................................................................................................................................................
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    l Check and se CO eve a eng ne d ng speed .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    F g 2 21 Re er chap er 4 - Fue ubr ca on and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    exhaus sys em or carbure or c ean ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    procedure .....................................................................................................................................................................................................
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    M O
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    Q M
    .....................................................................................................................................................................................................
    d ng CO% RTR-160 0 8 ~1 8 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    O
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    d ng CO% RTR-180 2~3

    2
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    F g 2 21
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    21 Test dr ve .....................................................................................................................................................................................................
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    l Tes dr ve he veh c e and ascer a n smoo h .....................................................................................................................................................................................................
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    unc on ng o a con ro s and par s .....................................................................................................................................................................................................
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    l C ean he veh c e be ore de very .....................................................................................................................................................................................................
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    Periodic maintenance 2-9
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    MAINTENANCE AND TUNE-UP .....................................................................................................................................................................................................
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    PROCEDURE .....................................................................................................................................................................................................
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    A R CLEANER ASSEMBLY .....................................................................................................................................................................................................
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    nspect and c ean at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. Rep ace the parts f .....................................................................................................................................................................................................
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    necessary. .....................................................................................................................................................................................................
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    l The c ogged a r c eaner assemb y ncreases he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    res s ance or a r n ake resu ng n decreased .....................................................................................................................................................................................................
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    power ou pu and ncreased ue consump on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    Check and c ean he er comp e e a r c eaner n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    he o ow ng procedure: .....................................................................................................................................................................................................
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    l Loosen and remove M6X16 - 1 no CRR pan head .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    screw rom cover rame L moun ng F g 2 22 .....................................................................................................................................................................................................
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    Ph ps head screw dr ver .....................................................................................................................................................................................................
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    l Take ou cover rame L by care u y d s oca ng .....................................................................................................................................................................................................
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    rom ugs .....................................................................................................................................................................................................
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    F g 2 22
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    l Loosen and remove CRR pan head screws .....................................................................................................................................................................................................
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    M5x16 - 4 nos Take ou n e comp e e a r .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    c eaner and rap comp e e ame a ong w h he .....................................................................................................................................................................................................
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    er comp e e a r c eaner F g 2 23 .....................................................................................................................................................................................................
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    Ph ps head screw dr ver .....................................................................................................................................................................................................
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    F g 2 23
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    l Separa e he er comp e e a r c eaner bo h .....................................................................................................................................................................................................
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    ayers rom rap comp e e ame F g 2 24 .....................................................................................................................................................................................................
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    F g 2 24
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    ...............................................................................................................................................................
    Periodic maintenance 2-10
    PERIODIC MAINTENANCE

    l Fill a pan of suitable size with cleaning solvent


    (Kerosene). Immerse the filter complete air cleaner
    in solvent and wash it thoroughly. KEROSENE
    (Fig. 2.25)

    Caution:
    Do not use benzine for cleaning the filter
    complete air cleaner.
    1 2
    l Squeeze the solvent off the washed filter by
    pressing it between palms of hands. Do not twist or
    wring the filter, else it will develop fissures. 4T OIL

    l Immerse the filter in a pool of 4T oil, and squeeze


    the excess oil off the filter to make it slightly wet.

    l Clean case complete air cleaner thoroughly.

    l Reassemble parts in the reverse order of 3 4


    dismantling.

    Caution: Fig. 2.25


    Before and after cleaning operation,
    examine the filter complete air cleaner for
    any tear or cut. Replace if found torn or cut.

    Position the filter complete air cleaner snugly


    and correctly, so that no incoming air will by
    pass it. Remember, rapid wear of valves, B
    guide valves, seals valve stem oil, piston,
    rings piston and cylinder is often caused by a
    defective or incorrectly fitted filter element.

    Check that gasket inlet (A) and gasket trap


    flame (B) is intact and in good condition. A
    (Fig. 2.26)

    Fig. 2.26
    CARBURETTOR ASSEMBLY

    Clean & adjust at every 3000 km

    l If engine performance is good, the adjuster (A)


    (MCS screw) need not be disturbed. The idling
    speed can be adjusted only by the adjuster (B)
    (idling screw) to 1400 ± 100 rpm. Rotating the A
    adjuster in clockwise direction increases the rpm
    and rotating in counter clockwise decreases the B
    rpm. (Fig. 2.27)

    Note:
    Inspect and set idling speed after attending
    other maintenance jobs.

    Fig. 2.27

    Periodic maintenance 2-11


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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    l here s per ormance de er ora on c ean he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    carbure or and une .....................................................................................................................................................................................................
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    Note: .....................................................................................................................................................................................................
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    Before tun ng carburettor, correct the free .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    p ay of cab e assemb y thrott e to 1.0 mm to .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    2.0 mm. (refer page no. 2-22 for deta s) .....................................................................................................................................................................................................
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    Tune the carburettor as ment oned be ow: .....................................................................................................................................................................................................
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    l Turn he m x ure vo ume con ro screw o spec ed .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    urns ou rom he u y n gh pos on F g 2 28 .....................................................................................................................................................................................................
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    MCS Pos on .....................................................................................................................................................................................................
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    Apache RTR 160 2 ±1 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    Apache RTR 180 3 ±2 .....................................................................................................................................................................................................
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    F a screw dr ver sma .....................................................................................................................................................................................................
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    Caut on: .....................................................................................................................................................................................................
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    Do not over t ghten the m xture vo ume .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    contro screw aga nst ts seat as t w damage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    the m x ng body assemb y and ts seat ng. .....................................................................................................................................................................................................
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    l S ar he eng ne and a ow o warm up F g 2 28
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    l Connec achome er cord o he H T Lead o know .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    he eng ne rpm .....................................................................................................................................................................................................
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    Tachome er .....................................................................................................................................................................................................
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    l Ad us d ng screw so ha eng ne rpm d es a .....................................................................................................................................................................................................
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    1400 ± 100 rpm F g 2 29 .....................................................................................................................................................................................................
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    l A er ad us ng d ng rpm check CO% and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    read us he m x ure vo ume con ro screw .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    necessary re er chap er ”Fue ubr ca on and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    exhaus sys em“ page no 4-11 or de a s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    C ean ng Procedure .....................................................................................................................................................................................................
    F g 2 29
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l For remov ng d sman ng and c ean ng o he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    carbure or assemb y re er chap er “ ue o and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    exhaus sys em” page no 4-9 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    After remount ng carburettor assemb y check .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    for smooth operat on of gr p comp ete .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    thrott e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    HOSE FUEL .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace at every three years .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec hose ue and connec ons or any damage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and eakage F g 2 30 any eakage no ced .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rep ace he par F g 2 30
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-12
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    CAP FUEL STRA NER .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Change at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D r y cup ue s ra ner w h sed men or wa er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a ec s he smoo h ow o benz ne and may cause .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    oss o eng ne power .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove cup ue s ra ner re a n ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cock assemb y ue n OFF pos on F g 2 31 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 31
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    10mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove O r ng and er F g 2 32 .....................................................................................................................................................................................................
    F LTER
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l C ean er and cup ue s ra ner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    O R NG
    .....................................................................................................................................................................................................
    l Reassemb e par s n he reverse order o remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ENG NE CUM TRANSM SS ON O L CHANGE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 32
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l A er cer a n per od o use he eng ne cum .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ransm ss on o w ge con am na ed and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    acce era es he wear o s d ng and n er ock ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sur ace Rep ace eng ne cum ransm ss on o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    per od ca y by o ow ng he procedure g ven .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    be ow: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l S ar he eng ne and a owo warm up Remove .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    gauge o eve o ac a e easy dra n ng o o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 33 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Keep a bow under he eng ne .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    F g 2 33
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove hexagona ange head bo s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    M6x20 - 3 nos F g 2 34 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    8 mm spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove cap o s ra ner a ong w h O r ng and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    dra n he eng ne cum ransm ss on o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    F g 2 34
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-13
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Loosen CRR pan head screw M4x10 - 2 nos and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    remove he s ra ner comp e e eng ne o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 35 nspec s ra ner or any damage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace necessary O herw se c ean and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reassemb e n he reverse order o remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Wh e reassemb ng, ensure that ‘O’ r ng s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    f tted n cap o stra ner. .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l F recommended 4T o re er chap er ”genera .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    n orma on” page no 1-9 or o recommenda on .....................................................................................................................................................................................................
    F g 2 35
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    1000 m Dur ng serv ce .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    O Quan y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    1100 m Dur ng overhau .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e gauge o eve .....................................................................................................................................................................................................
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    ENG NE CUM TRANSM SS ON O L LEVEL .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    l P ace he veh c e on cen re s and on a a sur ace .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Unscrew gauge o eve and w pe c ean y nser .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he gauge n o s pos on by hread ng n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    l Check o eve The o eve shou d be be ween .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    m n mum and max mum eve F g 2 36 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l o eve s be ow he m n mum eve op-up w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he recommended o up o he max mum eve .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Reassemb e gauge o eve MAX MUM
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    O R NG
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F LTER COMPLETE ENG NE O L .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    M N MUM
    .....................................................................................................................................................................................................
    Rep ace at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    there after. .....................................................................................................................................................................................................
    F g 2 36
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Be ore remov ng er comp e e eng ne o dra n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he eng ne cum ransm ss on o as per he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    procedure men oned above .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove hexagona ange bo s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    M6x65 - 2 nos and M6x16 - 1 no F g 2 37 .....................................................................................................................................................................................................
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    8 mm spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 37
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-14
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Remove cap o er a ong w h O r ng and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    spr ng o er cap .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove er comp e e eng ne o A and O r ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    B F g 2 38 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Keep a bow wh e open ng cap o f ter to A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    co ect the eft over o . .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Wh e reassemb ng, remember to assemb e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the ‘O‘ r ngs (A & D) and spr ng o f ter (B). .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    (F g. 2.39) .....................................................................................................................................................................................................
    F g 2 38
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Locate sea end (C) of the f ter towards .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    crankshaft. (F g. 2.39) A
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Whenever the f ter comp ete eng ne o s .....................................................................................................................................................................................................
    B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rep aced, t s recommended that the eng ne .....................................................................................................................................................................................................
    C
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cum transm ss on o s a so rep aced. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    D
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e par s n he reverse order o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sman ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    COMPRESS ON PRESSURE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 39
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect every 6000 km upto 18000 km and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    every 3000 km there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Warm-up he eng ne o norma opera ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    empera ure be ore s ar ng es .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Sw ch o he eng ne d sconnec sparkp ug cap .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and remove sparkp ug .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Moun he compress on gauge adap or o spark .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    p ug ho e ensur ng no eak F g 2 40 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Compress on gauge and spec a adap or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l W h he ue cock knob and gn on sw ch n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    OFF pos on open he hro e u y Now crank .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he eng ne by k ck s ar er or ve o s x k cks No e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he h ghes read ng on compress on gauge s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    compress on pressure .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Compress on Pressure .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    S andard 10 - 13 kg/cm² 142 - 184 ps .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Serv ce L m 8 kg/cm² 113 ps .....................................................................................................................................................................................................
    F g 2 40
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-15
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l compress on pressure s h gh nd ca es h gh .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    carbon depos on on combus on chamber and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    p s on crown .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l compress on pressure s ow pour 3 o 5 cc o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    resh eng ne o n o he cy nder hrough .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sparkp ug ho e and re-check he compress on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l compress on ncreases rom prev ous va ue .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    check or: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Leaky gaske cy nder head .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Worn p s on r ngs .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Worn cy nder and p s on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - P s on r ng s ruck n he grooves .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l compress on s same as he prev ous va ue .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    check he va ves or eakage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    HEAD COMPLETE CYL NDER, P STON AND .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    P STON R NGS .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Decarbon se at every 18000 km. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Carbon depos s n he combus on chamber o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    head comp e e cy nder and on p s on crown w .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ncrease he compress on ra o and may cause .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    pre- gn on or over hea ng Carbon depos on a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    exhaus s de o head comp e e cy nder w .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    preven smoo h ow o exhaus reduc ng he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    eng ne power ou pu Remove carbon depos s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    per od ca y us ng su ab e c ean ng so ven .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 41 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Decarbon se the combust on chamber after .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    remov ng both the va ves. F g 2 41
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Ensure no o damage he sur ace o he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    combus on chamber wh e decarbon s ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    VALVE, GU DE VALVE AND SEAT VALVE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Decarbon se at every 18000 km. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Carbon depos s on va ve s em F g 2 42 rubs .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    con nuous y on gu de va ve and h s w resu n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ncreased c earance be ween he va ve and gu de .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    va ve .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 42
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-16
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Check and c ean carbon depos s on va ve s em .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and gu de va ve .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Carbon depos on on va ve sea ng causes .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mproper sea ng o va ve hereby caus ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    eakage and h s w a ec d ng rpm p ck up and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ue consump on Th s w a so ead o erra c .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    runn ng and s ar ng roub e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l C ean sea va ve w h benz ne and nspec or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wear Rep ace va ve here s any p ng or sharp .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    edges a he sea ng area re er chap er “serv c ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o eng ne“ or va ve gu de va ve and va ve sea .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    serv c ng procedure .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    VALVE (TAPPET) CLEARANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove cover rame R by un ock ng he cover .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rame ock us ng con ro key F g 2 43 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Take ou cover rame R by care u y d s oca ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rom he ugs .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 43
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Gen y pu ou cab e comp e e sea and ake ou .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he sea assemb y by d s oca ng rom he ug .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 44 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Turn ue cock knob o OFF pos on and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sconnec ue hose rom he carbure or assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 44
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove hexagona ange bo M8x25 - 1no .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rom he ue ank moun ng a ong w h bush ue .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ank rear moun ng F g 2 45 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove ue ank comp e e rom s pos on by .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d s oca ng rom he cush on ue ank ron and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sconnec ng ue sender un w r ng socke .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Wh e reassemb ng fue tank comp ete, .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ensure that fue sender un t w r ng socket s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    connected and fue tank dra n hose s routed .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    proper y. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 45
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-17
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D sconnec HT H gh Tens on card and remove .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he sparkp ug A F g 2 46 B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    B
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    P ug spanner .....................................................................................................................................................................................................
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    l Remove bo h he cap nspec on ho e B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    F g 2 46
    A
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    17 mm spanner .....................................................................................................................................................................................................
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    F g 2 46
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    .....................................................................................................................................................................................................
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    l Remove p ug TDC A and p ug cranksha ho e B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 47 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A
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    17 mm spanner .....................................................................................................................................................................................................
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    10 mm a en key .....................................................................................................................................................................................................
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    B
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    F g 2 47
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l A gn he TDC mark A on ro or assemb y w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cen re o he nspec on ho e prov ded n he cover .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    magne o by ro a ng he ro or assemb y F g 2 48 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A
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    17 mm ubu ar spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    At th s po nt both the rocker arm shou d have .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    free p ay. Otherw se rotate the rotor .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    assemb y one more comp ete round and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    a gn the mark aga n. .....................................................................................................................................................................................................
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    F g 2 48
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    l Measure va ve c earance when he eng ne s n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    co d cond on F g 2 49 .....................................................................................................................................................................................................
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    0310100 Fee er gauge .....................................................................................................................................................................................................
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    Va ve Standard .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    n e va ve 0 06 mm .....................................................................................................................................................................................................
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    Exhaus 0 08mm .....................................................................................................................................................................................................
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    F g 2 49
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    Periodic maintenance 2-18
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    l c earance measured s ncorrec oosen he nu .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    appe ad us ng F g 2 50 .....................................................................................................................................................................................................
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    9 mm spanner .....................................................................................................................................................................................................
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    l Ad us va ve c earance us ng a spec a oo .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 50 .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    M1310010 Too appe ad us er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
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    Fee er gauge .....................................................................................................................................................................................................
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    l A er ob a n ng spec ed c earance gh en he nu F g 2 50
    .....................................................................................................................................................................................................
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    appe ad us ng ho d ng he screw appe .....................................................................................................................................................................................................
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    ad us ng n he same pos on us ng spec a oo .....................................................................................................................................................................................................
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    SPARKPLUG .....................................................................................................................................................................................................
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    l Check sparkp ug or s ype F g 2 51 .....................................................................................................................................................................................................
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    Sparkp ug BOSCH UR5DDC .....................................................................................................................................................................................................
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    C ean at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
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    there after. Rep ace at every 8000 km. .....................................................................................................................................................................................................
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    l s very mpor an o ake spec a care or .....................................................................................................................................................................................................
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    F g 2 51
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sparkp ug a ng wh ch eads o s ar ng .....................................................................................................................................................................................................
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    prob em and poor per ormance .....................................................................................................................................................................................................
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    l Carbon depos s on sparkp ug gap preven good .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    spark ng and cause m s r ng Remove sparkp ug .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    and c ean proper y .....................................................................................................................................................................................................
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    Caut on: .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Before remov ng sparkp ug, use compressed .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    a r to b ow away any d rt around sparkp ug .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    mount ngto prevent t from fa ng ns de the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    cy nder. C ose the p ug ho e w th c ean c oth. .....................................................................................................................................................................................................
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    l Check spark p ug or wear o cen ra and ground .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    e ec rodes e her o hem are worn-ou rep ace .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    he sparkp ug w h a new one .....................................................................................................................................................................................................
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    Caut on: .....................................................................................................................................................................................................
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    Do not ad ust the spark p ug e ectrode gap .....................................................................................................................................................................................................
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    Do not use f ared stee cab es to c ean .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    sparkp ug. .....................................................................................................................................................................................................
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    Use on y recommended make and type of .....................................................................................................................................................................................................
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    sparkp ug .....................................................................................................................................................................................................
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    l Do no over gh en or cross hread he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sparkp ug as o herw se a um n um hreads o .....................................................................................................................................................................................................
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    head comp e e w be damaged .....................................................................................................................................................................................................
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    Periodic maintenance 2-19
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    BATTERY ASSEMBLY .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Check and top-up at n t a 500 km and every .....................................................................................................................................................................................................
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    3000 km there after. .....................................................................................................................................................................................................
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    l V sua y nspec he sur ace o ba ery assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    con a ner any s gn o crack ng or e ec ro y e .....................................................................................................................................................................................................
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    eakage rom s des o he ba ery assemb y are .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    no ced rep ace ba ery assemb y w h a new one .....................................................................................................................................................................................................
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    l he ba ery assemb y ead erm na s are ound .....................................................................................................................................................................................................
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    rus y w h an ac d c wh e powdery subs ance hen .....................................................................................................................................................................................................
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    c ean hem w h sand paper .....................................................................................................................................................................................................
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    l Check ou pu vo age o he ba ery .....................................................................................................................................................................................................
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    l shou d be more han 12 8 V when measured .....................................................................................................................................................................................................
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    us ng a mu me er F g 2 52 .....................................................................................................................................................................................................
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    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    f battery output vo tage s ess than 11V, .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    then the battery shou d be recharged .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Add d s ed wa er as necessary o keep he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    sur ace o he e ec ro y e above he ower eve ne F g 2 52
    .....................................................................................................................................................................................................
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    bu no above he upper eve ne F g 2 53 .....................................................................................................................................................................................................
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    Caut on: .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Do not add tap water or ac d for topp ng up .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the battery assemb y. Use on y d st ed water. .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wh e remov ng the battery assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    term na s, remove ’– ve’ term na f rst. Wh e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reconnect ng, connect ’+ ve’ term na f rst. .....................................................................................................................................................................................................
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    F g 2 53
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    l Per od ca y check he e ec ro y e or spec c .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    grav y by us ng a hydrome er o nd he s a e o .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    charge ba ery s ge ng d scharged requen y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    check he charg ng sys em F g 2 54 HYDROMETER
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    1 24
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    E ectro yte spec f c grav ty at 30° C .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Battery type Charged Under charged .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    12V 9 0 Ah 1 28 1 24 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l spec c grav y read ng s no n norma .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cond on nd ca es ha ba ery assemb y needs F g 2 54
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    recharg ng Recharge he ba ery assemb y w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cons an curren ba ery charger .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-20
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    HEAD LAMP BEAM ADJUSTMENT .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Keep ng he b ke n a s ra gh ne s on he b ke o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a m he head amp beam ver ca y Focus head amp .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    h gh beam on a ver ca screen wh ch s a a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d s ance o 10 me ers rom he head amp s cen re .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    po n Ad us head amp assemb y such ha he oca .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    po n o h gh beam on he screen s 100 mm ower .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    han he head amp beam cen re F g 2 55 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Head amp focus shou d be ad usted on y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    when the head amp n h gh beam. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    R DER WE GHT
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Head amp ens cen e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    100 mm

    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Head beam oca po n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    10 me e s .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 55 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l For ad us ng he beam ocus s gh y oosen .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hexagona screw M6x20 - 1 no o hous ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    head amp ron bo om moun ng F g 2 56 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Care u y ad us he head amp assemb y by .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    press ng orward or reverse o ob a n he spec ed .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ocus eng h Ho d ng he head amp n ha .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    pos on gh en he screw .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 56
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-21
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    CABLE ASSEMBLY THROTTLE - FREE PLAY .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at every 3000 km. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l For check ng cab e assemb y hro e p ay rs .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d s oca e he boo hro e A rom s pos on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 57 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Gen y pu he cab e assemb y hro e ho d ng he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us er B o check he ree p ay ree p ay s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    more or ess ad us as o ows: .....................................................................................................................................................................................................
    A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Free p ay 1 0 - 2 0 mm .....................................................................................................................................................................................................
    F g 2 57
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen ock nu A and urn ad us er B n or ou .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    un he spec ed p ay s ob a ned F g 2 58 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    8 mm spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l T gh en ock nu A wh e ho d ng he ad us er B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    n p ace F g 2 58 A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l A er ad us ng s ar he veh c e e he eng ne run .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    n d e urn he hand e bar o ex reme r gh and e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    check whe her d ng rpm var es var es check .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    rou ng o cab e and read us he ree p ay B


    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 58
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    CABLE ASSEMBLY CLUTCH - FREE PLAY .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Cab e assemb y c u ch ree p ay s one o he mos .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mpor an ad us men s wh ch may need o check .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    regu ar y or smoo her gear sh ng and be er e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o he c u ch p a es .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Measure ree p ay a he ever assemb y c u ch end .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    as shown n he gure F g 2 59 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    Note: F g 2 59
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Ad ust c utch p ay when the eng ne s n co d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cond t on. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Free p ay 5 - 10 mm .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l p ay s more or ess oosen he ock nu A and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    urn he ad us ng nu B C ockw se ro a on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    reduces he p ay and coun er c ockw se ro a on B


    .....................................................................................................................................................................................................
    A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ncreases he p ay A er ad us ng o spec ed p ay .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    gh en he ock nu A ho d ng he ad us ng nu .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    B n he ha pos on F g 2 60 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    12 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 60
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-22
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    BRAKES .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Warn ng: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brakes are for persona safety and shou d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a ways be ma nta ned n proper cond t on. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    FRONT BRAKE (D SC BRAKE) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Check and top-up brake f u d at n t a 500 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    km and every 3000 km there after. Change .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the brake f u d and rep ace the pr mary, .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    secondary cups of cy nder assemb y master .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    (p ston k t) at every 20000 km. Rep ace hose .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp ete brake at every three years. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brake f u d and ts hand ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect ng brake f u d eve .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Be sure o check u d eve n he reservo r For .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspec ng brake u d eve p ace he b ke rm y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    on cen er s and w h he hand ebar pos oned .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s ra gh .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l he eve s ound o be ower han he mark .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    LOWER prov ded on he reservo r rep en sh he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 61
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reservo r w h he resh brake u d F g 2 61 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brake u d DOT 3 or DOT 4 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    S nce the G yco based brake f u d used by .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the manufacturer n these b kes, do not use, .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    do not use or m x d fferent types of f u d such .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    as s con based and petro eum based f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    for ref ng the system, otherw se damage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    susta ned w be ser ous. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not use any brake f u d taken out from o d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    or used, or unsea ed conta ners. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Ensure no water enters the brake f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    conta ner. Because brake f u d has .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hygroscop c property, and ts bo ng po nt .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    fa s excess ve y f water s m xed w th t. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Check brake hose for any cracks and hose .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o nts for eakage. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not squeeze the brake ever when the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reservo r cap s removed, otherw se brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    f u d w somet mes sp out. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-23
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not put the removed reservo r cap on the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    speedometer or tachometer. Brake f u d w .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    damage the pa nt surface and nstrument .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    c uster enses. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A r b eed ng from brake system .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l brake ever rave becomes excess ve or he ever .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ee s a so or spongy ee ng a r b eed ng mus be .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    carr ed ou as per o ow ng procedure: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    t s best, f two persons perform a r b eed ng. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Keep the f u d eve n the reservo r ust above .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the ‘Lower‘ mark dur ng the b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    procedure. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    1 A ach b eeder ube o he b eeder screw a er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    remov ng he cap b eeder as shown n F g 2 62 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A ransparen ube s use u n nd ng a r bubb e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    expe ed rom he sys em .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    2 The open end o ube mus be submerged n a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    c ean con a ner par a y ed w h brake u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3 F he reservo r w h he brake u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    4 F x he cap on he reservo r o preven a spou o F g 2 62
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    brake u d and en ry o dus .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    5 Deve op pressure n he hydrau c sys em by .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    opera ng rap d y he brake ever severa mes and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hen ho d ng he ever gh .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    6 Unscrew open he b eeder by ha urn and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    depress he ever a he way ns de Do no re ease .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he ever un he b eeder screw s gh ened u y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 63 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    10 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    7 Repea s ep 5 and 6 un a r bubb es d sappear n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he b eeder ube or con a ner and screw n c ose F g 2 63
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he b eeder screw secure y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    8 Remove b eeder ube and ns a he b eeder va ve .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    dus cap .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    9 Check u d eve n he reservo r and rep en sh .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    necessary a er he comp e on o b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    opera on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    10 Re ns a d aphragm and gh en reservo r cap .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    secure y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not reuse the brake f u d dra ned from the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    system. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-24
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brake f u d rep acement .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Bo ng po n o brake u d a s cons derab y w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    absorp on o mo s ure wh ch may ake p ace .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    dur ng a ong per od o use There ore s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    recommended o rep ace o d brake u d w h resh .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    one per od ca y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace brake u d every 1 year or 20 000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l On chang ng brake u d ex reme a en on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    shou d be pa d so as no o m x any ore gn .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ma er a s because hey wou d b ock he re urn por .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o he mas er cy nder resu ng n he brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    dragg ng or squeak ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    When brake u d needs o be changed per orm he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o ow ng procedure: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    1 A ach a b eeder ube o he b eeder Dra n ou .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o d brake u d by squeez ng he brake ever w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    b eeder opened cond on un he brake u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sappears n he b eeder ube .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    2 Once he brake u d s dra ned ou rom he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sys em comp e e y carry ou he same procedure .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    as descr bed n a r b eed ng rom brake sys em .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Hose comp ete brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec hose comp e e brake or any cracks or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    eakage eakages ound rep ace hose as be ow: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l F ush brake u d by open ng b eeder a ca per .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    assemb y w h a ube on he b eeder head o a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    c ean con a ner re er a r b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove ban o bo s 2 nos a bo h ends o he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hose comp e e brake Take ou he gaske s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 64A & 2 64B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    12 mm spanner F g 2 64A F g 2 64B


    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove he screw a ong w h spr ng washer and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ake ou c amp hose under bracke F g 2 65 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove hexagona screw a ong w h he spr ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    washer and ake ou c amp brake hose F g 2 65 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove brake hose rom he veh c e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 65
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-25
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mmed ate y w pe off the brake f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    contact ng any part of the b ke. The f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reacts chem ca y w th pa nt, p ast cs, rubber .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mater a s etc., and w damage them .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    severe y. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e new brake hose n he reserve order o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sman ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l T gh en ban o bo s a bo h he ends a ong w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    gaske s 2 nos each s de .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    12 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Ensure to assemb e new gaskets on the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ban o bo ts. Do not use o d gaskets. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l B eed he a r rom he brake c rcu a er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reassemb ng he brake hose re er a r b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    sys em page 2-24 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace brake hose a every 3 year or 60 000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brake pads rep acement .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove ca per moun ng bo s and ake ou he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ca per F g 2 66 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    12 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Remove front brake ever before d smant ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the ca per assemb y. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    C ean mud and dust off around the front .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    whee and ca per pr or to d smant ng. .....................................................................................................................................................................................................
    F g 2 66
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove p ug p n 2 nos rom he body ca per .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 67 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F a head screw dr ver .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 67
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-26
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and ake ou p n hanger 2nos F g 2 68 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    5 mm a en key .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 68
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Pu ou pad comp e e nner and pad comp e e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ou er by hand F g 2 69 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect on of brake pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Observe wear m ne marked on he pad and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    check wear cond on o brake pads F g 2 70 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wear exceeds he m ne hen rep ace he pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    as a se w h a new one .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Brake pad wear can be checked w thout .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 69
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    remov ng the ca per assemb y from the fork. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    t s recommended to rep ace brake pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    on y as a set for better brak ng performance. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l App y grease o he p n bo s o he bracke .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e ron .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l For reassemb y o brake pads o ow he reverse .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    order o d sman ng procedure .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 70
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    REAR BRAKE (DRUM BRAKE MODEL) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Measure he rave d s ance o brake peda .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e by app y ng he rear brake F g 2 71 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Peda ree p ay 15 - 25 mm .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    F g 2 71
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-27
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l d s ance s more or ess urn he rear brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us ng nu o ge he spec ed p ay C ockw se .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ro a on o nu decreases he p ay and coun er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    c ockw se ro a on ncreases he p ay F g 2 72 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    14 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Brake n ng wear nd ca or A s prov ded on he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    pane assemb y rear re er page 2-32 or brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wear m de a s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    REAR BRAKE (D SC BRAKE MODEL) .....................................................................................................................................................................................................
    F g 2 72
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect ng brake f u d eve .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Be sure o check u d eve n he reservo r For .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspec ng brake u d eve pu he b ke rm y on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cen er s and and remove cover rame R re er .....................................................................................................................................................................................................
    MAX MUM LEVEL
    .....................................................................................................................................................................................................
    M
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    page 2-17 or remov ng cover rame R .....................................................................................................................................................................................................
    M M N MUM LEVEL
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l eve s ound o be ower han he mark M N .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    prov ded on he reservo r rep en sh w h he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    spec ed resh brake u d F g 2 73 re er page .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    2-24 or brake u d and s hand ng a r b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and brake u d rep acemen de a s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 73
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Hose comp ete brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec hose comp e e brake or any damage or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    eakage eakages ound rep ace he hose as .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    be ow: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l F ush he brake u d by open ng b eeder screw a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ca per assemb y w h a ube on he b eeder head .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o a c ean con a ner re er brake b eed ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove ban o bo s 2 nos a bo h he ends o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hose comp e e brake and ake ou gaske s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 74A & F g 2 74B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    12 mm spanner F g 2 74A F g 2 74B


    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D s oca e hose rom he gu de hose sw ng arm .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 75 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove brake hose rom he veh c e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mmed ate y w pe off the brake f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    contact ng any part of the b ke. The f u d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reacts chem ca y w th pa nt, p ast cs, rubber .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    mater a s etc., and w damage them .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    severe y. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 75
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-28
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e new brake hose n he reserve order o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d sman ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l T gh en ban o bo s a bo h he ends a ong w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    gaske s 2 nos each s de .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Ensure that new gaskets are assemb ed w th .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the ban o bo ts. Do not use o d gaskets. A so .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    take spec a care to ensure that brake hose s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    not n contact w th any mov ng component. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l B eed a r rom he brake c rcu a er reassemb ng .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he brake hose re er a r b eed ng sys em .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace brake hose every 3 year or 60 000 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rear Brake pads rep acement .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove rear whee ax e U nu .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 76A .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    22 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l S gh y pu ou ax e rear rom he e s de wh e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 76A F g 2 76B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    gen y app ng a r gh s de F g 2 76B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D s oca e ca per assemb y rom he s o prov ded .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    on sw ng arm comp e e by pu ng owards rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s de .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove spacer rear ax e R F g 2 77 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 77
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove p ug p n 1no rom he body .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e ca per assemb y F g 2 78A .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F a head screw dr ver .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and ake ou p n hanger 1no .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 78B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    5 mm a en key .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 78A F g 2 78B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-29
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Pu ou pad comp e e nner and pad comp e e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ou er by hand F g 2 79 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect on of brake pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Observe he wear m ne marked on he pad .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and check wear cond on o brake pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 70 wear exceeds he m ne hen .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rep ace he pads as a se w h a new one Re er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    page no 2-27 or nspec on o brake pads .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    WHEEL ASSEMBLY FRONT (D SC BRAKE MODEL) .....................................................................................................................................................................................................
    F g 2 79
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l P ace he b ke on cen er s and and p ace a ack or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    b ock o keep he ron whee o he ground .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove U nu a ong w h he punched washer .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 80 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    17 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 80
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Draw ou ax e ron rom L s de a ong w h washer .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wh e gen y app ng a R s de F g 2 81 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Take ou whee assemb y ron a ong w h he d sc .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    p a e and spacer comp e e L .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Take ou speed sensor rom he whee assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ron and hang on he rame se .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    After tak ng out front whee assy keep some .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cush on n between the brake pads, to avo d .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    b nd ng. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 81
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Reassemb y .....................................................................................................................................................................................................
    B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e whee assemb y ron n he reverse .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    order o d sassemb y and remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Be ore assemb ng ron whee assemb y ubr ca e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he ax e ron and bear ngs .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Make sure ha he s o A n he speed sensor s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    over he s opper B on he ron ork ou er ube L .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 82 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 82
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-30
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove ack or b ock p aced wh e remov ng he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    whee assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Be ore gh en ng U nu o ax e ron s roke he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ork assemb y ron severa mes o check or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    proper ork ac on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l T gh en U nu .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Wh e remount ng front whee assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ensure to ocate the d sc n between the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    brake pads after remov ng cush on. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    WHEEL ASSEMBLY REAR (DRUM BRAKE MODEL) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove nu rear brake rod ad us er A F g 2 83 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    14 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A C
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove sp pn B rom he orque nk rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    moun ng F g 2 83 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Nose p er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove hexagona nu M8 C a ong w h he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 83
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    wave spr ng washer and ake ou bo orque nk .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rear F g 2 83 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    14 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D s oca e rod rear brake comp e e rom he ever .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rear brake cam .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Take ou p n rear brake rod spr ng rear brake rod .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us er and punched washer .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen and remove U nu M14x1 5 rom he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ax e comp e e rear a ong w h he washer .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 84 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 84
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    22 mm spanner .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Pu ou ax e comp e e rear by gen y app ng a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o her s de F g 2 85A .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove spacer rear ax e R F g 2 85B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Wh e ng he b ke o he e s de ake ou he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    whee assemb y rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 85A F g 2 85B
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-31
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Take ou pane assemb y rear rom he whee .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    assemb y rear F g 2 86 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    F g 2 86
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Pane assemb y (rear whee ) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Remove brake shoe se rear rom he pane .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    assemb y rear a ong w h spr ng brake shoe .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 87 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    NSPECT ON .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Before nspect on, c ean a necessary .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    components w th su tab e c ean ng so vent .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and ubr cate them. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 87
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Shoe comp ete brake .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec n ng brake shoe sur ace or g aze M nor .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    g aze can be correc ed by c ean ng w h coarse .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    emery paper .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    After po sh ng shoe comp brake, c ean the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    surface w th dry c oth. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l H gh y g azed shoes mus be rep aced .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Measure n ng brake shoe h ckness as shown .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 88 he h ckness measured s ess han .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    he serv ce m rep ace shoe comp e e brake w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a new one as a se .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Vern er ca per .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Serv ce m 1 5 mm .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Rep ace shoe comp ete brake on y as a set . .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec brake shoe spr ng or correc s ness and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    any damage .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 88
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-32
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    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    Brake drum (a oy whee rear) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Measure nner d ame er o he brake drum rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    whee a 3 o 4 p aces d ame er exceeds he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    serv ce m hen rep ace he a oy whee rear w h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a new one F g 2 89 .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Vern er ca per .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Serv ce m 130 7 mm .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l nspec brake drum nner sur ace or grease or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    scra ches Use a rag soaked n acquer h nner or .....................................................................................................................................................................................................
    F g 2 89
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    so ven o c ean he drum M nor scra ches can be .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    po shed w h an emery paper .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l he brake drum scored heav y hen rep ace he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    a oy whee rear .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    WHEEL ASSEMBLY REAR (D SC BRAKE MODEL) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    Remova .....................................................................................................................................................................................................
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    l Remove U nu M14x1 50 rom he ax e .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e rear a ong w h washer F g 2 90A .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 90A F g 2 90B
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    22mm spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Pu ou ax e comp e e rear by gen y app ng a .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    o her end F g 2 90B .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l D s oca e ca per assemb y rom he s o prov ded .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    on sw ng arm comp e e by pu ng owards rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s de .....................................................................................................................................................................................................
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    l Remove spacer rear ax e R F g 2 91 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Wh e ng he b ke o he e s de ake ou .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    whee assemb y rear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................

    Reassemb y F g 2 91
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e whee assemb y rear n he reverse .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    order o d sassemb y and remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Make sure ha he p pe A n he ca per assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s be ween he gu des B on he sw ng arm .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e F g 2 92 .....................................................................................................................................................................................................
    B
    .....................................................................................................................................................................................................
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    A
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 92
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    .....................................................................................................................................................................................................
    ...............................................................................................................................................................
    Periodic maintenance 2-33
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    CHA N ASSEMBLY DR VE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect, c ean and ad ust at n t a 500 km .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    and every 3000 km. f necessary, check and .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad ust at every 1000 km. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Lubr cate on the veh c e at every 1000 km by .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    proper ubr cant. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l P ace he b ke rm y on cen re s and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Pu he ransm ss on n neu ra gear and urn he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rear whee s ow y by hand .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l V sua y nspec cha n assemb y dr ve or he be ow .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s ed poss b e abnorma es .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Loose p ns .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Damaged ro ers .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Rus ed nks .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Tw s ed or se zed nks .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    - Excess ve wear .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l any de ec s ound cha n assemb y dr ve mus be .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rep aced w h a new one .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Cha n s ackness: .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l P ace he b ke rm y on cen re s and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Check he dr ve cha n or spec ed s ackness .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 93 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    S ackness 20 - 30 mm .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l s ackness ound more or ess ad us as o ows: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    F g 2 93
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen U nu o ax e comp e e rear F g 2 94 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    22 mm spanner .....................................................................................................................................................................................................
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    F g 2 94
    .....................................................................................................................................................................................................
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    ...............................................................................................................................................................
    Periodic maintenance 2-34
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen hexagona nu o sprocke drum assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    moun ng F g 2 95 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    27 mm spanner .....................................................................................................................................................................................................
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    2
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    F g 2 95
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Loosen ock nu A and B and urn he nu cha n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us er C and D ook ng a he ne mark on cha n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ad us er L and R E and F Thread ng n reduces he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s ackness and hread ng ou ncreases he s ackness .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A er ach ev ng spec ed s ackness gh en he ock .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    C
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nu A and B F g 2 96 & F g 2 97 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    10 mm spanner .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    l T gh en U nu o ax e comp e e rear and E
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hexagona nu o sprocke drum assemb y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    A
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    moun ng o he spec ed orque Re er chap er-7 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    “Serv ce n orma on” page no 7-8 or orque .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 96
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    de a s .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Caut on: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    To ma nta n proper whee a gnment, ad ust .....................................................................................................................................................................................................
    F
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    both the cha n ad uster un form y. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    D
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Warn ng: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Ad ustment of cha n s ackness w d sturb the .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    or g na brake ad ustment. Hence t s h gh y .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    essent a to check and read ust the rear .....................................................................................................................................................................................................
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    brake. .....................................................................................................................................................................................................
    B
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    F g 2 97
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    Cha n c ean ng .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    C ean and ubr cate cha n assemb y dr ve off .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the veh c e at every 3000 Km. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Loosen hex bo s M6x12 - 2 nos rom cover .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    comp e e cha n and ake ou cover comp e e .....................................................................................................................................................................................................
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    cha n F g 2 98 .....................................................................................................................................................................................................
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    10 mm spanner .....................................................................................................................................................................................................
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    F g 2 98
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    Periodic maintenance 2-35
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    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    l Un ock nk se o cha n assemb y dr ve and .....................................................................................................................................................................................................
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    remove F g 2 99 .....................................................................................................................................................................................................
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    Comb na on p er .....................................................................................................................................................................................................
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    l C ean cha n assemb y dr ve by d pp ng n .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    kerosene or d ese Brush o any d r s ck ng o .....................................................................................................................................................................................................
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    l A er ak ng ou rom he soak ng w pe o excess .....................................................................................................................................................................................................
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    kerosene or d ese w h so c o h and a ow o dry .....................................................................................................................................................................................................
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    Warn ng: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not use meta w re brush or any other .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    hard brushes, as th s w damage ‘O’ r ng. F g 2 99
    .....................................................................................................................................................................................................
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    Do not soak the cha n n kerosene or d ese .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    for more than 10 m ns. .....................................................................................................................................................................................................
    1 2 3 19 20 21
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    Cha n wear .....................................................................................................................................................................................................
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    l Coun 21 p ns on he cha n assemb y dr ve and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    measure he d s ance be ween 20 p ch .....................................................................................................................................................................................................
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    F g 2 100 measured d s ance exceeds he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    serv ce m rep ace he cha n w h a new one .....................................................................................................................................................................................................
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    Serv ce m 256 mm .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Vern er ca per .....................................................................................................................................................................................................
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    F g 2 100
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    Cha n ubr cat on .....................................................................................................................................................................................................
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    measured d s ance s w h n he m ubr ca e cha n .....................................................................................................................................................................................................
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    by carry ng ou o ow ng s eps : .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l M x grease and 4T eng ne o n 1:1 propor on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    horough y .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    l Lubr ca e he cha n by sock ng n h s m x ure or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    m n mum 15 m ns F g 2 101 .....................................................................................................................................................................................................
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    l Dra n he excess m x ure by hang ng cha n n .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ver ca d rec on or 10m ns .....................................................................................................................................................................................................
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    Caut on: F g 2 101
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Do not use mo ten grease to ubr cate ‘O’ .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    r ng cha n. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Reassemb e cha n n he reverse order o remova .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    D RECT ON OF TRAVEL
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Before reassemb ng cha n assemb y, c ean .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    the sprocket eng ne and sprocket rear. .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Warn ng: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Assemb e nk set cha n ock p ate n such .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    way that the s t end faces the oppos te .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    d rect on of the cha n rotat on to avo d severe .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    damages. (F g. 2.102) .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 102
    .....................................................................................................................................................................................................
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    ...............................................................................................................................................................
    Periodic maintenance 2-36
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    .....................................................................................................................................................................................................
    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    STEER NG .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nspect and ad ust at n t a 500 km and every .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    3000 km there after. .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l S eer ng shou d be ad us ed correc y or smoo h .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    movemen o hand ebar and or sa e r d ng S .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s eer ng preven s smoo h movemen o hand e bar .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    resu ng n poor d rec ona s ab y and oo oose .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s eer ng causes v bra on and damage o he .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s eer ng bear ngs .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    l Check o see ha here s no p ay n he s eer ng .....................................................................................................................................................................................................
    F g 2 103
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    bear ngs F g 2 103 any p ay s ound ad us .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    he s eer ng as exp a ned be ow: .....................................................................................................................................................................................................
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    l Remove hexagona socke head screw M6x30 - .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    2 nos rom he cover upper bracke moun ng .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
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    and remove cover upper bracke F g 2 104 .....................................................................................................................................................................................................
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    5mm A en key .....................................................................................................................................................................................................
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    F g 2 104
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    l S gh y oosen he ock nu s eer ng F g 2 105 .....................................................................................................................................................................................................
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    32 mm spanner .....................................................................................................................................................................................................
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    l Us ng spec a oo urn he arres or s eer ng s em F g 2 105
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    e her c ockw se or an c ockw se o reduce or o .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    ncrease s eer ng p ay respec ve y F g 2 106 .....................................................................................................................................................................................................
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    0313801 Un versa c amp wrench .....................................................................................................................................................................................................
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    l T gh en ock nu s eer ng o he spec ed orque .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Re er chap er-7 “Serv ce n orma on” page no .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    7-8 or orque de a s .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    After ad ustment ensure smooth movement .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    of hand e bar. When s ow y moved by hand, .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    t shou d move free y from the centre pos t on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    to e ther eft or r ght w th ts own we ght. .....................................................................................................................................................................................................
    F g 2 106
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    ...............................................................................................................................................................
    Periodic maintenance 2-37
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    l any p ay s s ound nspec o ow ng ems and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    rep ace a ec ed par s wherever necessary re er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
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    chap er “chass s“ or remova check ng and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    reassemb y procedures .....................................................................................................................................................................................................
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    • Wear o race s eer ng nner and ou er .....................................................................................................................................................................................................
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    • Wear o cup bo om and cone bo om .....................................................................................................................................................................................................
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    • Wear or damage o ba s s eer ng .....................................................................................................................................................................................................
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    • Number o ba s .....................................................................................................................................................................................................
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    • D s or on o ower bracke comp e e .....................................................................................................................................................................................................
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    Number of ba s .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Upper race 22 nos 4 762 mm d a .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Lower race 19 nos 6 35 mm d a .....................................................................................................................................................................................................
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    FRONT FORK O L .....................................................................................................................................................................................................
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    nspect for eakage at n t a 500 km and .....................................................................................................................................................................................................
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    every 3000 km there after. Change every .....................................................................................................................................................................................................
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    18000 km. .....................................................................................................................................................................................................
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    l Remove bo h eg assemb es ron ork Re er .....................................................................................................................................................................................................
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    chap er “chass s“ or remova c ean ng and .....................................................................................................................................................................................................
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    assemb y procedures .....................................................................................................................................................................................................
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    l Dra n ork o and c ean he eg assemb es .....................................................................................................................................................................................................
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    l Pour recommended brand o o spec ed amoun .....................................................................................................................................................................................................
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    rom he op o he nner ube assemb y .....................................................................................................................................................................................................
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    F g 2 107 .....................................................................................................................................................................................................
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    O quant ty per eg .....................................................................................................................................................................................................
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    G L make 140 ± 2 0 m .....................................................................................................................................................................................................
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    TOP make 152 ± 2 5 m .....................................................................................................................................................................................................
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    Spec ca on Te eshockab o .....................................................................................................................................................................................................
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    Warn ng: .....................................................................................................................................................................................................
    F g 2 107
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    Apache RTR comes w th ‘G L or TOP’ make of .....................................................................................................................................................................................................
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    front fork, care must be taken such that eg .....................................................................................................................................................................................................
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    assemb y o quant ty a ways matches w th ts .....................................................................................................................................................................................................
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    respect ve make. .....................................................................................................................................................................................................
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    TYRES .....................................................................................................................................................................................................
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    nspect at n t a 500 km and at every 3000 .....................................................................................................................................................................................................
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    km there after. .....................................................................................................................................................................................................
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    F g 2 108
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    Periodic maintenance 2-38
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    Tyre tread cond t on: .....................................................................................................................................................................................................
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    l Us ng he veh c e w h excess ve y worn yres w .....................................................................................................................................................................................................
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    decrease r d ng s ab y and consequen y nv e a .....................................................................................................................................................................................................
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    dangerous s ua on due o oss o con ro s .....................................................................................................................................................................................................
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    h gh y recommended o rep ace he yre w h a .....................................................................................................................................................................................................
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    new one when he groove dep h o yre rom read .....................................................................................................................................................................................................
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    sur ace reaches he o ow ng spec ca ons: .....................................................................................................................................................................................................
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    F g 2 108 .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................

    2
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    Serv ce m t .....................................................................................................................................................................................................
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    Fron 1 5 mm .....................................................................................................................................................................................................
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    F g 2 109
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    Rear 1 5 mm .....................................................................................................................................................................................................
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    Tyre dep h gauge .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Note: .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Tyre depth a so can be checked by tyre wear .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    nd cator. (F g. 2.109) .....................................................................................................................................................................................................
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    Tyre pressure: .....................................................................................................................................................................................................
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    l Under n a ed yres wear as er a ec s ab y and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    smoo h corner ng Over n a ed yres decrease .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    area o yre con ac w h ground caus ng sk d or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 110
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    oss o con ro .....................................................................................................................................................................................................
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    l Ma n a n proper yre pressure or good road .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    s ab y and onger yre e n a e yres n co d .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    cond on o he pressure as g ven be ow: .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    F g 2 110 .....................................................................................................................................................................................................
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    Tyre pressure gauge .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    Tyre pressure Front Rear .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    Kg/cm² ps Kg/cm² ps .....................................................................................................................................................................................................
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    So o r d ng 1 75 25 2 00 28 .....................................................................................................................................................................................................
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    Dua r d ng 1 75 25 2 25 32 .....................................................................................................................................................................................................
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    BOLTS AND NUTS .....................................................................................................................................................................................................
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    nspect and t ghten at n t a 500 km and .....................................................................................................................................................................................................
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    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    every 3000 km there after. .....................................................................................................................................................................................................
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    l A he nu s and bo s mus be n good cond on .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    or sa e y They mus be checked and re - gh ened .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    as necessary o he spec ed orque Re er .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    chap er-7 “serv ce n orma on“ page no 7-8 or .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    .....................................................................................................................................................................................................
    orque de a s .....................................................................................................................................................................................................
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    ...............................................................................................................................................................
    Periodic maintenance 2-39
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    PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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    LUBRICATION POINTS .....................................................................................................................................................................................................
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    Warn ng: .....................................................................................................................................................................................................
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    Do not app y too much grease to the brake cam shafts. f grease gets on the n ngs, brake s ppage w
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    resu t. .....................................................................................................................................................................................................
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    Note: .....................................................................................................................................................................................................
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    Lubr cate exposed parts wh ch are sub ect to rust, w th e ther motor o or grease whenever the veh c e has
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    been operated under wet or ra ny cond t ons. .....................................................................................................................................................................................................
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    Before ubr cat ng each part, c ean off any rusty spots and w pe off any grease, o , d rt or gr me.
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    STEER NG STEM BEAR NGS .....................................................................................................................................................................................................
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    G ease THROTTLE GR P G ease
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    BRAKE CAM G ease
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    n case o d um b ake
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    K CK STARTER PEDAL P VOT
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    DR VE CHA N
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    G ease + 4T o
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    BRAKE PEDAL SHAFT
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    SW NG ARM BEAR NGS G ease
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    Periodic maintenance 2-40

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