Contents
Notice .................................................................................................................................................... 4
Preparing documents ...................................................................................................................... 5
General Safety ................................................................................................................................ 5
Inspection / Adjustment ................................................................................................................. 20
Inspection and maintenance of electrical system ................................................................................ 40
1. Battery/Charging System ............................................................................................................ 41
1.1 Preparing documents .............................................................................................................. 41
1.2 Failure diagnosis ..................................................................................................................... 42
1.3 Battery ..................................................................................................................................... 42
1.4 Charging system ...................................................................................................................... 43
1.5 Voltage/current regulator ......................................................................................................... 44
1.6 Magneto charging coil ............................................................................................................. 45
1.7 Magneto disassembly .............................................................................................................. 45
2. Ignition System ............................................................................................................................ 47
2.1 Preparing documents .............................................................................................................. 47
2.2 Failure diagnosis ..................................................................................................................... 48
2.3 Ignition system check .............................................................................................................. 49
2.4 RELATED PARTS Group ........................................................................................................ 51
2.5 Ignition coil ................................................................................................................................ 51
2.6 Trigger ...................................................................................................................................... 52
3.. Startup System ............................................................................................................................... 54
3.1 Preparing documents .............................................................................................................. 54
3.2 Failure diagnosis ..................................................................................................................... 55
3.3 Startup motor ........................................................................................................................... 55
3.4 Starter relay ............................................................................................................................. 56
4.. Bulbs/Switches/Meters ................................................................................................................. 58
4.1 Preparing documents .............................................................................................................. 58
4.2 Failure diagnosis ..................................................................................................................... 58
4.3 Replacement of headlamp bulbs ............................................................................................. 58
4.4 Replacement of front steering lamp bulbs ............................................................................... 58
4.5 Replacement of tail lamp bulbs ............................................................................................... 59
4.6 Meter ........................................................................................................................................ 59
4.7 Main switch .............................................................................................................................. 59
4.8 Horn ......................................................................................................................................... 60
4.9 Handlebar switch ..................................................................................................................... 60
Inspection and maintenance of vehicle ................................................................................................ 61
5.. Brake ................................................................................................................................................ 63
5.1 Maintenance instruction........................................................................................................... 63
5.2 Failure diagnosis ..................................................................................................................... 63
5.3 Front disc brake ....................................................................................................................... 64
5.4 Rear disc brake........................................................................................................................ 65
6. Body ............................................................................................................................................ 65
7. Front Wheel/Front Suspension ................................................................................................... 67
7.1 Preparing documents .............................................................................................................. 72
7.2 Failure diagnosis ..................................................................................................................... 72
7.3 Front wheel .............................................................................................................................. 73
7.4 Steering handle ....................................................................................................................... 75
7.5 Front fork ................................................................................................................................. 76
7.6 Radiator/expansion tank assembly ......................................................................................... 77
8.. Rear Wheel/Rear Suspension ....................................................................................................... 80
8.1 Preparing documents ............................................................................................................... 80
8.2 Failure diagnosis ...................................................................................................................... 80
8.3 Rear wheel ................................................................................................................................ 80
8.4 Rear absorber/rear swing arm .................................................................................................. 82