TABLE OF CONTENTS
3
11.3 Bleeding the fork legs.................................. 41
11.4 Cleaning the dust boots of the fork legs..... 42
11.5 Removing the fork legs ........................... 42
11.6 Installing the fork legs ............................. 43
11.7 Removing the fork protector ...................... 44
11.8 Installing the fork protector........................ 44
11.9 Removing the lower triple clamp ............ 45
11.10 Installing the lower triple clamp ............. 46
11.11 Checking the steering head bearing play ... 48
11.12 Adjusting the steering head bearing
play .......................................................... 49
11.13 Lubricating the steering head bearing .... 50
11.14 Removing the start number plate............... 50
11.15 Installing the start number plate ................ 50
11.16 Removing front fender................................ 51
11.17 Installing front fender ................................. 51
11.18 Removing the shock absorber ................ 51
11.19 Installing the shock absorber .................. 52
11.20 Removing the seat....................................... 52
11.21 Mounting the seat....................................... 52
11.22 Removing the air filter box cover................ 53
11.23 Installing the air filter box cover ................. 53
11.24 Removing the air filter ............................ 53
11.25 Cleaning the air filter and air filter
box ........................................................... 54
11.26 Installing the air filter .............................. 54
11.27 Removing the main silencer........................ 55
11.28 Installing the main silencer ......................... 55
11.29 Changing the glass fiber yarn filling of
the main silencer ..................................... 55
11.30 Removing the fuel tank ........................... 56
11.31 Installing the fuel tank ............................. 57
11.32 Checking for chain dirt accumulation......... 58
11.33 Cleaning the chain....................................... 59
11.34 Checking the chain tension ......................... 59
11.35 Adjusting the chain tension ........................ 60
11.36 Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 61
11.37 Checking the frame ................................. 63
11.38 Checking the link fork .............................. 63
11.39 Checking the throttle cable routing............ 63
11.40 Checking the rubber grip ............................ 64
11.41 Adjusting the basic position of the clutch
lever............................................................. 64
11.42 Checking the fluid level of the hydraulic
clutch ........................................................... 65
11.43 Correcting the fluid level of the hydraulic
clutch ........................................................... 65
11.44 Changing the hydraulic clutch fluid ........ 66
12 BRAKE SYSTEM........................................................... 68
12.1 Checking the free travel of the hand
brake lever................................................... 68
12.2 Adjusting the free travel of the
handbrake lever .......................................... 68
12.3 Checking the brake discs............................. 68
12.4 Checking the front brake fluid level............ 69
12.5 Adding the front brake fluid ................... 69
12.6 Checking the front brake linings ................. 71
12.7 Changing the brake linings of the front
brake ........................................................ 71
12.8 Checking the free travel of foot brake
lever............................................................. 73
12.9 Adjusting the basic position of the foot
brake lever ............................................... 74
12.10 Checking the rear brake fluid level ............. 74
12.11 Adding rear brake fluid ........................... 75
12.12 Checking the rear brake linings................... 76
12.13 Changing the rear brake linings .............. 76
13 WHEELS, TIRES........................................................... 79
13.1 Removing the front wheel ...................... 79
13.2 Installing the front wheel ........................ 79
13.3 Removing the rear wheel ........................ 80
13.4 Installing the rear wheel ......................... 81
13.5 Checking the tire condition......................... 82
13.6 Checking tire pressure................................. 83
13.7 Checking spoke tension............................... 83
14 COOLING SYSTEM...................................................... 85
14.1 Cooling system ............................................ 85
14.2 Radiator cover ............................................. 85
14.3 Installing the radiator cover........................ 85
14.4 Removing the radiator cover ...................... 86
14.5 Checking the antifreeze and coolant
level.............................................................. 87
14.6 Checking the coolant level .......................... 88
14.7 Draining the coolant ................................ 88
14.8 Refilling with coolant ............................... 89
14.9 Changing the coolant .............................. 90
15 TUNING THE ENGINE................................................. 92
15.1 Checking the play in the throttle cable....... 92
15.2 Adjusting the play in the throttle
cable ........................................................ 92
15.3 Carburetor tuning........................................ 93
15.4 Carburetor – idle setting ............................. 95
15.5 Carburetor – adjusting the idle speed .... 96
15.6 Emptying the carburetor float
chamber .................................................. 97
15.7 Plug-in connector of ignition timing map
adjustment .................................................. 98
15.8 Changing the ignition timing map............... 98
15.9 Checking the basic position of the shift
lever............................................................. 98
15.10 Adjusting the basic position of the shift
lever ......................................................... 98
16 SERVICE WORK ON THE ENGINE ............................ 100
16.1 Checking the gear oil level ....................... 100
16.2 Changing the gear oil ........................... 100
16.3 Adding the gear oil ............................... 101
17 CLEANING, CARE..................................................... 103
17.1 Cleaning the motorcycle .......................... 103
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