TABLE OF CONTENTS
3
11.16 Removing the start number plate............... 47
11.17 Installing the start number plate ................ 47
11.18 Removing front fender................................ 48
11.19 Installing the front fender ........................... 48
11.20 Removing the shock absorber ................ 49
11.21 Installing the shock absorber .................. 49
11.22 Removing the seat....................................... 50
11.23 Mounting the seat....................................... 50
11.24 Removing the air filter ............................ 50
11.25 Installing the air filter .............................. 51
11.26 Cleaning the air filter and air filter
box ........................................................... 51
11.27 Removing the main silencer........................ 52
11.28 Installing the main silencer ......................... 52
11.29 Changing the glass fiber yarn filling of
the main silencer ..................................... 52
11.30 Removing the engine sprocket cover ......... 53
11.31 Installing the engine sprocket cover........... 53
11.32 Checking the chain for dirt.......................... 54
11.33 Cleaning the chain....................................... 54
11.34 Checking the chain tension ......................... 55
11.35 Adjusting the chain tension ........................ 55
11.36 Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 56
11.37 Adjusting the chain guide ....................... 58
11.38 Checking the frame ................................. 58
11.39 Checking the link fork .............................. 59
11.40 Checking the throttle cable routing............ 59
11.41 Checking the rubber grip ............................ 59
11.42 Additionally securing the rubber grip ......... 60
12 BRAKE SYSTEM........................................................... 61
12.1 Checking play of handbrake lever............... 61
12.2 Adjusting the play of the hand brake
lever............................................................. 61
12.3 Adjusting the basic position of the hand
brake lever................................................... 61
12.4 Checking the brake discs............................. 62
12.5 Checking the front brake fluid level............ 62
12.6 Adding the front brake fluid ................... 64
12.7 Checking the front brake linings ................. 65
12.8 Changing the brake linings of the front
brake ........................................................ 65
12.9 Checking the free travel of the foot
brake lever................................................... 68
12.10 Adjusting the free travel of the foot
brake lever ............................................... 69
12.11 Adjusting the basic position of the foot
brake lever ............................................... 69
12.12 Checking the rear brake fluid level ............. 70
12.13 Adding rear brake fluid ........................... 70
12.14 Checking the brake linings of the rear
brake............................................................ 71
12.15 Changing the rear brake linings .............. 72
13 WHEELS, TIRES........................................................... 75
13.1 Removing the front wheel ...................... 75
13.2 Installing the front wheel ........................ 75
13.3 Removing the rear wheel ........................ 76
13.4 Installing the rear wheel ......................... 77
13.5 Checking the tire condition......................... 78
13.6 Checking tire pressure................................. 79
13.7 Checking spoke tension............................... 79
14 COOLING SYSTEM...................................................... 81
14.1 Cooling system ............................................ 81
14.2 Checking the antifreeze and coolant
level.............................................................. 81
14.3 Checking the coolant level .......................... 82
14.4 Draining the coolant ................................ 82
14.5 Refilling with coolant ............................... 83
14.6 Changing the coolant .............................. 84
15 TUNING THE ENGINE................................................. 86
15.1 Checking the play in the throttle cable....... 86
15.2 Adjusting the play in the throttle
cable ........................................................ 86
15.3 Carburettor – idle speed ............................. 87
15.4 Carburetor – adjusting the idle speed .... 87
15.5 Checking the clutch setting ..................... 88
15.6 Removing the clutch cover ..................... 89
15.7 Adjusting the clutch ................................ 89
15.8 Installing the clutch cover ....................... 90
16 SERVICE WORK ON THE ENGINE ............................... 91
16.1 Checking the gear oil level .......................... 91
16.2 Changing the gear oil .............................. 91
16.3 Adding the gear oil .................................. 92
17 CARBURETOR............................................................. 94
17.1 Removing the carburetor ........................ 94
17.2 Installing the carburetor ......................... 95
18 CLEANING, CARE........................................................ 97
18.1 Cleaning the motorcycle ............................. 97
19 STORAGE.................................................................... 99
19.1 Storage......................................................... 99
19.2 Preparing for use after storage................ 100
20 TROUBLESHOOTING ............................................... 101
21 TECHNICAL DATA.................................................... 103
21.1 Engine ....................................................... 103
21.2 Engine tightening torques........................ 103
21.3 Carburetor with carburetor tuning.......... 104
21.4 Capacities.................................................. 104
21.4.1 Gear oil ................................................ 104
21.4.2 Coolant ................................................ 104
21.4.3 Fuel ...................................................... 104
21.5 Chassis ...................................................... 104
21.6 Tires .......................................................... 105
21.7 Fork........................................................... 105
21.8 Shock absorber......................................... 106
21.9 Chassis tightening torques ....................... 106
22 SUBSTANCES........................................................... 108
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