MAINTENANCE
1.1 GENERAL
Servicing a New Motorcycle...............................................1-1
Safe Operating Maintenance..............................................1-1
Shop Practices...................................................................1-1
Repair Notes...............................................................1-1
Safety..........................................................................1-1
Removing Parts...........................................................1-1
Cleaning......................................................................1-1
Disassembly and Assembly........................................1-2
Checking Torques on Fasteners with Lock Patches.....1-2
Magnetic Parts Trays...................................................1-2
Repair and Replacement Procedures................................1-2
Hardware and Threaded Parts....................................1-2
Threadlocking Agents..................................................1-2
Wiring, Hoses and Lines.............................................1-2
Instruments and Gauges.............................................1-2
Bearings......................................................................1-2
Bushings.....................................................................1-2
Gaskets.......................................................................1-2
Lip Type Seals.............................................................1-2
O-Rings (Preformed Packings)....................................1-3
Gears..........................................................................1-3
Shafts..........................................................................1-3
Part Replacement........................................................1-3
Exhaust System Leakage............................................1-3
Cleaning.............................................................................1-3
Part Protection............................................................1-3
Cleaning Process........................................................1-3
Rust or Corrosion Removal.........................................1-3
Bearings......................................................................1-3
Tool Safety..........................................................................1-3
Air Tools.......................................................................1-3
Wrenches....................................................................1-3
Pliers/Cutters/Pry bars................................................1-3
Hammers.....................................................................1-4
Punches/Chisels..........................................................1-4
Screwdrivers................................................................1-4
Ratchets and Handles.................................................1-4
Sockets........................................................................1-4
Storage Units...............................................................1-4
1.2 MAINTENANCE SCHEDULE
General...............................................................................1-5
1.3 FUEL AND OIL
Fuel....................................................................................1-8
Gasoline Blends.................................................................1-8
Engine Lubrication..............................................................1-8
Winter Lubrication..............................................................1-9
1.4 ENGINE OIL AND FILTER
Checking and Adding Oil..................................................1-10
Type of Oil.................................................................1-10
Checking with Cold Engine.......................................1-10
Checking with Warm Engine.....................................1-10
Changing Oil and Filter.....................................................1-11
1.5 BULB REQUIREMENTS
General.............................................................................1-12
1.6 BRAKES
Fluid Inspection................................................................1-13
Rear Pedal Height............................................................1-13
1.7 AIR CLEANER AND EXHAUST SYSTEM
Removal...........................................................................1-15
Installation........................................................................1-15
Exhaust System Leak Check............................................1-16
1.8 TIRES AND WHEELS
Tires.................................................................................1-17
Tire Replacement.............................................................1-17
Wheel Bearings................................................................1-18
Wheel Spokes..................................................................1-18
1.9 PRIMARY CHAIN
General.............................................................................1-19
Changing Primary Chaincase Lubricant...........................1-19
1.10 TRANSMISSION LUBRICANT
Changing Transmission Lubricant.....................................1-21
1.11 CLUTCH
Adjustment.......................................................................1-22
1.12 REAR BELT AND SPROCKETS
General.............................................................................1-24
Cleaning...........................................................................1-24
Inspection.........................................................................1-24
Sprockets..................................................................1-24
Rear Belt...................................................................1-24
1.13 REAR BELT DEFLECTION
Inspection.........................................................................1-26
Adjustment.......................................................................1-27
1.14 THROTTLE CABLES
Cable Inspection, Lubrication and Adjustment.................1-28
Inspection and Lubrication........................................1-28
Adjustment................................................................1-28
1.15 BLEEDING BRAKES
General.............................................................................1-29
Procedure.........................................................................1-29
1.16 BRAKE PADS AND DISCS
Inspection.........................................................................1-30
Brake Pads................................................................1-30
Brake Disc Thickness................................................1-30
Brake Disc Lateral Runout and Warpage..................1-30
Brake Pad Replacement...................................................1-30
Rear Brake Caliper....................................................1-30
Front Brake Caliper...................................................1-31
1.17 BATTERY MAINTENANCE
General.............................................................................1-33
Cleaning and Inspection...................................................1-34
Voltmeter Test...................................................................1-34
Voltmeter Test............................................................1-34
Charging Battery..............................................................1-34
Safety Precautions....................................................1-34
Using a Battery Charger............................................1-34
Disconnection and Removal.............................................1-35
Storage.............................................................................1-36
Installation and Connection..............................................1-36
1.18 SUSPENSION ADJUSTMENTS
Rear Shock Preload Adjustment......................................1-38
III
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