IMPORTANT NOTES 6
LOCATION OF SERIAL NUMBERS
VIN (VEHICLE IDENTIFICATION NUMBER)
AND FRAME PLATE 7
ANTI TEMPERING LABEL 7
ENGINE NUMBER 7
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7
GENERAL SPECIFICATIONS
VEHICLE SPECIFICATION 8
SPECIFIC TIGHTENING TORQUE 10
GENERAL TIGHTENING TORQUE 11
SPECIAL TOOLS
SPECIAL TOOLS 12
1. PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHART
CHECKLIST OF CONSTANT MAINTENANCE 15
IMPORTANT PREPARATION REFERENCES
IMPORTANT PREPARATION REFERENCES 18
FUEL SYSTEM
AIR CLEANER 21
CHANGING INTERVALS 21
THROTTLE WIRE INSPECTION/ ADJUSTMENT 21
IDLE ADJUSTMENT 22
CARBURETTOR ADJUSTMENT 22
FUEL HOSE INSPECTION 22
FUEL FILTERS CLEANING 23
ENGINE
ENGINE OIL LEVEL INSPECTION 23
ENGINE OIL LEVEL SENSOR INSPECTION 24
OIL PUMP INSPECTION 24
OIL PUMP ADJUSTMENT 26
TRANSMISSION OIL LEVEL INSPECTION 27
SPARK PLUG INSPECTION 27
SPARKPLUG IMAGES AND ANALYSIS 28
SPARK PLUG REPLACEMENT 28
CYLINDER PRESSURE INSPECTION 28
CLUTCH
CLUTCH CABLE FREE PLAY ADJUSTMENT 29
ADJUSTING THE CLUTCH CABLE FREE PLAY
ON THE ENGINE SIDE 29
CLUTCH ADJUSTMENT 30
WHEELS
AIR PRESSURE INSPECTION 30
WHEEL BEARING AND WHEEL AXLE
DAMAGE INSPECTION 31
BRAKES
BRAKE FLUID LEAK INSPECTION FRONT 31
BRAKE FLUID LEAK INSPECTION REAR 31
BREAK OPERATION INSPECTION FRONT 31
BREAK OPERATION INSPECTION REAR 32
BRAKE FLUID LEVEL INSPECTION FRONT 32
BRAKE FLUID LEVEL INSPECTION REAR 32
FRONT BRAKE PADS INSPECTION 33
REAR BRAKE PADS INSPECTION 33
FRONT BRAKE DISC INSPECTION 34
REAR BRAKE DISC INSPECTION 35
FRONT BRAKE LEVER/ MASTER BRAKE
CYLINDER REPLACEMENT 35
FOOT BRAKE LEVER/ MASTER BRAKE
CYLINDER REPLACEMENT 36
FRONT BRAKE CALLIPER REPLACEMENT 36
REAR BRAKE CALLIPER REPLACEMENT 36
FRONT BRAKE HOSE REPLACEMENT 37
REAR BRAKE HOSE REPLACEMENT 37
FRONT BRAKE LEVER ADJUSTMENT 38
REAR BRAKE LEVER ADJUSTMENT 38
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION 39
DRIVE CHAIN SLACK ADJUSTMENT 39
DRIVE CHAIN LUBRICATION 39
DRIVE CHAIN WEAR INSPECTION 40
SUSPENSION
FRONT FORK OPERATION INSPECTION 40
FRONT FORK OIL LEAK INSPECTION 40
REAR SHOCK OPERATION INSPECTION 41
REAR SHOCK OIL LEAK INSPECTION 41
STEERING
STEERING PLAY INSPECTION 41
STEERING BEARING LUBRICATION 42
ELECTRICAL SYSTEM
BATTERY INSPECTION/ CHARGING 43
FUSES 44
LIGHT AND SWITCHES OPERATION INSPECTION 44
HEADLIGHT AIMING INSPECTION 45
2. REPAIR AND DIAGNOSTIC
CHASSIS
EXPLODED VIEW / PART LOCATION - FRAME 47
EXPLODED VIEW / PART LOCATION - REAR
SWING ARM 48
EXPLODED VIEW / PART LOCATION - SEAT 48
FUEL SYSTEM
EXPLODED VIEW / PART LOCATION - FUEL SYSTEM 50
SPECIFICATION 51
CARBURETTOR
EXPLODED VIEW / PART LOCATION - CARBURETTOR 52
CARBURETTOR REMOVAL 53
CHOKE/ CABLE REMOVAL 53
CARBURETTOR UPPER COVER REMOVAL 54
CARBURETTOR ADJUSTMENT 54
FUEL SUPPLY
FUEL SUPPLY INSPECTION 54
FUEL TANK REMOVAL 55
FUEL COCK 56
ENGINE
EXPLODED VIEW / PART LOCATION - CYLINDER/
CYLINDER COVER 57
EXPLODED VIEW / PART LOCATION - CRANK
ASSEMBLY 58
EXPLODED VIEW / PART LOCATION - CRANKCASE 59
SPECIFICATION 60
TROUBLESHOOTING 61
ENGINE OVERHAUL/ REMOVAL 62
ENGINE PREPARATION 62
ENGINE REMOVAL 62
ENGINE TOP END
CYLINDER COVER REMOVAL 63
CYLINDER REMOVAL 63
PISTON REMOVAL 63
OIL PUMP REMOVAL 64
WATER PUMP REMOVAL 64
CRANKCASE (RIGHT) REMOVAL 64
CLUTCH REMOVAL 65
CRANKSHAFT GEAR AND MAIN SHAFT GEAR REMOVAL 66
MEMBRANE 66
SPROCKET REMOVAL 66
CRANKCASE COVER (LEFT) REMOVAL 67
INDEX
3
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