Page 8 of 442
4. When transporting the machine in
another vehicle, be sure is kept
upright and that the fuel cock is
turned to the “OFF”. If it should lean
over, gasoline may leak out of the car-
buretor or fuel tank.
5. Never start your engine or let it run for
any length of time in a closed area.
The exhaust fumes are poisonous and
may cause loss of consciousness and
death within a short time. Always
operate your machine in an area with
adequate ventilation.
6. Always wear a helmet, gloves, boots,
trousers, and jacket for motocross
riding.
Page 10 of 442
SAFETY INFORMATION
1. Do not ride it on the street.
2. Do not run the engine inside a building.
3. This is a one-seater motorbike. Do not give
any person a ride.
4. Let’s learn how to ride properly. Ask your
parents for any question.
5. When riding the machine, be sure to wear
the protective apparel as illustrated.
1
Helmet
2
Goggles
3
Mouth guard
4
Gloves
5
Boots
6
Motocross pants
7
Long sleeved trainer
8
Protector
Page 368 of 442
5 - 17
CHAS
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1Dust boot 1
2Cap bolt 1 Refer to “REMOVAL POINTS”.
3Spacer 1
4Washer 1
5Fork spring 1 Drain the fork oil.
6Dust seal 1
Use special tool.
Refer to “REMOVAL POINTS”. 7Stopper ring 1
8Bolt (damper rod) 1
9Damper rod 1
0Inner tube 1
AOil flow stopper 1
BPiston metal 1
COil seal 1
DOuter tube
1
2
1
FRONT FORK
Page 380 of 442
5 - 23
CHASFRONT FORK
9. Compress the front fork fully.
10. Fill:
lFront fork oil 1
CAUTION:
lBe sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
lNever allow foreign materials to enter the
front fork.
Recommended oil:
Fork oil 10W or equivalent
Quantity (each front fork leg):
159 cm
3
(5.60 Imp oz, 5.38 US oz)
11. After filling, pump the inner tube slowly
up and down more than 10 times to dis-
tribute the fork oil.
12. Measure:
lOil level a
Out of specification ® Adjust.
Standard oil level:
122 mm (4.80 in)
From the top of the inner tube,
with the inner tube fully com-
pressed, and without the fork
spring.
13. Install:
lFork spring
lWasher
lSpacer
lCap bolt 1
lDust boot
NOTE:
Temporarily tighten the cap bolt.
Page 382 of 442
5 - 24
CHASFRONT FORK
Installation
1. Install:
lFront fork
NOTE:
lTemporarily tighten the pinch bolt (lower
bracket).
lDo not tighten the pinch bolt (upper bracket)
yet.
2. Tighten:
lCap bolt 1
3. Adjust:
lFront fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
4. Tighten:
lPinch bolt (lower bracket) 1
lPinch bolt (upper bracket) 2
lScrew (dust boot) 3
NOTE:
lMake sure that the dust boot holes a are
positioned outward.
lTighten the screw (dust boot) until the top of
the dust boot is touching the lower bracket.
T R..60 Nm (6.0 m · kg, 43 ft · lb)
T R..25 Nm (2.5 m · kg, 18 ft · lb)
5. Install:
lCap 1
Page 416 of 442
5 - 41
CHAS
2. Install:
lOil seals 1
lCollars 2
lBushing 3
lDust covers 4
lDust covers 5
lRubber boot 6
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bushing, collar, oil seal lip and dust cover lip.
3. Install:
lCollar 1
lDust covers 2
On connecting arm.
NOTE:
Apply the molybdenum disulfide grease on the
collar and dust cover lip.
4. Install:
lRelay arm 1
lBolt (relay arm)
lPlain washer
lNut (relay arm)
On swingarm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (relay arm).
5. Install:
lConnecting arm 1
lBolt (connecting arm)
lPlain washer
lNut (connecting arm)
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (connecting arm).
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..35 Nm (3.5 m · kg, 25 ft · lb)
SWINGARM