3 - 2
INSP
ADJ
 
MAINTENANCE INTERVALS 
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect 
c 
Inspect wear
ROTOR NUT
Retighten 
cc 
MUFFLER
Inspect
Clean
Replace
Retighten 
cc
ccc 
*Whichever comes first
CRANK
Inspect and clean 
cc 
CARBURETOR
Inspect, adjust and clean 
cc 
When using a high-pres-
sure washer, make sure 
that water does not enter 
the accelerator pump.
SPARK PLUG
Inspect and clean
Replace 
cc
c 
DRIVE CHAIN
Lubricate, slack, alignment
Replace 
cc
c 
Use chain lube
Chain slack: 40 ~ 50 mm 
(1.6 ~ 2.0 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses 
cc
cc
c 
Every two years
OUTSIDE NUTS AND BOLTS
Retighten 
cc 
Refer to “STARTING AND 
BREAK-IN” section in the 
CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace 
cc
c 
Use foam air-filter oil
OIL STRAINER (frame)
Clean 
c 
FRAME
Clean and inspect 
cc 
FUEL TANK, COCK
Clean and inspect 
cc 
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper 
bolts, master cylinder bolts and union 
bolts
Replace pads
Replace brake fluid 
c
c
c
c
cc
c
c
c
c
c
c 
Every one year
FRONT FORKS
Inspect and adjust
Replace oil
Replace oil seal 
c
cc
c
c 
Suspension oil “01” ItemAfter 
break-inEvery 
race 
Every 
third
(or 
500 km)Every 
fifth
(or 
1,000 km) 
As re-
quiredRemarks 
3 
5 - 21
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
[Front]
lMaster cylinder kit 1 
lPush rod 2 
lPlain washer 3 
lCirclip 4 
lMaster cylinder boot 5 
lLocknut 6 
To master cylinder 7.
[Rear]
lMaster cylinder kit 1 
lPush rod 2 
lCirclip 3 
lMaster cylinder boot 4 
lLocknut 5 
To master cylinder 4.
NOTE:
lApply the brake fluid on the master cylinder
kit.
lApply the lithium soap base grease on the tip
of the push rod.
lWhen installing the circlip, use a long nose
circlip pliers.
Front
õRear
õ
Front master cylinder
1. Install:
lMaster cylinder 1 
lMaster cylinder bracket 2 
lBolt (master cylinder bracket) 3 
NOTE:
lInstall the bracket so that the arrow mark a
face upward.
lFirst tighten the bolts on the upper side of the
master cylinder bracket, and then tighten the
bolts on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)