Page 12 of 389
LOCATION OF THE WARNING AND
SPECIFICATION LABELS .......................1-1
SAFETY INFORMATION .........................2-1
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................3-1
Identification number records ...............3-3
Key identification number .....................3-5
Vehicle identification number ...............3-7
Model label ...........................................3-9
CONTROL FUNCTIONS .........................4-1
Main switch ...........................................4-1
Handlebar switches ..............................4-3
Throttle lever ........................................4-5
Throttle OverRide System ....................4-7
Speed limiter ........................................4-9
Clutch lever ........................................4-11
4321
Front brake lever ................................4-11
Rear brake pedal ................................4-13
Parking brake .....................................4-13
Shift pedal ..........................................4-17
Kick starter .........................................4-17
Fuel tank cap ......................................4-19
Fuel cock ............................................4-19
Starter (choke) ....................................4-21
Seat ....................................................4-23
Front shock absorber adjustment .......4-25
Rear shock absorber adjustment .......4-27
PRE-OPERATION CHECKS ...................5-1
Front and rear brakes ...........................5-5
Fuel ....................................................5-11
Engine mixing oil ................................5-15
Transmission oil .................................5-17
Chain ..................................................5-19
Throttle lever ......................................5-19
5
EBU00015
CONTENTS
5FK-9-63-0~3 2/7/02 1:24 PM Page 12
Page 14 of 389
Cooling system ...................................8-23
Spark plug inspection .........................8-39
Air filter cleaning .................................8-43
Carburetor settings .............................8-51
Idle speed adjustment ........................8-67
Throttle lever adjustment ....................8-71
Front and rear brake pad
inspection .........................................8-73
Inspecting the brake fluid level ...........8-75
Brake fluid replacement ......................8-79
Front brake adjustment ......................8-81
Rear brake adjustment .......................8-83
Parking brake adjustment ...................8-85
Adjusting the rear brake light switch ...8-89
Clutch adjustment ...............................8-91
Drive chain slack check ......................8-91
Drive chain slack adjustment ..............8-93
Lubricating the drive chain .................8-95
Cable inspection and lubrication ........8-99Brake and shift pedal/brake and
clutch lever lubrication ....................8-101
Upper arm and lower arm pivot
lubrication .......................................8-101
Rear arm pivot lubrication ................8-103
Wheel removal .................................8-105
Wheel installation .............................8-105
Replacing the headlight bulb ............8-107
Headlight beam adjustment ..............8-109
Tail/brake light bulb replacement .....8-111
Troubleshooting ................................8-113
Troubleshooting chart .......................8-117
CLEANING AND STORAGE ...................9-1
A. Cleaning ...........................................9-1
B. Storage ............................................9-7
SPECIFICATIONS .................................10-1
109
5FK-9-63-0~3 2/7/02 1:24 PM Page 14
Page 328 of 389
8-91
EBU00539Clutch adjustment
The clutch lever free play should be 5 ~ 10 mm.
If the free play is incorrect, adjust as follows.
1. Loosen the locknut.
2. Turn the adjusting bolt so that clutch lever
free play is 5 ~ 10 mm.
3. Tighten the locknut.EBU00350Drive chain slack check
Inspect the drive chain while all tires are touch-
ing the ground. Check the slack at the position
shown in the figure. The normal vertical deflec-
tion is approximately 15 ~ 20 mm. If the deflec-
tion exceeds 20 mm, adjust the chain slack.
q
w
a
a
1. Locknut 2. Adjusting bolt a. Free play1. Contre-écrou 2. Boulon de réglage a. Jeu1. Tuerca de bloqueo 2. Perno de adjuste a. Juego libre
a. 15 ~ 20 mm
5FK-9-63-8 2/7/02 1:28 PM Page 92
Page 330 of 389
8-93
EBU00351Drive chain slack adjustment
1. Loosen the rear wheel hub bolts.
2. Loosen the adjuster locknuts on each side.
To tighten the chain, turn the chain
adjuster clockwise. To loosen the chain,
turn the adjuster counterclockwise and
push the wheel forward. Turn each
adjuster exactly the same amount to main-
tain correct axle alignment.
There are marks on each side of the
swingarm and on each chain adjuster. Use
them to check for proper alignment.
3. After adjusting, be sure to tighten the lock-
nuts and the wheel hub bolts.
q
w
e
q w
1. Upper wheel hub bolt (×2) 2. Lower wheel hub bolt (×2)1. Boulon supérieur de moyeu de roue (×2)
2. Boulon inférieur de moyeu de roue (×2)1. Tornillo superior del buje de rueda (×2)
2. Tornillo inferior del buje de rueda (×2)
1. Locknut 2. Ajuster 3. Alignment marks1. Contre-écrou 2. Dispositif de réglage
3. Repères d’alignement1. Contratuerca 2.
Tensor
3.Marcas de alineación
Upper wheel hub bolt:
120 Nm (12.0 m0kg)
Lower wheel hub bolt:
60 Nm (6.0 m0kg)
5FK-9-63-8 2/7/02 1:28 PM Page 94
