CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS................... 3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE................................ 3-4
ENGINE...................................................... 3-5
CHASSIS................................................. 3-16
ELECTRICAL........................................... 3-36
CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS.................................. 4-1
EXHAUST PIPE AND SILENCER............. 4-2
RADIATOR................................................ 4-3
CARBURETOR AND REED VALVE......... 4-6
CYLINDER HEAD, CYLINDER
AND PISTON........................................... 4-15
CLUTCH AND PRIMARY
DRIVEN GEAR........................................ 4-26
KICK SHAFT, SHIFT SHAFT
AND PRIMARY DRIVE GEAR................. 4-33
WATER PUMP......................................... 4-41
CDI MAGNETO........................................ 4-45
ENGINE REMOVAL................................. 4-49
CRANKCASE AND CRANKSHAFT........ 4-53
TRANSMISSION, SHIFT CAM
AND SHIFT FORK................................... 4-59
4 - 49
ENG
EC4M0000
ENGINE REMOVAL
5PA41490
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator hose 1 Disconnect at cylinder head side.
Radiator hose 2 Disconnect at water pump side.
Spark plug cap
Disconnect the CDI magneto
lead.
ENGINE REMOVAL
