3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh mixture of oil and gasoline is filled in the fuel
tank. Check the fuel line for leakage.P.1-12
Transmission oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-12 ~ 13
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-16 ~ 21
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-22 ~ 24
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-31 ~ 32
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-32 ~ 34
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-24 ~ 30
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Exhaust pipe and silencerCheck that the exhaust pipe is tightly mounted and has no
cracks.P.4-2
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-35
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 19
5 - 7
CHAS
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts (brake disc) in stage, using a
crisscross pattern.
5PA50160
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Rear wheel sprocket 1
Bolt (rear wheel sprocket) 2
Washer (rear wheel sprocket) 3
Nut (rear wheel sprocket) 4
NOTE:
Tighten the nuts (rear wheel sprocket) in
stage, using a crisscross pattern.5PA50170
T R..42 Nm (4.2 m · kg, 30 ft · lb)
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5PA50180
5. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5PA50190
6. Install:
Drive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
5PA50200
FRONT WHEEL AND REAR WHEEL
