Page 24 of 506
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL....... 5-1
FRONT BRAKE AND REAR BRAKE....... 5-9
FRONT FORK.......................................... 5-27
HANDLEBAR........................................... 5-41
STEERING............................................... 5-46
SWINGARM............................................. 5-51
REAR SHOCK ABSORBER.................... 5-58
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM........................... 6-1
IGNITION SYSTEM.................................... 6-2
CHAPTER 7
TUNING
ENGINE...................................................... 7-1
CHASSIS................................................. 7-10
Page 58 of 506
GEN
INFO
1 - 16
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Frame construction
Combined seat and fuel tank
Engine mounting
Steering Steering stem to
handlebar
Suspension Front Steering stem to front
fork
Rear For link type
Rear Installation of rear
shock absorber
Rear Installation of swin-
garm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to rear frame
Fuel tank to frame
Frame to engine
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Rear shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to rear wheel sprocket
Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Brake caliper to bracket
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.
Page 77 of 506
SPEC
2 - 12
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m kg, 27 ft lb) by using the steering
nut wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m kg, 2.9 ft lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Upper bracket and outer tube M8 × 1.25 2 22 2.2 16
Lower bracket and outer tube M8 × 1.25 4 20 2.0 14
Upper bracket and steering stem M22 × 1.0 1 125 12.5 90
Handlebar holder and upper bracket M8 × 1.25 4 27 2.7 19
Steering stem and steering ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and front fork cap bolt M40 × 1.0 2 28 2.8 20
Front fork and base valve M22 × 1.0 2 55 5.5 40
Front fork cap bolt and damper rod M10 × 1.0 2 15 1.5 11
Front fork bleed screw and front fork cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and front fork protector M6 × 1.0 6 7 0.7 5.1
Front fork and brake hose guide M5 × 0.8 1 4 0.4 2.2
Front fork and brake hose holder M6 × 1.0 1 10 1.0 7.2
Throttle grip cap M5 × 0.8 2 4 0.4 2.2
Throttle cable cap M4 × 0.7 2 1 0.1 0.7
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Clutch lever holder M5 × 0.8 2 4 0.4 2.2
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Front brake hose union bolt M10 × 1.25 2 26 2.6 19
Front fork and brake caliper bracket M8 × 1.25 2 30 3.0 22
Brake caliper support bolt M8 × 1.25 1 23 2.3 17
Front brake caliper and bleed screw M7 × 1.0 1 6 0.6 4.3
Rear brake caliper and brake caliper bracket M8 × 1.25 2 23 2.3 17
Rear brake caliper and pad pin M10 × 1.0 2 18 1.8 13
Rear brake caliper and bleed screw M8 × 1.25 1 6 0.6 4.3
Front wheel axle and axle nut M12 × 1.25 1 70 7.0 50
Front brake disc M6 × 1.0 3 12 1.2 8.7
Rear brake disc M6 × 1.0 4 12 1.2 8.7
Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2
Rear brake reservoir tank M6 × 1.0 1 10 1.0 7.2
Rear brake hose union bolt M10 × 1.25 2 26 2.6 19
Rear wheel axle and axle nut M14 × 1.5 1 90 9.0 65
Page 127 of 506
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
Page 184 of 506
3 - 32
INSP
ADJ
EC36T000
WHEEL INSPECTION
1. Inspect:
Wheel runout
Elevate the wheel and turn it.
Abnormal runout → Replace.
5PA30700
2. Inspect:
Bearing free play
Exist play → Replace.
5PA30710
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering stem
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play → Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust steering ring
nut.
5PA30720
5PA30730
WHEEL INSPECTION/
STEERING HEAD INSPECTION AND ADJUSTMENT
