INSP
ADJINTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS
3-1
PERIODIC INSPECTION AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as to new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
ODOMETER READING (x 1,000 km)
ANNUAL N0. ITEM CHECK OR MAINTENANCE JOB
110 2030 40CHECK
1
*Fuel line• Check fuel hoses for cracks or damage. ✓✓ ✓✓ ✓•
• Check condition.
✓✓
2 Spurk plug• Clean and regap.
• Replace.✓✓
3 * Valves• Check valve clearance.
✓✓ ✓✓
• Adjust.
4Air filter element• Clean.✓✓
• Replace. ✓✓
5 Clutch• Check operation.
✓✓ ✓ ✓✓
• Adjust.
• Check operation, fluid level and vehicle for fluid leakeage.
6 * Front brake•(See NOTE). ✓✓ ✓ ✓✓ ✓•
• Replace brake pads. Whenever worm to the limit
• Check operation, fluid level and vehicle
•for fluid leakage. ✓✓ ✓ ✓✓ ✓
7 * Rear brake•(See NOTE).
• Replace brake pads. Whenever worm to the limit
8 * Brake hoses• Check for cracks or damage.✓✓✓✓ ✓• Replace. (See NOTE). Every 4 years
9 * Wheels• Check runout, spoke tightness and for damage.
✓✓✓ ✓
• Tighten spokes if necessary.
• Check tread depth and for damage.
10 * Tyres• Replace if necessary.
✓✓✓✓ ✓
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings• Check bearing for looseness or damage.✓✓✓✓
12 * Swingarm• Check operation and for excessive play.✓✓✓✓
• Check chain slack.
13 * Drive chain• Make sure that the rear wheel is properly aligned.Every 500 km and after washing the
• Clean and lubricate.motorcycle or riding in the rain.
14 *Steering • Check bearing play and steering for roughness. ✓✓ ✓ ✓✓bearings
• Lubrificate with lithium-soap-based grease. Every 20,000 km
15 *Chassis • Make sure that all nuts, bolts and screws are properly
✓✓ ✓✓ ✓
fasteners•tightened.
16Sidestand• Check operation.
✓✓ ✓✓ ✓
• Lubricate.
17
*Sidestand
• Check operation and for oil leakage. ✓✓ ✓ ✓✓ ✓
switch
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ELECLIGHT SYSTEM
7-45
*
CORRECT
DEFECTIVE CONNECTIONS Repair.6. Harness connections.
•Check the connections of the entire light
system.
Check the conditions of each circuit for the
entire light system.
See the “ELECTRIC CIRCUIT DIAGRAM”.
5. Starter circuit cut-off relay.
•Connect the pocket tester (DC 20V) and
the battery (12V) to the cut-off relay con-
nector terminal of the starter circuit.
Battery terminal (+) ➔
White/Black terminal (1)
Battery terminal (–) ➔Black terminal (2)
Tester terminal (+) ➔Brown terminal (3)
Tester terminal (–) ➔Earth
DISCONTINUITY
The starter circuit cut-off relay is defective.
Replace.
•Turn the main switch to ON.
•Check the voltage (12V) on the
“Brown/Blue” and “Brown” cable to the
connector terminal of the starter circuit
cut-off relay.
IN COMPLIANCE WITH
SPECIFICATIONS (12V)
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SIGNAL SYSTEM
7-54
ELEC
*
3. Main switch.
•Disconnect the main switch connector
(Blue, Red and Brown) from the wire har-
ness.
•Connect the pocket tester ( Ωx 1) to the
main switch cables. Refer to “SWITCH CHECK” section.
Tester terminal (+) ➔Red cable (1)
Tester terminal (–) ➔Brown cable (2)
Tester terminal (–) ➔Blue cable (3)
CORRECT
DISCONTINUITY
The main switch is defective. Replace.
CORRECT
UNCERTAIN CONNECTIONS Repair.4. Harness connections
•Check the connections of the entire signal
system.
Check the condition of each signal system.
Refer to “ELECTRICAL CIRCUIT DIAGRAM”
section.
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