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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 filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-13 ~ 17
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.3-24 ~ 30
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-31 ~ 33
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-41 ~ 42
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-42 ~ 44
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-33 ~ 40
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.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-31
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
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 ~ 21
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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering shaft
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.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:
Remove the number plate.
Remove the handlebar and handle crown.
Loosen the ring nut 1 using the ring nut
wrench 2.
Ring nut wrench:
YU-33975/90890-01403
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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the ring nut 3 using ring nut
wrench 4.
NOTE:
Apply the lithium soap base grease on the
thread of the steering shaft.
Set the torque wrench to the ring nut
wrench so that they form a right angle.
Ring nut wrench:
YU-33975/90890-01403
T R..
Ring nut (initial tightening):
38 Nm (3.8 m kg, 27 ft lb)
Loosen the ring nut one turn.
Retighten the ring nut using the ring nut
wrench.
WARNING
Avoid over-tightening.
T R..
Ring nut (final tightening):
7 Nm (0.7 m kg, 5.1 ft lb)
Check the steering shaft by turning it lock
to lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
Install the plain washer 5, handle crown
6, plain washer 7, steering shaft nut 8,
steering shaft cap 9, handlebar 0, han-
dlebar holder A and number plate B.
NOTE:
The upper handlebar holder should be
installed with the punched mark a for-
ward.
Install the handlebar so that the marks b
are in place on both sides.
Insert the end of fuel breather hose C into
the hole in the steering shaft cap.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
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INSP
ADJ
T R..
Steering shaft nut:
145 Nm (14.5 m kg, 105 ft lb)
Handlebar upper holder:
28 Nm (2.8 m kg, 20 ft lb)
Pinch bolt (handle crown):
23 Nm (2.3 m kg, 17 ft lb)
Number plate:
7 Nm (0.7 m kg, 5.1 ft lb)
STEERING HEAD INSPECTION AND ADJUSTMENT
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CHASHANDLEBAR
9. Install:
“ENGINE STOP” button 1
Clutch lever holder 2
Bolt (clutch lever holder) 3
Hot starter lever holder 4
Bolt (hot starter lever holder) 5
Clamp 6
NOTE:
The “ENGINE STOP” button, clutch lever
holder and clamp should be installed accord-
ing to the dimensions shown.
Pass the “ENGINE STOP” button lead in the
middle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
10. Install:
Clutch cable 1
Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.
11. Adjust:
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT” sec-
tion in the CHAPTER 3.
Hot starter lever free play
Refer to “HOT STARTER LEVER
ADJUSTMENT” section in the CHAPTER
3.
12. Clamp the clamp portion a of the number
plate to the handlebar.
13. Insert the end of the fuel breather hose 1
into the hole in the steering shaft cap 2.
2 1a
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CHAS
EC560000
STEERING
Extent of removal:
1 Under bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Number plate
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Steering shaft cap 1
2 Steering shaft nut 1
3 Front fork 2 Refer to “FRONT FORK” section.
4 Handle crown 1
5 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
6 Under bracket 1
7 Bearing race cover 1
8 Bearing (upper) 1
9 Bearing (lower) 1
Refer to “REMOVAL POINTS”.
10 Bearing race 2
2
1
STEERING
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CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the ring nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Ring nut wrench:
YU-33975/90890-01403
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long rod
2 and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
Steering shaft 1
Bend/damage → Replace.
STEERING
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CHASSTEERING
Bearing and bearing race
1. Wash the bearings and bearing races with
a solvent.
2. Inspect:
Bearing 1
Bearing race
Pitting/damage → Replace bearings and
bearing races as a set.
Install the bearing in the bearing races.
Spin the bearings by hand. If the bearings
hang up or are not smooth in their opera-
tion in the bearing races, replace bear-
ings and bearing races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Under bracket
1. Install:
Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Bearing race
Bearing (upper) 1
Bearing race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and bearing race cover lip.
3. Install:
Under bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing, the portion a and thread of the steer-
ing shaft.