3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Inspect:
Coolant level
Coolant level should be between the
maximum a and minimum b marks.
Coolant level is below the “LOW” level
line → Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for sev-
eral minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant settles.
a
b
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT
3 - 10
INSP
ADJCLUTCH ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
EC359020
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side
using the adjuster 3.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Slide the adjuster cover.
Loosen the locknut 1.
Turn the adjuster 2 until the specified free
play is obtained.
Tighten the locknut.
21
3 - 11
INSP
ADJTHROTTLE LUBRICATION/
HOT STARTER LEVER ADJUSTMENT
THROTTLE LUBRICATION
1. Remove:
Cover (throttle cable cap) 1
Cover (grip cap) 2
Throttle cable cap 3
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebar to right and left and make sure
that the engine idling does not run faster.
2. Apply:
Lithium soap base grease
On the throttle cable end a.
3. Install:
Throttle cable cap
Screw (throttle cable cap)
Cover (grip cap)
Cover (throttle cable cap)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HOT STARTER LEVER ADJUSTMENT
1. Check:
Hot starter lever free play a
Out of specification → Adjust.
2. Adjust:
Hot starter lever free play
NOTE:
After adjustment, check proper operation of
hot starter.
Hot starter lever free play
a:
3 ~ 6 mm (0.12 ~ 0.24 in)
Hot starter lever free play adjustment
steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
INSP
ADJ
NETTOYAGE DU FILTRE A AIR
N.B.:
Un bon entretien du filtre à air est la
meilleure façon d’éviter l’usure et
l’endommagement prématurés du
moteur.
ATTENTION:
Ne jamais faire tourner un moteur
lorsque l’élément du boîtier du filtre à
air n’est pas en place. Des crasses et
des poussières pourraient pénétrer
dans le moteur et provoquer son usure
prématurée et d’éventuels dommages.
1. Déposer:
Couvercle du boîtier de filtre à air
1
N.B.:
Desserrer la vis de serrage rapide 2 et
tirer le couvercle du boîtier de filtre à air
pour le déposer car ses pattes a sont
insérées dans le couvercle latéral comme
illustré.
2. Décrocher:
Fixation 1
3. Déposer:
Elément du boîtier de filtre à air
1
Guide de filtre 2
4. Nettoyer:
Elément du boîtier de filtre à air
Nettoyer à l’aide d’un solvant.
N.B.:
Après nettoyage, éliminer l’excès de sol-
vant en pressant l’élément.
NETTOYAGE DU FILTRE A AIR
LUFTFILTER REINIGEN
LIMPIEZA DEL FILTRO DE AIRE
3 - 12
LUFTFILTER REINIGEN
HINWEIS:
Sachgemäße Luftfilter-Wartung ist
ausschlaggebend im Schutz vor früh-
zeitigen Motorschäden und -ver-
schleiß.
ACHTUNG:
Der Motor darf unter keinen
Umständen mit ausgebautem Luft-
filter betrieben werden, da ungefil-
terte Ansaugluft zu erhöhtem
Verschleiß und Motorschäden füh-
ren kann.
1. Demontieren:
Luftfilter-Gehäusedeckel
1
HINWEIS:
Die Schnellverschlussschraube
2
lockern und den Luftfilter-Gehäuse-
deckel, wie abgebildet, verschieben,
um die Haltenasen
a an der Innen-
seite des Deckels zu lösen.
2. Aushaken:
Halterung
1
3. Demontieren:
Luftfiltereinsatz
1
Filterrahmen
2
4. Reinigen:
Luftfiltereinsatz
(in Lösungsmittel)
HINWEIS:
Anschließend überschüssiges
Lösungsmittel vorsichtig aus dem Fil-
tereinsatz ausdrücken.LIMPIEZA DEL FILTRO DE AIRE
NOTA:
El mantenimiento adecuado del filtro de
aire es un factor clave para prevenir el
desgaste prematuro y el deterioro del
motor.
ATENCION:
No ponga nunca en marcha el motor
sin el elemento del filtro de aire; de lo
contrario, penetrarán suciedad y
polvo en el motor que provocarán un
desgaste rápido y posibles averías del
mismo.
1. Extraer:
Tapa de la carcasa del filtro de
aire 1
NOTA:
Afloje el tornillo 2 levante la tapa de la
carcasa del filtro de aire para extraerla,
pues sus pinzas a están introducidas en
la cubierta lateral como se muestra.
2. Desenganchar:
Sujeción 1
3. Extraer:
Elemento del filtro de aire 1
Guía del filtro 2
4. Limpiar:
Elemento del filtro de aire
Límpielo con disolvente.
NOTA:
Después de limpiarlo, elimine los restos
de disolvente estrujando el elemento.
3 - 19
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
VALVE CLEARANCE ADJUSTMENT
NOTE:
The valve clearance should be adjusted
when the engine is cool to the touch.
The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove:
Seat
Fuel tank
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
2. Remove:
Carburetor
Refer to “CARBURETOR” section in the
CHAPTER 4.
Spark plug
Engine stay (upper)
Cylinder head cover
Refer to “CAMSHAFTS” section in the
CHAPTER 4.
3. Remove:
Timing plug 1
Straight plug 2
O-ring
1
2
4. Check:
Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve:
0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)
Exhaust valve:
0.20 ~ 0.25 mm
(0.0079 ~ 0.0098 in)
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.
b
a
INSP
ADJ
N.B.:
Le piston est au point mort haut lors-
que le repère poinçonné c de l’arbre
à cames d’échappement et le repère
poinçonné d de l’arbre à cames
d’admission sont alignés avec la sur-
face de la culasse comme le montre
l’illustration.
Mesurer le jeu aux soupapes e à
l’aide d’une jauge d’épaisseur à
lames 1.
N.B.:
Enregistrer la valeur mesurée si le jeu
est incorrect.
5. Régler:
Jeu aux soupapes
Etapes du réglage:
Desserrer le boulon capuchon du
tendeur de chaîne de distribution.
Déposer le tendeur de chaîne de
distribution et les chapeaux d’arbre
à cames.
N.B.:
Déposer les boulons du chapeau
d’arbre à cames en croix, en procé-
dant de l’extérieur vers l’intérieur.
Déposer les arbres à cames (échap-
pement 1 et admission 2).
N.B.:
Attacher un fil 3 à la chaîne de dis-
tribution pour l’empêcher de tomber
dans le carter moteur.
REGLAGE DU JEU AUX SOUPAPES
VENTILSPIEL EINSTELLEN
AJUSTE DE LA HOLGURA DE VÁLVULAS
3 - 20
HINWEIS:
Der Kolben befindet sich im obe-
ren Totpunkt, wenn die Körner-
markierung
c am Auslass-
Nockenwellenrad und die Körner-
markierung
d am Einlass-
Nockenwellenrad, wie in der
Abbildung gezeigt, mit der Zylin-
derkopf-Passfläche fluchten.
Das Ventilspiel
e mit einer
Fühlerlehre
1 messen.
HINWEIS:
Entspricht das gemessene Ventil-
spiel nicht der Vorgabe, muss das
Messergebnis für spätere Zwecke
notiert werden.
5. Einstellen:
Ventilspiel
Arbeitsvorgang:
Die Steuerkettenspanner-Ver-
schlussschraube lokkern.
Die Steuerkettenspanner-Ver-
schlussschraube und die Nok-
kenwellen-Lagerdeckel
demontieren.
HINWEIS:
Die Schrauben des Nockenwel-
len-Lagerdeckels müssen von
außen nach innen über Kreuz
gelockert werden.
Die Auslass-Nockenwelle
1
und Einlass-Nockenwelle
2
demontieren.
HINWEIS:
Die Steuerkette mit einem Draht
3 sichern, damit sie nicht in das
Kurbelgehäuse hinabfällt.
NOTA:
Para estar seguro de que el pistón se
encuentra en el punto muerto supe-
rior, la marca perforada c en el eje
de levas de escape y la marca perfo-
rada d en el eje de levas de admisión
deben alinearse con la superficie de
la culata, como se muestra en la ilus-
tración.
Mida la holgura de las válvulas e
con una galga 1.
NOTA:
Anote la medición si la holgura es
incorrecta.
5. Ajustar:
Holgura de las válvulas
Procedimiento de ajuste:
Afloje el perno capuchino del ten-
sor de la cadena de distribución.
Extraiga el tensor de la cadena de
distribución y las tapas del eje de
levas.
NOTA:
Extraiga los tornillos de las tapas del
eje de levas en cruz, desde fuera
hacia adentro.
Desmonte los ejes de levas (admi-
sión 1 y escape 2).
NOTA:
Ate un alambre 3 a la cadena de dis-
tribución para impedir que caiga al
cárter.
3 - 22
INSP
ADJ
6. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of
their removal.Locate the rounded-off value and the mea-
sured valve clearance in the chart “PAD
SELECTION TABLE”. The field where
these two coordinates intersect shows the
new pad number to use.
NOTE:
Use the new pad number only as a guide
when verifying the valve clearance adjust-
ment.
Install the new pads 6 and the valve lift-
ers 7.
NOTE:
Apply the engine oil on the valve lifters.
Apply the molybdenum disulfide oil on the
valve stem ends.
Valve lifter must turn smoothly when
rotated with a finger.
Be careful to reinstall valve lifters and
pads in their original place.
Install the camshafts (exhaust and intake),
the timing chain and the camshaft caps.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m kg, 7.2 ft lb)
Install the timing chain tensioner.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.
NOTE:
Turn the crankshaft counterclockwise sev-
eral turns so that the installed parts settle
into the right position.
Recheck the valve clearance.
If the clearance is still incorrect, repeat all
the clearance adjustment steps until the
specified clearance is obtained.
VALVE CLEARANCE ADJUSTMENT
3 - 26
INSP
ADJ
FRONT BRAKE ADJUSTMENT
3. Install:
Protector (rear brake)
Reservoir float (front brake)
Diaphragm
Master cylinder cap
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the
reservoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
EC362040
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever position a
Brake lever position
a:
Standard position Extent of adjustment
95 mm (3.74 in)76 ~ 97 mm
(2.99 ~ 3.82 in)
2. Remove:
Lever cover
3. Adjust:
Brake lever position
4. Install:
Lever cover Brake lever position adjustment steps:
Loosen the locknut 1.
Turn the adjusting bolt 2 until the lever
position a is within specified position.
Tighten the locknut.
T R..
Locknut:
5 Nm (0.5 m kg, 3.6 ft lb)
CAUTION:
Be sure to tighten the locknut, as it will
cause poor brake performance.