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INSP
ADJFRONT FORK COMPRESSION DAMPING FORCE
ADJUSTMENT
STANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
* For EUROPE
** For AUS, NZ and ZA
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
EC36J001
FRONT FORK COMPRESSION DAMPING
FORCE ADJUSTMENT
1. Remove:
Rubber cap
2. Adjust:
Compression damping force
By turning the adjuster 1.
Standard position:
10 clicks out
* 11 clicks out
** 13 clicks out
Stiffer
a
→Increase the compression
damping force. (Turn the
adjuster
1 in.)
Softer
b
→Decrease the compression
damping force. (Turn the
adjuster
1 out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out (from
maximum position)
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INSP
ADJ
REAR SHOCK ABSORBER INSPECTION
STANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
* For EUROPE
** For AUS, NZ and ZA
CAUTION:
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
3. Install:
Rubber cap
Standard position:
11 clicks out
* 8 clicks out
** 12 clicks out
EC36K000
REAR SHOCK ABSORBER INSPECTION
1. Inspect:
Swingarm smooth action
Abnormal noise/unsmooth action →
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage → Replace.
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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 (upper) A and headlight B.
NOTE:
The handlebar holder (upper) 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 the 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 (upper), and then
tighten the bolts on the rear side.
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INSP
ADJ
BATTERY INSPECTION AND CHARGING
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling
or working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
BATTERY INSPECTION AND CHARGING
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INSP
ADJ
BATTERY INSPECTION AND CHARGING
ÈRelationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
(These values vary with the temperature, the
condition of the battery plates, and the electro-
lyte level.)
ÉOpen-circuit voltage
ÊCharging time (hours)
ËTime (minutes)
ÌCharging condition of the battery
ÍAmbient temperature 20 °C (68 °F)
aCharging
bCheck the open-circuit voltage.
5. Charge:
Battery
(refer to the appropriate charging method
illustration)
WARNING
Do not quick charge a battery.
CAUTION:
Never remove the MF battery sealing
caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to
remove it from the machine. (If charging
has to be done with the battery mounted
on the machine, disconnect the negative
battery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery. Check the charge of the battery, as shown
in the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30%
È
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INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
Fuse cover
Seat Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage.
Set on the switches to verify if the electri-
cal circuit is operational.
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage
ratingQ’ty
Main fuse 10 A 1
REPLACING THE HEADLIGHT BULBS
1. Remove:
Headlight
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
2. Remove:
Headlight bulb holder cover 1
3. Detach:
Headlight bulb holder 1
4. Remove:
Headlight bulb 2
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb unit it has cooled
down.
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ENGRADIATOR
EC456000
HANDLING NOTE
WARNING
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
EC444100
Radiator
1. Inspect:
Radiator core 1
Obstruction → Blow out with compressed
air through rear of the radiator.
Bent fin → Repair/replace.
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:
Pipe 1 1
Hose 1 2
Pipe 2 3
Hose 3 4
Hose 4 5
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
2. Install:
Hose 2 1
Radiator (left) 2
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
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ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is nodanger of it falling over.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM”
section.
Clutch cable and guide Disconnect at the engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “AC MAGNETO AND
STARTER CLUTCH” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.
