GENERAL SPECIFICATIONS
2 - 2
SPEC
Oil capacity:
Engine oil
Periodic oil change 1.1 L (0.97 Imp qt, 1.16 US qt)
With oil filter replacement 1.2 L (1.06 Imp qt, 1.27 US qt)
Total amount 1.4 L (1.23 Imp qt, 1.48 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
Reserve 1.1 L (0.24 Imp gal, 0.29 US gal)
Carburetor:
Type FCR-MX37
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR9E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 57/17 (3.353)
Secondary reduction system Chain drive
Secondary reduction ratio 50/13 (3.846)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 31/13 (2.385)
2nd 28/16 (1.750)
3rd 23/17 (1.353)
4th 23/21 (1.095)
5th 17/19 (0.895)
Chassis: USA, ZA, CDN EUROPE, AUS, NZ
Frame type Semi double cradle←
Caster angle 27.0°26.6°
Trail 115 mm (4.53 in) 114 mm (4.49 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN and ZA)
90/90-21 54R (For EUROPE, AUS and NZ)
Size (rear) 100/100-18 59M (For USA, CDN and ZA)
130/90-18 69R (For EUROPE, AUS and NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
1
2
3
4
5
6
7
3 - 16
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice, 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.3-35 ~ 41
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-49
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-51 ~ 59
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-41 ~ 43
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-43 ~ 45
Brakes Check the play of front brake and effect of front and rear brake. P.3-77 ~ 89
Drive chainCheck drive chain slack and alignment. Check that the drive
chain is lubricated properly.P.3-91 ~ 95
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-111 ~ 113
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-113 ~ 117
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-97 ~ 109
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 pipeCheck that the exhaust pipe is tightly mounted and has no
cracks.P.3-27 ~ 31
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-89
Lubrication Check for smooth operation. Lubricate if necessary. P.3-119
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-59
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are
connected tightly.P.1-9
SettingsIs the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done?P.4-1 ~ 40
4 - 1
TUNSETTING
EC700000
TUNING
EC710000
ENGINE
Carburetor setting
The air/fuel mixture will vary
depending on atmospheric condi-
tions. Therefore, it is necessary to
take into consideration the air
pressure, ambient temperature,
humidity, etc., when adjusting the
carburetor.
Perform a test run to check for
proper engine performance (e.g.,
throttle response) and spark plug(-
s) discoloration or fouling. Use
these readings to determine the
best possible carburetor setting.
NOTE:It is recommended to keep a record
of all carburetor settings and external
conditions (e.g., atmospheric condi-
tions, track/surface conditions, lap
times) to make future carburetor set-
ting easier.
WARNING
The carburetor is a part of the
fuel line. Therefore, be sure to
install it in a well-ventilated area,
away from flammable objects
and any sources of fire.
Never look into the carburetor
intake. Flames may shoot out
from the pipe if the engine back-
fires while it is being started.
Gasoline may be discharged
from the accelerator pump noz-
zle when the carburetor has
been removed.
MISE AU POINT
MOTEUR
Réglage du carburateur
Le mélange air/carburant varie en
fonction des conditions atmosphéri-
ques. Il est donc nécessaire de tenir
compte de la pression de l’air, de la
température ambiante, de l’humidité,
etc., pour le réglage du carburateur.
Effectuer un essai de conduite pour
contrôler les performances du moteur
(par ex. la réponse du moteur) et l’état
des bougies (décoloration ou encrasse-
ment). Utiliser les valeurs obtenues
pour effectuer le meilleur réglage pos-
sible du carburateur.
N.B.:
Il est recommandé de conserver un enre-
gistrement de tous les réglages du carbu-
rateur et des conditions extérieures
(conditions atmosphériques, conditions
de la piste/de la surface, temps intermé-
diaire) pour faciliter les réglages ulté-
rieurs du carburateur.
AVERTISSEMENT
Le carburateur fait partie du circuit
d’alimentation en carburant. Par
conséquent, veiller à effectuer le
montage dans un endroit bien aéré,
à l’écart de tout objet inflammable
ou de toute source d’incendie.
Ne jamais regarder dans l’admis-
sion du carburateur. Des flammes
peuvent surgir du tuyau en cas de
retour de flamme du moteur au
démarrage. De l’essence peut
s’écouler de l’injecteur de la pompe
de reprise lorsque le carburateur a
été déposé.
REGLAGE
4 - 3
TUNSETTING
CAUTION:
The carburetor is extremely sen-
sitive to foreign matter (dirt,
sand, water, etc.). During instal-
lation, do not allow foreign mat-
ter to get into the carburetor.
Always handle the carburetor
and its components carefully.
Even slight scratches, bends or
damage to carburetor parts may
prevent the carburetor from
functioning correctly. Carefully
perform all servicing with the
appropriate tools and without
applying excessive force.
When the engine is stopped or
when riding at no load, do not
open and close the throttle
unnecessarily. Otherwise, too
much fuel may be discharged,
starting may become difficult or
the engine may not run well.
After installing the carburetor,
check that the throttle operates
correctly and opens and closes
smoothly.
Atmospheric conditions and
carburetor settings
The air density (i.e., concentration
of oxygen in the air) determines
the richness or leanness of the air/
fuel mixture. Therefore, refer to the
above table for mixture settings.
That is:
Higher temperature expands the
air with its resultant reduced den-
sity.
Higher humidity reduces the
amount of oxygen in the air by so
much of the water vapor in the
same air.
Lower atmospheric pressure (at a
high altitude) reduces the density
of the air.
Air temp. HumidityAir
pressure
(altitude)Mixture Setting
High High Low (high) Richer Leaner
Low Low High (low) Leaner Richer
ATTENTION:
Le carburateur est extrêmement
sensible aux corps étrangers (pous-
sière, sable, eau, etc.). Pendant le
montage, veiller à ce qu’aucun
corps étranger ne puisse pénétrer
dans le carburateur.
Toujours manipuler le carburateur
et ses composants avec prudence.
Tout endommagement (rayures
même légères, courbures, etc.) peut
empêcher le carburateur de fonc-
tionner correctement. Effectuer soi-
gneusement tout entretien à l’aide
des outils adéquats et sans forcer.
Lorsque le moteur est arrêté, ou
tourne sans charge, ne pas ouvrir et
fermer inutilement les gaz. Cela ris-
querait d’amener trop de carburant
et de rendre le démarrage difficile
ou d’altérer le fonctionnement du
moteur.
Après avoir monté le carburateur,
contrôler que le papillon fonctionne
correctement et s’ouvre et se ferme
sans problème.
Conditions atmosphériques et réglages
du carburateur
La densité de l’air (c.-à-d. la concen-
tration d’oxygène dans l’air) déter-
mine la richesse ou la pauvreté du
mélange air/carburant. Il convient dès
lors de se conformer au tableau ci-des-
sus pour la composition du mélange.
Tenir compte des trois facteurs suivants:
La température de l’air: la densité de
l’air diminue au fur et à mesure que
l’air se dilate sous l’effet des tempéra-
tures élevées.
Le taux d’humidité de l’air: le taux
d’oxygène diminue au fur et à mesure
que le taux d’humidité augmente.
Pression atmosphérique (altitude): la
densité diminue au fur et à mesure que
la pression atmosphérique descend
(altitude élevée).
Temp.
de l’airHumiditéPression
d’air
(altitude)MélangeRégla-
ges
Haute HauteBasse
(élevée)Plus
richePlus
pauvre
Basse BasseHaute
(basse)Plus
pauvrePlus
riche
REGLAGE