Page 212 of 794
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INSP
ADJ
COOLANT REPLACEMENT
8. Fill:
Radiator
Engine
To specified level.
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or
oil.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant
1 and water
(soft water)
2 mixing ratio:
50%/50%
Coolant capacity:
1.0 L (0.88 Imp qt, 1.06 US qt)
Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
9. Install:
Radiator cap
Start the engine and warm it up for a
several minutes.
10. Check:
Coolant level
Coolant level low → Add coolant.
Page 218 of 794
3 - 10
INSP
ADJ
THROTTLE CABLE ADJUSTMENT
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.
T R..
Locknut:
4 Nm (0.4 m · kg, 2.9 ft · lb)
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
2. Adjust:
Throttle grip free play
Throttle grip free play
a:
3 ~ 5 mm (0.12 ~ 0.20 in)
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.
T R..
Locknut:
4 Nm (0.4 m kg, 2.9 ft lb)
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.
1 2
Page 226 of 794
3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
1. Stand the machine on a level surface.
NOTE:
When checking the oil level make sure that
the machine is upright.
Place the machine on a suitable stand.
WARNING
Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out. causing danger. Wait until the oil
cools down to approximately 70 °C (158 °F).
2. Idle the engine more than 3 minutes while
keeping the machine upright. Then stop the
engine and inspect the oil level.
3. Remove:
Oil tank plug 1
4. Inspect:
Oil level
Check that the engine oil is above the
level mark a and that the oil does not
come out when the check bolt 1 is
removed.
Below the level mark a → Add oil
through the filler cap hole until it is above
the level mark a.
Oil comes out at the check bolt → Drain
the oil until it stops coming out.
NOTE:
When inspecting the oil level, do not screw the
oil level gauge into the oil tank.
Insert the gauge lightly.
Page 248 of 794
3 - 24
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
WARNING
Be sure the exhaust pipe and silencer are
cool before cleaning the spark arrester.
Do not start the engine when cleaning the
exhaust system.
1. Remove:
Screw (silencer cap) 1
1
2. Remove:
Bolt (spark arrester) 1
1
3. Remove:
Tail pipe 1
Gasket (tail pipe) 2
Spark arrester 3
Pull the spark arrester out of the silencer.
Gasket (spark arrester) 4
4. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
5. Install:
Gasket (spark arrester)
Spark arrester
Insert the spark arrester into the silencer
and align the bolt holes.
Gasket (tail pipe)
Bolt (spark arrester)
12
34
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
6. Install:
Silencer cap
NOTE:
First tighten the two screws a located horizon-
tally apart, and then tighten the others.aa
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
SPARK ARRESTER CLEANING (For USA)
Page 250 of 794
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INSP
ADJ
CHASSIS/BRAKE SYSTEM AIR BLEEDING
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING
WARNING
Bleed the brake system if:
The system has been disassembled.
A brake hose has been loosened or
removed.
The brake fluid is very low.
The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not prop-
erly bled.
1. Remove:
Master cylinder cap
Diaphragm
Reservoir float (front brake)
Protector (rear brake)
2. Bleed:
Brake fluid
ÈFront
ÉRear
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 2 tightly to
the caliper bleed screw 1.
d. Place the other end of the tube into a con-
tainer.
e. Slowly apply the brake lever or pedal sev-
eral times.
f. Pull the lever in or push down on the
pedal. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever or
pedal limit has been reached; then
release the lever or pedal.
T R..
Bleed screw:
6 Nm (0.6 m kg, 4.3 ft lb)
i. Repeat steps (e) to (h) until of the air bub-
bles have been removed from the sys-
tem.
È
É
Page 252 of 794
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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.
Page 254 of 794
3 - 27
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification → Adjust.
Brake pedal height
a:
10 mm (0.39 in)
2. Adjust:
Brake pedal height
Pedal height adjustment steps:
Loosen the locknut 1.
Turn the adjusting nut 2 until the pedal
height a is within specified height.
Tighten the locknut.
WARNING
Adjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment, the bolt
3
end
b should protrude out of the
threaded portion
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).
After the pedal height adjustment, make
sure that the rear brake does not drag.
È
É
EC365080
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
Brake pad thickness a
Out of specification → Replace as a set.
2. Replace:
Brake pad
Brake pad thickness
a:
Standard
4.4 mm (0.17 in) 1.0 mm (0.04 in)
Brake pad replacement steps:
Remove the pad pin plug 1.
Page 262 of 794
3 - 31
INSP
ADJREAR BRAKE PAD INSULATOR INSPECTION/
BRAKE FLUID LEVEL INSPECTION
3. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
4. Check:
Brake pedal operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section.
EC36b000
REAR BRAKE PAD INSULATOR
INSPECTION
1. Remove:
Brake pad
Refer to “REAR BRAKE PAD INSPEC-
TION AND REPLACEMENT” section.
2. Inspect:
Rear brake pad insulator 1
Damage → Replace.
EC367001
BRAKE FLUID LEVEL INSPECTION
1. Place the master cylinder so that its top is
in a horizontal position.
2. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
aLower level
ÈFront
ÉRear
WARNING
Use only designated quality brake fluid to
avoid poor brake performance.
Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
Be sure that water or other contaminants
do not enter master cylinder when refill-
ing.
Clean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts.
Recommended brake fluid:
DOT #4
ÈÉ
