
TABLE OF CONTENTS
Replacing the fuse  ........................ 6-28
Replacing the headlight bulb  ........ 6-29
Replacing the tail/brake light 
bulb ........................................... 6-30
Replacing a turn signal light 
bulb ........................................... 6-31
Replacing the auxiliary light 
bulb ........................................... 6-31
Front wheel  ................................... 6-32
Rear wheel  ................................... 6-34
Troubleshooting ............................ 6-36
Troubleshooting chart  ................... 6-37
MOTORCYCLE CARE AND 
STORAGE.......................................... 7-1
Matte color caution  ......................... 7-1
Care ................................................ 7-1
Storage ...........................................7-3
SPECIFICATIONS ............................. 8-1
CONSUMER INFORMATION............. 9-1
Identification numbers  .................... 9-1
U27SE0E0.book  Page 2  Friday, February 22, 2008  8:54 AM 

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
CAUTION:
ECA10680
Do not overtighten the screws, oth-erwise the lens may break.
EAU24202
Replacing a turn signal light 
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.CAUTION:
ECA11190
Do not overtighten the screw, other-wise the lens may break.
EAU37270
Replacing the auxiliary light 
bulb If the auxiliary light bulb burns out, re-
place it as follows.
1. Remove the headlight unit by re-
moving the screws.
2. Remove the socket (together with
the bulb) by pulling it out.
1. Tail/brake light bulb
1
1. Screw
1
1. Screw
U27SE0E0.book  Page 31  Friday, February 22, 2008  8:54 AM 

SPECIFICATIONS
8-2
8
4th:
23/22 (1.045)
5th:
21/24 (0.875)
Chassis:Frame type:
Diamond
Caster angle:
27.42 °
Trail:
102.0 mm (4.02 in)Front tire:Type:
Tubeless
Size:
3.00-18 47P
Manufacturer/model:
CHENG SHIN/C-6039Rear tire:Type:
Tubeless
Size:
3.50-16 58P
Manufacturer/model:
CHENG SHIN/C-289Loading:Maximum load:
190 kg (419 lb)
(Total weight of rider, passenger, cargo and 
accessories)Tire air pressure (measured on cold 
tires):Loading condition:
0–90 kg (0–198 lb)Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
200 kPa (2.00 kgf/cm², 29 psi)
Loading condition:
90–190 kg (198–419 lb)
Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
280 kPa (2.80 kgf/cm², 41 psi)
Front wheel:Wheel type:
Cast wheel
Rim size:
J18M/CxMT1.85Rear wheel:Wheel type:
Cast wheel
Rim size:
J16M/CxMT2.15Front brake:Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 3 or 4Rear brake:Type:
Drum brake
Operation:
Right foot operation
Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
110.0 mm (4.33 in)Rear suspension:Type:
Swingarm
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
105.0 mm (4.13 in)Electrical system:Ignition system:
TCI (digital)
Charging system:
AC magnetoBattery:Model:
YTX7L-BS
Voltage, capacity:
12 V, 6.0 AhHeadlight:Bulb type:
IncandescenceBulb voltage, wattage × quantity:Headlight:
12 V, 35 W/35.0 W × 1
Tail/brake light:
12 V, 5.0 W/21.0 W × 1
Front turn signal light:
12 V, 10.0 W × 2
U27SE0E0.book  Page 2  Wednesday, February 27, 2008  2:29 PM 

INDEX
AAir filter element, cleaning .................... 6-10
Auxiliary light bulb, replacing ................ 6-31BBattery .................................................. 6-27
Brake and clutch levers, 
checking and lubricating ..................... 6-23
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever ............................................. 3-5
Brake pads and shoes, checking.......... 6-19
Brake pedal ............................................ 3-6
Brake pedal, checking and 
lubricating ........................................... 6-24
Brake pedal free play, adjusting ........... 6-17CCables, checking and lubricating .......... 6-23
Care ........................................................ 7-1
Carrier..................................................... 3-9
Catalytic converters ................................ 3-8
Centerstand and sidestand, 
checking and lubricating ..................... 6-24
Clutch lever............................................. 3-5
Clutch lever free play, adjusting ........... 6-16DDimmer switch ........................................ 3-4
Drive chain, cleaning and lubricating .... 6-22
Drive chain slack .................................. 6-21EEngine break-in ...................................... 5-3
Engine idling speed, checking .............. 6-12
Engine oil ................................................ 6-9
Engine trouble warning light ................... 3-2
FFront brake lever free play, checking .... 6-17
Front fork, checking...............................6-25
Fuel ......................................................... 3-7
Fuel consumption, tips for reducing ........ 5-3
Fuel gauge .............................................. 3-3
Fuel tank cap........................................... 3-6
Fuse, replacing...................................... 6-28HHandlebar switches ................................. 3-4
Headlight bulb, replacing....................... 6-29
High beam indicator light......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-10
Indicator and warning lights .................... 3-2KKey identification number ........................ 9-1
Kickstarter ............................................... 3-8MMain switch/steering lock ........................ 3-1
Matte color, caution .................................7-1
Model label .............................................. 9-2NNeutral indicator light .............................. 3-2PPanels, removing and installing .............. 6-6
Parking ....................................................5-4
Part locations .......................................... 2-1
Periodic maintenance and 
lubrication chart.....................................6-2
Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-18SSafety information ................................... 1-1
Self-diagnosis device .............................. 3-3
Shifting .................................................... 5-2
Shift pedal ............................................... 3-5
Shift pedal, checking............................. 6-18
Shock absorber assemblies, adjusting ... 3-8
Sidestand ................................................ 3-9
Spark plug, checking .............................. 6-7
Specifications.......................................... 8-1
Speedometer unit ................................... 3-2
Starting the engine.................................. 5-1
Start switch ............................................. 3-4
Steering, checking ................................ 6-26
Storage ................................................... 7-3
Swingarm pivots, lubricating ................. 6-25TTachometer............................................. 3-3
Tail/brake light bulb, replacing .............. 6-30
Throttle cable free play, adjusting ......... 6-12
Throttle grip and cable, 
checking and lubricating ..................... 6-23
Tires ...................................................... 6-13
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-36
Troubleshooting chart ........................... 6-37
Turn signal indicator light ........................ 3-2
Turn signal light bulb, replacing ............ 6-31
Turn signal switch ................................... 3-4VValve clearance .................................... 6-13
Vehicle identification number .................. 9-1
U27SE0E0.book  Page 1  Friday, February 22, 2008  8:54 AM