TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator lights ................................3-2
Speedometer unit ...........................3-3
Fuel gauge ......................................3-3
Handlebar switches ........................3-3
Shift pedal .......................................3-4
Brake lever .....................................3-4
Brake pedal ....................................3-5
Fuel tank cap ..................................3-5
Fuel .................................................3-6
Catalytic converter ..........................3-7
Starter (choke) lever .......................3-8
Kickstarter .......................................3-8
Seat ................................................3-8
Helmet holders ...............................3-9
Storage compartment .....................3-9
Carrier ...........................................3-10FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing the
cowling and panel ....................... 6-6
Checking the spark plug ................. 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Adjusting the carburetor ............... 6-11
Adjusting the engine idling
speed ........................................ 6-11
Checking the throttle cable free
play ........................................... 6-12Valve clearance ........................... 6-12
Tires ............................................. 6-13
Cast wheels ................................. 6-14
Adjusting the brake pedal free
play ........................................... 6-15
Checking the shift pedal .............. 6-16
Adjusting the rear brake light
switch ....................................... 6-16
Checking the front brake pads
and rear brake shoes ............... 6-16
Checking the front brake fluid
level .......................................... 6-17
Changing the brake fluid .............. 6-18
Drive chain slack .......................... 6-18
Cleaning and lubricating the
drive chain ................................ 6-20
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the
brake lever ................................ 6-21
Checking and lubricating the
brake pedal ............................... 6-22
Checking and lubricating the
centerstand ............................... 6-22
Lubricating the swingarm
pivots ........................................ 6-22
Checking the front fork ................. 6-23
Checking the steering .................. 6-23
Checking the wheel bearings ....... 6-24U40BE0E0.book Page 1 Wednesday, January 7, 2009 10:05 AM
DESCRIPTION
2-2
2
EAU10420
Right view
1234
76 5
1. Carrier (page 3-10)
2. Helmet holder (page 3-9)
3. Kickstarter (page 3-8)
4. Front brake fluid reservoir (page 6-17)
5. Air filter element (page 6-10)
6. Brake pedal (page 3-5)
7. Engine oil filler cap (page 6-8)
U40BE0E0.book Page 2 Wednesday, January 7, 2009 10:05 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-rial enters the crankcase.
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
7. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU47770
Cleaning the air filter element The air filter element should be cleaned
or replaced at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean or, if necessary, re-
place the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.1. Air filter case cover
2. Screw1
22
1. Air filter element
1. Air filter element
1
U40BE0E0.book Page 10 Wednesday, January 7, 2009 10:05 AM
SPECIFICATIONS
8-1
8
Dimensions:Overall length:
1885 mm (74.2 in)
Overall width:
675 mm (26.6 in)
Overall height:
1040 mm (40.9 in)
Seat height:
770 mm (30.3 in)
Wheelbase:
1200 mm (47.2 in)
Ground clearance:
130 mm (5.12 in)
Minimum turning radius:
1900 mm (74.8 in)Weight:With oil and fuel:
101.0 kg (223 lb)Engine:Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
110.3 cm³
Bore × stroke:
51.0 × 54.0 mm (2.01 × 2.13 in)
Compression ratio:
9.30 :1
Starting system:
Electric starter and kickstarter
Lubrication system:
Wet sump
Engine oil:Type:
SAE 10W-30, SAE 10W-40, SAE 20W-40
or SAE 20W-50
Recommended engine oil grade:
API service SE, SF, SG type or higher,
JASO standard MA
Engine oil quantity:
Periodic oil change:
0.80 L (0.85 US qt, 0.70 Imp.qt)Air filter:Air filter element:
Dry elementFuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
4.2 L (1.11 US gal, 0.92 Imp.gal)
Fuel reserve amount:
1.0 L (0.26 US gal, 0.22 Imp.gal)
Carburetor:Type × quantity:
VM17SH x 1Spark plug (s):Manufacturer/model:
TORCH/A7RTC
Manufacturer/model:
NGK/CR6HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
67/18 (3.722)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
35/15 (2.333)
Transmission type:
Constant mesh 4-speed
Operation:
Left foot operation
Gear ratio:
1st:
38/12 (3.166)
2nd:
33/17 (1.941)
3rd:
29/21 (1.380)
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
U40BE0E0.book Page 1 Wednesday, January 7, 2009 10:05 AM
INDEXAAir filter element, cleaning..................... 6-10
Auxiliary light bulb, replacing ................ 6-30BBattery................................................... 6-24
Brake fluid, changing ............................ 6-18
Brake fluid level, checking .................... 6-17
Brake lever .............................................. 3-4
Brake lever, checking and lubricating ... 6-21
Brake pads and shoes, checking .......... 6-16
Brake pedal ............................................. 3-5
Brake pedal, checking and
lubricating ........................................... 6-22
Brake pedal free play, adjusting............ 6-15CCables, checking and lubricating .......... 6-21
Carburetor, adjusting ............................ 6-11
Care ........................................................ 7-1
Carrier ................................................... 3-10
Catalytic converter .................................. 3-7
Centerstand, checking and
lubricating ........................................... 6-22
Cowling and panel, removing and
installing................................................ 6-6DDimmer switch ........................................ 3-4
Drive chain, cleaning and lubricating .... 6-20
Drive chain slack ................................... 6-18EEngine break-in ....................................... 5-3
Engine idling speed............................... 6-11
Engine oil ................................................ 6-8
Engine serial number .............................. 9-2
Engine, starting a warm .......................... 5-2
FFront fork, checking .............................. 6-23
Fuel......................................................... 3-6
Fuel consumption, tips for reducing........ 5-3
Fuel gauge.............................................. 3-3
Fuel tank cap .......................................... 3-5
Fuse, replacing ..................................... 6-26GGear position indicator lights .................. 3-2HHandlebar switches ................................ 3-3
Headlight bulb, replacing ...................... 6-27
Helmet holders ....................................... 3-9
High beam indicator light ........................ 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................ 9-1
Indicator lights ........................................ 3-2KKey identification number ....................... 9-1
Kickstarter............................................... 3-8LLicense plate light bulb, replacing ........ 6-30MMain switch/steering lock........................ 3-1
Maintenance and lubrication, periodic .... 6-3
Maintenance, emission control system... 6-2
Matte color, caution ................................ 7-1NNeutral indicator light .............................. 3-2PParking ................................................... 5-4
Part locations .......................................... 2-1
RRear brake light switch, adjusting ......... 6-16SSafety information ................................... 1-1
Seat ......................................................... 3-8
Shifting .................................................... 5-2
Shift pedal ............................................... 3-4
Shift pedal, checking ............................. 6-16
Spark plug, checking ............................... 6-7
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever................................ 3-8
Starting and warming up a cold engine ... 5-1
Start switch.............................................. 3-4
Steering, checking................................. 6-23
Storage.................................................... 7-3
Storage compartment.............................. 3-9
Swingarm pivots, lubricating ................. 6-22TTail/brake light bulb, replacing .............. 6-28
Throttle cable free play, checking ......... 6-12
Throttle grip and cable, checking and
lubricating ........................................... 6-21
Tires ...................................................... 6-13
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-35
Troubleshooting chart ........................... 6-36
Turn signal indicator light ........................ 3-2
Turn signal light bulb (front),
replacing ............................................. 6-28
Turn signal light bulb (rear), replacing... 6-29
Turn signal switch ................................... 3-4VValve clearance..................................... 6-12
U40BE0E0.book Page 1 Wednesday, January 7, 2009 10:05 AM