TABLE OF CONTENTS
SAFETY 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 ..................................... 3-1
Handlebar switches ........................ 3-1
Speed limiter .................................. 3-2
Shift pedal ......................................3-3
Brake lever ..................................... 3-3
Brake pedal .................................... 3-3
Fuel tank cap .................................. 3-4
Fuel ................................................ 3-4
Fuel tank breather hose ................. 3-6
Fuel cock ........................................ 3-6
Starter (choke) lever ....................... 3-7
Seat ................................................ 3-7
Sidestand ....................................... 3-8
Starting circuit cut-off system ......... 3-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS.............. 4-1
Pre-operation check list .................. 4-2OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Periodic maintenance chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Checking the spark plug ................ 6-5
Engine oil ....................................... 6-6
Cleaning the air filter element ........ 6-8
Cleaning the spark arrester ........... 6-9
Adjusting the carburetor ............... 6-10
Adjusting the engine idling
speed ........................................ 6-11
Adjusting the throttle cable free
play ........................................... 6-11
Valve clearance ........................... 6-12
Tires ............................................. 6-12
Spoke wheels .............................. 6-14
Adjusting the clutch free play ....... 6-14
Adjusting the brake lever free
play ........................................... 6-15Adjusting the brake pedal free
play ........................................... 6-16
Checking the shift pedal ............... 6-16
Checking the front and rear brake
shoes ........................................ 6-17
Drive chain slack .......................... 6-17
Cleaning and lubricating the drive
chain ......................................... 6-19
Checking and lubricating
the cables ................................. 6-20
Checking and lubricating
the throttle grip and cable ......... 6-20
Checking and lubricating
the brake lever .......................... 6-20
Checking and lubricating
the brake pedal ......................... 6-21
Checking and lubricating
the sidestand ............................ 6-21
Lubricating the swingarm pivots ... 6-21
Checking the front fork ................. 6-22
Checking the steering .................. 6-22
Checking the wheel bearings ....... 6-23
Battery .......................................... 6-23
Replacing the fuse ....................... 6-25
Supporting the motorcycle ........... 6-25
Front wheel .................................. 6-26
Rear wheel ................................... 6-28
Troubleshooting ........................... 6-29
Troubleshooting chart .................. 6-31
U1P683E0.book Page 1 Tuesday, April 29, 2008 2:05 PM
INDEXAAir filter element, cleaning....................... 6-8BBattery................................................... 6-23
Brake lever .............................................. 3-3
Brake lever, checking and lubricating ... 6-20
Brake lever free play, adjusting............. 6-15
Brake pedal ............................................. 3-3
Brake pedal, checking and
lubricating ........................................... 6-21
Brake pedal free play, adjusting............ 6-16
Brake shoes, checking .......................... 6-17CCables, checking and lubricating .......... 6-20
Carburetor, adjusting ............................ 6-10
Care ........................................................ 7-1
Clutch free play, adjusting..................... 6-14DDrive chain, cleaning and lubricating .... 6-19
Drive chain slack ................................... 6-17EEngine break-in ....................................... 5-3
Engine idling speed............................... 6-11
Engine oil ................................................ 6-6
Engine, starting a warm .......................... 5-2
Engine stop switch .................................. 3-2FFront fork, checking .............................. 6-22
Fuel ......................................................... 3-4
Fuel cock................................................. 3-6
Fuel tank breather hose .......................... 3-6
Fuel tank cap .......................................... 3-4
Fuse, replacing ..................................... 6-25
HHandlebar switches ................................ 3-1IIdentification numbers ............................ 9-1KKey identification number ....................... 9-1MMain switch ............................................. 3-1
Maintenance and lubrication, periodic .... 6-3
Maintenance, emission control system... 6-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-2PParking ................................................... 5-4
Part locations .......................................... 2-1
Pre-operation check list .......................... 4-2SSafety information................................... 1-1
Seat ........................................................ 3-7
Shifting.................................................... 5-2
Shift pedal............................................... 3-3
Shift pedal, checking ............................ 6-16
Sidestand................................................ 3-8
Sidestand, checking and lubricating ..... 6-21
Spark arrester, cleaning ......................... 6-9
Spark plug, checking .............................. 6-5
Specifications ......................................... 8-1
Speed limiter........................................... 3-2
Starter (choke) lever ............................... 3-7
Starting and warming up a cold
engine .................................................. 5-1
Starting circuit cut-off system ................. 3-8
Start switch ............................................. 3-2
Steering, checking ................................ 6-22Storage.................................................... 7-3
Supporting the motorcycle .................... 6-25
Swingarm pivots, lubricating ................. 6-21
TThrottle cable free play, adjusting ......... 6-11
Throttle grip and cable, checking and
lubricating ........................................... 6-20
Tires ...................................................... 6-12
Troubleshooting .................................... 6-29
Troubleshooting chart ........................... 6-31VValve clearance..................................... 6-12
Vehicle identification number .................. 9-1WWheel bearings, checking ..................... 6-23
Wheel (front) ......................................... 6-26
Wheel (rear) .......................................... 6-28
Wheels .................................................. 6-14
U1P683E0.book Page 1 Tuesday, April 29, 2008 2:05 PM