TABLE OF CONTENTS
LOCATION OF IMPORTANT
LABELS
............................................. 1-1
SAFETY INFORMATION
.................. 2-1
DESCRIPTION
.................................. 3-1
Left view .......................................... 3-1
Right view ........................................ 3-2
Controls and instruments ................ 3-3
INSTRUMENT AND CONTROL
FUNCTIONS
....................................... 4-1
Handlebar switch ............................ 4-1
Speed limiter and power
reduction plate ............................ 4-1
Front brake lever ............................ 4-2
Rear brake lever ............................. 4-3
Fuel tank cap .................................. 4-3
Fuel ................................................ 4-3
Fuel tank breather hose ................. 4-5
2-stroke engine oil .......................... 4-5
Fuel cock ........................................ 4-6
Starter (choke) lever “ ” ............... 4-6
Kickstarter ...................................... 4-7
Seat ................................................ 4-7
FOR YOUR SAFETY –
PRE-OPERATION CHECKS
.............. 5-1
OPERATION AND IMPORTANT
RIDING POINTS
................................. 6-1Starting and warming up a cold
engine ......................................... 6-1
Starting a warm engine .................. 6-1
Starting off ...................................... 6-2
Acceleration and deceleration ........ 6-2
Braking ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT
................................... 7-1
Owner’s tool kit ............................... 7-1
Periodic maintenance chart for
the emission control system ....... 7-2
General maintenance and
lubrication chart .......................... 7-3
Checking the spark plug ................. 7-5
Removing the power reduction
plate ............................................ 7-6
Transmission oil ............................. 7-7
Middle and final gear cases ........... 7-8
Cleaning the air filter element ........ 7-8
Cleaning the spark arrester ............ 7-9
Adjusting the carburetor ............... 7-10
Adjusting the engine idling
speed ........................................ 7-10
Checking the throttle cable free
play ........................................... 7-11
Tires ............................................. 7-11
Panel wheels ................................ 7-13Adjusting the front and rear
brake lever free play .................. 7-13
Checking the front and rear
brake shoes ............................... 7-14
Checking and lubricating the
cables ........................................ 7-15
Checking and lubricating the
throttle grip and cable ................ 7-15
Adjusting the Autolube pump ........ 7-16
Lubricating the front and rear
brake levers ............................... 7-16
Checking and lubricating the
centerstand ................................ 7-16
Checking the front fork .................. 7-17
Checking the steering ................... 7-17
Checking the wheel bearings ........ 7-18
Front wheel ................................... 7-18
Rear wheel .................................... 7-20
Troubleshooting ............................ 7-22
Troubleshooting chart ................... 7-24
MOTORCYCLE CARE AND
STORAGE
.......................................... 8-1
Matte color caution ......................... 8-1
Care ................................................ 8-1
Storage ........................................... 8-3
SPECIFICATIONS
............................. 9-1
CONSUMER INFORMATION
........... 10-1
Identification numbers ................... 10-1
PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
2
3
4
5
6
78
9
EAU41754
General maintenance and lubrication chart
NO. ITEM CHECK OR MAINTENANCE JOBINITIALTHEREAFTER
EVERY
1
month3
months6
months6
months12
months
1*Front brake
Check operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
2*Rear brakeCheck operation.Adjust brake lever free play.Replace brake shoes. Whenever worn to the limit
3*WheelsCheck runout and for damage.Replace if necessary.
4*TiresCheck tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.
5*Wheel bearingsCheck bearings for smooth operation.Replace if necessary.
6*Steering bearingsCheck bearing assemblies for looseness.Moderately repack with lithium-soap-based
grease every 2 years.
7*Middle and final gear
casesCheck for grease leakage.Check gears for damage and wear.Lubricate gears with lithium-soap-based grease.Every 2 years
8*Chassis fastenersCheck all chassis fitting and fasteners.Correct if necessary.
A 9*utolube pumpCheck operation.Correct if necessary.
