3-19
CHASSIS
CLEANING THE SPARK
ARRESTER (For USA)
• Be sure the exhaust pipe and si-lencer are cool before cleaning
the spark arrester.
• Do not start the engine when cleaning the exhaust system.
1. Remove:• Screw (silencer cap) "1"
2. Remove: • Bolt (spark arrester) "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 deposits.
5. Install: • Gasket (spark arrester)
• Spark arresterInsert the spark arrester into the
silencer and align the bolt holes.
• Gasket (tail pipe)
• Bolt (spark arrester) 6. Install:
• Silencer cap
First tighten the two screws "a" locat-
ed horizontally apart, and then tighten
the others.
CHASSIS
BLEEDING THE HYDRAULIC
BRAKE SYSTEM
Bleed the brake system if:
• The system has been disassem-bled.
• A brake hose has been loosened
or removed.
• The brake fluid is very low.
• The brake operation is faulty.
A dangerous loss of braking per-
formance may occur if the brake
system is not properly bled.
1. Remove: • Brake master cylinder cap
• Diaphragm
• Reservoir float (front brake)
• Protector (rear brake)
2. Bleed: •Brake fluid
Air bleeding steps:
a. Add proper brake fluid to the res- ervoir.
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". A. Front
B. Rear
d. Place the other end of the tube
into a container.
e. Slowly apply the brake lever or pedal several 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 to-
wards its limit.
h. Tighten the bleed screw when the
lever or pedal limit has been
reached; then release the lever or
pedal.
i. Repeat steps (e) to (h) until of the air bubbles have been removed
from the system.
If bleeding is difficult, it may be nec-
essary 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.
Check the operation of the brake
after bleeding the brake system.
3. Install:
• Protector (rear brake)
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap
Bolt (spark arrester): 7 Nm (0.7 m•kg, 5.1
ft•lb)
Silencer cap:5 Nm (0.5 m•kg, 3.6
ft•lb)
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
6-15
FRONT BRAKE AND REAR BRAKE
FILLING THE BRAKE FLUID
1. Fill:• Brake fluidUntil the fluid level reaches
"LOWER" level line "a".
• Use only the designated quality
brake fluid:
otherwise, the rubber seals may
deteriorate, causi ng leakage and
poor brake performance.
• Refill with the same type of brake fluid;
mixing fluids may result in a
harmful chemical reaction and
lead to poor performance.
• Be careful that water does not enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the flu-
id and may result in vapor lock.
Brake fluid may erode painted sur-
faces or plastic parts. Always
clean up spilled fluid immediately.
A. Front
B. Rear
2. Air bleed:
• Brake systemRefer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion in the CHAPTER 3.
3. Inspect: • Brake fluid level
Fluid at lower level →Fill up.
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section in
the CHAPTER 3. 4. Install:
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap "1"
• Screw (bolt) {brake master cylin-der cap} "2"
After installation, while pulling the
brake lever in or pushing down on
the brake pedal, check whether
there is any brake fluid leaking
where the union bolts are installed
respectively at the brake master
cylinder and brake caliper.
A. Front
B. Rear
5. Install: (rear brake only) • Protector "1"
• Bolt (protector) "2"
Recommended brake flu-
id:
DOT #4
Screw (bolt) {brake mas-
ter cylinder cap}:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (protector): 7 Nm (0.7 m•kg, 5.1
ft•lb)
