3-5
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item RoutinePage
Coolant Check that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage. P.3-6 – 7
Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage. P.1-13
Engine oil Check that the oil level is correct. Check the crankcase and oil line
for leakage.
P.3-9 – 10
Gear shifter and clutch Check that gears can be shifted correctly in order and that the
clutch operates smoothly. P.3-7
Throttle grip/Housing Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary. P.3-7 – 8
Brakes Check the play of front brake and ef fect of front and rear brake. P.3-14 – 16
Drive chain Check drive chain slack and alignment. Check that the drive chain
is lubricated properly.
P.3-17 – 18
Wheels Check for excessive wear and ti
re pressure. Check for loose
spokes and have no excessive play. P.3-20 – 21
Steering Check that the handlebar can be turned smoothly and have no ex-
cessive play. P.3-21 – 22
Front forks and rear shock
absorber Check that they operate smooth
ly and there is no oil leakage.
P.3-18 – 20
Cables (wires) Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.4-3 – 4
Rear wheel sprocket Check that the rear whee l sprocket tightening bolt is not loose.P.3-17
Lubrication Check for smooth operation. Lubricate if necessary. P.3-23
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-15
Lead connectors Check that the CDI magneto, CDI
unit, and ignition coil are con-
nected tightly. P.1-7
Settings Is the machine set suitably for the
condition of the racing course
and weather or by taking into account the results of test runs be-
fore racing? Are inspection and maintenance completely done? P.7-1 – 10
3-6
ENGINE
ENGINE
CHECKING THE COOLANT LEVEL
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When
the engine has cooled, place a
thick towel over the radiator cap,
slowly rotate the cap counter-
clockwise to the detent. This pro-
cedure allows any residual
pressure to escape. When the
hissing sound has stopped, press
down on the cap while turning
counterclockwise and remove it.
Hard water or salt water is harmful
to the engine parts. You may use
distilled water, if you can't get soft
water.
1. Place the machine on a level place, and hold it in an upright po-
sition.
2. Remove: • Radiator cap
3. Check: • Coolant level "a"Coolant level low →Add coolant.
1. Radiator
CHANGING THE COOLANT
Do not remove the radiator cap
when the engine is hot.
Take care so that coolant does not
splash on painted surfaces. If it
splashes, wash it away with water.
1. Place a container under the en- gine.
2. Remove: • Coolant drain bolt "1"
3. Remove: • Radiator capDrain the coolant completely.
4. Clean:
• Cooling systemThoroughly flush the cooling sys-
tem with clean tap water.
5. Install: • Copper washer
• Coolant drain bolt
6. Fill: • Radiator
•EngineTo specified level.
• Do not mix more than one type of
ethylene glycol antifreeze con-
taining corrosion inhibitors for
aluminum engine.
• Do not use water containing im- purities or oil.
Handling notes of coolant:
The coolant is harmful so it should be
handled with special care.
• When coolant splashes to your
eye.
Thoroughly wash your eye with
water and see your doctor.
• When coolant splashes to your clothes.
Quickly wash it away with water
and then with soap.
• When coolant is swallowed. Quickly make him vomit and take
him to a doctor.
7. Install:• Radiator cap
Start the engine and warm it up
for a several minutes.
8. Check:
• Coolant levelCoolant level low →Add coolant.
CHECKING THE RADIATOR CAP
1. Inspect: • Seal (radiator cap) "1"
• Valve and valve seat "2"Crack/damage →Replace.
Exist fur deposits "3" →Clean or
replace.
CHECKING THE RADIATOR CAP
OPENING PRESSURE
1. Attach: • Radiator cap tester "1" and adapt-er "2"
Apply water on the radiator cap seal.
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Recommended coolant: High quality ethylene
glycol anti-freeze con-
taining anti -corrosion
for aluminum engine
Coolant "1" and water
(soft water) "2" mixing ra-
tio: 50%/50%
Coolant capacity: 1.00 L (0.88 Imp qt, 1.06
US qt)
Radiator cap tester:
YU-24460-01/90890-
01325
Radiator cap tester
adapter: YU-33984/90890-01352
3-7
ENGINE
3. Radiator cap
2. Apply the specified pressure.
3. Inspect: • PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Replace.
CHECKING THE COOLING
SYSTEM
1. Inspect: • Coolant level
2. Attach: • Radiator cap tester "1" and adapt-
er "2"
3. Apply the specified pressure.
• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.
4. Inspect: • PressureImpossible to maintain the speci-
fied pressure for 10 seconds →
Repair.
•Radiator "1"
• Radiator hose joint "2" Coolant leakage →Repair or re-
place.
• Radiator hose "3" Swelling →Replace. ADJUSTING THE CLUTCH LEVER
POSITION
1. Adjust:
• Clutch lever position
Clutch lever position adjustment
steps:
a. Loosen the locknuts "1".
b. Turn the adjusting bolt "2" until the clutch lever position "a" is in the
desiered position .
c. Tighten the locknuts.
2. Adjust: • Clutch cable free play
Refer to "ADJUSTING THE
CLUTCH CABLE FREE PLAY".
ADJUSTING THE CLUTCH CABLE
FREE PLAY
1. Check: • Clutch lever free play "a"Out of specification →Adjust.
2. Adjust: • Clutch lever free play
Clutch lever free play adjustment
steps:
a. Loosen the locknuts "1".
b. Turn the adjuster "2" until free play "a" is within the specified lim-
its.
c. Tighten the locknuts.
• Before adjustment, expose the ad- juster by moving the boot "3" and
cap "4" away.
• Make minute adjustment on the le- ver side using the adjuster "5".
• After adjustment, check proper op-
eration of clutch lever.
3. Install:•Cap "1"
• Boot "2"
Place the tip "a" of the cap in the boot.
ADJUSTING THE THROTTLE
CABLE FREE PLAY
1. Check:• Throttle grip free play "a"
Out of specification →Adjust.
Radiator cap opening
pressure:
110 kPa (1.1 kg/cm
2,
15.6 psi)
Radiator cap tester: YU-24460-01/90890-
01325
Radiator cap tester
adapter:
YU-33984/90890-01352
Standard pressure: 180 kPa (1.8 kg/cm
2,
25.6 psi)
Locknut: 5 Nm (0.5 m•kg, 3.6
ft•lb)
Clutch lever free play "a"
: 7–12 mm (0.28–0.47 in)
Locknut: 4 Nm (0.4 m•kg, 2.9
ft•lb)
Throttle grip free play
"a": 3–5 mm (0.12–0.20 in)
4-6
RADIATOR
HANDLING NOTE
Do not remove the radiator cap
when the engine and radiator are
hot. Scalding hot fluid and steam
may be blown out under pressure,
which could cause serious injury.
When the engine has cooled, open
the radiator cap by the following
procedure:
Place a thick rag, like a towel, over
the radiator cap, slowly rotate the
cap counterclockwise to the de-
tent. This procedure allows any re-
sidual pressure to escape. When
the hissing sound has stopped,
press down on the cap while turn-
ing counterclockwise and remove
it.
CHECKING THE RADIATOR
1. Inspect:• Radiator core "1"
Obstruction →Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin →Repair/replace.
INSTALLING THE RADIATOR
1. Install: • O-ring "1"
• Radiator pipe 1 "2"
• Bolt (radiator pipe) "3"
Apply the lithium soap base grease
on the O-ring.
2. Install:• Radiator breather hose "1"
• Radiator hose 2 "2"
• Radiator hose 4 "3"
• Pipe "4"
• Radiator hose 5 "5"
• Radiator hose 3 "6"To right radiator "7".
3. Install: • Right radiator "1"
• Bolt (right radiator) "2"
• Radiator hose 5 "3"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
4. Install: • Left radiator "1"
• Bolt (left radiator) "2"
• Radiator hose 1 "3"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
5. Tighten:
• Radiator hose clamp "4" 6. Install:
• Radiator guard "1"
First fit the inner hook portion "a" and
then the outer one "b" onto the radia-
tor.
Bolt (radiator pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (right radiator):10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (left radiator): 10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 1: 2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose clamp: 2 Nm (0.2 m•kg, 1.4
ft•lb)