Page 90 of 132
8-21
84. Disconnect the coupler shown.5. Remove the air filter case cover by removing
the screw.
6. Remove the air filter element.
1. Panel
2. Quick fastener
1. Coupler
122
1
1
1. Air filter case cover
2. Screw
12
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Page 91 of 132
8-22
8 7. Tap the air filter element lightly to remove
most of the dust and dirt. Blow out the remain-
ing dirt with compressed air as shown.8. Check the air filter element and replace it if
damaged.
9. Install the air filter element into the air filter
case.
10. Install the air filter case cover by installing the
screw.
11. Connect the coupler, and then install the pan-
el by installing the quick fasteners.
12. Install the front carrier by installing the bolts,
and then tighten them to the specified torque.
1. Air filter element
1
1. Air filter elementTightening torque:
Front carrier bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1
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Page 99 of 132
8-30
8 3. Disconnect the coupler shown.4. Remove the V-belt air filter element cover by
removing the screw.
5. Loosen the locknut and fully turn in the brake
lever free play adjusting bolt at the brake le-
ver.
1. Panel
2. Quick fastener
1. Coupler
122
1
1
1. V-belt air filter element cover
2. Screw
12
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8-32
8 7. Tighten the locknut on each brake cable.
8. Turn the brake lever free play adjusting bolt in
direction (a) to increase the free play, and in
direction (b) to decrease it.
9. Tighten the locknut at the brake lever.
10. Install the V-belt air filter element cover by in-
stalling the screw.
11. Connect the coupler, and then install the pan-
el by installing the quick fasteners.
12. Install the front carrier by installing the bolts,
and then tighten them to the specified torque.
EBU30440Adjusting the rear brake lever free play The brake lever free play must be checked and, if
necessary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.TIPBefore adjusting the brake lever free play, check
the rear brake shoes for wear.The brake lever free play should measure 5.0–8.0
mm (0.20–0.31 in) as shown. If the free play is in-
correct, adjust it as follows.
1. Locknut
2. Brake lever free play adjusting bolt
3. Brake lever free play
3
1
2
(b)
(a)
Tightening torque:
Front carrier bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
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10-2
10
Type:
SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-40 or 20W-
50
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
Engine oil quantity:
Periodic oil change:
1.25 L (1.32 US qt, 1.10 Imp.qt)Transmission oil:Quantity:
0.6 L (0.63 US qt, 0.53 Imp.qt)Air filter:Air filter element:
Wet element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
7.0 L (1.85 US gal, 1.54 Imp.gal)
Fuel reserve amount:
1.3 L (0.34 US gal, 0.29 Imp.gal)Carburetor:Type × quantity:
VM18SH x 1Spark plug (s):Manufacturer/model:
NGK/CR7HSA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Dry, centrifugal automaticTransmission:Primary reduction system:
Helical gear/spur gear
Primary reduction ratio:
43/14 × 40/17 (7.226)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
32/12 (2.666)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
-20 -10 0
1020 304050 ˚C
SAE 15W-40
SAE 20W-40SAE 20W-50
SAE 10W-40
SAE 5W-30
SAE 10W-30
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INDEX
AAccessories and loading ................................................ 6-6
Air filter elements, engine and V-belt filter cleaning ..... 8-17BBattery ................................................................... 5-6, 8-41
Brake lever free play, adjusting the front ..................... 8-28
Brake lever free play (rear), adjusting .......................... 8-32
Brake lever, front ............................................................ 4-4
Brake lever, rear ............................................................ 4-5
Brake levers, checking and lubricating ........................ 8-38
Brakes .......................................................................... 8-27
Brakes, front and rear .................................................... 5-3
Brake shoes, checking the front and rear .................... 8-27CCables, checking and lubricating ................................. 8-37
Carburetor, adjusting ................................................... 8-25
Carrier, front ................................................................. 4-11
Carrier, rear .................................................................. 4-11
Chassis fasteners .......................................................... 5-6
Cleaning ......................................................................... 9-1DDrive chain ..................................................................... 5-3
Drive chain, lubricating ................................................. 8-36
Drive chain slack .......................................................... 8-34
Drive select lever ........................................................... 4-6
Drive select lever and driving in reverse ........................ 6-3EEngine break-in .............................................................. 6-4Engine, cold start ........................................................... 6-1
Engine idling speed ..................................................... 8-25
Engine oil .............................................................. 5-3, 8-11
Engine, starting a warm ................................................. 6-2
Engine stop switch ......................................................... 4-2
FFront knuckle pivots, lubricating .................................. 8-40
Fuel ......................................................................... 4-7, 5-3
Fuel cock ....................................................................... 4-8
Fuel tank cap ................................................................. 4-7
Fuse, replacing ............................................................ 8-44HHandlebar switches ....................................................... 4-2
Headlight beam, adjusting ........................................... 8-46
Headlight bulb, replacing ............................................. 8-44
Horn switch .................................................................... 4-3IIdentification numbers .................................................. 11-1
Indicator lights ................................................................ 4-2
Instruments, lights and switches .................................... 5-6LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-3MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label .................................................................. 11-2
U1PY60E0.book Page 1 Friday, March 11, 2011 9:30 AM