3-3
MAINTENANCE INTERVALS
BRAKES
Adjust lever position and
pedal height●●
Lubricate pivot point●●
Check brake disc surface●●
Check fluid level and leak-
age●●
Retighten brake disc bolts,
caliper bolts, master cylin-
der bolts and union bolts●●
Replace pads●
Replace brake fluid●Every one year
FRONT FORKS
Inspect and adjust●●
Replace oil●●Suspension oil "S1"
Replace oil seal●
FRONT FORK OIL SEAL
AND DUST SEAL
Clean and lube●●Lithium base grease
PROTECTOR GUIDE
Replace●
REAR SHOCK ABSORBER
Inspect and adjust●●
Lube●(After rain
ride)●Molybdenum disulfide grease
Replace spring seat●Every one year
Retighten●●
DRIVE CHAIN GUIDE AND
ROLLERS
Inspect●●
SWINGARM
Inspect, lube and retighten●●Molybdenum disulfide grease
RELAY ARM, CONNECT-
ING ROD
Inspect, lube and retighten●●Molybdenum disulfide grease
STEERING HEAD
Inspect free play and re-
tighten●●
Clean and lube●Lithium base grease
Replace bearing● ItemAfter
break-in
Every
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
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 Routine Page
CoolantCheck that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage.P. 3-6 – 7
FuelCheck that a fresh mixture of oil and gasoline is filled in the fuel
tank. Check the fuel line for leakage.P. 1-12
Transmission oilCheck that the oil level is correct. Check the crankcase for leak-
age.P. 3-8 – 9
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P. 3-7
Throttle grip/HousingCheck 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 effect of front and rear brake. P. 3-9 – 12
Drive chainCheck drive chain slack and alignment. Check that the drive chain
is lubricated properly.P. 3-12 – 13
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P. 3-16
SteeringCheck that the handlebar can be turned smoothly and have no ex-
cessive play.P. 3-17
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage.
P. 3-13 – 16
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.—
Muffler Check that the muffler is tightly mounted and has no cracks. P. 4-3 – 4
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P. 3-12
Lubrication Check for smooth operation. Lubricate if necessary. P. 3-18
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P. 1-13
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P. 1-7
SettingsIs 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 – 11
