CONTENTS
CHAPTER 1
GENERAL
INFORMATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
INCLUDED PARTS .......... 1-6
IMPORTANT
INFORMATION................. 1-6
CHECKING OF
CONNECTION .................. 1-7
SPECIAL TOOLS ............. 1-8
CONTROL
FUNCTIONS ................... 1-12
STARTING AND
BREAK-IN ...................... 1-13
TORQUE-CHECK
POINTS........................... 1-15
CLEANING AND
STORAGE ...................... 1-16
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-10
LUBRICATION
DIAGRAMS .................... 2-16
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR
INSPECTION AND
ADJUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-24
CHAPTER 4
ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-7
CARBURETOR................. 4-9
CAMSHAFTS.................. 4-16
CYLINDER HEAD........... 4-21
VALVES AND VALVE
SPRINGS ........................ 4-23
CYLINDER AND
PISTON ........................... 4-27
CLUTCH ......................... 4-31
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-35
BALANCER .................... 4-40
OIL PUMP ....................... 4-42
KICK SHAFT AND
SHIFT SHAFT ................. 4-46
CDI MAGNETO............... 4-51
ENGINE REMOVAL ....... 4-53
CRANKCASE AND
CRANKSHAFT ............... 4-57
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK................... 4-63
CHAPTER 5
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................5-1
FRONT BRAKE AND
REAR BRAKE ..................5-6
FRONT FORK .................5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-31
REAR SHOCK
ABSORBER ....................5-36
CHAPTER 6
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........6-2
IGNITION SYSTEM...........6-3
THROTTLE POSITION
SENSOR SYSTEM ...........6-6
CHAPTER 7
TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6
3-21
CHASSIS
A tight spoke will emit a clear, ringing
tone; a loose spoke will sound flat.
2. Tighten:• Spokes(with a spoke nipple wrench "1")
Be sure to retighten these spokes be-
fore and after break-in.
CHECKING THE WHEELS
1. Inspect:• Wheel runoutElevate the wheel and turn it.
Abnormal runout → Replace. 2. Inspect:
• Bearing free playExist play →Replace.
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Place a stand under the engine to raise the front wheel off the
ground. WARNING! Securely
support the vehicle so that
there is no danger of it falling
over.
2. Check: • Steering stemGrasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play →Adjust steering head.
3. Check: • Steering smooth actionTurn the handlebar lock to lock.
Unsmooth action →Adjust steer-
ing ring nut.
4. Adjust: • Steering ring nut
Steering ring nut adjustment
steps:
a. Remove the number plate.
b. Remove the handlebar and upper
bracket. c. Loosen the steering ring nut "1"
using the steering nut wrench "2".
d. Tighten the steering ring nut "3" using steering nut wrench "4".
• Apply the lithium soap base grease on the thread of the steering stem.
• Set the torque wrench to the steer-
ing nut wrench so that they form a
right angle.
e. Loosen the steering ring nut one turn.
f. Retighten the steering ring nut us- ing the steering nut wrench.
Avoid over-tightening.
g. Check the steering stem by turn-ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
Spoke nipple wrench:
YM-01521/90890-01521
Spokes: 3 Nm (0.3 m•kg, 2.2
ft•lb)
Steering nut wrench:YU-33975/90890-01403
Steering nut wrench: YU-33975/90890-01403
Steering ring nut (initial
tightening): 38 Nm (3.8 m•kg, 27
ft•lb)
Steering ring nut (final
tightening): 7 Nm (0.7 m•kg, 5.1
ft•lb)
