3-5
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, 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.3-9 – 10
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.P.1-18
Engine oilCheck that the oil level is correct. Check the crankcase and oil
line for leakage.P.3-12 – 13
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-10 – 11
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-11
Brakes Check the play of front brake and effect of front and rear brake. P.3-17 – 20
Drive chainCheck drive chain slack and alignment. Check that the drive chain
is lubricated properly.P.3-20 – 21
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-24
SteeringCheck that the handlebar can be turned smoothly and have no ex-
cessive play.P.3-24 – 25
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage.
P.3-21 – 24
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.3-8 – 9
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-20
Lubrication Check for smooth operation. Lubricate if necessary. P.3-26
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-20
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done?P.4-1 – 10
3-11
ENGINE
ADJUSTING THE THROTTLE GRIP
FREE PLAY
1. Check:
• Throttle grip free play "a"
Out of specification→Adjust.
2. Adjust:
• Throttle grip free play
Adjustment steps:
a. Slide the adjuster cover.
b. Loosen the locknut "1".
c. Turn the adjuster "2" until the
specified free play is obtained.
d. Tighten the locknut.
Prior to adjusting throttle grip free
play, the engine idling speed should
be adjusted.
After adjusting the throttle grip
free play, turn the handlebar to the
right and to the left to ensure that
this does not cause the engine
idling speed to change.
LUBRICATING THE THROTTLE
1. Remove:
• Cover (throttle cable cap) "1"
• Cover (grip cap) "2"
• Throttle grip cap "3"
2. Apply:
• Lithium soap base grease
On the throttle cable end "a".
3. Install:
• Throttle grip cap
• Screw (throttle grip cap)
• Cover (grip cap)
• Cover (throttle cable cap)
ADJUSTING THE HOT STARTER
LEVER FREE PLAY
1. Check:
• Hot starter lever free play "a"
Out of specification→Adjust.
2. Adjust:
• Hot starter lever free play
Hot starter lever free play adjust-
ment steps:
a. Loosen the locknut "1".
b. Turn the adjuster "2" until free
play "a" is within the specified lim-
its.
c. Tighten the locknut.
After adjustment, check proper oper-
ation of hot starter.
CLEANING THE AIR FILTER
ELEMENT
Proper air filter maintenance is the
biggest key to preventing premature
engine wear and damage.
Never run the engine without the
air filter element in place; this
would allow dirt and dust to enter
the engine and cause rapid wear
and possible engine damage.
1. Open the air filter case cover "1"
Loosen the quick screw "2" and pull
on it to open the air filter case cover.
2. Unhook:
•Binder "1"
3. Remove:
• Air filter element "1"
• Air filter guide "2" Throttle grip free play
"a":
3.0–5.0 mm (0.12–0.20
in)
Locknut:
4 Nm (0.4 m•kg, 2.9
ft•lb)
Screw (throttle grip cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Hot starter lever free play
"a":
3–6 mm (0.12–0.24 in)
Locknut:
4 Nm (0.4 m•kg, 2.9
ft•lb)
