Each jet size is indicated by a number. Described in this section are the bases for carburetor tuning required when coping with variations in air oxygen concentration. Page Oil Quantity Minor Adjustment Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability. Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak.
Spring rate Slit mark Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage. Page 76 — ml ml According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below.
Do not force the adjust screw past the stopped position, or you may damage the adjuster. Spring Part No. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.
NOTE: Mark the clutch cable at which the bracket slit set for correct reinstallation. NOTE: When installing a new connector, clean the exhaust pipe and joint of the muffler. NOTE: Loosen the camshaft journal holder bolts diagonally. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. Page Cam Chain No. Fill the intake and exhaust ports with gasoline to check for leaks. Page Camshaft Automatic Decomp. NOTE: Loosen the clutch spring set bolts little by little and diagonally.
Mark the paint mark. A Clutch driven No. NOTE: Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. Gearshift fork to groove clearance Service Limit: 0. Crankshaft runout Service Limit: 0. Install the snap ring in the groove and locate its end as shown in the illustration. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. Page Crankcase Installation 2. Keep heat, spark and flame away.
Clean the fuel strainer with compressed air. J 6 Starter jet 7 Pilot screw 8 Slow jet S. NOTE: Do not remove the throttle position sensor 2 unless it is neces- sary to replace it. Lateral direction: Horizontal Carburetor set position Page Replace the O-rings with new ones. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns.
If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water. If engine coolant is swallowed, induce vomiting and call a physician immediately. Is there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1 Measure the ignition coil primary peak voltage. Go to Step 3. Go to Step 9. Go to Step 8. Step 8 1 Check the stator.
Is the stator OK? Faulty stator Step 9 1 Measure the engine stop switch resistance. NOTE: Use the special tool needle pointed probe , to prevent the rub- ber of the water proof coupler from damage.
Service Limit: 2. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Page Brake Pads Replacement Replace the two pads as a set.
Page Caliper Inspection! Call your doctor immediately if brake fluid is swallowed, and induce vomiting. Apply handle grip bond. NOTE: Mark the paint mark A to the matching surface of handlebar holder and handlebars before removing.
Record the set- ting before turning the adjuster. Protect the axle holder with a rag when using a vise. If removed, the inner rod may slip into the damper rod, possibly causing the threaded section to damage the oil seal. Guide bushing 4 Seal retainer 5 Oil seal If it is damaged, replace it with a new one. If it has scratches or is bent, replace it with a new one. Replace the O-rings, oil seal and dust seal with new ones. Apply specified front fork oil when installing the O- rings, slide bushing, guide bushing, damper unit and sliding parts.
Do not clamp the axle holder too tight. NOTE: Mark the paint mark to the matching surface of handlebar holder and handlebars before removing. NOTE: Hold the steering stem lower bracket to prevent it from falling. Page Installation Install the steering in the reverse order of steering removal. Standard spring set length: 5. Page Be sure to extend the rod after filling the oil. Periodic maintenance Periodic maintenance Spark plug Air cleaner Engine oil, oil filter and oil strainers Engine coolant Clutch cable Throttle cable Hot starter Engine idle speed Crankcase breather hose Fuel hose Fuel filter Tapeet clearance Cylinder head, cylinder and piston Exhaust silencer Drive chain and sprockets Drive chain guide, buffer and tensioner roller Brakes Front fork Rear suspension Wheels and tires Steering Lubrication Compression pressure check Oil pressure check.
Machine Tuning Front fork tuning Rear suspension tuning Suspension balance. Cylinder head, cylinder and piston Construction Engine top side disassembly Engine top components inspection and service Engine top side assembly Cam chain, cam chain tensioner and cam chain. Clutch Construction Clutch plate Primary driven gear and clutch sleeve hub Clutch release chamshaft. Electrical system Cautions in servicing Location of electrical components Construction Generating system Ignition system Magneto rotor Stator.
Servicing information Service data Tightening Torque Special tools Wiring diagram Wire, cable and hose routing Cable routing Fuel hose routing Radiator hose routing Rear brake pedal set-up Clutch cable adjuster Hot starter lever installation Front brake hose routing Rear brake hose routing Handlebar set-up Rear wheels spokes installation Chain roller installation Specifications Optional parts Setting data.
Thursday, January 13,
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