02_Periodic maintenance.pdf

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PERIODIC MAINTENANCE SCHEDULE

. .. . . .. . . . .. . . .. . .. . . . .. . . .. . .. 2- 1

PERIODIC MAINTENANCE CHART

.. . . . . . . . . .. . . .. . . . .. . . .. . .. . . . 2- 1

LUBRICATION POINTS

. . . .. . .. . . . .. . . .. . . . . .. . . .. . . .. . . . . .. . .. . . . .. . .2_ 2

MAINTENANCE AND TUNE-UP PROCEDURES ..................2- 3

BATTERY.. .. . . .. . .. . .. . .. . . . .. . . .. . .. . . . .. . . .. . . . . .. .. . . . . .. . . .. . . .. . . .. . . . .2- 3

AIR CLEANERS

. . .. . . .. . .. . . . .. . .. . . .. . . . .. . . .. .. .. . . . .. . . . .. . . . .. . .. . .. . .2_ 4

VALVE CLEARANCE .. . . . .. . . .. . .. . .. . . . . . . .. . . . .. . . .. . . . .. . . .. . .. . .. . 2- 5

SPARK PLUGS .. . .. .. . .. . . .. . .. . . . .. . .. . . .. . . . . .. . .. . . . .. . . . .. . . .. . .. . .. .2- 7

ENGINE OIL AND OIL FILTER

. . .. . . .. . . . .. . . . . .. . . . .. . . .. . . . .. . .. . .2_ B

FUEL LINES

. . .. . . .. . .. . . . .. . . .. . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . .. . . . . 2- 9

CARBURETORS

. . . .. . .. . . . .. . . .. . .. . . . .. . . .. . . . . .. . . .. . . .. . .. . . . .. . .. . . .. .2_ g

COOLING SYSTEM

. . .. . . .. . . . .. . . .. . .. . . . . .. . . . . . . .. . . . .. . . .. . .. . .. . .. . 2- 10

CLUTCH

. . .. . .. . . .. . . . .. . .. . . .. . .. .. . . .. . .. . . . . .. . . . . . .. . . .. . . . . .. . .. . .. . .. . 2-10

FINAL GEAR OIL

. . . .. . . . .. . . .. . .. . . . .. . . .. . . . . .. . . . .. . . . .. . . . . .. . . .. . .. . 2-11

BRAKES

. . .. . . .. . .. . . . . .. . .. .. . .. . . .. . .. . . . .. . . . . . .. .. . . . .. . . . . . .. . .. . . . .. ..2_ 72

TIRES

. . .. . .. . . .. . .. . . . . .. . .. . . . .. . . .. . .. . . . . .. . . . .. .. . . . . .. . . .. . . . . .. . .. . . .. 2- 14

STEERING

. . . .. . . . .. . . .. . . .. . . . .. . .. . . . .. . . . . .. . . ... . . .. .. . . .. . . . .. . . .. . .. .2-15

FRONT FORKS

.. . . .. . . . .. . .. . . . . .. . .. . . . . .. . . . . .... .. . . .. . . . .. . . .. . . . .. . . 2- 15

REAR SHOCK ABSORBERS

. . . .. . . . . .. . . . .. .. . . .. . . . . .. . . . .. . . .. . . . .2_ 15

CHASSIS BOLTS AND NUTS

.. ..a.. . . . . .. .. . .. . . . . .. . . .. . . . . .. . . . .2_15

2-l PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

PERIODIC MAINTENANCE SCHEDULE

IMPORTANT: The periodic maintenance intervals and service requirements have been established in

accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not

exceed emission standards and it will also ensure the reliability and performance of the motorcycle.

NOTE:

More frequent servicing may be performed on motorcycles that are used under severe conditions however,

it is not necessary for ensuring emission level compliance.

The chart below lists the recommended intervals for all the required periodic service work necessary

keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms

kilometer, miles and time for your convenience.

PERIODIC MAINTENANCE CHART

INTERVALS: THIS INTERVAL SHOULD BE

1000

6000

12000

18000

24000

JUDGED BY ODOMETER READING OR

miles

600

4000

7500

11000

15000

MONTHS WHICHEVER COMES FIRST.

months

Battery (Specific gravity of electrolyte)

Air cleaner elements

Clean every 6000 km (4000 miles) and

replace every 12000 km (7500 miles)

Radiator hoses

Brake fluid

Replace every two vears

Brakes

Tires

Steering

I 1 I 1 I I I I

Front forks

Rear shock absorbers

Chassis bolts and nuts

NOTE:

R = Replace, T = Tighten,

I = Inspect and adjust, clean, lubricate or replace as necessary

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motor-

cycle. Major lubrication points are indicated below.

¦ Clutch lever holder and clutch cable

ElCenter stand pivot

El Side-stant pivot

and spring hook

¦ : Oil

and spring hook

¦ Footrest phot

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dart or grime.

* Lubricate exposed parts which are subject to rust, with oil or grease.

2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of

the Periodic Maintenance requirements.

BATTERY

Inspect every 6000 km (4000 miles or 12 months).

Remove the seat.

Remove the battery 0 and then @ lead wires from the

battery terminals.

Remove the battery from the battery holder.

Check the electrolyte level and specific gravity. Add distilled

water, as necessary, to keep the surface of the electrolyte

above the MIN. level line but not above the MAX. level line.

For checking specific gravity, use a hydrometer to deter-

mine the charged condition.

MAX.(UPPER)

MIN.(LOWER)

09900-28403 : Hydrometer

Standard specific gravity : 1.28 at 20°C (68” F)

An S.G. reading of 1.22 (at 20°C) or under means that the

battery needs recharging. Remove the battery from the ma-

chine and charge it with a battery charger.

CAUTION:

Never charge a battery while still in the machine as damage

may result to the battery or regulator/rectifier.

Hydrometer

Charge at a maximum of 1.6 amps.

To install the battery, reverse the procedure described above.

CAUTION:

When installing the battery lead wires, fix the @ lead first and

0 lead last.

Make sure that the breather hose is tightly secured and

undamaged, and is routed as shown in the figure.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4

AIR CLEANERS

Clean every 6000 km (4000 miles) and

replace every 12000 km (7500 miles).

Remove the seat, frame covers and fuel tank.

Remove the right and left side frame head covers (Photo A),

then remove the right and left air cleaner mounting screws

(Photo 9).

Disconnect the air cleaner drain hose from the front side air

cleaner case (Photo C).

Loosen the two clamp screws and disconnect the joint hose

from the carburetor, then rise up the front side air cleaner

assembly (Photo D).

Remove the four screws and pull out the front side air

cleaner element (Photo E).

Loosen the four screws and pull out the rear side air cleaner

element (Photo F).

Carefully use an air hose to blow the dust from the air

cleaner elements (Photo G).

CAUTION:

Always apply an air pressure on the outside of the air cleaner

elements. If air pressure is applied on the inside, dirt will be

forced into the pores of the cleaner element thus restricting

air flow through the cleaner element.

Reinstall the cleaned elements or new ones in reverse order

of removal,

CAUTION:

If driving under dusty conditions, clean the air cleaner elements

more frequently. The surest way to accelerate engine wear is

to use the engine without the elements or to use ruptured

elements. Make sure that the air cleaners are in good condition

at all times. Life of the engine depends largely on these com-

ponents !

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