Periodicmaintenance

CONTENTS~~~~~~~~~~PERIODICMAINTENANCESCHEDULE.........................................2-2

PERIODICMAINTENANCECHART.............................................2-2

LUBRICATIONPOINTS.................................................................2-3

MAINTENANCEANDTUNE-UPPROCEDURES............................2-4

AIRCLEANER...............................................................................2-4

SPARKPLUG................................................................................2-5

Valveclearance...................................................................2-8

ENGINEOILANDOILFILTER.....................................................2-13

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

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

·THROTTLEVALVESYNCHRONIZATION...................................2-15

THROTTLECABLEPLAY............................................................2-16

CLUTCH2-17

COOLINGSYSTEM.......................................................................2-18

DRIVECHAIN................................................................................2-20

BRAKE..........................................................................................2-22

TIRE...............................................................................................2-25

STEERING.....................................................................................2-26

FRONTFORK................................................................................2-27

REARSUSPENSION:..........................................................2-27

EXHAUSTPIPEBOLTANDNUT................................................2-27

CHASSISBOLTANDNUT...........................................................2-28

COMPRESS/ONPRESSURECHECK............................................2-30

OILPRESSURECHECK.................................................................2-31

PERIODICMAINTENANCESCHEDULE

Thechartbelowliststherecommendedintervalsforalltherequiredperiodicserviceworknecessarytokeepthemotorcycleoperatingatpeakperformanceandeconomy.Maintenanceintervalsareexpressedintermsofkilometer,milesandmonths,andaredependantonwhichevercomesfirst.

NOTES:

Morefrequentservicingmaybeperformedonmotorcyclesthatareusedundersevereconditions.

PERIODICMAINTENANCECHART

km100060001200018000₂₄₀₀₀

~Imiles600_{400075001100015000}

mmonths_16121824

Aircleanerelement Sparkplugs	. .	I I	IR	R I	I R
Valveclearance	-	-	-	-	I
Engineoil	R	R	R	A	R
Enaineoilfilter	R	-	.	R	-
Fuelline	-	I	I	I	I
		Replace	fuelhoseevery	4years.
Idlespeed	I	I	I	I	I

_{Throttlevalvesynchronization}

I

_(E-33only)^-I-I

PAIR(airsupply)system	-	-		I	-	I
Throttlecableolav	I	I		I	I	I
Clutch	-	I		I	I	I
Radiatorhoses	-	I		I	I	I
Enginecoolant			Replace	every2years.

Evaporativeemissioncontrolsystem_--I-I^{(E-33only)Rep}lacevaporhoseevery4years.

Drivechain_IIIIICleanandlubricateevery1000km(600miles).

^BrakesIIIII^Brakehoses-IIII

_{Replaceevery4years.}

Brakefluid			-		I		Replace	I every2vears.		I	I
Tires				-		I			I	I	I
Steering				I		-			I	-	I
Frontforks				-		-			I	-	I
Rearsuspension				-		-			I	-	I
Exhaustpipebolts	andmuffler	boltandnut		T		-			T	-	T

^{ChassisboltsandnutsTTTTT}

I=Inspectandadjust,clean,lubricateorreplaceasnecessary.R«Reptece

T=Tighten

LUBRICATIONPOINTS

Properlubricationisimportantforsmoothoperationandlonglifeofeachworkingpartofthemotorcycle.Majorlubricationpointsareindicatedbelow.

..@Brakeleverholder

NOTE:

*Beforelubricatingeachpart,cleanoffanyrustyspotsandwipeoffanygrease,oil,dirtorgrime.

•Lubricateexposedpartswhicharesubjecttorust,witharustpreventativespray.especiallywheneverthemotorcyclehasbeenoperatedunderwetorrainyconditions.

MAINTENANCEANDTUNE-UPPROCEDURES

Thissectiondescribestheservicingproceduresforeachitem_,

mentionedinthePeriodicMaintenancechart.

AIRCLEANER

Inspectevery6000km(4000miles,6months)andreplaceevery18000km(11000miles,18months).

•Removethefrontandrearseats.(c::::7'6-6)

•Liftandsupportthefueltank.(L?4-52)

•Removetheaircleanerelementbyremovingthescrews.

-

•Carefullyuseairhosetoblowthedustfromthecleanerele•

ment.

IACAUTIONI

Alwaysuseairpressureontheoutsideoftheaircleanerelement.Ifairpressureisusedontheinside,dirtwillbeforcedintotheporesoftheaircleanerelementthusre•strictingairflowthroughtheaircleanerelement.

•Reinstallthecleanedornewaircleanerelementinthere•

verseorderofremoval.

^1A_CAUTION]

Ifdrivingunderdustyconditions,cleantheaircleanerelementmorefrequently.Thesurestwaytoaccelerateenginewearistooperatetheenginewithouttheelementortouseatornelement.Makesurethattheaircleanerisingoodconditionatalltimes.Thelifeoftheenginede•pendslargelyonthiscomponent!

•Removethedrainplugsfromtheaircleanerboxtoallowanywatertodrainout.

SPARKPLUG

Inspectevery6000km(4000miles,6months)andreplaceevery12000km(7500miles,12months).

SPARKPLUGANDIGNITIONCOIUPLUGCAPREMOVAL

•Removethefrontandrearseat.(c::::7'6-6)

•Liftandsupportthefueltank.(CT4-52)

•RemovetheaircleanerboxG).(CT4-62)

•Disconnectalloftheleadwirecouplersfromeachignitioncoil/

plugcap.

IACAUTIONI

Donotremovetheignitioncoil/plugcapbeforediscon•

nectingitsleadwirecoupler.

•Removealloftheignitioncoils/plugcaps.

IACAUTIONI

*Donotpryuptheignitioncoil/plugcapwithadriverorabartoavoiditsdamage.

*Becarefulnottodroptheignitioncoil/plugcaptopre•

venttheshortoropenthecircuitofits.

•Removethesparkplugswithasparkplugwrench.

HEATRANGE

•Checktoseetheheatrangeoftheplug.

Iftheelectrodeoftheplugiswetappearingordarkcolor,re•placetheplugwithhottertypeone.Ifitiswhiteorglazedap•pearing,replacetheplugwithcoldertypeone.

Hottertype	NGKCASE	DENSOU24ESR-N
Standard Coldertvoe	CR9ECR10E	U27ESR-NU31ESR-N

NOTE:

"R''typesparkplughasaresistorlocatedatthecenterelectrodetopreventradionoise.

CARBONDEPOSITS

•Checktoseeiftherearecarbondepositsonthesparkplug.

•Ifcarbonisdeposited,removeitusingasparkplugcleanermachineorcarefullyuseatoolwithapointedend.

SPARKPLUGGAP

•Measurethesparkpluggapusingathicknessgauge.

•Ifoutofspecification,regapthesparkplug.

DSparkpluggap:

Standard:0.7-0.8mm(0.028-0.031in)

!fOOli09900-20803:Thicknessgauge

ELECTRODE'SCONDITION

•Checktheconditionoftheelectrode.

•Ifitisextremelywornorburnt,replacethesparkplug.Replacethesparkplugifithasabrokeninsulator,damagedthread,etc.

IACAUTIONI

Checkthethreadsizeandreachwhenreplacingthesparkplug.Ifthereachistooshort,carbonwillbedepositedonthescrewportionofthesparkplugholeandenginedamagemayresult.

0

-

Gap:

0.7-0.8mm

(0.028-0.031in)

-

SPARKPLUGANDIGNITIONCOIUPLUGCAPINSTALLATION

•Installthesparkplugstothecylinderheadbyfingertight,and

thentightenthemtothespecifiedtorque.

(!JSparkplug:11N·m(1.1kgf·m,8.0lb-ft)

IACAUTIONI

Toavoiddamagingthecylinderheadthreads,firstfin•gertightenthesparkplugandthentightenittothepropertorqueusingthesparkplugwrench.

•Installtheignitioncoils/plugcapsandconnecttheirleadwirecouplers.

JACAUTIONI

*Donotstriketheignitioncoil/plugcapwithaplastichammerwheninstallingit.

*Wheninstallingtheignitioncoil/plugcap,placeits

_{couplernottocontactwiththecylinderheadcover.}

CONTACT

INCORRECTINCORRECT