CONTENTS
CHAPTER 1
GENERAL
INFORMATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION.................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
STARTING AND
BREAK-IN ........................ 1-8
TORQUE-CHECK
POINTS........................... 1-11
CLEANING AND
STORAGE ...................... 1-12
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 .......................4-5
CARBURETOR................. 4-7
CAMSHAFTS..................4-14
CYLINDER HEAD...........4-19
VALVES AND VALVE
SPRINGS ........................4-21
CYLINDER AND
PISTON...........................4-25
CLUTCH .........................4-29
OIL FILTER ELEMENT
AND WATER PUMP.......4-33
BALANCER ....................4-37
OIL PUMP.......................4-39
KICK SHAFT AND
SHIFT SHAFT................. 4-42
CDI MAGNETO............... 4-47
ENGINE REMOVAL .......4-49
CRANKCASE AND
CRANKSHAFT ............... 4-53
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK...................4-59
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
