Owners Manual
Page 8
... maintenance and adjustment requirements contained in advance what riding techniques may be familiar with the motorcycle. Obtain permission to carry a passenger. Never allow your child. 6. This motorcycle is designed for beginners. Read and understand the owner's manual provided with motorcycle controls (location and function) and basic riding techniques. Review all items thoroughly before you are possible safety...
... maintenance and adjustment requirements contained in advance what riding techniques may be familiar with the motorcycle. Obtain permission to carry a passenger. Never allow your child. 6. This motorcycle is designed for beginners. Read and understand the owner's manual provided with motorcycle controls (location and function) and basic riding techniques. Review all items thoroughly before you are possible safety...
Owners Manual
Page 9
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...8 12 12 15 15 19 19 20 21 22 22 24 26 27 27 31 33 38 40 42 45 47 48 53 64 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Nuts and Bolts ...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...ENGINE AND SUSPENSION TUNING...Carburetor Tuning ...Suspension Tuning...Gearing...
......Periodic Maintenance Chart ...Transmission Oil...Cooling System ...Spark Plug...Ignition Timing ...Air Cleaner ...Throttle Cable...Carburetor ...Clutch ...Piston ...Exhaust System ...8 12 12 15 15 19 19 20 21 22 22 24 26 27 27 31 33 38 40 42 45 47 48 53 64 Drive Chain...Handlebar...Brakes ...Steering ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Nuts and Bolts ...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...ENGINE AND SUSPENSION TUNING...Carburetor Tuning ...Suspension Tuning...Gearing...
Owners Manual
Page 17
... side stand into the hole at the rear of the left footpeg. A. NOTE żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. Fuel Tank Capacity 5.5 liters (1.46 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. Fuel Tank Cap B. A. Hole WARNING Do not start the engine or attempt to ride the motorcycle when...
... side stand into the hole at the rear of the left footpeg. A. NOTE żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. Fuel Tank Capacity 5.5 liters (1.46 US gal) To open the fuel tank cap, pull out the breather hose from flowing out. Fuel Tank Cap B. A. Hole WARNING Do not start the engine or attempt to ride the motorcycle when...
Owners Manual
Page 25
... be smoothed with coolant. Cylinder Head: 7. 8. j Install the parts removed. Then, drain the coolant, remove and inspect the cylinder head, cylinder and piston. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep optimum engine performance, replace the piston rings after break-in , install a new standard spark plug, and change the transmission oil. żTo keep the engine trouble-free. NEVER...
... be smoothed with coolant. Cylinder Head: 7. 8. j Install the parts removed. Then, drain the coolant, remove and inspect the cylinder head, cylinder and piston. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep optimum engine performance, replace the piston rings after break-in , install a new standard spark plug, and change the transmission oil. żTo keep the engine trouble-free. NEVER...
Owners Manual
Page 26
... a safe, reliable ride. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ...Muffler ...Engine Sprocket ... WARNING Failure to perform these checks every day before you ride may result in serious damage or a severe accident. 24 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before you ride. No leakage Level correct No leakage Level correct (engine cold) Properly...
... a safe, reliable ride. Engine Transmission Oil ...Coolant ...Radiator Cap ...Spark Plug ...Cylinder Head Nut ...Cylinder Nut ...Clutch ...Carburetor ...Air Cleaner ...Muffler ...Engine Sprocket ... WARNING Failure to perform these checks every day before you ride may result in serious damage or a severe accident. 24 GENERAL INFORMATION j Daily Pre-Ride Checks Check the following items each day before you ride. No leakage Level correct No leakage Level correct (engine cold) Properly...
Owners Manual
Page 30
... FREQUENCY OPERATION Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check † Brake pad wear-check † Brake fluid level-check † *Brake fluid-change *Brake master cylinder cup and dust seal-replace *Brake caliper piston seal and dust seal-replace *Brake hose-replace Spoke tightness and rim runout-check †...
... FREQUENCY OPERATION Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check † Brake pad wear-check † Brake fluid level-check † *Brake fluid-change *Brake master cylinder cup and dust seal-replace *Brake caliper piston seal and dust seal-replace *Brake hose-replace Spoke tightness and rim runout-check †...
Owners Manual
Page 33
... the engine. Oil filler Cap C. MAINTENANCE AND ADJUSTMENT 31 Transmission Oil In order for all the oil to the center of the oil level gauge. the transmission oil level through the oil filler opening. If the oil level is too high, remove the excess oil using a syringe or other suitable device. j WARNING Motorcycle operation with insufficient, deteriorated, or contaminated transmission oil will pick up to drain. • • lower...
... the engine. Oil filler Cap C. MAINTENANCE AND ADJUSTMENT 31 Transmission Oil In order for all the oil to the center of the oil level gauge. the transmission oil level through the oil filler opening. If the oil level is too high, remove the excess oil using a syringe or other suitable device. j WARNING Motorcycle operation with insufficient, deteriorated, or contaminated transmission oil will pick up to drain. • • lower...
Owners Manual
Page 34
... transmission • Pour oil. the oil filler cap. • Install Check the oil level after kicking the engine over 3 • or 4 times. Recommended Transmission Oil Type Motor Oil Grade Viscosity API SE, SF or SG API SH, SJ or SL with its new gasket and • Install torque it to accommodate atmospheric conditions in the specified amount of used oil properly. 32 MAINTENANCE AND ADJUSTMENT WARNING Motor oil...
... transmission • Pour oil. the oil filler cap. • Install Check the oil level after kicking the engine over 3 • or 4 times. Recommended Transmission Oil Type Motor Oil Grade Viscosity API SE, SF or SG API SH, SJ or SL with its new gasket and • Install torque it to accommodate atmospheric conditions in the specified amount of used oil properly. 32 MAINTENANCE AND ADJUSTMENT WARNING Motor oil...
Owners Manual
Page 75
... change the brake fluid in loss of control. The brake fluid There are no parts on the brake lever or pedal action. j • • WARNING Always maintain proper brake adjustment. To adjust the brake lever position, loosen the locknut, and turn the adjuster to either side with the Periodic Maintenance Chart. If adjustment is improper, the brake could damage the brake assembly and possibly lock the wheel...
... change the brake fluid in loss of control. The brake fluid There are no parts on the brake lever or pedal action. j • • WARNING Always maintain proper brake adjustment. To adjust the brake lever position, loosen the locknut, and turn the adjuster to either side with the Periodic Maintenance Chart. If adjustment is improper, the brake could damage the brake assembly and possibly lock the wheel...
Owners Manual
Page 82
...caps on the lower end of the fork tubes. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Wear eye and face protection. Brake Hose Holder B. Use care when removing the top plugs. A. Fork Oil Level Adjustment the front wheel off the ground using a jack...the bottom of the outer tube. Bolt(s) C. the upper fork clamp bolts. • Loosen Remove the front fork top plugs. • WARNING The top plugs are under extreme spring pressure. the front fender. • Remove the brake hose holder. • Remove •...
...caps on the lower end of the fork tubes. Front Fork Protector the number plate. • Remove the handlebar clamp bolts and the han• Remove dlebar. Wear eye and face protection. Brake Hose Holder B. Use care when removing the top plugs. A. Fork Oil Level Adjustment the front wheel off the ground using a jack...the bottom of the outer tube. Bolt(s) C. the upper fork clamp bolts. • Loosen Remove the front fork top plugs. • WARNING The top plugs are under extreme spring pressure. the front fender. • Remove the brake hose holder. • Remove •...
Owners Manual
Page 97
..., possibly resulting in ·lb) 21 58 14 14 58 j Part Name Cylinder Drain Plug Cylinder Head Nuts Cylinder Nuts Transmission Oil Drain Plug Kick Pedal Pivot Bolt Shift Pedal Bolt Spark Plug Water Pump Cover Drain Plug Air Bleeder Bolt Cooling Hose Clamp Screws Carburetor Mounting Clamp Screws Clutch Spring Bolts Brake Caliper Bolts Brake Disc Screws Engine Mounting Bolts (Bracket Bolts) Front Axle Front Fork Clamp Bolts Front Axle Clamp Bolts Upper Lower N·m 4.9 25 25 20 9 9 25.5 4.9 1.0 1.5 1.5 9.3 25 10 29 79 20 20...
..., possibly resulting in ·lb) 21 58 14 14 58 j Part Name Cylinder Drain Plug Cylinder Head Nuts Cylinder Nuts Transmission Oil Drain Plug Kick Pedal Pivot Bolt Shift Pedal Bolt Spark Plug Water Pump Cover Drain Plug Air Bleeder Bolt Cooling Hose Clamp Screws Carburetor Mounting Clamp Screws Clutch Spring Bolts Brake Caliper Bolts Brake Disc Screws Engine Mounting Bolts (Bracket Bolts) Front Axle Front Fork Clamp Bolts Front Axle Clamp Bolts Upper Lower N·m 4.9 25 25 20 9 9 25.5 4.9 1.0 1.5 1.5 9.3 25 10 29 79 20 20...
Owners Manual
Page 99
... in an area where the roads are cool before washing. Use a soft cloth or sponge to prevent rusting. Lubricate the drive chain to wash your motorcycle. NOTE żAfter riding in • Avoid air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. j Washing Your Motorcycle your bike with cold water. a mild neutral detergent (designed for several times. Use a soft cloth to...
... in an area where the roads are cool before washing. Use a soft cloth or sponge to prevent rusting. Lubricate the drive chain to wash your motorcycle. NOTE żAfter riding in • Avoid air intakes, carburetors, brake components, electrical components, muffler outlets, and fuel tank openings. j Washing Your Motorcycle your bike with cold water. a mild neutral detergent (designed for several times. Use a soft cloth to...
Owners Manual
Page 104
...;This troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to assist you in tank • No Fuel turned off • Tank tap cap air vent obstructed • Fuel tap clogged • Fuel line clogged • Float valve clogged • Engine flooded level too high • Fuel Float • valve worn or stuck open to reach the engine.) Spark missing or weak Spark plug...
...;This troubleshooting guide is not exhaustive and starting technique (when the engine is meant simply as a quick guide to assist you in tank • No Fuel turned off • Tank tap cap air vent obstructed • Fuel tap clogged • Fuel line clogged • Float valve clogged • Engine flooded level too high • Fuel Float • valve worn or stuck open to reach the engine.) Spark missing or weak Spark plug...
Owners Manual
Page 105
... deposits) exhaust valves assembled incorrectly • KIPS Exhaust advancer spring damaged • Exhaust valve operating rod seized • KIPS rod seized in cylinder • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor low-speed performance Spark weak Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged Fuel-air mixture...
... deposits) exhaust valves assembled incorrectly • KIPS Exhaust advancer spring damaged • Exhaust valve operating rod seized • KIPS rod seized in cylinder • Other defective • Igniter Transmission oil viscosity too high • Brake dragging • Poor low-speed performance Spark weak Spark plug dirty, broken, or gap improperly adjusted Spark plug cap or high-tension wiring defective Spark plug cap shorted or not contacting properly Spark plug type incorrect Igniter defective Ignition coil defective Stator damaged Fuel-air mixture...
Owners Manual
Page 106
... • Cylinder gasket damaged • Reed valve damaged • Improper acceleration plunger stuck open • Starter Carburetor fuel level too high or too low • jet clogged • Main Throttle valve does not fully open • Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • Cylinder exhaust port clogged • Brake dragging • Clutch slipping • Engine overheating • Transmission oil level...
... • Cylinder gasket damaged • Reed valve damaged • Improper acceleration plunger stuck open • Starter Carburetor fuel level too high or too low • jet clogged • Main Throttle valve does not fully open • Air cleaner element clogged • Muffler clogged • Fuel contaminated with water or foreign matter • Cylinder exhaust port clogged • Brake dragging • Clutch slipping • Engine overheating • Transmission oil level...
Owners Manual
Page 107
...; Clutch release mechanism defective • Gear shifting faulty j Transmission does not go into gear; TROUBLESHOOTING GUIDE 105 Engine overheating Firing incorrect Spark plug dirty, broken, or gap improperly adjusted Spark plug type incorrect Igniter defective • Water pump not rotating Clutch operation faulty Clutch slipping No clutch lever play Clutch cable improperly adjusted Clutch cable defective Clutch plate worn or warped Clutch spring broken or weak Clutch release mechanism defective Clutch hub or housing unevenly worn • • • Fuel-air...
...; Clutch release mechanism defective • Gear shifting faulty j Transmission does not go into gear; TROUBLESHOOTING GUIDE 105 Engine overheating Firing incorrect Spark plug dirty, broken, or gap improperly adjusted Spark plug type incorrect Igniter defective • Water pump not rotating Clutch operation faulty Clutch slipping No clutch lever play Clutch cable improperly adjusted Clutch cable defective Clutch plate worn or warped Clutch spring broken or weak Clutch release mechanism defective Clutch hub or housing unevenly worn • • • Fuel-air...
Owners Manual
Page 108
...; Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts loose • Crankshaft bearing worn • Primary gear worn or chipped • j Abnormal drive train noise Clutch noise Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Engine noise abnormal Knocking Igniter defective Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
...; Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts loose • Crankshaft bearing worn • Primary gear worn or chipped • j Abnormal drive train noise Clutch noise Clutch housing/friction plate clearance excessive Clutch housing gear/primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Engine noise abnormal Knocking Igniter defective Carbon built up in combustion chamber Fuel quality poor or type incorrect Spark plug type incorrect Engine overheating...
Owners Manual
Page 109
... to turn Control cable incorrectly routed Wiring incorrect routed Steering stem locknut too tight Roller bearing damaged Steering bearing race dented or worn Steering stem inadequately lubricated Steering stem bent Tire air pressure too low • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad Pad surface glazed • Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. TROUBLESHOOTING GUIDE 107 Frame noise...
... to turn Control cable incorrectly routed Wiring incorrect routed Steering stem locknut too tight Roller bearing damaged Steering bearing race dented or worn Steering stem inadequately lubricated Steering stem bent Tire air pressure too low • • Rear shock absorber noise • Shock absorber damaged Disc brake noise installed incorrectly • Pad Pad surface glazed • Brake disc warped • Brake caliper • Brake master defective cylinder damaged • Other noise nut, bolt, etc. TROUBLESHOOTING GUIDE 107 Frame noise...
Owners Manual
Page 125
... to overheat the engine in muddy conditions and the radiator can add significantly to the weight of the vehicle. In muddy or sandy conditions, increase chain slack as the air cleaner collects dust, the mixture becomes richer and it may be advisable to • When the tires and other parts of the vehicle and therefore reduce performance. ENGINE AND SUSPENSION TUNING 123 Special...
... to overheat the engine in muddy conditions and the radiator can add significantly to the weight of the vehicle. In muddy or sandy conditions, increase chain slack as the air cleaner collects dust, the mixture becomes richer and it may be advisable to • When the tires and other parts of the vehicle and therefore reduce performance. ENGINE AND SUSPENSION TUNING 123 Special...
Owners Manual
Page 128
... Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw tightness Carburetor top cap tightness UNI-TRAK® lever rod bolt tightness UNI-TRAK® lever bolt torque Rear shock absorber bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket bolt or nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke tightness Front and rear tire air pressure Drive chain...
... Fuel tank installation All control cable routings Engine mounting bolt torque Engine sprocket installation Shift pedal bolt torque Transmission oil level Carburetor clamp screw tightness Carburetor top cap tightness UNI-TRAK® lever rod bolt tightness UNI-TRAK® lever bolt torque Rear shock absorber bolt torque Swingarm pivot shaft nut torque Rear axle nut torque Rear sprocket bolt or nut torque Rear brake pedal operation Seat installation Front and rear wheel spoke tightness Front and rear tire air pressure Drive chain...