Apply grease onto the dust seal lips and bearings. Loosen the lock nuts of rod. Install the piston, piston pin and a new piston pin clip. Remove the two screws attaching the brake fluid reservoir cap. If any defects are found, replace the bearing with a new one. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. Hold the clutch outer with the flywheel holder.
Apply a thin coat of grease to the two ends of the armature shaft. Remove the two bolts on the drive sprocket. Inspect the steering brackets and oil seal. Make sure that the boss on the caliper correctly engages with the locating slot on the caliper spring plate. Do not squeeze wires against the weld or its clamp. Install the brushes onto the brush holders. Shift Shaft Gear Remove the main axle.
Blow dirt out from between core fins with compressed air. Be careful not to damage the piston surface. Inspect the lower rear swing arm. Check if there is any loose wire. Remove the carburetor Nuts Float Chamber.
Screw Air Cleaner Holder Remove the screw and remove the air cleaner assembly from the air cleaner holder. Replace if wear or damage. Cotter Pin Remove the cotter pin and nut attaching the steering column under the frame body, then remove steering column and collar. Measure the V-belt width Service limit: 22mm Replace the drive belt if out of specification. Separate the left and right crankcase halves. Place a container under the engine. When a tire wear is out of specification, replace the tire immediately.
Never run the engine in a closed area. Spark Plug Cap Bolts Remove the three bolts and remove the outlet hose cover. Outlet Fuel Tube Reserve Fuel Tube. Upper Holder Lip Steering Bracket. Refer to the chapter 9 Remove the oil seal, circlip, screw and plate. Inspect the bearings for allow play in the transmission case cover or the bearings turn roughly.
Throttle Cable Compress the spring to disconnect the throttle cable by hand. Service Limit: Less than 0. This is just our way of saying we take care of our customers and to be careful of those who offer less than what you deserve to get. Reservoir protection Cover Remove the two bolts at the right foot peg attaching the right floor board holder. Support the machine securely so there is no danger of it falling over. Other cooling system service can be done with the engine installed in the frame. Dowel Pins Cylinder Screw Unscrew the clamp and disconnect the water hose.
Refer to chapter 3 Remove frame covers and exhaust pipe. Numbered instructions guide you through every repair procedure step by step. Inspect the diaphragm and spring for wear or damage. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly. Do not attempt to straighten a bent shaft, this may dangerously weaken the shaft.
Do not smoke or allow flames or sparks in your working area. Install the clutch outer, collar and washer. If any abnormal condition is noted, replace the caliper. There should be continuity between the yellow wires and no continuity between each yellow wire and ground. Replace it with a new one Capacity according to the specified capacity. Apply grease onto the collar, bush, pivot shaft and thrust cover.