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Table of Contents
- 4. General Considerations
- 5. Serial Number Location
- 6. Warnings for Servicing
- 7. Precautions for Servicing
- 8. Symbol Marks and Materials
- 9. Group Index
- 10. General instructions
- 11. Location of Parts
- 12. Fuel and Oil Recommendations
- 13. Operating Instructions
- 14. Transmission
- 15. Country and Area Codes
- 16. Periodic Maintenance
- 18. Inspection Before Practice
- 19. Periodic Maintenance Chart
- 21. Spark Plug
- 22. Air Cleaner Element Removal
- 23. Transmission Oil
- 24. Transmission Oil Level Inspection and Re...
- 25. Engine Coolant Level Check
- 26. Engine Coolant Replenishment
- 27. Clutch Cable
- 28. Fuel Hose
- 29. Cylinder Head
- 30. Exhaust Valve
- 31. Drive Chain Slack
- 32. Sprocket Inspection
- 33. Drive Chain Guide Buffer
- 34. Brake Pad
- 35. Front Fork
- 36. Spoke Nipple and Rim Lock
- 37. Lubrication
- 38. Tightening Torque
- 40. Troubleshooting
- 45. Machine Tuning
- 46. Carburettor Tuning
- 47. Pilot Jet
- 48. Needle Clip Position
- 49. Throttle Stop Screw
- 50. Carburetor Tuning in Practice
- 51. Judging Air/Fuel Mixture
- 53. Front Fork Tuning
- 54. Oil Quantity Minor Adjustment
- 55. Oil Change
- 57. Spring Change
- 59. Front Fork Tuning Procedure
- 60. Rear Suspension Tuning
- 61. Spring Pre-Load Adjustment
- 62. Rear suspension tuning procedure
- 64. Suspension Balance
- 65. Engine Removal and Installation
- 66. Exterior Parts
- 67. Engine Removal
- 72. Engine Installation
- 74. Cylinder, Piston and Exhaust Valve
- 75. Cylinder, Piston and Exhaust Valve Const...
- 76. Engine Top Side
- 77. Piston Removal
- 78. Exhaust Valve Removal
- 79. Cylinder Head Inspection
- 80. Piston and Piston Ring Inspection
- 81. Exhaust Valve Inspection
- 82. Piston Ring and Piston Reassembly
- 83. Cylinder Reassembly
- 85. Exhaust Valve Governor Removal and Disas...
- 86. Exhaust Valve Governor Inspection
- 87. Exhaust Valve Governor Reassembly and In...
- 88. Clutch
- 89. Clutch Construction
- 90. Clutch Plate Removal
- 91. Clutch Plate Inspection
- 92. Clutch Plate Reassembly
- 93. Primary Driven Gear Ass'y Removal
- 94. Primary Driven Gear Ass'y Inspection
- 95. Clutch Release Camshaft Removal
- 96. Clutch Release Camshaft installation
- 97. Kick Starter
- 98. Kick Starter Construction
- 99. Kick Starter Removal
- 100. Kick Starter Inspection
- 103. Gearshifting
- 104. Gearshifting Linkage Construction
- 105. Gearshift Linkage Removal
- 106. Gearshift Linkage Inspection
- 107. Gearshift Linkage Reassembly
- 110. Transmission and Crankshaft
- 111. Transmission and Crankshaft Construction
- 112. Engine Bottom Side
- 113. Crankcase Separation
- 114. Crankshaft Removal
- 115. Crankshaft inspection
- 116. Oil Seal Inspection, Removal and Install...
- 117. Bearing Inspection
- 118. Bearing Removal and Installation
- 119. Crankshaft installation
- 120. Transmission Reassembly
- 121. Crankcase Reassembly
- 122. Primary Drive Gear Reassembly
- 123. Fuel System
- 124. Carburetor Construction
- 125. Carburetor Removal and Disassembly
- 127. Carburetor Cleaning
- 128. Carburetor Reassembly
- 129. Reed Valve Removal
- 130. Cooling System
- 131. Cooling System Construction
- 132. Engine Coolant Replacement
- 133. Radiator Removal
- 134. Radiator Installation
- 135. Water Pump Reassembly
- 138. Electrical System
- 139. Electrical System Construction
- 140. Ignition System Peak Voltage Inspection
- 141. Ignition Coil Inspection
- 142. Stator Coil Inspection
- 143. Magneto Rotor and Stator Reassembly
- 145. Front and Rear Wheels
- 146. Front and Rear Wheels Construction
- 147. Front Wheel Removal
- 148. Bearing Replacement
- 149. Disc Plate Replacement
- 150. Rear Wheel Removal
- 153. Front and Rear Brakes
- 154. Front and Rear Brakes Construction
- 155. Brake Fluid Air Bleeding
- 156. Brake Fluid Replacement
- 157. Brake Pads Replacement
- 158. Brake Disc inspection
- 159. Front Caliper Removal and Disassembly
- 160. Rear Caliper Removal and Disassembly
- 161. Caliper Cleaning
- 162. Rear Caliper Reassembly
- 163. Master Cylinder
- 164. Rear Master Cylinder Removal and Disasse...
- 165. Master Cylinder inspection
- 166. Rear Master Cylinder Reassembly
- 167. Brake Pedal Reassembly
- 168. Front Fork and Steering
- 169. Front Fork and Steering Construction
- 170. Handlebar Controls
- 171. Front Fork Removal
- 172. Front Fork Disassembly
- 175. Inner Tube
- 176. Front Fork Inspection
- 177. Inner Tube and Outer Tube
- 178. Front Fork Reassembly
- 179. Compression Damper Unit
- 185. Steering Removal
- 186. Steering Stem
- 187. Steering Bearing replacement
- 192. Rear Suspension Construction
- 193. Rear Shock Absorber Removal
- 194. Rear Shock Absorber Spring Replacement
- 195. Rear Shock Absorber Inspection
- 196. Oil replacement
- 197. Oil Replacement Procedure
- 199. Rear Shock Absorber Disassembly and Insp...
- 201. Rear Shock Absorber Reassembly
- 202. Rear Shock Absorber Disposal
- 203. Swingarm Removal
- 204. Swingarm Inspection
- 205. Swingarm Bearing Replacement
- 206. Swingarm Installation
- 207. Rear Suspension Linkage Removal
- 208. Rear Suspension Linkage Bearing Replacem...
- 209. Rear Suspension Linkage Reassembly
- 212. Servicing Information
- 213. Service data
- 218. Special Tools
- 220. Wiring Diagram
- 221. Wire, Cable and Hose Routing
- 230. Specifications
- 232. Spare Parts list
Page 1 of 233
Table of Contents
- 4. General Considerations
- 5. Serial Number Location
- 6. Warnings for Servicing
- 7. Precautions for Servicing
- 8. Symbol Marks and Materials
- 9. Group Index
- 10. General instructions
- 11. Location of Parts
- 12. Fuel and Oil Recommendations
- 13. Operating Instructions
- 14. Transmission
- 15. Country and Area Codes
- 16. Periodic Maintenance
- 18. Inspection Before Practice
- 19. Periodic Maintenance Chart
- 21. Spark Plug
- 22. Air Cleaner Element Removal
- 23. Transmission Oil
- 24. Transmission Oil Level Inspection and Re...
- 25. Engine Coolant Level Check
- 26. Engine Coolant Replenishment
- 27. Clutch Cable
- 28. Fuel Hose
- 29. Cylinder Head
- 30. Exhaust Valve
- 31. Drive Chain Slack
- 32. Sprocket Inspection
- 33. Drive Chain Guide Buffer
- 34. Brake Pad
- 35. Front Fork
- 36. Spoke Nipple and Rim Lock
- 37. Lubrication
- 38. Tightening Torque
- 40. Troubleshooting
- 45. Machine Tuning
- 46. Carburettor Tuning
- 47. Pilot Jet
- 48. Needle Clip Position
- 49. Throttle Stop Screw
- 50. Carburetor Tuning in Practice
- 51. Judging Air/Fuel Mixture
- 53. Front Fork Tuning
- 54. Oil Quantity Minor Adjustment
- 55. Oil Change
- 57. Spring Change
- 59. Front Fork Tuning Procedure
- 60. Rear Suspension Tuning
- 61. Spring Pre-Load Adjustment
- 62. Rear suspension tuning procedure
- 64. Suspension Balance
- 65. Engine Removal and Installation
- 66. Exterior Parts
- 67. Engine Removal
- 72. Engine Installation
- 74. Cylinder, Piston and Exhaust Valve
- 75. Cylinder, Piston and Exhaust Valve Const...
- 76. Engine Top Side
- 77. Piston Removal
- 78. Exhaust Valve Removal
- 79. Cylinder Head Inspection
- 80. Piston and Piston Ring Inspection
- 81. Exhaust Valve Inspection
- 82. Piston Ring and Piston Reassembly
- 83. Cylinder Reassembly
- 85. Exhaust Valve Governor Removal and Disas...
- 86. Exhaust Valve Governor Inspection
- 87. Exhaust Valve Governor Reassembly and In...
- 88. Clutch
- 89. Clutch Construction
- 90. Clutch Plate Removal
- 91. Clutch Plate Inspection
- 92. Clutch Plate Reassembly
- 93. Primary Driven Gear Ass'y Removal
- 94. Primary Driven Gear Ass'y Inspection
- 95. Clutch Release Camshaft Removal
- 96. Clutch Release Camshaft installation
- 97. Kick Starter
- 98. Kick Starter Construction
- 99. Kick Starter Removal
- 100. Kick Starter Inspection
- 103. Gearshifting
- 104. Gearshifting Linkage Construction
- 105. Gearshift Linkage Removal
- 106. Gearshift Linkage Inspection
- 107. Gearshift Linkage Reassembly
- 110. Transmission and Crankshaft
- 111. Transmission and Crankshaft Construction
- 112. Engine Bottom Side
- 113. Crankcase Separation
- 114. Crankshaft Removal
- 115. Crankshaft inspection
- 116. Oil Seal Inspection, Removal and Install...
- 117. Bearing Inspection
- 118. Bearing Removal and Installation
- 119. Crankshaft installation
- 120. Transmission Reassembly
- 121. Crankcase Reassembly
- 122. Primary Drive Gear Reassembly
- 123. Fuel System
- 124. Carburetor Construction
- 125. Carburetor Removal and Disassembly
- 127. Carburetor Cleaning
- 128. Carburetor Reassembly
- 129. Reed Valve Removal
- 130. Cooling System
- 131. Cooling System Construction
- 132. Engine Coolant Replacement
- 133. Radiator Removal
- 134. Radiator Installation
- 135. Water Pump Reassembly
- 138. Electrical System
- 139. Electrical System Construction
- 140. Ignition System Peak Voltage Inspection
- 141. Ignition Coil Inspection
- 142. Stator Coil Inspection
- 143. Magneto Rotor and Stator Reassembly
- 145. Front and Rear Wheels
- 146. Front and Rear Wheels Construction
- 147. Front Wheel Removal
- 148. Bearing Replacement
- 149. Disc Plate Replacement
- 150. Rear Wheel Removal
- 153. Front and Rear Brakes
- 154. Front and Rear Brakes Construction
- 155. Brake Fluid Air Bleeding
- 156. Brake Fluid Replacement
- 157. Brake Pads Replacement
- 158. Brake Disc inspection
- 159. Front Caliper Removal and Disassembly
- 160. Rear Caliper Removal and Disassembly
- 161. Caliper Cleaning
- 162. Rear Caliper Reassembly
- 163. Master Cylinder
- 164. Rear Master Cylinder Removal and Disasse...
- 165. Master Cylinder inspection
- 166. Rear Master Cylinder Reassembly
- 167. Brake Pedal Reassembly
- 168. Front Fork and Steering
- 169. Front Fork and Steering Construction
- 170. Handlebar Controls
- 171. Front Fork Removal
- 172. Front Fork Disassembly
- 175. Inner Tube
- 176. Front Fork Inspection
- 177. Inner Tube and Outer Tube
- 178. Front Fork Reassembly
- 179. Compression Damper Unit
- 185. Steering Removal
- 186. Steering Stem
- 187. Steering Bearing replacement
- 192. Rear Suspension Construction
- 193. Rear Shock Absorber Removal
- 194. Rear Shock Absorber Spring Replacement
- 195. Rear Shock Absorber Inspection
- 196. Oil replacement
- 197. Oil Replacement Procedure
- 199. Rear Shock Absorber Disassembly and Insp...
- 201. Rear Shock Absorber Reassembly
- 202. Rear Shock Absorber Disposal
- 203. Swingarm Removal
- 204. Swingarm Inspection
- 205. Swingarm Bearing Replacement
- 206. Swingarm Installation
- 207. Rear Suspension Linkage Removal
- 208. Rear Suspension Linkage Bearing Replacem...
- 209. Rear Suspension Linkage Reassembly
- 212. Servicing Information
- 213. Service data
- 218. Special Tools
- 220. Wiring Diagram
- 221. Wire, Cable and Hose Routing
- 230. Specifications
- 232. Spare Parts list
File size: 20.70 MB
Created: March 11, 2023
Last updated: April 03, 2023
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