Contents
Notice.................................................................................................................................................... 4
Preparing documents......................................................................................................................5
General Safety................................................................................................................................5
Inspection /Adjustment.................................................................................................................20
Inspection and maintenance of electrical system ................................................................................40
1. Battery/Charging System............................................................................................................41
1.1 Preparing documents ..............................................................................................................41
1.2 Failure diagnosis .....................................................................................................................42
1.3 Battery .....................................................................................................................................42
1.4 Charging system......................................................................................................................43
1.5 Voltage/current regulator......................................................................................................... 44
1.6 Magneto charging coil .............................................................................................................45
1.7 Magneto disassembly..............................................................................................................45
2. Ignition System............................................................................................................................ 47
2.1 Preparing documents ..............................................................................................................47
2.2 Failure diagnosis .....................................................................................................................48
2.3 Ignition system check..............................................................................................................49
2.4 RELATED PARTS Group........................................................................................................51
2.5Ignition coil................................................................................................................................51
2.6 Trigger......................................................................................................................................52
3.. Startup System...............................................................................................................................54
3.1 Preparing documents ..............................................................................................................54
3.2 Failure diagnosis .....................................................................................................................55
3.3 Startup motor...........................................................................................................................55
3.4 Starter relay.............................................................................................................................56
4.. Bulbs/Switches/Meters................................................................................................................. 58
4.1 Preparing documents ..............................................................................................................58
4.2 Failure diagnosis .....................................................................................................................58
4.3 Replacement of headlamp bulbs.............................................................................................58
4.4 Replacement of front steering lamp bulbs...............................................................................58
4.5 Replacement of tail lamp bulbs...............................................................................................59
4.6 Meter........................................................................................................................................59
4.7 Main switch..............................................................................................................................59
4.8 Horn.........................................................................................................................................60
4.9 Handlebar switch.....................................................................................................................60
Inspection and maintenance of vehicle................................................................................................61
5.. Brake................................................................................................................................................63
5.1 Maintenance instruction...........................................................................................................63
5.2 Failure diagnosis .....................................................................................................................63
5.3 Front disc brake.......................................................................................................................64
5.4 Rear disc brake........................................................................................................................65
6. Body............................................................................................................................................65
7. Front Wheel/Front Suspension...................................................................................................67
7.1 Preparing documents ..............................................................................................................72
7.2 Failure diagnosis .....................................................................................................................72
7.3 Front wheel..............................................................................................................................73
7.4 Steering handle .......................................................................................................................75
7.5 Front fork .................................................................................................................................76
7.6 Radiator/expansion tank assembly.........................................................................................77
8.. Rear Wheel/Rear Suspension....................................................................................................... 80
8.1 Preparing documents ...............................................................................................................80
8.2 Failure diagnosis ......................................................................................................................80
8.3 Rear wheel................................................................................................................................80
8.4 Rear absorber/rear swing arm..................................................................................................82
