PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE. . PERIODIC MAINTENANCE PROCEDURES BATTERY .. een ceeteeee eee : CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS . AIR CLEANER ELEMENT TAPPET CLEARANCE SPARK PLUGS. FUEL LINE Ppeereeees CONTACT BREAKER POINTS IGNITION TIMING. . . ENGINE OIL, ENGINE OIL FILTER ENGINE IDLING SPEED . 60 THROTTLE CABLE ........02..00005 CHOKE CABLE . CLUTCH DRIVE SHAFT GEAR OIL .... TIRES BRAKES, BRAKE HOSES STEERING . FRONT FORKS seen CHASSIS NUTS AND BOLTS .. BTPERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE MAINTENANCE CHART The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner. —_KXiQUQ” inital 1000km | Every $000k | Every 10000 km Item ~ — | 00 mi) (3.000 mi) (6.000 mi) Bevery —_ Theck Check = finder Hrd nuts and exhaust Retighten a Air eleane element ee Clean = Tappet Clearance Check Check [spark plug Clean and Adjust gop [ Clean and Adjuit gap | Reslce Fuel hose Replace every 2 years Contact breaker points Check and Adjust | Check and Adjust ~ Tenition timing “Adjust Engine oil filter Change Engine ing speed ‘Adjust [ Throile cable Adjust Clutch play ‘Adjust ‘Adjust e Ti Check every day [Cirakeyetan Check Check = Brake hose and fluid Replace every 2 years and change every year ‘Steering, —_ Check ‘Check = Front fork and Rear shock absorber Check every 6 months ‘Chassis bolts and nuts Retighten Retighten = LUBRICATION CHART [eo | Initial 1000km | Every 2500km | Every 5 000km | Every 10000 km tom (600 mi) (1 500 mi) G.000 mi) (6.000 miy Throttle cable = = [Mowrol | | Clutch cable [ = = Motor oil = Tachometer cable t = = Motor oi - [ Speedometer cable i — — — Grease. Choke cable 5 = Motor oil = Theol gr = = = Grease Contact bresker cam oll lt S = Motor all 5 ‘Wheel bearings tee Grease every 2 years or 20 000 km (12 000 mi) Steering stem bearings ‘Siwinging arm bearings Brake pedal = = Grease or Motor oll = Engine oil Change Change = - ‘Secondary aad final gear oll Change 5 - Change Front fork of Change Ss - Change 32PERIODIC MAINTENANCE PROCEDURES This section describes the service procedures for each section of the Periodic Maintenance requirements, BATTERY Check Initial 1 000 km (600 mi) and Every 5 000 km (3 000 mi) 1. Remove right frame cover to check bat- tery 2.Check that the breather pipe is tightly secured and undamaged, and is routed as shown below, Fig. 3-1 Check electrolyte for level and specific gravity. Add distilled water, as necessary, to keep the surface of the electrolyte above the LOWER level line but not above the UPPER level line. Fig. 3-2 For checking specific gravity, use a hydrometer to determine the charge Standard specific | 1.280 at 20°C gravity (68°F) PERIODIC MAINTENANCE An S.G. reading of 1.22 (at 20°C) or under means that the battery needs recharging off the machine: take it off and charge it from a recharger. Charging the battery in place can lead to failure of the regulator/rectifier. CYLINDER HEAD NUTS A EXHAUST PIPE BOLTS Retighten Initial 1000 km (600 mi) and very 5.000 km (3 000 1. CYLINDER HEAD Remove the fuel tank Tighten the twelve 10 mm nuts (14 mm wrench) to the specified torque with a torque wrench sequentially in ascending numerical order with the engine cold. 3.5-4.0 ke-m 9.0 Ib-ft) Cylinder head nut tightening torque: | (25. After firmly tightening the 12 nuts, tighten three 6 mm bolts (indicated as) to the torque value below: Head bolt tightening | 0.7—1.1 kg-m torque (5.0-8.0 Ib-f) 2. EXHAUST PIPE Tighten the exhaust pipe bolts to the specified torque with a torque wrench. Exhaust pipe bolt. | 0.9-1.2 kg-m tightening torque: | (6.5-8.5 Ib-ft) 33PERIODIC MAINTENANCE AIR CLEANER ELEMENT Clean Initial 1 000 km (600 mi) and Every 5 000 km (3 000 If the air cleane: is clogged with dust, intake resistance will te increased with a resultant decrease in output and an increase in fuel consumption, Check and clean the element in the following manner. 1. Take out air deaner element from the air cleaner case by unscrewing screw 2 ~~ Fig. 3-4 2. Fill a washing pan of a proper size with non-flammable cleaning solvent. Immerse the element in the cleaning solvent and wash it clean, 3. Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears. 4. Immerse the element in motor oil, and squeeze the oil out of the element leaving it slightly wet with oil. CAUTION: Before and during the cleaning operation, inspect the element for tears. A torn element must be replaced. 34 Fig, 3-5 Motor oilTAPPET CLEARANCE Check Initial 1 000 km (600 mi) and Every 5 000 km (3 000 mi) The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce the engine power; too large a tappet clearance increases valve noise and hastens valve and seat wear. When the tappets are set to the specified clearance, the engine will run without ex- cessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear-resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit. Tappet clearance adjustment must be checked and adjusted 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are disturbed by removing them for servicing, CHECKING THE TAPPET CLEARANCE, Tappet clearance specification (for | 0,03—-0.08 mm both intake and | (0.001—0.003 in) exhaust valves) PERIODIC MAINTENANCE Fig, 3-7 1. Turn crankshaft to bring the exhaust cam of No. 1 cylinder to this position. In this condition, read the clearance at the exhaust tappets of Nos. 1 and 2 cylinders. Use special tool Don all tappets ‘Thickness gauge (09900-20803, NOTE: 1) The cam must be at position ®) or @) 10 check the tappet clearance or to remove the shim disc. Clearance readings should not be taken with the ‘cam in any other position than these two positions. 2) The clearance specification is for a COLD engine. 3) To turn the crankshaft for clearance checking, be sure to use a 19-mm wrench and to rotate in the normal running direction. All spark plugs should be removed. Fig, 3-8 2.After setting the clearance to the specification at the exhaust tappets of Nos. 1 and 2 cylinders, turn the crankshaft 180° (half rotation) to bring the intake cam of No. 1 cylinder to the position indicated. 35PERIODIC MAINTENANCE Read the clea-ance at the intake tappets of Nos. 1 and 2 cylinders and, if necessary, adjust the clearance to each specification. Fig. 3-9 3.Turn the crankshaft a further 180°, bringing the exhaust cam of No. 4 cylinder to the position indicated. Under this condition, repeat the checking and ad- justing process outlined in step “1” at the exhaust tappets of Nos. 3 and 4 cylinders. Fig. 3-10 4. Again turn the crankshaft a further 180°, bringing the intake cam of No. 4 cylinder to the position indicated. Similarly check and adjust the clearance at the intake tappets of Nos. 3 and 4 cylinders, TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thi dise. 1. Place a fingertip on the tappet, and turn it in place to bring notch to the position indicated, ner Fig, 3-12 2. Using the special tool, push down the tappet. NOTE: Make sure the tool exerts pressure on the ‘appet correctly, as shown, with the tip hitched securely. Tappet depressor 09516-645103. Take out the tappet shim from the tappet, using special tool ©. Forceps 09916-84510 PERIODIC MAINTENANCE Tappet shim sie chart No [Thickness (mm) [Part No. 1 2.5 12592-4500 | 2 220 12892-48001 3 238 12a92-48002 4 230 12992-85003 A 235 aas-45008 6 240 12592-48005 7 2as | _1289245006 5 280 12592-45007 a 2s 12592-48008 7 20 or) [ou 268 12892-45010 Fig. 3-14 B 25 12892-45012 ie 200 ras2013 4. Check the figures printed on the shim. 3 Bas Tas 018 These figures indicate the thickness of the 16 2.90, 12892-45015 shim, as illustrated. 7 295 12892-45016 rn 300 125245017 2 240 929019 Ce) Dt 2s mm NOTE: Before fitting the tappet shim to the tappet, be sure to apply engine oil to its top and bottom faces. Fig, 3-15 5. Select a replacement shim that will provide a clearance within the specified range (0.03—0.08 mm). For the purpose of this adjustment, a total of 20 sizes of tappet shim are available ranging from 2.15 to 3.10 mm in steps of 0.05 mm. Fit the selected shim to the tappet, with numbers toward tappet. Be sure to check shim size with micrometer to insure its size. 6. After replacing the tappet shim, rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement. then check the clearance again to confirm that it is within the specified range. 37we SHIM SELECTION CHART PART NUMBER — PREFIX 12592 Pan surrix- [4s0oo [+so01 | 48002 J 45003 [S008 [+3005 T2s008 [5007] «soos 35009] 45010] «sor [as012 | «3013 | 48014 [ as0rs [sone [ as017 [ «5078 [5019 Rael PRESENT SHIM SIZE — mm (mm) 2is_| 220 | 22s | 230 | 235 [240 | 245 [250 [25s | 260 [ 25 | 220 [ 275 | 20 | a6 | 200 | 20 | a00 | 308 | a0 | 000~002 aus | 220 | 225 [230 | 235 [240 | 24s [250 | 28s | 200 | 265 | 270 | ans | 240 | 285 | 290 | 295 | 300 | 30s [0.03 ~008 ‘SPECIFIED CLEARANCE/NO. ADJUSTMENT REQUIRED - ~~ ‘009~013] [220 [225 [ 230 [ 235 | 240 | 24s | 250 | 255 [260 | 265 | 270 | 275 | 280 | 288 | 290 | 298 [300 | 30s | a0 ous~oi8| [2as_ [230 [23s [240 | 24s | 250 | 255 [260 20s | 270 | 27s | 280 | 2as | 290 | 295 | 300 | 305 | 30 oiv~023] [230 [2s | 240 | 24s | 250 | 28s | 260 | 265 [270 | 275 | 280 | 2s | 290 | 298 | 300 | a0s | a10 ‘o2~028 | [23s [240 | 24s [250 | 255 [260 | 265 | 270 [27s | 280 | 28s | 290 | 295 | 300 | sos | 310 ov~033| [240 [24s | 250 | 25s | 260 | 268] 270 | 278 [2a | 298 | 300 | 295 | 300 o36~038| [24s [250 | 28s | 260 | 265 | 290 | 275 | 200 [2as | 290 | 295 | 300 | 30s | 310 ose~oas] [250 [255 | 200 | 265 | 270 | 295 | 280 | 285 [200 | 295 | 300 | 305 | 3.10 0.44 ~0.48 235_[ 260 | 26s | 270 | 275 | 280 | 28s | 290 ]2.95 | 300 | 30s | 3.10 049~0583 260 [265 | 270 | 275 | 280 | 28s | 290 | 295 [300 | 30s | 3.10 [oss~0s8| 265 [270 | 275 [280 | 2as | 290 | 295 | 300 [30s | 310 Joso~os| Jano | a7s | 200 | 28s | 290 | 298 | 300] 305 [x0 fe x 0.64~0.68 275 | 280 | 285 | 290 | 295 | 3.00 | 305 | 3.10 1 O65 ~173. 280 | 285 | 290 | 295 [300 | 3.05 | 3.10 |0.74~0.78 2as_ | 290 | 295 | 3.00 | 30s | 3.10 [0.79~0.83, 290_| 295 | 3.00 | 30s [310° ost~0a8| [295 [300 | 308 | 3x0 2 [os9~093] F500 | 30s [ 3.10 Y | 094~05 30s | 3.10 jaso~ 3.10 4, uu Measure tappet clearance. “ENGINE COLD" Measure present shim sie “Match clearance in vertical column with present shim siz in horizon tal colin, EXAMPLE Tappet clearance is — OSS mm Present shim size — 240 mm Shim size to be used — 290 mm SONWNALNIVIV DIGOINIASPARK PLUGS | Clean and Adjust Initial 1 000 km (600 mi) and Every 5 000 km (3 000 mi), Replace Every 10 000 km (6 000 mi) ‘At initial 1000 km, remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0.6—0.8 mm (0.024—0.031 in), measuring with a thickness gauge. Replace the plugs every 10000 km and remove the carbon deposits and adjust the gap every 5 000 km after replacing the plugs. Whenever removing the carbon deposits, be sure to observe the appearance of the plug, noting the color of the carbon deposit. The color indicates whether the standard plug is suitable or not. If the standard plug is apt to get wet, a hotter plug should be used. If the standard plug is apt to overheat, with the porcelain having a whitish appearance, replace with a colder one. OTE. To check the spark plugs, keep the | engine running on unleaded gasoline, | and if all of the four are either sooty with | carbon or burnt white, replace them altogether. [| nck | Nirron Denso | Hot type | B7ES W22ES Standard | BSES | W24ES Cold type | BES | __W27ES Gap 06-08 FP (0.024-0.081 in) Fig, 3-16 PERIODIC MAINTENANCE FUEL HOSE (Replace every two years) Replace the fuel hose every two years. Fig. 317 CONTACT BREAKER POINTS: “Cheek Initial 1 000 km (600 mi) and Every 5000 km (3 000 mi) Check and adjust the contact points as outlined on the next page. Inspect the contact points for wear and burning. If the point faces are dirty, wipe them clean with a clean and dry cloth. TT WT AL NORMAL, WORN TT aL NOT PARALLEL pirty Fig. 3-18 IGNITION TIMING ‘Adjust Initial 1 000 km (600 mi) Every 5 000 km (3 000 mi) Ignition timing specifications . 03-04 mm fener (Gi012=0.6 in) 060.8 mm Spark pine ga (0.024008 in.) TT. B.T.D.C. below ition timing 100 r/min and " MP RTD.C above 2500 r/minPERIODIC MAINTENANCE ‘NOTE: 1) Be sure to use a 19-mm wrench to turn the crankshaft in the direction shown. 2)Remove all four plugs until ad- Justment is completed. TIMING ADJUSTMENT FOR NOS. 1 AND 4 CYLINDERS 1. Set the contact point gap Oto 0.3—0.4 mm (0.012—0.016 in) in the Nos. 1 & 4 breaker. To adjust the gap, loosen screw @and displace terminal 3 Fig. 3-21 3:10 2. Connect timing tester@between the (+) terminal of the breaker and ground. Timing tester (09900-27003 3. Slowly turn the crankshaft ir the normal direction until index mark Q(on the Nos. 1&4 side of the advance governor) is aligned with tim D: Corresponding to T.D.C. of Nos. 1 & 4 pistons ®: Timing index mark “F1.4" : Ignition advance timing mark ng mark @ Fig. 3-22 4. With the pistons brought to the specified B.T.D.C. position in Nos. 1 and 4 cylinders, as shown above, loosen three screws (securing the breaker plate and turn the plate slowly counterclockwise until the contact points begin to separate. Secure the plate in that fosition by tightening screws 5.To check, turn the crankshaft slowly, observing the timing tester. If the breaker contact begins to open just when mark@comes in line with mark@®, the adjustment is correct and the ignition is timed as specified for Nos. 1 and 4 cylinders.TIMING ADJUSTMENT FOR NOS. 2 AND 3 CYLINDERS The procedure is identical to the foregoing except for two points: 1. Bring mark “F” (on Nos. 2 & 3 side in the advance governor) into line with the timing, mark. Loosen two screws and move plate @ counterclockwise to determine its position at the beginning of opening action. Fig. 3-24 CHECKING IGNITION TIMING WITH THE TIMING LIGHT After setting the contact points of the twin breakers by adjusting in the above-described ‘manner, check the performance of the timing mechanism using the timing light (09900- 27311), Mluminate the advance governor with the timing light and vary the engine speed to see if the ignition is correctly timed or not The procedure is as follows: 1. Run the engine at a speed not exceeding, 1500 r/min. Under this condition, “F” mark and timing mark should be in perfect alignment: if not, readjust the twin breaker referring to these marks in the advance governor. Fig. 3-25 PERIODIC MAINTENANCE 2. Run the engine at a speed above 2 500 r/min, and similarly observe the position of mark relative to mark@. If the two marks are in line, the ignition is properly advanced, 3. Carry out above steps 1 and 2 for Nos. 2 and 3 cylinders. The oil should be changed with the engine hot, The procedure is as follows: * Keep the motorcycle upright, supported on the center stand. * Place an oil pan below the engine and drain the oil by removing drain plug @and filler cap @PERIODIC MAINTENANCE Fig. 3-28 © Fit drain plug securely, and add fresh oil through the ‘iller. The engine will hold about 2.8 L(3,0/2.5 US/Imp qt) of oil Use API classification of SE or SD oil with SAE 10W/40 viscosity © Start up the engine and allow it to run for several seconcs at idling speed. © Turn off the engine and wait about one minute, then check the oil level in level gauge). If the level is below mark “F, supply oil to that level. Fig. $29 NOTE: * When replacing the oil filter, the amount of oil to be replaced ts 3.6 L (3.8/3.2 USjimp qv) = When performing engine overhaul, the amount of oil 10 be replaced is 3.8 L (4.0/3.3 USitmp qt). ENGINE OIL FILTER Change Initial 1.000 km (600 mi) and Every 5.000 km (3 000 mi) 3:12 Oi filter replacement at the above intervals should be done together with engine oil change as described in the previous section, After draining engine oil and securely tightening the engine oil drain plug, perform the following 1 Remove three nuts cover @ and drain oil 2. Pull out old fier 3), replace with new 2, and remove the 3. Replace cover, secure nuts ing Thread Lock Cement 4, Add engine oil @ with apply- NOTE: Pour about 3.6 L (3.8/3.2 US/Imp gt) of engine oil into the engine only when | changing oil and replacing oil filter at the same time, Fig. 3-30 ENGINE IDLING SPEED Adjust Initial | 000 km (600 mi) and Every 5 000 km (3 000 mi) T-Start up the engine and warm it up by running it at 2.000 r/min for 10 minutes in summer, when ambient temperature is 30°C (86°F), or for 20 minutes in winter, when ambient temperature is down to approx. =5°C (23°F). 2. After the engine warms up, turn the throttle stop screw in or out so that engine ns at 950—1_ 150 r/min, | caurion No adjustment except the procedure ‘mentioned above is necessary because calibration is performed by carburetor manufacturer.Fig. 3-31 At the same intervals, adjust the throttle cable play in the following manner: THROTTLE CABLE [ Aajus: Initial 1 000 km (600 mi) and [___Bvery $000 km (3 000 mip PERIODIC MAINTENANCE Fig. 333 Returning cable play 1, Reduce the play @to zero by turning the adjusting nut while holding the throttle grip fully open position, and securely tighten the lock nut. CHOKE CABLE A twin throttle cable system is used on the GS850G: One cable is for pulling and the other cable ® for returning, Pulling cable play The throttle cable should be adjusted to have a slackDof 3—5 mm (0.12—0.20 in) at the middle point between adjusting holder @ and throttle cable end @on the carburetor side. Inspect the cable slack periodically, and if necessary, adjust it to the specified | value. The cable end will come out if the | Play is excessive 1, Loosen lock nut @) 2. Turn adjusting nut®to obtain a cable play ®of 0.5—1.0 mm (0,020.04 in). 3. Tighten lock nut @. { Adjust Initial 1 000 km (600 mi) and | Every 5 000 km (3 000 mi) ‘The choke cable should be adjusted to have a play ® of 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) by turning the adjuster @ after loosening lock nut @ Fig, 3-34 Tur and adjust the lock nut @ for smooth operation of the choke knob. 3BPERIODIC MAINTENANCE CLUTCH Adjust Initial 1 000 km (600 mi) and Every 5.000 km (3 000 mi) CLUTCH CABLE ADJUSTMENT Loosen lock nuts Don the lever side of the clutch cable and screw adjust nut @fully in on the clutch lever side. Fig, 3-36 Loosen the cable lock nut, tighten the adjust nut to provide play in the outer cable. Adjust the play of the cable with adjusting nut until play@of the clutch lever is 2—3 mm (0,080.12 in). Next, firmly secure lock nut ® Fig, 3-37 If the specified play can not be obtained with adjusting aut @ shown in the above photo, carry out the adjustment using the adjust nut on the clutch lever side DRIVE SHAFT GEAR OIL Change Initial 1000 km (600 miyand | Every 10 000 km (6 000 mi) Change the drive shaft gear oil in the following way. Use SAE #90 hypoid gear oil SECONDARY GEAR Om 1. Keep the motorcycle erect, supporting it on the center stand. 2. Remove gear shift lever @ and secondary cover ® 3. Drain oil by removing filler cap@and drain plug ®) 4,Refit drain plug®, remove oil level screw Sand pour the specified oil in through the filler hole until it runs out from the oil level hole. 5.Refit oil level screw, filler cap@, secondary cover ® and geer shift lever NOTE: ] | The amount of oil to be replaced is 340—400 ml (11.5-13.5]12.0-14.1 US Imp 02). Fig, 3-39INAL GEAR OIL 1. Drain oil by removing filler cap Mand drain plug 2. 2. Refit drain plug @and pour the specified oil in through the filler hole until it runs ‘out from the filler hole. 3. Refit filler cay NOTE: The amount of oil to be replaced is 280—330 mil 9.5—11.2/9.9-11.6 US|lmp Fig. 3-40 TIRES Check Every day Inspect the tires for wear and damage and check the tite tread depth as shown. Replace a badly worn or damaged tire. A tire with its tread worn down to the limit (in terms of tread depth) must be replaced, Tread depth service limit: ‘ront 1.6 mm (0.06 in) Rear: 2.0 mm (0.08 in) | PERIODIC MAINTENANCE Fig, 3-41 Check the tire pressure, and examine the valve for evidence of air leakage. Solo Riding [Dual Riding 1 |kg/om| pil kPa] kavem| pil NORMAL ji7s| 1.95 [2s |a7s| 17s [5] RIDING ao0| 2.00 [28 [295] 2.25 [32 [conTINUOUS| Front|200| 2.00 [28] 200] 200 [28 HIGH SPEED. RIDING | Rear [225| 2.25 | 32| 280] 2.80 [40 3.15PERIODIC MAINTENANCE BRAKES Check Initial 1 000 km (600 mi) and Every 5000 km (3 000 mi) Check the front and rear brake systems for the following items: 1. Insufficient brake power 2. Breke squeaking 3. Excessive brake lever stroke 4, Leakage of brake fluid If these troubles are detected, repair or replace the damaged parts as indicated in the art below. Symptom and possible cause ‘Countermesstre INSUFFICIENT BRAKE POWER 1) Leakage of brake Maid From hydraulic sytem 2) Worn pads 3) Oiladhesion on engasing surface of pads 4) Ween dise 5) Airin hydraulic system Repair or replace Replace Clean dige an pas Replace Bleed air BRAKE SQUEAKING. 1) Carbon adhesion on pad surface 2) Tiled pad 3) Damaged whee! bearing 44) Loose Frontvheel axle or rear-wheel axle 5) Worn pads 6) Forsign materia in beake fluid 7) Clozged return port of master eylinder Repair surface with sandpaper Modify pad fing Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master ender EXCESSIVE BRAKE LEVER STROKE 1) Air in hydrautie system 2) Worn brake lever cam 3) lnsfFcien brake fluid 4) Improper quality af brake uid, Bleed air Replace brake lever Replenish tid to specified ove Replace with sorret fluid TEAKAGE OF BRAKE FLUID 1) Insufficient ightening of connection joints 2) Cr 3) Worn piston and/or cup cd hose Tighten to specified torque Replace Replace piston and/or cup BRAKE HOSES AND FLUID (Replace every 2 years and change every year) Replace the brake hoses with new ones. (Change brake fluid, see page 10-29) 3-16STEER. Check Initial 1 000 km (600 mi) and Every 5 000 km (3 000 mi) — Cheek that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground. With wheel straight ahead, grasp lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as de- seribed in page (10-18) of this manual. FRONT FORKS Check Every 6 months FOR GENERAL, U.S.A, CANADA AND AUSTRALIA SPECIFICATIONS Check the front fork air pressure, when the fork is cold, every 6 months in the following manner. 1) Place the motorcycle on its center stand and keep the front wheel off the ground. 2) Measure the air pressure by placing the pressure gauge on the valve as shown PERIODIC MAINTENANCE 3) If necessary, use a hand tire pump to raise the fork air pressure. CAUTION: Do not use compressed air to adjust the fork air pressure, since compressed air is stored at much higher pressures than the forks require, and seal damage ‘may result. NOTE: 1, Just before charging air confirm thar_| the valve is tight, 2. Try to equalize the air pressure of the to legs, right and left, as closely as possible. The maximum permissible difference is 0.1 kg/cm*(1.4 psi). FOR ALL SPECIFICATIONS. Inspect the front fork for oil leakage, scoring and scratches on the outer surfece of the inner tube every 6 months and replace the defective parts, if necessary. (Change fork oil and adjust oil level see page 10-14)PERIODIC MAINTENANCE CHASSIS NUTS AND BOLTS Retighten Initial 1 000 km (600 mi) and Every 5 000 km (3 000 mi) following nuts and bolts on the motoreycle.) The nuts and bolts listed below are important safety parts. They must be retightzned when necessary to the specified torque with a torque wrench. (Refer to page 3-19 for the locations of the 1) Handlebar camp bol 1220kem ( SSE SITY 2) Front ferk upper bracke rear bol 1S-2Skem (10-1801) 3) Froat fork upper bracker bol (Rand) 2030kem eS 2ST 4) Steeingstem head bolt 33-S0kem 25536016 5) Brake hese union bolt 13iShem (930i (6) Maser ender bolt 0508kem (356016 7) Front ork lower bracket bole (Rand L) TS—2Skem 10-1801) '8) Caliper ieedr bat D6—09kgm 185-68 9) Caliper bat 23—-40kem URO—2901e-1y To) Rear torque ink aut 2030kem (esa STEAD TH) Rearsheak absorber nat 20-30kem (eS—21STETY 12) Rearanlenu SS—11 Shem (61583016 13) Swinging arm bearing hale bole 035045 Kem 23.251) 14) Swinging arm bearing austment lock ma T0180 Kem (79.5980 15) Disc bolt ~1S=2 Shem (0-18.01 16) Front axe holder nut TS-2Skem (0-18 OID 17) Frontaxenvr 36S Pham 260-37 STO 1) Final gearease nut 35-S0kem 2553601610 318PERIODIC MAINTENANCE Fig. 3-44 Fig. 3-48 Fig, 3-47 Fig, 3-51