BLEEDING AIR FROM THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus in- terferes with the full braking performance of the disc brake. The presence of air is indicated by “sponginess!” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purg- ed of air in the following manner: * Fill up the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dirt. * Attach a pipe to the bleeder valve, and insert the other end of the pipe into @ receptacle containing a small amount of brake fluid. Make sure that the end of the pipe is kept submerged in the brake fluid. This will keep air from being drawn back in the brake system during the bleeding operation. 6-9Nm aiceservave | ge gh Tateing wxaue | (OS-0.8KE-m) * Front brake: Squeeze and release the brake lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the recep- tacle no longer contains air bubbles. NoTI Replenish the brake fluid reservoir as nec- essary while bleeding the brake system. Make sure that there is always some fluid PERIODIC MAINTENANCE AND TUNE UP PROCEDUREE 2.14 * Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the upper of inspec tion window CAUTION: | Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rub- ber matenals, etc. © Rear brake: Defferences hetween front and rear are that the master cylinder is actuated by a pedal.2.15 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES BRAKE PADS 7.0 mm (0.04 in) Wearing condition of brake pads can be checked by observing the service limit. When the wear exceeds the corvice limit, replace the pads with new ones (See page 6-9, 30) Service Limit | _ 1.0 mm (0.04 in) CAUTION: Replace the pads as a set, atherwise brak- ing performance will adversely affected. L_ BRAKE PEDAL HEIGHT * Loosen the lock nut @ and turn the stopper bolt @ away from the stopper lug. * Loosen the lock nut @, and rotate the push rod @ to locate the brake pedal 5 mm (0.2 in) @® below the top face of the footrest © Retighten the lock nut @ to secure the push rod @ in the proper position. + Adjust the clearance between the tip of the stopper bolt @ and the stopper lug so that the clearance is very little or none. Be sure to measure this clearance carefully. * Retightan the lock nut @. PARKING BRAKE * Loosen the lock nut @ and tighten the adjust bolt ® until resistance is felt, then loosen it 1/2 turn. © Tighten the lock nut ©. TIRES Inspect Every time before riding. Inspect the tires for wear and damage. Check the tire tread depth as shown. Replace a badly worn or damaged tire. A tire with its tread worn down to limit (in terms, of tread depth) must be replaced. TREAD DEPTH SERVICE LIMIT on 4,0 mm (0.16 in) RearTIRE PRESSURE Check the tire pressue, and examine the valve for evidence of air leakage. Standard tire pressure LOAD CAPACITY UP TO 70 kg 70-120 kg (155 Ihe) (155— 965 ths) 20 kPa 35 kPa FRONT| (0.20 kalem’) | (0.35 kalem?) 2.8 psi 5.0 psi 20 kPa 20 kPa REAR (° 20 kalem?) (029 xslem) 2.8 psi 2.8 psi CAUTION - To mi ry of tire damage from overinflation, we strongly recommend that a manual type air pump be used rather than a high pressure tire filler as found in gas stations. When pumping air in, never exceed 70 kPa (0.7 kg/cm?, 10 ps STEERING Inspect Initial 1 month (200 km, 100 miles) ize the possi and Every 6 months (1 000 km, 600 miles) Steering system should be adjusted properly for smooth manipulation of handlebars and safe running. TOE-IN * Place the vehicle on level around ‘* Make sure the tire pressure for both tires is the same and set to the proper specification. © The front wheels are set in straightahead po- sition. ‘* Measure the distance (A and B in illustration) of front wheels with a toe-in gauge as shown in illustration and caliculate the difference between A and B. 11-19 mm Teen (0.4—0.7 in) Not When measuring the distance (A and B), | set the front shock absorber length C (290 mm, 11.4 in) in illustration by placing the rider or weight. * If the toe-in ie off the specification, bring it into the specified range. (See page 6-26) PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-102-17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES BOLTS AND NUTS ighten Initial 1 month (200 km, 100 mil and Every 6 months (1 000 km, 600 miles) ENGINE MOUNTING BOLTS AND NUTS Tightening torque M10 Lars ¢ ® | 80-95 | 80-95 |68.0-68.5 m0 sky é 1 d @ | 60-72 | 60-7.2 |43.5-52.0 9 ke © | 40-60 | 40-60 |29.0-43.5 niaites) © 37-45 3.7-4.5 |27.0-32.5 os © | 18-28 | 18-26 |13.0-20.0} ny ¥ ©. CHASSIS BOLTS AND NUTS ma iiz M10 4100 The bolts and nuts listed below orc important spacer Laos) M2 #100 parts, and they must be in good condition for iM safety. They must be retightened, as necessary, 3 to the specified torque with a torque wrench. by Item - Nem kg-m Ib-ft @® | Handlebars clamp bolt 1828 182.8 13.0-20.0 ® | Steering shaft holder bott 18-28 18-28 13.0-20.0 ®_| Front wheel set nut 20-31 2.0—3.1 14.5—22.5 @_| Front wheel hub nut 50-80 5.0-8.0 36.0—58.0 © _| Tie rod lock nut 22-35 22-36 16.0-25.5 @®_| Tie rod end nut 40-60 4.0-6.0 29.0-43.5 | © | [Gent shock absorber mounting bolt) 49_0 4.0-6.0 29.0-43.6 @ _| Lower wishbone arm outer bolt 120-170 | 12.0-17.0 | 87.0—123.0 @_| Upper wishbone arm outer bolt 35-45 35-45 25.5— 32.5 loner & tees 50-70 5.0-7.0 | 36.0-50.5 @_|_ Knuckle arm end nut 40-60 4.0-6.0 | 29.5-43.5 @ _|_ Steering shaft lower nut 38—60 3.8—6.0 27.5—43.5 | @ | Footrest bolt | 40-60 4.0-6.0 29.0—43.5 @ | Knuckle arm bolt 35—45 35-45 25.5—32.5 @ | Knuckle arm lower bolt 44—66 44-66 320-475 @ | Front brake caliper mounting bolt 15—25 1.5 11.0-18.0PrAIODIC MAINTENANCE AND TUNC-UP Pnoccouncs 2-10 em Nm kom Ib-ft CR a alee 6-9 06-09 45-65 @ | Front brake master oylinder bolt 5-8 0.5—0.8 3.5—6.0 @_| Brake hose union bolt 20-25 20-25 14.5—18.0 | @ | Front brake pipe connecting nut 13-18 1.3-1.8 9.5—13.0 @ | Rear swingarm pivot shaft nut 50-80 5.0-8.0 36.0— 58.0 @ | Rear wheel hub nut 7 a5—115 25-115 | 61.5830 @ | Rear wheel set nut 45-65 45-65 32.5—47.0 | @ | Rearaxle nut and lock nut 160—200 16.0—20.0 | 115.5—144.5 @ | Rear shock absorber mounting bok 7 an ae @ | Rear brake master cylinder bolt 15-25 15-25 11.0-18.0 @ | Rear brake caliper mounting bolt 15-25 15-25 11.0—18.0 @ | Rear torque link nut (Front 8mm) | 20-31 2.0-3.1 14.5—22.5 (Rear 10 mm) 44-66 44-66 32.0—47.5 [ Chain adjuster lock bolt 18—28 1.8—2.8 13.0—20.0 | @2.19 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES