3.

MAINTENANCE

Service information 3-1 Drive Chain Slider 3-15

Maintenance Schedule 3-3 Battery Voltage 3-16
Fuel Lines 3-4 Electric Starter Switch 3-16
Throttle Operation 3-4 Brake Fluid 3-16
Engine Idle Speed 3-6 Stop Lamp Switch 3-18
Air Cleaner 3-6 Headlamp Focus (Twin Bulb) 3-18
Spark Plug 3-7 Clutch System 3-18
3
Exhaust Emission 3-8 Side Stand/ Main Stand/
Valve Clearance 3-9 Side Stand Switch/Suspension 3-19
Engine Oil 3-10 Nuts, Bolts, Fasteners/ Wheel/Tyres 3-20
Engine Oil Strainer/ Steering Head Bearings 3-21
Rotor Filter Cleaning 3-11 Crankcase Breather 3-22
Drive Chain 3-13

SERVICE INFORMATION
GENERAL
! WARNING
• If the engine is running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area
The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run
the engine in an open area or exhaust evacuation system in an enclosed area.
• Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced.
• Petrol is extremely inflammable and is explosive under certain condition. Work in a well ventilated area with the engine in
stop condition. Do not smoke, allow flames, sparks in the work area where petrol is stored.
• Park the motorcycle on ramp before starting any work.
• The oil filter screen and oil filter rotor cleaning and oil pump servicing can be done with engine in the frame.
• Some maintenance jobs requires removal of body panels. Refer to SECTION-2 for the removal/installation of required body panels.
SPECIFICATIONS Unit:mm
ITEM SPECIFICATIONS
Throttle grip free play 2-6
Spark plug NGK-DPR 8EA9, BOSCH XR6DE
Spark plug gap 0.8-0.9
Intake 0.10
Valve clearance (cold condition)
Exhaust 0.10
At oil change 0.90 Litre
Engine oil capacity
At disassambly 1.20 Litres
Hero 4T Plus Genuine Engine Oil,
Recommended engine oil API Service Classification: SJ
Viscosity : SAE 10W-30 SJ GRADE (JASO MA)
Engine Idle speed 1400±100 rpm
Cylinder compression 14.0±2.0 kgf/cm2
Drive chain slack 25
Recommended brake fluid Castrol Q Stop-DoT-3 or DoT-4
Clutch lever free play 10-20

3-1
MAINTENANCE

Front 80/100x18-47 P (Tubeless)

Tyre size
Rear 120/80x18-62 P (Tubeless)
Front 2.00 kgf/cm2 (29 psi)
Rider only
Rear 2.00 kgf/cm2 (29 psi)
Cold tyre pressure
Front 2.00 kgf/cm2 (29 psi)
Rider and pillion
Rear 2.25 kgf/cm2 (33 psi)
Front 1.5
Minimum tyre tread depth
Rear 2.0

TORQUE VALUES

SPARK PLUG : 1.8 kgf-m

TAPPET ADJUSTING SCREW LOCK NUT : 1.4 kgf-m
TAPPET ADJUSTING HOLE CAP : 1.5 kgf-m
TIMING HOLE CAP : 1.0 kgf-m
REAR AXLE NUT : 6.8 kgf-m
OIL STRAINER SCREEN CAP : 1.5 kgf-m
OIL DRAIN BOLT : 3.4 kgf-m
For other nuts, bolts, fasteners etc. refer to standard torque values (SECTION-1).

SPECIAL TOOLS

TAPPET ADJUSTER
WITH SOCKET (10 mm)
PART NO: 070 HH KFN 001

TAPPET COVER WRENCH

PART NO: 070 HH 198 011

MUFFLER PLUG
PART NO: 070 HH K06 004

3-2
 MAINTENANCE

MAINTENANCE SCHEDULE
We would strongly recommend the following schedule, to keep your motorcycle in perfect running condition and healthy
environment. Motorcycle subjected to severe use or ridden in dusty area will require more frequent servicing.

st nd rd th th th
1
1st 60
2
Next 100
3
Next 100
4 5
Next 100 Next 100 Next 100
6
3
12000- 15000-
3000-3500 6000-6500 9000-9500 3000 6000 9000 12000 15000
12500 15500

Carburetor C,A A C,A A C,A A A C,A

Air Cleaner* Do not open air cleaner element unless there is a drivability problem R
Spark Plug

Engine Oil**

Electric Starter

Drive Chain I,C,L,A at every 1000 kms I,C,L,A at every 1000 kms
Drive Chain Slider
Battery Voltage
Brake shoe/Pads wear
Brake Fluid****
Brake system (Brake Cam
- C,L - C,L - C,L - C,L
& Brake Pedal)
Stop Lamp Switch
Headlamp Focus

Side Stand Switch I,C I,C I,C I,C I,C I,C I,C
Fasteners***

Front Suspension/Oil***
Secondary Air Injection - - - - -
Muffler (Catalytic Converter) - - I,E - I,E - - I,E

* Early replacement may be required when riding in dusty areas.

** Replace engine oil once in every 6000 kms. Top up once in every 3000 kms.
*** Inspect & maintain specified torque.
**** Replace once in every two years or 30000 kms. whichever is earlier.
• Check idle CO emission along with idle rpm/idle CO adjustment (if required).
NOTE:- Always wipe the water from the motorcycle after washing. Use clean soft cloth or pressurised air for completely drying
the water.
I: INSPECT R: REPLACE C: CLEAN L: LUBRICATE A: ADJUST IF REQUIRED O: OIL CHANGE T:TOP UP E: EMISSION CHECK

3-3
MAINTENANCE
FUEL HOSE
FUEL LINES
Check the fuel hose for any leakage, deterioration,
damage, cracks or any other defects.
Replace the fuel hose if necessary.

Check for loose or improperly position fuel hose clips. HOSE

NOTE HOSE JOINT
• When attaching the fuel hose to the joint, insert the fuel
hose deeply to the joint so that the clip is past the
protruding area. CORRECT
• Do not install the clip on the protruding area of the joint.

CLIP
INCORRECT

THROTTLE OPERATION
Check for any deterioration or damage to the throttle cables.
2-6mm
Check the throttle grip for smooth operation. Check that the
throttle grip returns from the full open to the full closed
position smoothly and automatically in all steering positions.
If the throttle grip does not return properly, lubricate the
throttle grip housing.
For cable lubrication: Disconnect the throttle cables at their
upper ends (page 12-4). Thoroughly lubricate the cables
and their pivot points with a commercially available cable
lubricant or a light weight oil.
If the throttle grip still does not return properly, replace the
throttle cables.

3-4
 MAINTENANCE

! WARNING
Reusing a damaged or abnormally bent or kinked throttle
cable can prevent proper throttle operation and may lead
to a loss of throttle control while riding.
With the engine idling, turn the handlebar all the way to the A
right and left to ensure that idle speed does not change.
If idle speed increases, check the throttle grip free play and 3
the throttle cable connection and cable routing.
B
Measure the throttle grip free play at the throttle grip flange.
FREE PLAY : 2-6 mm
LOCK NUT ADJUSTER

A-DECREASE FREE PLAY B-INCREASE FREE PLAY

If the throttle grip free play is not correct, adjust as follows:
Minor free play adjustment can be made with the adjuster
on the throttle grip side.
Slide the dust cover off the adjuster.
Loosen the lock nut and turn the adjuster as required.
(Replace the throttle cable if the above procedure is no
longer effective.)
After adjustment, tighten the lock nut and reposition the
dust cover.
NOTE THROTTLE
THROTTLE
Make sure that the throttle cable A and B should be CABLE B CABLE A
positioned as shown in the figure

Recheck the throttle operation in all steering positions.

0
29

0
(32) 18

BOTTOM VIEW

LOCK NUT ADJUSTER

Major adjustment can be made with the lower adjusting
nut at the throttle body.
Loosen the lock nut on the pull side of the cable and turn
the adjusting nut.
After adjustment is complete, tighten the lock nut while
holding the adjusting nut.
Recheck the throttle operation.

3-5
MAINTENANCE

ENGINE IDLE SPEED

IDLE SPEED INSPECTION
NOTE
Inspect the idle speed after all other engine maintenance
items have been performed and are within specification.
Before checking the idle speed, inspect the following
items.
- Spark plug condition (page 3-7).
- Air cleaner condition (page 3-6).
The engine must be warm for accurate idle speed
inspection.
1
Use a tachometer with graduations of 50 min- (rpm) or
1
smaller that will accurately indicate a 50 min- (rpm) change.
Start the engine and warm it up to its normal operating
temperature (60 to 65°C).
Stop the engine and connect a tachometer according to
the tachometer operating instructions and start the engine
let it idle, check the idle speed.
ENGINE IDLE SPEED 1400±100 (rpm)
If the idle speed is out of the specification, check the following :
- Throttle operation and throttle grip free play (page 3-4, 3-5).
- Intake air leak or engine top-end problem (page 7-3).

AIR CLEANER HOUSING COVER

AIR CLEANER
NOTE
When riding in dusty areas, more frequent replacement
may be necessary.

Remove the following :

- Seat (page 2-2)
- Left side cover (page 2-3)
Remove the air cleaner cover screws/washers and the cover.

SCREWS

Remove the air cleaner element.

CAUTION
• Never wash or clean the viscous filter. Replace paper
filter element every 15000 kms.
• Replace it earlier if it becomes very dirty, damaged on
surface or on the sealing area.

AIR CLEANER ELEMENT

3-6
 MAINTENANCE

Do not clean with solvent to remove dust and also do not

use forced air on it. The viscous oil will be lost and filter
becomes dry. As the base filter paper is coarse, it cannot
block fine dust when it becomes dry.

Do not place air cleaner element horizontally on any

surface as dust can stick to the filter due to oil present. If
necessary place it vertically. Install immediately after
inspection.
Install the air cleaner element in the reverse order of
removal.

NOISE SUPPRESSOR CAP

SPARK PLUG
Disconnect the noise suppressor cap and clean any dirt
around the spark plug base.
NOTE
Clean around the spark plug bases with compressed air
before removing, and be sure that no debris is allowed to
enter the combustion chamber.
Remove the spark plugs using the spark plug wrench.
Inspect or replace as described in the maintenance
schedule (page 3-3).
RECOMMENDED SPARK PLUGS: NGK- DPR 8 EA9
BOSCH XR6DE

INSPECTION
Check the following and replace if necessary
Insulator for damage
Electrodes for wear
Burning condition, coloration
- Dark to light brown indicates good condition.
- Excessive lightness indicates malfunctioning ignition
system or learn mixture.
- Wet or black sooty deposit indicates over-rich mixture.
SPARK PLUG

3-7
MAINTENANCE
SIDE ELECTRODE
REUSING A SPARK PLUG
Clean the spark plug electrodes in a spark plug cleaner. 0.8-0.9mm
Check the gap between the center and side electrodes with
a wire-type feeler gauge. If necessary, adjust the gap by
bending the side electrodes carefully.
SPARK PLUG GAP: 0.8-0.9 mm
CAUTION
To prevent damage to the cylinder head, hand tighten the
spark plug before using a wrench to tighten to the special
torque.
TORQUE: 1.8 kgf-m
CENTER ELECTRODE
REPLACING A SPARK PLUG
NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP
Set the plug gap to specification with a wire-type feeler
gauge.
CAUTION
Do not over tighten the spark plug.
Install and tighten the new spark plug, then tighten it about
1/4 of turn after sealing washer contacts the seat of the
plug hole.
Reinstall the noise suppressor cap securely.

SPARK PLUG
EXHAUST EMISSION
MEASUREMENT AT IDLE
4 GAS ANALYZER
1. Check the following items before inspection ;
- Air cleaner
- Spark plug
- Crankcase breather
- Ignition timing
2. Park the motorcycle on the main stand on a level surface. 30 cm
(12 in)

3. Connect an appropriate pipe or hose (heat resistant,

chemical resistant) to the muffler so that the probe can
be inserted by more than 30 cm (12 inch).
4. Warm up the engine to the normal operating temperature
(Engine oil temperature: 60 to 65°C).
5. Check the engine idle speed.
Idle speed:1400±100 rpm
6. Insert the probe into the muffler and measure the
carbon monoxide (CO%) and hydrocarbon (HC ppm)
concentration.
CO Measurement at idle:0.02-0.4%

HC Measurement at idle:Below 4500 ppm

3-8
 MAINTENANCE

VALVE CLEARANCE
NOTE
Inspect and adjust the valve clearance when the engine is
cold (below 35°C/95°F).
Remove the fuel tank (page 2-10).
Remove the valve adjusting hole cap.
3
TAPPET COVER WRENCH
PART No : 070HH198011

Remove the crankshaft hole cap and timing hole cap.

Rotate the crankshaft counterclockwise and align the “T”
mark on the flywheel with the index mark on the left
crankcase cover.
Make sure that the piston is at TDC (Top Dead Centre) on
the compression stroke. (The rocker arms should be loose
because both valves are closed in this condition.)

CRANKSHAFT HOLE CAP

FEELER GAUGE
Apply clean engine oil on the feeler gauge.
Check the valve clearance by inserting a feeler gauge
between the valve adjusting screw and the valve stem.

VALVE CLEARANCE
Intake : 0.10 mm
Exhaust : 0.10 mm

TAPPET ADJUSTER
Adjust the valve clearance by loosening the lock nut and
turning the adjusting screw until there is slight drag on the
feeler gauge.
Hold the adjusting screw and tighten the lock nut.

TAPPET SCREW ADJUSTER WITH SOCKET 10 mm

PART No : 070HHKFN001
Recheck the valve clearance.

3-9
MAINTENANCE
VALVE ADJUSTING HOLE CAP
Check that the O-ring on the valve adjusting hole cap is in
good condition.
Coat the O-ring with engine oil, and install and tighten the
valve adjusting hole cap.
TORQUE: 1.5 kgf-m

O-RING
O-RING
Check that the O-ring on the crankshaft hole cap is in
good condition.
Coat O-ring with engine oil and install and tighten the
crankshaft hole cap.
Check that the O-ring on the timing hole cap is in good
condition.
Coat the O-ring with engine oil, and install and tighten
the timing hole cap.

CRANKSHAFT HOLE CAP O-RING

OIL LEVEL DIPSTICK
ENGINE OIL
OIL LEVEL INSPECTION
1. Park the motorcycle on its main stand.
2. Start the engine and let it idle for 3-5 minutes.
3. Stop the engine and wait for 2-3 minutes.
4. Remove the oil level dipstick, wipe it clean and insert
without screwing it in.
5. Remove the oil level dipstick and check the oil level.
6. If required add the specified oil up to the upper level
mark. Do not overfill.
7. Quantity of the oil to be filled is approximately 0.90 litre
during oil change when right crankcase cover is not
removed.
8. Reinstall oil level dipstick and check for oil leaks.

OIL CHANGE
NOTE
• Drain engine oil while engine is warm and the motorcycle
is on the main stand or held upright. This ensures
complete and rapid draining.
• While inspecting the oil level do not screw in the oil level
dipstick in the right crankcase cover.

OIL LEVEL DIPSTICK

3-10
 MAINTENANCE
SEALING WASHER
1. To drain the oil, remove oil level dipstick and drain plug.
2. After the oil has completely drained, reinstall the drain
plug with new sealing washer and tighten it to the
specified torque.
TORQUE
OIL DRAIN BOLT: 3.4 kgf-m
3

DRAIN PLUG
O-RING OIL LEVEL DIPSTICK
3. Fill the crankcase with recommended engine oil (Approx.
0.90 litre when right crankcase cover is not removed)
Engine Oil Capacity : 1.20 litres at disassembly of
right crankcase cover.
0.90 litre at oil change
4. Reinstall the oil level dipstick with a new O-ring.
5. Make sure that the oil level is till the upper level mark and
UPPER
there are no oil leaks.

LOWER

STRAINER SCREEN
OIL STRAINER SCREEN CLEANING
Drain the engine oil (page 3-11).
Remove the spring and oil strainer screen.
Clean the oil strainer screen thoroughly.
Check the screen for damage and the sealing rubber for
damage or deterioration and replace if necessary.
Install the oil strainer screen cap and fill the crankcase with
recommended engine oil (page 3-1).

SPRING
OIL FILTER ROTOR COVER
OIL FILTER ROTOR CLEANING
Remove the right crankcase cover (page 9-3).
Remove the three screws and the rotor oil filter cover and
gasket.
Engage GPD holder while removing the rotor oil filter cover.
NOTE
It is recommended to use pneumatic tools to remove the
rotor oil filter cover.

SCREWS

3-11
MAINTENANCE

Clean the oil filter rotor cover and the inside of the oil
filter rotor using a clean dirt-free cloth. Wash with non-
flammable high flash point solvent (Kerosene).

OIL FILTER ROTOR

OIL THROUGH COVER OIL THROUGH
While pressing down the oil through from the reverse side,
remove the slip pin.
CAUTION
• Do not allow dust or dirt to enter the crankshaft oil assage.
• Do not use compressed air to clean the filter rotor.

Remove the oil through and spring. Blow and clean the oil
through with compressed air.
Apply clean engine oil to the oil through surface and
install the spring and oil through.

SLIP PIN SPRING SLIP PIN

COVER
Install the oil filter rotor cover with a new gasket aligning
the screw holes in the cover and gasket.
Install and tighten the three screws.
TORQUE: 0.5 kgf-m
Install the right crankcase cover (page 9-18).

GASKET SCREWS

OIL CIRCULATION
Remove the valve adjusting hole cap.
Start the motorcycle and check the oil circulation by
removing the valve adjusting hole cap.

VALVE ADJUSTING HOLE CAP

3-12
 MAINTENANCE
BOLTS
DRIVE CHAIN
! WARNING
Never inspect and adjust the drive chain while the engine
is running.
DRIVE CHAIN SLACK INSPECTION
NOTE
Excessive chain slack, 50 mm or more, may damage the frame.
3
Park the motorcycle on its main stand.
Turn “OFF” the ignition switch, shift the transmission into
neutral.
Remove the lower chain guard by removing the bolts. LOWER CHAIN GUARD
Check the slack in the drive chain lower run midway
DRIVE CHAIN SLACK
between the sprockets.
Drive chain slack (3) should be checked in the lower run
midway between the sprockets. Move the drive chain up
and down by hand and chain slack should be adjusted to
25 mm vertical movement by hand.
Drive Chain Slack: 25 mm
Rotate the wheel and check drive chain slack as the wheel
rotates. Drive chain slack should remain constant as the 25mm
wheel rotates. If the chain is slack in one section and tight
in another, some links are kinked and bound. Binding can
frequently be eliminated by lubrication.

DRIVE CHAIN
CHAIN LOCK PLATE
Turn the chain to view chain lock plate. Ensure that the
chain lock plate open end is installed in the opposite
direction of the chain rotation.
Rotate the rear wheel slowly, inspect the drive chain and
sprockets for any of the following conditions.
Drive chain
• Damaged rollers
• Loose pins
• Dry or rusted links
• Kinked or binding links
• Excessive wear
• Improper adjustment
MASTER LINK OPEN END
• Damaged or missing O-rings
Sprockets
• Excessively worn teeth
• Broken or damaged teeth
If the drive chain has damaged rollers, loose links or
missing O-rings, replace it. If the chain is dry or rusted, it
should be lubricated.
NOTE
Never install a new drive chain on a worn sprocket or a
worn chain on new sprocket. Always replace drive chain
and both sprockets as set.

3-13
MAINTENANCE
REAR AXLE
ADJUSTMENT
CAUTION
If the adjustment is not the same, the wheel is out of alignment
and can cause excessive tyre, sprocket and chain wear.
Park the motorcycle on its main stand with the transmission
is in neutral and the ignition switch in “OFF” position.
Loosen the rear axle nut and sleeve nut.
Loosen the both adjuster lock nuts.
Turn both adjusting nuts until the correct drive chain slack is
obtained. Turn the adjusting nut clockwise to decrease the
slack or anticlockwise to increase the slack of the chain.
Make sure the index mark on both adjusters are aligned
with the rear edges of the axle slots in the swingarm.
If the drive chain slack is excessive when the rear axle is REAR AXLE NUT
moved to the farthest limit of adjustment, the drive chain is SLEEVE NUT LOCK NUT
worn and must be replaced.
CAUTION
If the double headed arrow on the chain adjuster reaches
the red line (REPLACE) on the chain wear indicator label,
then the drive chain kit must be replaced.

Tighten the rear axle nut and sleeve nut to the specified torque.
REAR AXLE NUT
TORQUE:6.8 kgf-m
SLEEVE NUT
TORQUE:5.9 kgf-m
Tighten the both adjusting nuts and lock nuts.
INDEX MARKS ADJUSTING NUT
Recheck the drive chain slack and free wheel rotation.
Install the lower chain guard by installing the bolts.
Check the rear brake pedal free play.

CLEANING
If the drive chain becomes extremely dirty, it should be MIXTURE OF
CHAIN CLEANER
removed and cleaned prior to lubrication. KEROSENE &
Dip a soft nylon brush in a mixture of kerosene and 10W30 ENGINE OIL
10W30 engine oil (in the ratio of 1:1) and clean the dirt
accumulated on the chain with the help of this soft brush.
Wait for approx 3-5 minutes to allow the mixture to (2) CLEAN
penetrate in between bush and roller for proper cleaning
(3) WIPE AND
of the drive chain. Repeat the process few times depending
DRY SAE 90
on the dirt accumulation on the drive chain.
GRADE OIL
Finally wipe the chain with a dry shop towel to remove the
(4) LUBRICATE
oil + kerosene traces from it. Visibly inspect the chain after
cleaning and ensure no mud or dust is left out.

NOTE
• Ensure that the cleaner & lubricant used is the one
recommended for use on an o-ring chain, otherwise O-ring
may deteriorate, fail and lose their sealing properties.
• Inspection, cleaning, lubrication and adjustment of drive
chain at every 1000 kms.

3-14
 MAINTENANCE

LUBRICATION
Apply SAE 90 Grade oil on the inner side of the entire
length of the chain using the oil can.
Wait for 7-10 minutes for penetration of the lubricant
inside the bush & roller for better lubrication. Wipe the
excess lubricant from the chain and nearby parts by using
a dry shop towel.
CAUTION 3
• Steam cleaning, high pressure washers and certain
solvents can damage the drive chain O-rings.
• While lubricating and cleaning hold the rear wheel with
one hand to prevent the possibility of your finger being
trapped between the chain and sprocket.
• The drive chain is fitted with o-rings between the link
plates. These O-rings retain grease inside the chain to
improve its service life. However, special precautions
must be taken when adjusting, lubricating, washing and
replacing the chain.
• Regular adjustment and lubrication as per the
maintenance schedule world ensure high performance
and longer life.
BOLTS
DRIVE CHAIN SLIDER
Remove two bolts and the left crankcase rear cover.

LEFT CRANKCASE REAR COVER

CUTOUT WEAR LIMIT
Check the drive chain slider for wear, the chain slider must be
replaced if it is worn to the bottom of the cutout or wear limit.
Wear limit : 4 mm
For removal and installation (page 13-20).

DRIVE CHAIN SLIDER

3-15
MAINTENANCE
BATTERY (+VE) TERMINAL
BATTERY VOLTAGE
It is not necessary to check the battery electrolyte level or add
distilled water as the battery is a Maintenance-Free (sealed) type.
Remove the right side cover (page 2-4).
Measure the battery voltage using a MF-Battery Tester
(page 16-6).
VOLTAGE
Under charged : Below 12.4 V
For battery charging procedure (page 16-12).
! WARNING
BATTERY (-VE) TERMINAL
This vehicle is equipped with a Maintenance-Free Battery and can
be permanently damaged if the cap sealing strip is removed.

ELECTRIC STARTER SWITCH

Check for the operation of electric starter switch for stickey
moment.
NOTE
Do not operate the electric starter for more than 10 seconds,
to avoid drainage of battery.

ELECTRIC STARTER SWITCH

MASTER CYLINDER RESERVOIR
BRAKE FLUID
CAUTION
• Do not remove the cover or cap unless the reservoir is
in level or else fluid may spill out.
• Do not mix different types of fluid, as they are not
compatible with each other.
• Do not allow foreign material to enter the system when
filling the reservoir.
• Avoid spilling of fluid on painted, plastic or rubber
parts. Place a rug over these parts whenever the system
is serviced.

LWR LEVEL MARK RESERVOIR CAP

When the fluid level is low, check the brake pads for wear
(page 3-17). A low fluid level may be due to wear of the
brake pads.
If brake pads are worn, the caliper piston is pushed out,
and this accounts for low reservoir level. If the brake pads
are not worn and the fluid level is low, check the entire
system for leaks.

3-16
 MAINTENANCE
DIAPHRAGM
Turn the handlebar so that the reservoir is in level and
check the front brake reservoir level through the sight
glass.
If the level is near LWR (lower) mark, check the brake pad
wear.
To top up the brake fluid, remove the cover, set plate and
diaphragm and fill the reservoir to the casting edge with
Castrol Q Stop-DoT-3 or DoT-4 brake fluid from a sealed 3
container.

FRONT MASTER CYLINDER

BRAKE PAD WEAR

Check the brake pads for wear.
Replace the brake pads if either pad is worn to the bottom
of wear limit groove.
Brake pad replacement (page 15-6).
CAUTION
Always replace the brake pads in pairs to assure even
pressure is applied on disc.

BRAKE PAD WEAR LIMIT GROOVES

BRAKE PEDAL FREE PLAY

NOTE
Perform brake pedal free play adjustment after adjusting
brake pedal height.
Check the brake pedal free play at the tip of the pedal.
20-30 mm
Free play : 20-30 mm
Adjust the brake pedal free play by turning the adjusting nut.

NOTE
• Make sure that the cut away in the adjusting nut is
seated on the brake arm joint.
• After adjusting the brake pedal free play, check the rear
stop lamp switch operation and adjust if necessary.

CUT- OUT IMPROPERLY INSTALLED CUT- OUT PROPERLY INSTALLED

ADJUSTING NUT

3-17
MAINTENANCE
STOP LAMP SWITCH
STOP LAMP SWITCH
NOTE
• Perform stop lamp switch adjustment after adjusting the
brake pedal height.
• The front stop lamp switch does not require adjustment.
Check that the stop lamp comes “ON” when the brake
pedal is depressed and the brake engagement begins.
To adjust, hold the switch body and turn the adjusting nut.
NOTE
Do not turn the stop lamp switch body.
ADJUSTING NUT
LO BEAM
HEADLAMP FOCUS (TWIN BULB)
! WARNING
An improperly adjusted headlamp may blind oncoming
drivers, or it may fail to light the road for a safe distance.
Park the motorcycle on level ground.
Remove the front cowl (page 2-6).

FRONT COWL HI BEAM

(A) LO BEAM ADJUSTING BOLT HEADLAMP ASSEMBLY
Headlamp adjustment is done by the headlamp adjusting
bolt (A) for “Lo” beam & (B) for “Hi” beam located behind
the headlamp assembly.

Adjust the headlamp beam vertically by turning the

adjusting bolts clockwise & anticlockwise for correct focus
adjustment.

(B) HI BEAM ADJUSTING BOLT

CLUTCH LEVER FREE-PLAY CLUTCH LEVER ADJUSTER
CLUTCH SYSTEM
Measure the clutch lever free play at the end of the lever.
Free play: 10-20 mm
Minor adjustment is made with the upper adjuster at the 10-20 mm
clutch lever. Turn the adjuster. If the adjuster is threaded out
near its limit and the correct free-play cannot be obtained,
turn the adjuster all the way in and back out one turn.
NOTE
The adjuster may be damaged if it is positioned too far out,
leaving minimal thread engagement.

LOCK NUT

3-18
 MAINTENANCE
LOCK NUT ADJUSTING NUT
Major adjustment is performed at the clutch lifter lever.
Loosen the lock nut and turn the adjusting nut to adjust the
free-play.
Tighten the lock nut while holding the adjusting nut.
If proper free-play cannot be obtained, or the clutch slips
during test ride, disassemble and inspect the clutch.
B
3
A

A-INCREASE FREE PLAY B-DECREASE FREE PLAY

PIVOT NUT/BOLT
SIDE STAND/MAIN STAND
Park the motorcycle on the level surface.
Check the side stand/main stand return spring for damage
or loss of tension.
Check the side stand/main stand for freedom of movement.
Lubricate the side stand pivot if necessary.
Make sure the side stand is not bend.

SIDE STAND MAIN STAND

SIDE STAND SWITCH
SIDE STAND SWITCH
A side stand switch is provided on the side stand, if the
side stand is down, the side stand indicator on the
speedometer console glows.
Inspect the side stand switch for any wear or physical
damage. Clean the side stand switch periodically as per
the maintenance schedule.
CAUTION
Never remove the side stand switch from its mounting for
cleaning.

SUSPENSION
Loose, worn, or damaged suspension parts impair SUSPENSION
motorcycle stability and control. Repair or replace any ACTION
damaged components before riding. Riding a motorcycle
with faulty suspension increases your risk of an accident
and possible injury.
FRONT
Check the action of the forks by operating the front brakes
and compressing the front suspension several times.
Check the entire fork assembly for signs of leaks, damage
or loose fasteners.
Replace damaged components which cannot be repaired.

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MAINTENANCE

REAR
Support the motorcycle securely and raise the rear wheel
off the ground.
Check for worn swing arm needle bearing by grabbing the
rear wheel and attempting to move the wheel side to side.
Replace the bearing if found loose (page 13-4).
Check the action of the shock absorbers by compressing
them several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.

NUTS, BOLTS, FASTENERS

Tighten bolts and nuts at regular interval shown as per the
maintenance schedule.
Check that all chassis nuts and bolts are tightened to
correct torque values (page 1-12).
Check that all cotter pins, safety clips, hose clamps and
cable stays are in place.

WHEELS/TYRES
Make sure the fork is not allowed to move, raise the front
wheel and check for play. Turn the wheel and check that it
rotates smoothly with no unusual noise.
If faults are found, inspect the wheel bearings.
Support the motorcycle securely and raise the rear wheel
off the ground.
Check for play in either the wheel or the swingarm pivot.
Turn the wheel and check that it rotates smoothly with no
unusual noise.

If abnormal conditions are suspected, check the rear wheel

bearings.
NOTE
As the swing arm pivot is included in this check, be sure to
confirm the location of the play; i.e. from the wheel
bearings or the swingarm pivot.
Check the tyre for cuts, imbedded nails, or any other
damage.
Measure the tyre pressure.
Check and adjust the tyre pressure.

3-20
 MAINTENANCE

NOTE
The tyre pressure should be checked when the tyres are
COLD.

Cold tyre pressure

Front Rear
kgf/cm2(psi)
3
Rider only 2.00 (29 psi) 2.00 (29 psi)

Rider and pilliion 2.00 (29 psi) 2.25 (33 psi)

TYRE PRESSURE GAUGE
TYRE WEAR INDICATOR
Measure the tread depth at the centre of tyre. Replace the
tyre when the tread depth reaches the following limits:

Minimum tread depth: Front: 1.5 mm

Rear: 2.0 mm

STEERING HEAD BEARINGS

NOTE
Check that the control cables do not interfere with the
handlebar rotation.

Raise the front wheel off the ground by placing a jack or

other support under the engine.
Check that the handlebar rotates freely from side to side. If
the handlebar moves unevenly, binds, or has play, inspect
and adjust the steering head bearings.

Check for worn steering stem bearings by grabbing the front

fork leg and attempting to move the front fork side to side.
Adjust/replace the bearings if any play is observed.

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MAINTENANCE

CRANKCASE BREATHER CARBURETOR

RESONATOR AIR
CHAMBER
AIR CLEANER
HOUSING

Check the crankcase breather hose for deterioration,

damage or loose connection. Make sure that the hoses
are not kinked, pinched or cracked.

Service more frequently when ridden in rain at full throttle

or after the motorcycle is washed.
CRANKCASE
BREATHER HOSE

FRESH AIR

BLOW- BY GAS

Remove the drain plug from the air cleaner housing drain
hose and drain deposit into a container.
Reinstall the drain plug.

DRAIN PLUG

3-22