(0.028 — 0.032 in) Spark Plug Standard NGK B8ES NGK BR8ES Plug Plug 0.7 ~ 0.8mm (0,028 ~ 0.032 in) Tightening 27N-m Torque (2.8 kg-m, 20 ft-lb) : Canadian model Air Cleaner A clogged air cleaner restricts the engine's air intake, increasing fuel con- sumption, reducing engine power, and causing spark plug fouling. The air cleaner element must be cle- aned and replaced in accordance with the Periodic Maintenance Chart. In dusty areas, the element should be cle- aned more frequently than the recom- mended interval. After riding through rain or on muddy roads, the element should be cleaned immediately. The el- ement should be replaced if it is dam- aged. Element Removal @Remove the air cleaner cover screws, and take off the cover. 61aim A. Air Cleaner Cover B. Screws @Pull out the air cleaner element 62 A. Element @Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering. @Separate the sponge filter and paper filter.A. Sponge Filter B. Paper Filter @lnspect the element material and sponge gasket for damage. If any part of the element is damaged, the ele- ment must be replaced AWARNING lf dirt or dust is allowed to pass through into the carburetor, the throt- tle may become stuck, possibly caus- ing accident. lf dirt gets through into the engine, ex- cessive engine wear and possibly en- gine damage will occur. NOTE O€Flement installation is performed in the reverse order of removal. CAUTION When installing the element, insert it into the body in the direction shown in the label attached back the air cleaner cover. Installation in wrong direction might cause damage to the engine. Element Cleaning @Clean the paper filter by tapping it lightly to loosen dust. 63@Blow away the remaining dust by ap- plying compressed air from the inside to outside (from the clean side to the dirty side). @Clean the sponge filter in a bath of a high flash-point solvent. @Squeeze it dry in a clean towel. @After cleaning, saturate the sponge fil- ter with a high-quality foam air filter oil, squeeze out the excess oil, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the element. PENILE) Clean the element in a well ventilated area, and take care thal there are no sparks or flame anywhere near the working area; this includes any appli- ance with a pilot light. Do not use gas- oline or a low flash-point solvent to clean the element. A fire or explosion could result. 64 Throttle Control Cable The throttle control cable is actually an assembly of three cables: the throttle cable, the carburetor cable, and the oil pump cable. The throttle cable runs from the throttle grip to the cable as- sembly junction where it connects to both the carburetor cable which leads to the carburetor, and the oil pump cable which leads to the oil pump. Cable stretch will cause delayed en- gine response and upset the oil pump synchronization, necessitating periodic adjustment. To compensate for cable stretch, adjust the throttle cable and the oil pump cable in accordance with the Periodic Maintenance Chart.Throttle Cable: Inspection @Check to see that the outer cable end of the throttle cable is fully seated in the adjusting nut. @Check the throttle cable play. When lightly turning the throttle grip, the grip should have 2 ~ 3 mm (0.08 ~ 0.12 in) of play. If the throttle cable has improper play, adjust it. A, Throttle Grip B. 2 ~ 3mm (0.08 ~ 0.12 in) Adjustment @Loosen the locknut at the throttle ca- ble, and turn the adjusting nut until the proper amount of throttle grip play is obtained. Tighten the locknut. A. Adjusting Nut B. Locknut @Check the oil pump cable. 65Oil Pump Cable: Inspection @Warm up the engine, and check the engine idling. (See the Carburetor section.) @Check the throttle cable. @Unscrew the oil pump cover screw and remove the oil pump cover. Y elie ar A, Oil Pump Cover B, Screws @Check to see that the outer cable end of the oil pump cable is fully seated in the cable adjuster. 66 @Check to see that the tang on the oil pump lever is bent to hold the oil pump inner cable. A. Adjuster Cc. Marks B. Tang @Check the synchronization between the carburetor and the oil pump while idling the engine. Listening to ex- haust noise, gradually open the thrat- tle grip, and stop turning the grip at the point where the engine speed just begins to increase from the idle speed.@Without changing the position of the throttle grip, check whether or not the mark on the oil pump lever lines up with the mark on the lever stop. A. Adjuster B. Locknut Cc. Marks If the oil pump does not synchronize with the carburetor, adjust it. Adjustment @Start the engine. @Loosen the locknut at the oil pump cable adjuster, and turn the adjuster so that the marks on the pump lever and the lever stop line up when the idle speed is at the point of increasing. @Tighten the locknut. @Check that the throttle grip has the proper amount of play. @/nstall the oil pump cover. 67Carburetor The following procedure covers the idling adjustment, which should be per- formed in accordance with the Periodic Maintenance Chart or whenever the idle speed is disturbed. Adjustment @Start the engine, and warm it up thor- oughly. @Adjust the idle speed with the idle ad- 7 = justing screw to the lowest stable A. Idle Adjusting Screw speed obtainable, which will normally B. Increases speed. be 1,200. ~ 1,400 r/min (rpm). C. Decreases speed. @Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if neces- sary. @With the engine idling, turn the han- dlebar to each side. If handlebar movement changes the idle speed, the throttle cable may be improperly ad- justed or incorrectly routed, or it may 68be damaged. Be sure to correct any of these conditions before riding. PWNS TiN (e) Operation with a damaged cable could result in an unsafe riding conditio! Spark Arrester This motorcycle is equipped with a spark arrester approved for off-road use by the U.S. Forest Service. It must be properly maintained to ensure its effi- ciency. In accordance with the Periodic Maintenance Chart, clean the spark ar- rester, The spark arrester must be installed correctly and functioning properly to provide adequate fire protection. Spark Arrester Cleaning AWARNING To avoid burns, wear gloves while cle- Since the aning the spark arrester. engine must be run during this proce- dure, the muffler will become hot. 69@Remove the spark arrester mounting bolt from the muffler. @Pull the spark arrester out of the muf- fler. i A. Spark Arrester @ln an open area away from combusti- da ble materials, start the engine with the transmission in neutral. A. Mounting Bolt @Raise and lower engine speed while tapping on the muffler with a rubber mallet until carbon particles are purged from the muffler. 70CaN Me) Never run the engine with the spark arrester removed near combustible materials, Hot carbon particles may start a fire. Do not run the engine in a closed area. Exhaust gases contain carbon monox- ide: a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxia- tion, and death. @Stop the engine @Scrape carbon deposits off the spark arrester and slide it back into the muf- fler. @install the mounting bolt and tighten it securely. Clutch Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accord- ance with the Periodic Maintenance Chart. AWARNING To avoid a serious burn, never touch a hot engine or exhaust pipe during clutch adjustment. Inspection @Check that the clutch lever has 2 ~ 3 mm (0.08 ~ 0.12 in) of play as shown in the figure. 71A. Adjuster B. Locknut C. 2 ~ 3mm (0.08 ~ 0.12 in) If the play is incorrect, adjust the le- ver play as follows. Adjustment @Slide the carburetor rubber cap out of place, and remove the carburetor cover 72 a = A. Carburetor Cover B. Rubber Cap CAUTION If the cover gasket is damaged, re- place it with a new one, First, check the clutch release as fol- lows: @While pulling the clutch lever in lightly to take up ail the clutch lever play, check to see that the mark on the C. Screwsclutch release lever is aligned with the mark on the engine cover. This is the point where the clutch is just starting to release. B. Marks A. Clutch Release Lever @/f the marks are not aligned, adjust the clutch release using the following four steps. @Loosen the locknuts, and turn in fully the clutch cable adjusters to give the cable plenty of play. A. Adjuster B. Locknut @Loosen the locknut, and turn in or out the clutch release adjusting screw so that the marks are aligned when the clutch lever is lightly pulled in. 73B. Locknut A. Adjusting Screw @Tighten the locknut for the release ad- justing screw. @Adjust the clutch lever play. Next, check the clutch lever play as follows: @Check that the clutch lever has 2 ~ 3 mm (0.08 ~ 0.12 in) of play as shown in the figure. @lf it does not, adjust the lever play as follows. 74 @Loosen the locknuts, and turn the clutch cable adjusters so that the clutch lever will have 2 ~ 3 mm (0.08 ~ 0.12 in) of play. A. Adjuster B. Locknut C.2 ~ 3 mm (0.08 ~ 0.12 in) @Tighten the locknuts, and install the removed parts.NOTE Automatic Side Stand Return Mechanism The motorcycle is equipped with the automatic side stand return mechanism. The side stand should be returned to its rest position when the clutch lever is pulled in. OAfter the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly. A. Automatic Side Stand Return Mechanism B. Locknut C. Adjuster 75PAs SLES Before putting the motorcycle up on its side stand, make sure that the side stand is placed in the full forward po- sition. If this is done carelessly, the motorcycle may move forward, caus- ing the motorcycle to fall over. Check and adjust the automatic side stand return mechanism whenever it does nat work satisfactorily. inspection @Situate the motorcycle so that it is perpendicular to the ground. @Swing down the side stand and pull in the clutch lever. The side stand should return to its rest position when the clutch lever is pulled in. If it is not, adjust the mechanism. 76 Adjustment @Loosen the locknut at the lower end of the mechanism cable. @Turn the adjuster so that the proper adjustment is obtained @Tighten the locknut @Check the mechanism operation, and readjust if necessary.Drive Chain The drive chain must be checked, ad- justed, and lubricated in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear, |f the chain becomes badly worn or mal- adjusted — either too loose or too tight — the chain could jump off the sprock- ets or break AWARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, se- verely damaging the motorcycle and causing it to go out of control. Slack laspection @Stand the motorcycle up on its side stand. @ Rotate the rear wheel to find the posi- tion where the chain is tightest, and measure the maximum chain slack by pulling up and pushing down the chain midway between the engine sprocket and rear wheel sprocket. > On A.15 ~ 25 mm (0.6 ~ 1.0 in) @lf the drive chain is too tight or too loose, adjust it so that the chain slack will be within the standard value. 77Drive Chain Slack Standard | 15 ~ 20 mm (0.6 ~ 0.8 in) more than 25 mm (1.0 in) less than 15 mm (0.6 in) Adjustment - @Loosen the rear torque link nut. Do not forget to loosen the torque link nut. 78 A. Torque Link Nut @Loosen the left and right chain adjus- ter locknuts. @Loosen the axle nut and sleeve nut.A Sleeve Nut B. Axle Nut C. Locknut D. Adjusting Bolt @lf the chain is too tight, back out the left and right chain adjusting bolts evenly, and kick the wheel forward until the chain is too loose. ®Turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch on the left chain adjuster should align with the same swingarm mark that the right chain adjuster notch aligns with, A, Marks NOTE OWheel alignment can also be checked using the straightedge or string method. AWARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. 79@Tighten both chain adjuster locknuts. @Tighten the sleeve nut securely. AWARNING Tighten the sleeve nut before tighten- ing the axle nut. If the nut tightening order is reversed, the rear axle will not be securely mounted on the swing- arm. This may cause misalignment of the wheels, and result in loss of con- trol. @Center the brake panel assembly in the brake drum. This is done by tighten- ing the axle nut lightly, spinning the wheel, and depressing the brake pedal forcefully. The partially tightened axle nut allows the brake panel assembly to center itself within the brake drum 80 NOTE OThis procedure can prevent a soft. or “spongy feeling” brake. @Tighten the axle nut to the specified torque. @Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary, @Tighten the rear torque link nut to the specified torque. Tightening Torque 32 N- AxleNut | 73.3 kg-m, 24 ft-lbs) Torque Link | 29 N-m Nut (3.0 kg-m, 22 ft-lbs) AWARNING lf the axle or torque link nuts are not securely tightened, an unsafe riding condition may result.@Check the rear brake. (See the Brakes section), Wear Inspection : @Stretch the chain taut either by using the chain adjusters, or by hanging a 10 kg (20 Ib) weight on the chain. @ Measure the length of 20° links on the straight part of the chain from pin center of the 1st pin to pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. @\f the length exceeds the service limit, the chain should be replaced. Drive Chain 20-Link Length 259 mm (10.2 Service AWARNING For safety, use only the standard chain. Have it installed by an author- ized Kawasaki dealer. B. Measure A. Weight © @Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links. @Also inspect the sprockets for une- venly or excessively worn teeth, and damaged teeth 81NOTE O Sprocket wear is exaggerated for illus- tration. See Service Manual for wear limits. seROcKET Worn Tooth (Rear Sprocket! Worn Tooth lengine Sprocket! Deeection at tataven @lf there is any irregularity, have the drive chain and/or the sprockets re- placed by an authorized Kawasaki dealer. 82 Lubrication Lubrication is also necessary after rid- ing through rain or on wet roads, or any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubri- cation, @Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Wipe off any excess oil.@If the chain is especially dirty, clean it using diesel oil or kerosine and then apply oil as described above. Brakes Brake Wear Inspection In accordance with the Periodic Maintenance Chart, inspect the brakes for wear. On both the front and rear brake pan- els is a brake lining wear indicator. If the brake lining wear indicator does not point within the USABLE RANGE when the brake is fully applied, the brake shoe linings have worn past the service limit. In this case, the brake shoes must be re- placed and the drum and other brake parts examined by an authorized Kawa- saki Dealer. 83A. Front B. Rear C. USABLE RANGE D. Brake Lining Wear Indicator Front Brake: In accordance with the Periodic Maintenance Chart, inspect the front brake as follows. Inspection @Slide the front brake lever dust cover out of place. 84 @Check that the brake lever has 4 ~ 5 mm (0.16 ~ 0.20 in) of play when the brake is lightly applied. A. Adjuster B. Locknut C. 4 ~ 5 mm (0.16 ~ 0.20 in) @Rotate the wheel to check for brake drag. @Operate the lever a few times to see that it returns to its rest position im- mediately upon release. @Check braking effectiveness.@lf the lever has improper play, adjust it. Adjustment @Loosen the locknut, and turn the ad- juster at the brake lever and/or adjust- ing nut at the bottom of the inner brake cable so that the lever has 4 ~ 5 mm (0.16 ~ 0.20 in) of play. A. Adjusting Nut ®Tighten the locknut. @Slide back the dust cover. Rear Brake: In accordance with the Periodic Maintenance Chart, inspect the brake pedal play. Pedal Play Inspection @The brake pedal should have 20 ~ 30 mm (0.8 ~ 1.2 in) of play when the pedal is pushed down lightly by hand. 85Pedal Play Adjustment @Turn the adjusting nut at the brake cam lever so that the pedal has 20 ~ 30 mm (0.8 ~ 1.2 in) of play. A. Brake Pedal - B. 20 ~ 30 mm (0.8 ~ 1.2 in) @Rotate the wheel to check for brake drag. = Ea 4 @Operate the pedal a few times to see A. Adjusting Nut that it returns to its rest position im- mediately upon release. @Check braking effectiveness. elf the pedal has improper play, adjust it. 86Brake Light Switches When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no ad- justment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Inspection @Turn the ignition key to "ON". @The brake light should go on when the front brake is applied. @/f it does not, ask your authorized Ka- wasaki dealer to inspect the front brake light switch. @Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after about 15 mm (0.6 in) of pedal travel. A. Brake Pedal B. 15mm (0.6 in) @lf it does not, adjust the rear brake light switch. Adjustment @Adjust the rear brake light switch by maving the switch up or down, To change the switch position, turn the adjusting nut. 87To avoid damaging the electrical con- nections inside the switch, be sure that the switch body does not turn dur- ing adjustment. A. Rear Brake Light Switch B. Adjusting Nut C. Lights sooner. D. Lights later. 88 Rear Shock Absorbers Spring Adjustment The spring adjuster on each rear shock absorber has 5 positions so that the spring can be adjusted for different road and loading conditions. | A. AdjusterIf the spring action feels too soft or too stiff, adjust it in accordance with the SelM following table: if both spring adjusters are not ad- rays] Spring Action justed equally, handing may be im- paired and a hazardous condition may result. A. Screwdriver Bit 89Wheels Tires: Payload and Tire Pressure Failure to maintain proper inflating pressures or observe payload limits for your tires may adversely affect handling and performance of your motorcycle and can result in loss of control. The maxi- mum recommended load in addition to vehicle weight is 150 kg (330 Ib), in- cluding rider, baggage, and accessories. eCheck the tire pressure often, using an accurate gauge. Tire Air Pressure (when cold) 150 kPa (1.5 kg/em?, 21 psi) Up to 97.5 kg | 200 kPa Rear | (21 ad 2.0 kg/cm’, 28 psi) 97.5 ~ 150 kg | 225 kPa (215 ~ 330 Ib)] (2.25 kg/c load 32 psi) 90 NOTE OMeasure the tire pressure when the tires are cold (that is, when the mo- toreycle has not been ridden more than a mile during the past 3 hours). OTire pressure is affected by changes in ambient temperature and altitude, and so the tire pressure should be checked and adjusted when your riding in- volves wide variations in temperature or altitude.Tire Wear, Damage As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. @|n accordance with the Periodic Main- tenance Chart, measure the depth of the tread with a depth gauge, and re- place any tire that has worn down to the minimum allowable tread depth. Minimum Tread Depth Front and Rear 2mm (0.08 in) A. Tire Depth Gauge @Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage. Swelling or high spots indi- cate internal damage, requiring tire re- placement. @Remove any imbedded stones or other foreign particles from the tread. 91NOTE OHave the wheel balance inspected whenever a new tire is installed. To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure. Standard Tire 2.75-19 43P BRIDGESTONE TRAIL WING-15 3.00-17 45P BRIDGESTONE TRAIL WING-12 92 FAVS NTN] New tires are slippery and may cause loss of control and injury. A break-in period of 160 km (100 miles) is necessary to establish nor- mal tire traction. During break-in, avoid sudden and maximum braking and acceleration, and hard cornering.Battery Battery Electrolyte Level Inspection The battery electrolyte level must be kept between the upper and lower level lines. Check the electrolyte level in each cell in accordance with the Periodic Maintenance Chart. @Remove the battery from the motorcy- cle (see Battery Removal). @ Check that the electrolyte level in each cell is between the upper and lower level lines. @lf the electrolyte level is low in any cell, fill with distilled water as follows. @Remove the battery filler caps and fill with distilled water until the electro- lyte level in each cell reaches the up- per level line. A. Upper Level B. Lower Level C. Filler Caps D. Battery Vent Hose Add only distilled water to the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery. 93Battery Charging @Remove the battery from the motorcy- cle (see Battery Removal). Always remove the battery from the motorcycle for charging. If the battery is charged while still Installed, battery electrolyte may spill and corrode the frame or other parts of the motorcycle. ®@Before charging, check the electrolyte level in each cell. If the electrolyte level is low in any cell, fill to above the lower level line but not up to the upper level line since the level rises during charging @Remove the caps from all the cells, and connect the battery charger leads to the battery leads (red to +, black to -) 94 AWARNING Because the battery gives off an ex- plosive gas mixture of hydrogen and oxygen, keep any sparks or open flame away from the battery during charging. When using a battery char- ger, connect the battery to the charger before turning on the charger, This procedure prevents sparks at the bat- tery terminals which could ignite any ballery gases,A. Battery Charger B. Filler Caps C. {(—) Leads D. (+) Leads @Charge the battery at a rate that is 1/10th of the battery capacity. For example, the charging rate fora 10 Ah battery would be 1.0 ampere. Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charging rate can be reduced to the level re- quired for motorcycle batteries. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher than normal charging rates also cause the plates to shed active material. Depos- its will accumulate, and can cause in- ternal shorting. If the temperature of the electrolyte rises above 45°C (115°F) during charging, reduce the charging rate to lower the temper- ature, and increase charging time pro- portionately. 95@After charging, check the electrolyte level in each cell. If the level has fal- len, add distilled water to bring it back up to the upper level line. @Install the caps on the cells. @Install the battery. Battery Removal @Unlock the seat and swing it open. ®Disconnect the leads from the battery, first from the (—) lead and then the (+) lead. @Take the battery out of the case. @Clean the battery using a solution of baking soda and water. Be sure that the lead connections are clean. 96 Battery Installation @Check that the battery case rubber damper is properly in place, @Put the battery in the battery case, and route the battery vent hose as shown on the caution label. @Connect the white lead to the (+) lead, and then connect the black lead to the (—) lead. VA A. (—) Lead B. (+) LeadCAUTION Make sure the battery vent hose is kept away from the drive system and ex- haust system. Battery electrolyte can corrode and dangerously weaken the drive system. Do not let the vent hose become folded, pinched, or melted by the exhaust system. An unvented bat- tery will not keep a charge and it may crack from buill-up gas pressure. Headlight Beam Horizontal Adjustment The headlight beam is adjustable hor- izontally. If not properly adjusted hor- izontally, the beam will point to one side rather than straight ahead. @Turn the adjusting screw on the head- light rim in or out until the beam points straight ahead, Turning the ad- justing screw clockwise makes the headlight beam point to the ‘eft. A. Adjusting Screw 97Vertical Adjustment The headlight beam is adjustable ver- tically. If adjusted too low, neither low nor high beam will illuminate the road far enough ahead. If adjusted too high, the high beam will fail to illuminate the road close ahead, and the low beam will blind oncoming drivers. @Loosen the headlight housing mount- ing bolts, and adjust the headlight vertically. A. Mounting Bolt 98 @Tighten the headlight housing mount- ing bolts. NOTE OOn high beam, the brightest point should be slightly below horizontal. The proper angle is 0.4 degrees below horizontal. This is a 50mm (2 in) drop at 7.6 m (25 ft) measured from the center of the headlight, with the motorcycle on its wheels and the rider Seated.Fuse The fuse case is located under the seat. If a fuse is blown during opera- tion, inspect the electrical system to de- termine the cause, and then replace it with a new fuse of proper amperage. AWARNING Do not use any substitute for the stan- dard 10 A fuse. A. Fuse Case Fuel System : Accumulation of moisture or sedi- ment in the fuel system will restrict the flow of fuel and cause carburetor mal- function. The system should be checked in accordance with the Periodic Maintenance Chart. AWARNING Gasoline is extremely flammable and can be explosive under certain condi- tions, Turn the ignition key to “OFF”. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this in- cludes any appliance with a pilot light. Make sure the engine is cold before working. Wipe any fuel off the engine before starting it. 99Jnspectian @Turn the fuel tap lever to the OFF po- on. @Unscrew the sediment cup from the bottom of the fuel tap, and check to see if water or dirt has accumulated in the sediment cup. A. Sediment Cup @Being careful not to damage the gas- ket and filter, remove them out of the fuel tap using a thin screwdriver. 100 @Using a piece of cloth, wipe out the inside of the fuel tap, wash the cup and filter in a high flash-point solvent, @If water has accumulated in the sedi- ment cup; holding a container under the fuel tap, open the fuel tap until only fuel cames out, then shut off the fuel tap. @Visually inspect the gasket and filter. Replace them with new ones if they are damaged. “= © ® © A. Sediment Cup B. Filter C. Gasket@lnstall the filter and gasket in the tap, and tighten the sediment cup NOTE OTurn the fuel tap lever to the RES po- sition, and check for fuel leaks. O/f any water or dirt appears during the above operation, have the fuel system checked by a competent mechanic following the procedure in the Service Manual. General Lubrication Lubricate the points shown here, with either motor oil or regular grease, in ac- cordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime NOTE OA few drops of oi! are effective to keep bolts and nuts from rusting and Sticking. This makes removal easier. Badly rusted nuts, bolts, etc., should be replaced with new ones. 101Apply Motor Oil to the following Pivots: © Side Stand © Kick Pedal © Clutch Lever © Front Brake Lever © Front Brake Cable Joint © Front Brake Cam Lever O Rear Brake Pedal © Rear Brake Rod Joint © Rear Brake Cam Lever Lubricate the following Cables with a Pressure Cable Lever O Brake Inner Cable O Clutch Inner Cable © Throttle Inner Cable Apply Grease to the following Points: O Brake Inner Cable Upper End © Clutch Inner Cable Upper End “O Speedometer Inner Cable "Grease the lower part of the inner cable sparingly. @ A. Grease 102NOTE OAfter connecting the cables, adjust them. OAfter installing the switch housing, cheek the throttle grip play and adjust it if necessary. OCheck that the throttle grip turns properly and that the inner cable slides smoothly. Olnsert the speedometer inner cable into the speedometer gear housing while turning the wheel so that the slot in the end of the cable will seat in the tongue of the speedometer pinion. Cleaning For the prolonged life of your motor- cycle, wash it down immediately after it has been splashed with seawater or ex- posed to the sea breeze; operated on rainy days, rough roads, or in dusty ar- eas; or operated on roads on which salt has been scattered for ice removal. Preparations for Washing Before washing, these precautions must be taken to keep water off the fol- lowing places: @Rear opening of the muffler — Cover with a plastic bag secured with a rub- ber band. @Clutch and brake levers, switch hous- ings on the handlebar - Cover with plastic bags. @lgnition switch — Cover the keyhole with tape. @Ajr cleaner intake — Close up the in- take with tape, or stuff with rags. 103Where to be Careful Avoid spraying water with any great force near the following places: ® Meter Unit @Front and rear hubs — If water gets inside the hubs, the brakes will not function until they dry out. @Under the fuel tank — If water gets into the ignition coil or into the spark plug cap, the spark will jump through the water and be grounded out. When this happens, the motorcycle will not start and the affected parts must be wiped dry. @Steering pivot (steering stem head pipe) ; @Swingarm pivot NOTE OCoin operated, high pressure spray washers are not recommended. The water may be forced into bearings and ather components causing eventual failure from rust and corrosion. Some 104 of the soaps which are highly alkaline leave a residue or cause spotting. After Washing @Remove all plastic bags and tape, and clean the air cleaner intake. @Lubricate the points listed in the Gen- eral Lubrication Section. @Test the brakes before motorcycle op- eration. @Start the engine and run it for 5 min- utesBolt and Nut Tightening In accordance with the Periodic Maintenance Chart, it is very important to check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. Refer to the Service Manual for torque values. wn Front Fork Clamp Bolt Handlebar Clamp Bolts . Clutch Lever Holder Bolts . Steering Stem Head Bolts 5, Muffler Mounting Nuts and Bolts Rear Shock Absorber Nuts and Bolts Brake Cam Lever Bolt Spokes Front Fender Mounting Bolts Engine Mounting Bolts . Shift Pedal Bolt . Footpeg Mounting Bolts . Side Stand Bolt . Pivot Shaft Nut Rear Axle Nut 105106 16. 7. 18. 19 20. 21 Cylinder Head Nuts Front Brake Lever Pivot Bolt Stem Head Clamp Bolt Torque Link Nuts Kick Pedal Bolt Front Axle Nut