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Manual do proprietario corsa wind 2000 download |
Manual do proprietario corsa wind 2000 download
Radiator 1 Radiator hose joint 2 Coolant leakage Repair or replace. Radiator hose 3 Swelling Replace. Check: Throttle grip free play a Out of specification Adjust. Adjust: Throttle grip free play Throttle grip free play adjustment steps: Remove the throttle cable cover 1.
Remove: Rubber cover 1 Throttle grip cap 2 2. Apply: Lithium soap base grease On the throttle cable end a. Install: Throttle grip cap Screw throttle grip cap 4 Nm 0. Adjust: Decompression lever free play Adjustment steps: Loosen the locknut 1. Turn the adjuster 2 in or out until the adjustment is suitable. Tighten the locknut.
CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebar is turned fully both ways. Arbeitsschritte Fasi di regolazione: Serrer ou desserrer le dispositif de Die Sicherungsmutter 1 lok- Svitare il controdado 1. Inspect: Air filter element Damage Replace. Apply: Foam-air-filter oil or engine oil to the ele- ment. NOTE: Squeeze out the excess oil. Element should be wet but not dripping.
Endommagement Rempla- Danni Sostituire. Remove: Oil tank cap 1 4. Inspect: Oil level Oil level should be between maximum a and minimum b marks.
Oil level is low Add oil to proper level. NOTE: When inspecting the oil level, do not screw the oil tank cap into the oil tank. Recommended oil: Refer to the following chart for 10W selection of oils which are suited 10W to the atmospheric temperatures. Remove: Oil tank cap 1 Frame oil drain bolt 2 Crankcase oil drain bolt 3 Oil filter element drain bolt 4 Drain the crankcase and oil tank frame of its oil. Remove: Lower engine bracket Oil hose clamp 1 Bolt oil hose 2 Oil hose Install: Copper washer 1 Oil strainer frame 2 90 Nm 9.
Check: Oil pressure Checking steps: Slightly loosen the oil pressure check bolt Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. Start the engine and thoroughly warm it 2. Attach: Inductive tachometer To spark plug lead. Adjust: Engine idling speed Adjustment steps: Adjust the pilot screw. NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily. Align the T. The field where these two coordinates intersect shows the new pad number to use.
NOTE: Use the new pad number only as a guide when verifying the valve clearance adjust- ment. A brake hose has been loosened or removed. The brake fluid is very low. The brake operation is faulty. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared.
Add brake fluid to the level line on the reservoir. Check: Brake pedal height a Out of specification Adjust. Brake pedal height a: 5 mm 0. Adjust: Brake pedal height Pedal height adjustment steps: Loosen the locknut 1. Remove the brake hose holder 3 and brake caliper 4 from the front fork. Remove the pad pin and brake pads 5.
Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end. Svitare la spina della pastiglia 2. Pad pin plug: 3 Nm 0. Check: Brake lever operation A softy or spongy feeling Bleed brake system. Installer le bouchon de goupille de Installare la spina delle pastiglie plaquette B. Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. Loosen the bleed screw and push the brake caliper piston in.
Check: Brake pedal operation A softy or spongy feeling Bleed brake system. Inspect: Sprocket teeth a Excessive wear Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. Remove: Master link clip Joint 1 Drive chain 2 2.
Adjust: Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. Adjust chain slack by turning the adjusters To tighten Turn adjuster 3 counter- clockwise. To loosen Turn adjuster 3 clockwise and push wheel forward. The adjuster may be damaged. Uneven adjustment can cause poor handling and loss of stability. Elevate the rear wheel by placing the suitable stand under the engine. Remove: Rear frame 3. Loosen: Locknut 1 4.
Adjust: Spring preload By turning the adjuster 2. Stiffer Increase the spring preload. Adjust: Rebound damping force By turning the adjuster 1. Stiffer a Increase the rebound damp- ing force. Turn the adjuster 1 in. Softer b Decrease the rebound damp- ing force. Adjust: Low compression damping force By turning the adjuster 1.
Stiffer a Increase the low compres- sion damping force. Softer b Decrease the low compres Adjust: High compression damping force By turning the adjuster 1. Stiffer a Increase the high compres- sion damping force.
Softer b Decrease the high compres Measure: Tire pressure Out of specification Adjust. Standard tire pressure: kPa 1. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. Inspect: Bearing free play Exist play Replace. Elevate the front wheel by placing a suit- able stand under the engine. Check: Steering shaft Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth.
Il y a du jeu Remplacer. Esiste gioco Sostituirlo. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Remove: Spark plug 2. Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color Check the engine condition.
NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in Remove: Timing mark accessing screw 1 2. Attach: Timing light Inductive tachometer To the spark plug lead.
Check: Ignition timing Checking steps: Start the engine and let it warm up. Inspect: Gasket 1 Damage Replace. Install: Gasket Exhaust pipe 1 Nut exhaust pipe 2 13 Nm 1. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter Install: Right radiator 1 Bolt right radiator 2 10 Nm 1. Install: Left radiator 1 Bolt left radiator 2 10 Nm 1. Clamp Throttle position sensor lead cou- pler Throttle cable cover Throttle cable Throttle shaft assembly Push rod link lever assembly Intake joint Pilot air jet Main air jet Cold starter plunger Hot starter plunger red 4 - Contamination Clean.
NOTE: Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. Measure: Float height a Out of specification Adjust.
Float height: 8. NOTE: Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. Accelerator pump 1. Dirt Clean. Install: Spring 1 1 Lever 1 2 To lever 2 3. NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. Install: Spring 2 1 To lever 2 2. Install: Push rod link lever assembly 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.
Fit the projection a on the throttle shaft assembly into the slot b in the throttle posi- tion sensor. Check the float for smooth movement. Install: Pilot screw 1 Spring 2 Washer 3 O-ring Montieren: Monter: Install: Throttle valve assembly 1 Screw throttle shaft 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve.
Tighten: Screw air filter joint 1 3 Nm 0. Camshaft cap Clip Exhaust camshaft Intake camshaft Remove: Timing mark accessing screw 1 Crankshaft end accessing screw 2 2. Align: T. Checking steps: Turn the crankshaft counterclockwise with a wrench. Measure: Cam lobe length a and b Out of specification Replace. Measure: Camshaft-to-cap clearance Out of specification Measure bearing diameter camshaft Camshaft-to-cap clearance: 0.
Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
Damage improper valve timing will result. Install the clips, camshaft caps 4 and bolts camshaft cap 5. Bolt camshaft cap : 10 Nm 1. Page Cylinder head cover 3 Bolt cylinder head cover 4 10 Nm 1. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm 1. Eliminate: Carbon deposits from the combustion chambers Use a rounded scraper.
Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden. Install: Decompression shaft 1 Copper washer 2 Bolt decompression shaft 3 10 Nm 1. Install: Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side Valve lifter Use special tool. Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
Check: Valve sealing Leakage at the valve seat Inspect Clearance stem to guide : Intake: 0. Measure: Runout valve stem Out of specification Replace. Runout limit: 0. If the valve is removed or replaced always replace the oil seal. Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.
Lapping steps: Apply a coarse lapping compound to the valve face. Measure: Valve spring free length a Out of specification Replace. Free length valve spring : Intake: Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. Install: Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters.
To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Bolt cylinder Cylinder Piston pin clip Piston pin Use special tool. Before removing each piston pin, deburr the clip groove and pin hole area.
If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4. Measure: Ring side clearance Use a feeler gauge 1.
Out of specification Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Utilizzare uno spessimetro 1. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter piston pin If out of specification, replace the piston pin.
Outside diameter piston pin : Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. Install: Cylinder gasket 1 Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand.
Be careful not to damage the timing chain guide 4 during installation. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - Measure: Friction plate thickness Out of specification Replace friction plate as a set. Measure at all four points.
Friction plate thickness: 2. Mesurer chaque disque en qua- erneuern. Install: Push lever shaft 1 Bolt push lever shaft 2 10 Nm 1. Apply the engine oil on the push lever shaft. Bend the lock washer 1 tab. Install the cushion spring with the paint b facing out. Install: Pressure plate 1 9.
Install: Clutch spring 1 Bolt clutch spring 2 8 Nm 0. Oil seal Bearing 4 - Fur deposits Clean. EC Impeller shaft gear 1. EC4H Bearing 1. Inspect: Bearing Rotate inner race with a finger. Impeller shaft 1. Install: Impeller shaft 1 Washer 2 Impeller 3 14 Nm 1. Install: Right crankcase cover 1 Bolt right crankcase cover 2 10 Nm 1. Mesh the impeller shaft gear 3 with primary drive gear 4. Install: Water pump housing 1 Bolt water pump housing 2 10 Nm 1.
Straighten the lock washer tab. Loosen: Nut primary drive gear 1 Nut balancer shaft driven gear 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4. When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft.
Fit the dowel pin into the groove in the inner rotor 1. EC4C Shift guide and shift lever assembly 1. Spring 2 Broken Replace. Install: Torsion spring 1 Stopper lever 2 Bolt stopper lever 3 10 Nm 1. Install: Bolt shift guide 1 10 Nm 1. Install: Torsion spring 1 To kick shaft 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft. Install: Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring.
Remove: Nut rotor 1 Washer 2 Use the rotor holding tool 3. Remove: Rotor 1 Use the flywheel puller 2. Page Apply the sealant on the grommet of the CDI magneto lead. Tighten the screws using the T30 bit.
Install: Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Screw left crankcase cover 3 10 Nm 1. Support the machine securely so there is no danger of it falling over. Loosen the nut while applying the rear brake. Install: Engine 1 Install the engine from right side. Pivot shaft 2 85 Nm 8. Install: Lock washer 1 Nut drive sprocket 2 75 Nm 7. Bend the lock washer tab to lock the nut.
Clutch cable holder Right crankcase Left crankcase Oil strainer Separate: Right crankcase Left crankcase Separation steps: Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. Remove: Crankshaft 1 Use the crankcase separating tool 2.
Crankcase bearing 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification Replace. Use the dial gauge and a thickness gauge. Install: Bearing Bearing stopper Screw bearing stopper 10 Nm 1. Page 10 Nm 1. Apply: Sealant On the right crankcase 1. Install: Dowel pin Tighten: Hose guide 1 Clutch cable holder 2 Bolt crankcase 3 12 Nm 1.
Install: Oil delivery pipe 2 1 O-ring 2 Bolt oil delivery pipe 2 3 10 Nm 1. Remove assembly carefully. Check: Shift fork movement Unsmooth operation Replace shift fork. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift fork.
Install: 2nd wheel gear 28T 1 4th wheel gear 27T 2 3rd wheel gear 29T 3 5th wheel gear 25T 4 1st wheel gear 30T 5 O-ring 6 To drive axle 7. NOTE: Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end surface. NOTE: Apply the molybdenum disulfide oil on the shift fork grooves. EC Wheel bearing if necessary 1. Measure: Wheel axle bends Out of specification Replace. Measure: Cam lobe length a and b Out of specification Replace.
Measure: Camshaft-to-cap clearance Out of specification Measure bearing diameter camshaft Camshaft-to-cap clearance: 0. Check: While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly. Damage improper valve timing will result. Install the clips, camshaft caps 4 and bolts camshaft cap 5. Bolt camshaft cap : 10 Nm 1. Page Cylinder head cover 3 Bolt cylinder head cover 4 10 Nm 1. Install: Oil tank breather hose Cylinder head breather hose Spark plug 13 Nm 1.
Eliminate: Carbon deposits from the combustion chambers Use a rounded scraper. Einen abgerundeten Scha- Utilizzare un raschietto arro- ber verwenden. Install: Decompression shaft 1 Copper washer 2 Bolt decompression shaft 3 10 Nm 1. Install: Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side Valve lifter Use special tool.
Remove: Valve lifter 1 Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. Check: Valve sealing Leakage at the valve seat Inspect Clearance stem to guide : Intake: 0. Measure: Runout valve stem Out of specification Replace. Runout limit: 0. If the valve is removed or replaced always replace the oil seal. Lap: Valve face Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.
Lapping steps: Apply a coarse lapping compound to the valve face. Measure: Valve spring free length a Out of specification Replace. Free length valve spring : Intake: Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. Install: Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters.
To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Bolt cylinder Cylinder Piston pin clip Piston pin Use special tool. Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4.
Measure: Ring side clearance Use a feeler gauge 1. Out of specification Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.
Utilizzare uno spessimetro 1. Measure: Piston pin-to-piston clearance Measurement steps: Measure the outside diameter piston pin If out of specification, replace the piston pin.
Outside diameter piston pin : Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. Install: Cylinder gasket 1 Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. Be careful not to damage the timing chain guide 4 during installation. Clutch boss Thrust washer Primary driven gear Push lever shaft 4 - Measure: Friction plate thickness Out of specification Replace friction plate as a set.
Measure at all four points. Friction plate thickness: 2. Mesurer chaque disque en qua- erneuern. Install: Push lever shaft 1 Bolt push lever shaft 2 10 Nm 1. Apply the engine oil on the push lever shaft. Bend the lock washer 1 tab. Install the cushion spring with the paint b facing out. Install: Pressure plate 1 9. Install: Clutch spring 1 Bolt clutch spring 2 8 Nm 0.
Oil seal Bearing 4 - Fur deposits Clean. EC Impeller shaft gear 1. EC4H Bearing 1. Inspect: Bearing Rotate inner race with a finger.
Impeller shaft 1. Install: Impeller shaft 1 Washer 2 Impeller 3 14 Nm 1. Install: Right crankcase cover 1 Bolt right crankcase cover 2 10 Nm 1. Mesh the impeller shaft gear 3 with primary drive gear 4. Install: Water pump housing 1 Bolt water pump housing 2 10 Nm 1. Straighten the lock washer tab. Loosen: Nut primary drive gear 1 Nut balancer shaft driven gear 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4.
When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft. Fit the dowel pin into the groove in the inner rotor 1. EC4C Shift guide and shift lever assembly 1.
Spring 2 Broken Replace. Install: Torsion spring 1 Stopper lever 2 Bolt stopper lever 3 10 Nm 1. Install: Bolt shift guide 1 10 Nm 1. Install: Torsion spring 1 To kick shaft 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft. Install: Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring.
Remove: Nut rotor 1 Washer 2 Use the rotor holding tool 3. Remove: Rotor 1 Use the flywheel puller 2. Page Apply the sealant on the grommet of the CDI magneto lead.
Tighten the screws using the T30 bit. Install: Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Screw left crankcase cover 3 10 Nm 1.
Support the machine securely so there is no danger of it falling over. Loosen the nut while applying the rear brake. Install: Engine 1 Install the engine from right side.
Pivot shaft 2 85 Nm 8. Install: Lock washer 1 Nut drive sprocket 2 75 Nm 7. Bend the lock washer tab to lock the nut. Clutch cable holder Right crankcase Left crankcase Oil strainer Separate: Right crankcase Left crankcase Separation steps: Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3.
Remove: Crankshaft 1 Use the crankcase separating tool 2. Crankcase bearing 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance Crank width d Out of specification Replace.
Use the dial gauge and a thickness gauge. Install: Bearing Bearing stopper Screw bearing stopper 10 Nm 1. Page 10 Nm 1. Apply: Sealant On the right crankcase 1. Install: Dowel pin Tighten: Hose guide 1 Clutch cable holder 2 Bolt crankcase 3 12 Nm 1. Install: Oil delivery pipe 2 1 O-ring 2 Bolt oil delivery pipe 2 3 10 Nm 1. Remove assembly carefully. Check: Shift fork movement Unsmooth operation Replace shift fork.
NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift fork. Install: 2nd wheel gear 28T 1 4th wheel gear 27T 2 3rd wheel gear 29T 3 5th wheel gear 25T 4 1st wheel gear 30T 5 O-ring 6 To drive axle 7.
NOTE: Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end surface.
NOTE: Apply the molybdenum disulfide oil on the shift fork grooves. EC Wheel bearing if necessary 1. Measure: Wheel axle bends Out of specification Replace. Use the dial gauge 1. Wheel axle bending limit: 0. Use a socket that matches the outside diam- eter of the race of the bearing. Install: Nut wheel axle 1 Nm Tighten: Bolt axle holder 1 23 Nm 2. Install: Rear wheel sprocket 1 Bolt rear wheel sprocket 2 Washer rear wheel sprocket 3 Nut rear wheel sprocket 4 42 Nm 4.
NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. Install: Copper washer 1 Union bolt 2 30 Nm 3.
Install: Brake disc cover 1 Bolt brake disc cover 2 7 Nm 0. Install: Copper washer 1 Brake hose 2 Union bolt 3 30 Nm 3. Clean: Brake master cylinder Brake master cylinder kit Clean them with brake fluid. NOTE: Apply the brake fluid on the brake master cyl- inder cup. Install: Brake lever 1 Bolt brake lever 2 6 Nm 0.
Front brake hose 1. Install: Brake hose 1 10 Nm 1. Install: Brake hose holder 1 Screw brake hose holder 2 4 Nm 0. Inspect: Brake fluid level Fluid at lower level Fill up. Fork spring Drain the fork oil. So it is recommended that the front fork be main- tained at the dealers. Page N. Remove: Dust seal 1 Stopper ring 2 Using slotted-head screwdriver. Remove: Inner tube 1 Oil seal removal steps: Push in slowly a the inner tube just before it bottoms out and then pull it back quickly Repeat this step until the inner tube can be pulled out from the outer tube.
O-ring 2 Damage Replace. EC Fork spring 1. Measure: Fork spring free length a Out of specification Replace. Fork spring free length: mm O-ring 2 Remplacer. Joint torique 2 O-Ring 2 Danni Sostituire. Endommagement Rempla- cer. Wash the all parts in a clean solvent. Install: Damper rod 1 To inner tube 2. Install: Spring guide 1 Locknut 2 To damper rod 3. NOTE: Install the spring guide with its cut a facing upward.
With its thread b facing upward, fully finger tighten the locknut onto the damper rod. Install: Slide metal 1 Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Compress the front fork fully. Fill: Front fork oil Until outer tube top surface with recom- mended fork oil 1. Kontrollieren: Ripetere le fasi da 2 a Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level.
NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Zehn Minuten warten, bis et- Measure: Distance a Out of specification Turn into the locknut. Distance a: 20 mm 0. Messen: Mesurer: Sicherungsmutter hineindre- controdado. Tighten: Front fork cap bolt locknut 1 29 Nm 2. Hold the locknut 5 and tighten the front fork cap bolt with specified torque.
Festziehen: Serrer: Tighten: Pinch bolt upper bracket 1 23 Nm 2. Decompression cable Disconnect at the lever side. Decompression lever holder Clutch cable Disconnect at the lever side. Keep the brake master cylinder cap side horizontal to prevent air from coming in. Install: Handlebar 1 Handlebar upper holder 2 Bolt handlebar upper holder 3 28 Nm 2.
First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side. Install: Collar 1 Throttle cables 2 To tube guide 3. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion.
Install: Throttle cable cap 1 Screw throttle cable cap 2 4 Nm 0. Install: Engine stop switch 1 Clutch lever holder 2 Bolt clutch lever holder 3 4 Nm 0. Remove: Steering ring nut 1 Use the steering nut wrench 2. Lower bearing 1.
Remove: Lower bearing 1 Use the floor chisel 2. Wash the bearings and ball races with a solvent. Install the bearing in the ball races. Spin the bearings by hand. If the bear- ings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. Install: Washer 1 Steering ring nut 2 7 Nm 0.
After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. Adjust: Front fork top end a Front fork top end standard a: 5 mm 0. Swingarm 1. Install: Bearing 1 Oil seal 2 To swingarm. NOTE: Apply the molybdenum disulfide grease on the bearing when installing.
NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings and oil seal lips. Install: Collar 1 To relay arm 2. NOTE: Apply the molybdenum disulfide grease on the collars, bearings and oil seal lips. NOTE: Apply the molybdenum disulfide grease on the bolt.
Do not tighten the nut yet. Install: Swingarm 1 Pivot shaft 2 85 Nm 8. Tighten: Nut connecting rod 1 80 Nm 8. Tighten: Nut relay arm 1 80 Nm 8.
Reihen- Demontage-Arbeiten Bauteil Anz. Page 1. Remove: Stopper ring upper bearing 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. Install: Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Tighten: Adjuster 1 3. Adjust: Spring length installed a Spring length installed a: Standard Extent of length adjustment mm 9.
Apply the lithium soap base grease on the bushing, collars and dust seals. Install the dust seals with their lips facing outward. Sky blue 2 Throttle position sensor B Black W White Br Brown 3 Neutral switch Y Yellow G The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.
Disconnect the spark plug cap from spark plug. Connect the dynamic spark tester 1 ignition checker 2 as shown. Inspect: Primary coil resistance Out of specification Replace. Fuori specifica Regolare. Inspect: Charging coil 1 resistance Out of specification Replace.
No good Check entire ignition Repair or replace. No good Check throttle position Throttle posi- Replace. Inspect: Throttle position sensor coil resistance Out of specification Replace.
Remove: Throttle position sensor coupler Screw throttle position sensor 1 Washer 2 Throttle position sensor 3 NOTE: Loosen the screws throttle position sensor using the T20 bit tamper resistant fastener type.
Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc. Perform a test run to check for proper engine performance e. During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carbure- tor parts may prevent the carburetor from functioning correctly. Bien veiller, lors Schmutz, Sand, Wasser usw.
Standard main jet If the air-fuel mixture is too rich or too lean, the Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. Discoloration of spark plug Hard breathing Gradually If tan color, it is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat Clogged fuel hose The front fork setting includes the following three factors: 1.
Setting of air spring characteristics Change the fork oil level.
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