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Suzuki RM250 manuals available for free PDF download: Owner's Service Manual
Suzuki RM250 Owner's Service Manual (270 pages)
Bike
Brand:
Suzuki
| Category:
Motorcycle
| Size: 28.24 MB
Table of Contents
General Information 1
10
Serial Number Location
5
Replacement Parts
7
Table of Contents
10
Location of Parts
11
Parts List
11
General Information
11
Fuel and Oil Recommendation
12
Operating Instructions
13
Starting the Engine
13
Stopping the Engine
14
Transmission
14
Break-In (Running-In)
14
When the Motorcycle Is New
14
When Engine Parts Are Replaced
14
Periodic Maintenance 2
16
Periodic Maintenance
18
Periodic Maintenance Chart
18
Inspection before Practice
20
INSPECTION before RACE (All Items of Inspection before Practice above Plus)
20
Spark Plug
21
Air Cleaner
22
Air Cleaner Element Removal
22
Washing
22
Installation
22
Transmission Oil
24
Transmission Oil Level Inspection and Replenishment
24
Transmission Oil Change
25
Engine Coolant
26
Engine Coolant Level Check
26
Engine Coolant Replenishment
27
Engine Cooling System Inspection
27
Clutch
28
Major Adjustment
28
Minor Adjustment
28
Throttle Cable
28
Fuel Hose
29
Fuel Valve
29
Cylinder Head, Cylinder and Piston
30
Cylinder Head
30
Cylinder
30
Piston
30
Exhaust Valve
30
Exhaust Silencer
31
Drive Chain and Sprockets
31
Drive Chain Slack
31
Drive Chain Adjustment
31
20Th Pitch Length
32
Drive Chain Lubrication
32
Sprocket Inspection
32
Drive Chain Guide, Buffer, Control Roller
33
Drive Chain Guide
33
Drive Chain Guide Buffer
33
Drive Chain Control Roller
33
Brakes
33
Brake Fluid Level
33
Brake Pad
34
Front Brake Lever Adjustment
34
Brake Pedal Height Adjustment
35
Front Fork
35
Air Pressure Adjustment
35
Steering
35
Rear Suspension
36
Wheels and Tires
36
Tire Pressure
36
Wheel Rim
36
Spoke Nipple
36
Lubrication
38
Machine Tuning
46
Carburetor Tuning
47
Components and Functions
47
Principles of Carburetor Tuning
47
Carburetor Tuning in Practice
51
Front Fork Tuning
54
Compression Damping Force Adjustment
54
Rebound Damping Force Adjustment
54
Oil Quantity Minor Adjustment
55
OIL CHANGE (Only for Outer Tube Oil Chamber)
56
Spring Change
58
Front Fork Tuning Procedure
60
Rear Suspension Tuning
61
Compression Damping Force Adjustment
61
Rebound Damping Force Adjustment
61
Spring Pre-Load Adjustment
62
Rear Suspension Tuning Procedure
63
Suspension Balance
65
Engine Removal and Installation
66
Exterior Parts
67
Construction
68
Seat Rail, Drive Chain Control Roller
68
Engine Dismounting
69
Engine Mounting
73
Inspection after Engine Mounting
75
Cylinder, Piston and Exhaust Valve
76
Construction
77
Cylinder, Piston
77
Exhaust Pipe, Silencer
78
Exhaust Valve
79
Removal
80
Cylinder Head
80
Cylinder
80
Piston and Piston Ring
81
Inspection
82
Cylinder Head
82
Cylinder
82
Piston to Cylinder Clearance
83
Conrod
83
Piston and Piston Ring
83
Installation
85
Piston and Piston Ring
85
Cylinder
86
Cylinder Head
87
Inspection after Installation
87
Exhaust Valve
88
Disassembly
88
Inspection
90
Reassembly
91
Exhaust Valve Governer and Actuator
94
Disassembly
94
Inspection
95
Reassembly
95
Clutch
98
Construction
99
Removal
100
Clutch Plate
100
Primary Driven Gear and Clutch Sleeve Hub
101
Clutch Release Camshaft
102
Inspection
102
Drive Plate
102
Driven Plate
102
Clutch Spring
103
Clutch Push Rod and Push Piece
103
Primary Driven Gear and Clutch Sleeve Hub
103
Bearing and Spacer
103
Clutch Release Camshaft
103
Oil Seal and Bearing
104
Installation
104
Primary Driven Gear
104
Clutch Plate
105
Clutch Cover
106
Clutch Release Camshaft
106
Inspection after Installation
106
Kick Starter
108
Construction
109
Removal
110
Inspection
111
Oil Seal
111
Kick Starter
111
Kick Starter Idle Gear
111
Reassembly
112
Inspection after Reassembly
113
Gearshifting
114
Construction
115
Removal
116
Inspection
118
Reassembly
119
Transmission and Crankshaft
122
Construction
123
Crankshaft and Crankcase
123
Transmission
124
Engine Bottom Side
125
Primary Drive Gear Removal
125
Crankcase Separation
126
Transmission Removal
127
Crankshaft Removal
127
Transmission Inspection
127
Crankshaft Inspection
129
Oil Seal Inspection
130
Oil Seal Removal
130
Oil Seal Installation
131
Bearing Inspection
132
Bearing Removal
133
Bearing Installation
134
Crankshaft Installation
134
Transmission Reassembly
135
Crankcase Reassembly
136
Primary Drive Gear Reassembly
137
Inspection after Installation
137
Fuel System
138
Carburetor
139
Construction
139
Removal and Disassembly
140
Cleaning
142
Inspection
143
Reassembly and Remounting
144
Carburetor Solenoid
145
Removal and Inspection
145
Reassembly
145
Throttle Position Sensor
146
Inspection
146
Removal
147
Reed Valve
148
Construction
148
Removal
148
Inspection
149
Reassembly
149
Cooling System
150
Construction
151
Cooling Circuit
152
Inspection
152
Radiator
153
Removal
153
Inspection
153
Installation
153
Water Pump
154
Removal
154
Inspection
155
Reassembly
156
Electrical System
158
Cautions in Servicing
159
Connector
159
Coupler
159
Semi-Conductor Equipped Part
159
Using the Multi-Circuit Tester
159
Switch
159
Location of Electrical Components
160
Construction
161
Magneto Rotor and Stator
161
Electrical Circuit
162
TROUBLESHOOTING (no Spark or Poor Spark)
162
Inspection
164
Ignition System Peak Voltage
164
Ignition Coil
165
Stator Coil
166
Magneto Rotor and Stator
167
Removal
167
Installation
168
Front and Rear Wheels
170
Front Wheel
171
Construction
171
Removal
172
Inspection
172
Bearing Replacement
173
Disc Plate Replacement
174
Installation
174
Rear Wheel
175
Construction
175
Removal
176
Inspection
176
Bearing Replacement
177
Disc Plate Replacement
177
Rear Sprocket Replacement
178
Installation
178
Front and Rear Brakes
180
Brake Pad Replacement
181
Front Brake Pads
181
Rear Brake Pads
181
Brake Fluid Replacement
183
Brake Fluid Air Bleeding
184
Brake Disc Inspection
185
Front Brake
186
Construction
186
Caliper
187
Master Cylinder
190
Brake Lever
192
Rear Brake
193
Construction
193
Caliper
194
Master Cylinder
197
Brake Pedal
199
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Suzuki RM250 Owner's Service Manual (230 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 39.37 MB
Table of Contents
Safety Precautions
3
Group Index
3
How to Use this Manual
4
Component Parts and Work to be Done
4
Symbol
5
General Information/Contents
6
Warning/Cautions for Servicing
7
Wear a Helmet and Googles/Protective Gear
10
Inspect Your Machine before Riding
10
Practice on Level Ground
10
Precautions
10
Serial Number Location
11
Location of Parts
12
Fuel and Oil Recommendation
13
Starting the Engine
14
Stopping the Engine
15
Transmission
15
Break-In (Running-In)
15
When Engine Parts Are New/Replaced
15
Country and Area Codes
16
Periodic Maintenance/Contents
17
Periodic Maintenance Chart
19
Inspection before Practice/Race
21
Spark Plug
22
Air Cleaner Element Removal
23
Washing
23
Installation
23
Transmission Oil Level Inspection and Replenishment
25
Transmission Oil Change
26
Engine Coolant Level Check
27
Engine Coolant Density-Freezing Point Curve
27
Engine Coolant Replenishment
28
Engine Cooling System Inspection
28
Clutch Major/Minor Adjustment
29
Throttle Cable
29
Fuel Hose/Valve
30
Cylinder/Cylinder Head
31
Piston
31
Exhaust Valve
31
Exhaust Silencer
32
Drive Chain Slack/Adjustment
32
20Th Pitch Length
33
Drive Chain Lubrication
33
Sprocket Inspection
33
Drive Chain Guide/Guide Buffer
34
Drive Chain Control Roller
34
Brake Fluid Level
34
Brake Pad
35
Front Brake Lever Adjustment
35
Brake Pedal Height Adjustment
36
Front Fork
36
Air Pressure Adjustment
36
Steering
36
Rear Suspension
37
Tire Pressure
37
Wheel Rim
37
Spoke Nipple
37
Rim Lock
38
Lubrication
39
Engine Dismounting and Mounting/Contents
40
Engine Dismounting
41
Engine Mounting
44
Inspection after Engine Mounting
45
Cylinder, Cylinder Head and Piston/Contents
46
Constrtuction
47
Cylinder/Cylinder Head Removal
48
Piston and Piston Ring Removal
49
Cylinder/Cylinder Head Inspection
50
Piston to Cylinder Clearance
50
Conrod
51
Piston and Piston Ring Inspection
51
Piston and Piston Ring Installation
52
Cylinder Installation
53
Cylinder Head Installation
54
Inspection after Installation
54
Clutch/Contents
55
Clutch Construction
56
Clutch Plate Removal
57
Primary Driven Gear Removal
58
Clutch Release Camshaft Removal
58
Drive/Driven Plate Inspection
59
Clutch Spring Inspection
59
Clutch Push Rod/Release Camshaft Inspection
60
Primary Driven Gear and Clutch Sleeve Hub Inspection
60
Bearing and Spacer Inspection
60
Oil Seal and Bearing Inspection
60
Primary Drive Gear Installation
61
Clutch Plate/Cover
62
Magneto Cover Installation
63
Kick Starter/Contents
64
Kick Starter Construction
65
Kick Starter Removal/Inspection
66
Kick Starter Reassembly
67
Magneto Rotor and Stator/Contents
69
Magneto Rotor and Stator Construction
70
Magneto Rotor and Stator Removal
71
Magneto Rotor and Stator Installation
72
Transmission and Crankshaft/Contents
74
Crankshaft and Crankcase Construction
75
Transmission Construction
76
Gearshift Linkage Removal
77
Primary Drive Gear Removal
77
Crankcase and Transmission Removal
78
Crankshaft Removal
79
Gearshift Shaft Inspection
79
Gearshift Cam Driven Gear Inspection
79
Transmission Inspection
79
Crankshaft Inspection
81
Conrod Inspection
81
Oil Seal Inspection and Removal
82
Oil Seal Installation
82
Bearing Inspection, Removal and Installation
83
Crankshaft Installation
84
Transmission Installation
84
Crankcase Installation
85
Gearshift Linkage Installation
86
Fuel System/Contents
88
Fuel System Construction
89
Carburetor Tuning
90
Carburetor Specifications
90
Carburetor Components and Fnctions
90
Slow/Power Jet
91
Air Screw
91
Needle Clip Position
92
Jet Needle
92
Needle Number
92
Main Jet
92
Throttle Stop Screw
93
Variation in Air (Oxygen) Concentration and Carburetor Conditions
94
Judging Air/Fuel Mixture
95
Tuning Procedure
95
Included Parts and Optional Parts
95
Carburetor Removal and Disassembly
97
Carburetor Inspection
99
Carburetor Reassembly and Remounting
99
Carburetor Solenoid Removal and Inspection
100
Carburetor Reassembly
100
Throttle Position Sensor Inspection
101
Throttle Position Sensor Removal and Remounting
102
Reed Valve Removal/Inspection/Reassembly
102
Cooling System/Contents
103
Cooling System Construction
104
Cooling Circuit Inspection
105
Radiator Cap Inspection
105
Rediator Removal
105
Water Pump Removal
106
Radiator Inspection
106
Impeller and Gear Shaft Inspection
107
Water Pump Bearing Inspection
107
Oil Seal Inspection
107
Bearing Replacement
107
Water Pump Reassembly
108
Exhaust Valve/Contents
110
Exhaust Valve Construction
111
Exhaust Side Valve (RH) Disassembly
112
Exhaust Side (Lh)/Main Valve Disassembly
113
Exhaust Valve Inspection/Reassembly
114
Exhaust Valve Governer and Actuator Disassembly
117
Exhaust Valve Governer and Actuator Inspection/Reassembly
118
Constructions/Contents
120
Exterior Parts
121
Handlebar Controls
122
Removal
122
Remounting
123
Seat Rail, Drive Chain Control Roller
125
Front and Rear Wheels/Contents
126
Front and Rear Wheels Construction
127
Front Wheel Removal and Reassembly
128
Rear Wheel Removal
128
Rear Wheel Reassembly
129
Spacer and Dust Seal Inspection
129
Axle Shaft Inspection
129
Wheel Rim Inspection
129
Wheel Bearing Inspection
130
Front/Rear Wheel Bearing Removal
130
Front/Rear Wheel Bearing Reassembly
131
Disc Plate Replacement
131
Rear Sprocket Replacement
132
Front and Rear Brakes/Contents
133
Front and Rear Brakes Construction
134
Bruid Fluid Air Bleeding
135
Brake Fluid Replacement
136
Front/Rear Brake Pads Replacement
137
Brake Disc Inspection
138
Caliper
138
Front Caliper Removal and Disassembly
139
Rear Caliper Removal and Disassembly
140
Caliper Inspection
140
Caliper Cleaning
141
Front Caliper Reassembly
141
Rear Caliper Reassembly
142
Front Master Cylinder Removal and Disassembly
143
Rear Master Cylinder Removal and Disassembly
144
Master Cylinder Inspection
144
Master Cylinder Cleaning
145
Front Master Cylinder Reassembly
145
Rear Master Cylinder Reassembly
146
Brake Pedal Removal/Reassembly
146
Front Fork and Steering/Contents
147
Front Fork and Steering Construction
148
Front Fork Tuning
149
Compression Damping Force Adjustment
149
Rebound Damping Force Adjustment
149
Oil Quantity Minor Adjustment
150
Adding/Reducing the Fork Oil
150
Oil Change (Only for Outer Tube Oil Chamber)
151
Spring Change
153
Front Fork Tuning Procedure
155
Suspension Balance
156
Balance Test/Tips
156
Front Fork Removal
157
Front Fork Disassembly
158
Inner Tube Removal
161
Center Bolt Inspection
162
Compression Damper Unit Inspection
162
Inner/Outer Tube Inspection
163
Damper Rod Inspection
163
Spring Coller Inspection
163
Fork Spring Inspection
163
Slide Bushing and Guide Bushing Inspection
164
Inner Tube Reassembly
164
Compression Damper Unit
165
Steering Removal
171
Suzuki RM250 Owner's Service Manual (230 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 29.73 MB
Table of Contents
Group Index
3
Component Parts and Work to be Done
4
Symbol
5
General Information
6
Warning/Caution/Note
7
General Considerations
10
Serial Number Location
11
Location of Parts
12
Fuel and Oil Recommendation
13
Operating Instructions
14
Starting the Engine
14
Stopping the Engine
15
Transmission
15
Break-In (Running-In)
15
When the Motorcycle Is New
15
Country and Area Codes
16
Periodic Maintenance
17
Periodic Maintenance Chart
19
Inspection before Practice
21
Inspection before Race
21
Spark Plug
22
Air Cleaner Element Removal
23
Washing
23
Transmission Oil Level Inspection and Replenishment
25
Transmission Oil Change
26
Engine Coolant Level Check
27
Engine Coolant Replenishment
28
Engine Cooling System Inspection
28
Clutch Major Adjustment
29
Clutch Minor Adjustment
29
Throttle Cable
29
Fuel Hose
30
Fuel Valve
30
Cylinder Head
31
Cylinder
31
Piston
31
Exhaust Valve
31
Exhaust Silencer
32
Drive Chain Slack
32
Drive Chain Adjustment
32
20Th Pitch Length
33
Drive Chain Lubrication
33
Sprocket Inspection
33
Drive Chain Guide
34
Drive Chain Guide Buffer
34
Drive Chain Control Roller
34
Brake Fluid Level
34
Brake Pad
35
Front Brake Lever Adjustment
35
Brake Pedal Height Adjustment
36
Front Fork
36
Air Pressure Adjustment
36
Steering
36
Rear Suspension
37
Wheels and Tires
37
Tire Pressure
37
Spoke Nipple
37
Lubrication
39
Engine Dismounting and Mounting
40
Cylinder, Cylinder Head and Piston
46
Construction
47
Cylinder Head Removal
48
Cylinder Removal
48
Piston and Piston Ring
49
Cylinder Head Inspection
50
Cylinder Inspection
50
Piston to Cylinder Clearance
50
Piston and Piston Ring Inspection
51
Piston and Piston Ring Installation
52
Cylinder Installation
53
Cylinder Head Installation
54
Inspection after Installation
54
Clutch
55
Clutch Construction
56
Clutch Plate Removal
57
Primary Driven Gear
58
Clutch Release Camshaft
58
Drive Plate Inspection
59
Driven Plate Inspection
59
Clutch Spring Inspection
59
Clutch Push Rod
60
Primary Driven Gear and Clutch Sleeve Hub
60
Oil Seal and Bearing
60
Clutch Plate
62
Magneto Cover
63
Kick Starter
64
Kick Starter Construction
65
Kick Starter Removal
66
Kick Starter Inspection
66
Kick Starter Reassembly
67
Kick Starter Inspection after Reassembly
68
Magneto Rotor and Stator
69
Magneto Rotor and Stator Construction
70
Magneto Rotor and Stator Removal
71
Magneto Rotor and Stator Installation
72
Magneto Rotor and Stator Inspection after Installation
73
Transmission and Crankshaft
74
Crankshaft and Crankcase Construction
75
Transmission Construction
76
Gearshift Linkage
77
Primary Drive Gear
77
Crankcase
78
Gearshift Shaft Inspection
79
Gearshift Cam Driven Gear Inspection
79
Transmission Inspection
79
Crankshaft Inspection
81
Conrod Inspection
81
Crankcase Oil Seal Inspection and Removal
82
Oil Seal Installation
82
Bearing Inspection, Removal and Installation
83
Fuel System
88
Fuel System Construction
89
Carburetor Tuning
90
Principles of Carburetor Tuning
90
Carburetor Components and Functions
90
Carburetor Specifications
90
Slow Jet
91
Air Screw
91
Power Jet
91
Needle Clip Position
92
Jet Needle
92
Needle Number
92
Main Jet
92
Throttle Stop Screw
93
Throttle Valve Opening
93
Carburetor Tuning in Practice
94
Variation in Air (Oxygen) Concentration and Carburetor Conditions
94
Judging Air/Fuel Mixture
95
Included Parts and Optional Parts
95
Carburetor Removal and Disassembly
97
Carburetor Solenoid
100
Throttle Position Sensor
101
Reed Valve
102
Cooling System
103
Cooling System Construction
104
Cooling Circuit Inspection
105
Radiator Cap
105
Radiator
105
Water Pump
106
Water Pump Bearing
107
Oil Seal
107
Exhaust Valve Disassembly
112
Exhaust Side Valve (LH)
113
Exhaust Main Valve
113
Exhaust Valve Governer and Actuator
117
Constructions
120
Exterior Parts
121
Handlebar Controls
122
Seat Rail, Drive Chain Control Roller
125
Front and Rear Wheels
126
Front and Rear Wheels Construction
127
Front Wheel Removal
128
Front Wheel Reassembly
128
Rear Wheel Removal and Reassembly
128
Rear Wheel Removal
128
Rear Wheel Reassembly
129
Front and Rear Wheel Inspection
129
Spacer and Dust Seal Inspection
129
Axle Shaft Inspection
129
Wheel Bearing Inspection
130
Front Wheel Bearing Removal
130
Rear Wheel Bearing Removal
130
Front Wheel Bearing Reassembly
131
Rear Wheel Bearing Reassembly
131
Disc Plate Replacement
131
Rear Sprocket Replacement
132
Front and Rear Brakes
133
Front and Rear Brakes Construction
134
Brake Fluid Air Bleeding
135
Brake Fluid Replacement
136
Brake Pads Replacement
137
Front Brake Pads
137
Rear Brake Pads
137
Brake Disc Inspection
138
Caliper
138
Front Caliper Removal and Disassembly
139
Rear Caliper Removal and Disassembly
140
Caliper Inspection
140
Caliper Cleaning
141
Front Caliper Reassembly
141
Rear Caliper Reassembly
142
Master Cylinder
143
Front Master Cylinder Removal and Disassembly
143
Rear Master Cylinder Removal and Disassembly
144
Master Cylinder Inspection
144
Master Cylinder Cleaning
145
Front Master Cylinder Reassembly
145
Rear Master Cylinder Reassembly
146
Brake Pedal Removal
146
Brake Pedal Reassembly
146
Front Fork and Steering
147
Front Fork and Steering Construction
148
Front Fork Tuning
149
Compression Damping Force Adjustment
149
Rebound Damping Force Adjustment
149
Oil Quantity Minor Adjustment
150
Adding the Fork Oil
150
Reducing the Fork Oil
150
Oil Change
151
Spring Change
153
Front Fork Tuning Procedure
155
Suspension Balance
156
Balance Test
156
Balancing Tips
156
Front Fork Removal
157
Front Fork Disassembly
158
Inner Tube
161
Center Bolt
162
Compression Damper Unit
162
Inner Tube and Outer Tube
163
Damper Rod
163
Spring Cooler
163
Fork Spring
163
Slide Bushing and Guide Bushing
164
Steering Removal
171
Steering Inspection
172
Steering Bearing Replacement
172
Steering Installation
173
Steering Inspection after Installation
173
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Suzuki RM250 Owner's Service Manual (152 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 18.85 MB
Table of Contents
Foreword
3
General Considerations
3
Warning/Caution/Note
3
Competition Motorcycles
3
Warnings for Servicing
4
Precaution for Servicing
5
Replacement Parts
5
Symbol Marks an Materials
6
Table of Contents
9
General Instructions
10
Location of Parts
10
Fuel
11
Operating Instructions
12
Starting the Engine
12
Stopping the Engine
12
When the Motorcycle Is New
13
Choke/Idle Adjust Knob
13
Break-In
13
Transmission
13
Inspection before Practice
14
Inspection before Race
14
Periodic Maintenance
14
Periodic Maintenance Chart
15
Spark Plug
16
Air Cleaner
16
Standard Spark Plug
16
Air Cleaner Element Removal
16
Washing
17
Installation
17
Transmission Oil Change
18
Transmission Oil
18
Transmission Oil Level Inspection and Replenishment
18
Engine Coolant
18
Cooling System Inspection
19
Clutch
20
Throttle Cable
20
Fuel Hose
20
Major and Minor Adjustment
20
Exhaust Silencer
21
Silencer Inspection and Replacement
21
Exhaust Valve
21
Cylinder Head, Cylinder Aand Piston
21
Drive Chain and Sprocket
22
Drive Chain Slack
22
Drive Chain Adjustment
22
Silencer Reassembly
22
Drive Chain Guide, Buffer, Tensioner Roller
23
Sprocket Inspection
23
Brakes
24
Drive Chain Tensioner Roller
24
Brake Fluid Level
24
Brake Pad
25
Front Brake Lever Adjustment
25
Brake Pedal Height Adjustment
25
Wheels and Tires
26
Steering
26
Rear Suspension
26
Front Fork
26
Lubrication
27
Tightening Torque
28
Engine
30
Troubleshooting
30
Chassis
33
Carburetor
34
Principles of Carburetor Tuning
34
Carburetor Specifications
34
Machine Tuning
34
Slow Jet
35
Air Screw
35
Main Jet
36
Jet Needle
36
Needle Number
36
Needle Clip Position
36
Carburetor Tuning in Practice
37
Variation in Air(Oxygen) Concentration and Carburetor Condition
37
Judging Air/Fuel Mixture
38
Tuning Procedure
38
Setting Parts and Optional Parts
38
Rebound Damping Force Adjustment
41
Compression Damping Force Adjustment
41
Air Pressure Adjustment
41
Front Fork Oil Level Adjustment
42
Front Fork Oil Air Bleeding
42
Front Fork Mounting Height Adjustment
43
Front Fork Tuning Procedure
44
Spring Pre-Load Adjustment
45
Rear Suspension Tuning Procedure
46
Balance Test
47
Balancing Tips
47
Suspension Balance
47
Engine Dismounting and Mounting
48
Cylinder, Piston and Exhaust Valve
51
Cylinder Head Removal
52
Cylinder Removal
52
Piston Removal
53
Exhaust Valve Removal
53
Cylinder Head Inspection
53
Cylinder Inspection
53
Piston and Piston Ring Inspection
54
Exhaust Valve Inspection
55
Exhaust Valve Reassembling
56
Conrod Inspection
56
Piston Ring and Piston Reassembling
56
Cylinder Reassembling
57
Clutch
59
Clutch Plate Removal
60
Clutch Plate Inspection
60
Drive Plate
60
Driven Plate
60
Rack and Pinion Inspection
61
Clutch Plate Reassembling
61
Primary Driven Gear Assy Removal
61
Primary Driven Gear Assy Inspection
62
Primary Driven Gear Assy Reassembly
62
Kick Starter
65
Kick Starter Removal
66
Kick Starter Inspection
66
Kick Starter Reassembly
67
Transmission and Crankshaft
69
Gearshift Linkage Removal
70
Primary Drive Gear
70
Crankcase Separation
70
Transmission Removal
71
Crankshaft Removal
71
Transmission Inspection
72
Crankshaft Inspection
73
Oil Seal Inspection, Removal and Installation
73
Bearing Inspection, Removal and Installation
74
Transmission Reassembly
75
Crankshaft Installation
75
Crankcase Reassembly
76
Gearshift Linkage Reassembly
77
Fuel System
79
Carburetor Removal
80
Reed Valve
81
Carburetor Inspection
81
Carburetor Reassembly
81
Reed Valve Removal
81
Cooling System
83
Engine Coolant Replacement
84
Radiator Cap Inspection
84
Radiator Removal/Reassembly
84
Water Pump Removal
84
Water Pump Reassembly
85
Electrical System
87
Ignition Coil Inspection
88
Checking with Electro Tester
88
Electrical Circuit
88
CDI Unit Inspection
89
Checking with Pocket Tester
89
Stator Coil Inspection
90
Magneto Rotor and Stator Removal and Reassembly
90
Magneto Rotor and Stator Reassembly
91
Front and Rear Wheels
93
Front and Rear Wheel Inspection
94
Axle Shaft Inspection
94
Rear Wheel Removal and Reassembly
94
Front Wheel Disassembly and Reassembly
94
Wheel Bearing Removal and Reassembly
95
Rear Wheel Spacer Inspection
95
Wheel Bearing Inspection
95
Disc Plate Replacement
96
Rear Sprocket Replacement
96
Front and Rear Brakes
97
Brake Fluid Air Bleeding
98
Brake Fluid Replacement
99
Brake Pads Replacement
99
Front Brake Pads
99
Rear Brake Pads
99
Brake Disc Inspection
100
Caliper
100
Front Caliper Removal and Disassembly
101
Rear Caliper Removal and Disassembly
102
Caliper Inspection
102
Caliper Cleaning
102
Front Caliper Reassembly
103
Rear Caliper Reassembly
103
Master Cylinder
104
Front Master Cylinder Removal and Disassembly
104
Rear Master Cylinder Removal and Disassembly
105
Master Cylinder Inspection
105
Master Cylinder Cleaning
106
Front Master Cylinder Reassembly
106
Rear Master Cylinder Reassembly
106
Brake Pedal Removal and Reassembly
107
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