Table of Contents
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CONTENTS
1. OPERATING INSTRUCTIONS ...........................
Fuel .................................................................
Basic Operation .............................................
• Starting The Engine ...............................
• Stopping The Engine .............................
• Break-In Procedure .................................
Controls ..........................................................
Control Adjustment .......................................
• Clutch Lever Free Play ...........................
• Clutch Lever Position .............................
• Throttle Grip ...........................................
• Front Brake Lever ...................................
• Brake Pedal Height .................................
Adjustment For Personal Fit .........................
• Control Positioning ................................
Adjustments ............................................
2. SPECIFICATIONS ...............................................
3. OPTIONAL PARTS ...........................................
4. SERVICE AND MAINTENANCE ....................... 11
Pre-ride Inspection Check List ..................... 11
Maintenance Schedule ................................. 11
General Service Information ....................... 12
Maintenance ................................................. 12
After Race Maintenance ............................... 13
• After Race Lubrication .......................... 13
• Routine Cleaning ................................... 13
• Pressurized Spray Washers .................. 13
• Condensation Control ........................... 13
• After Cleaning Lubrication .................... 13
General Maintenance ................................... 14
Maintenance Preparations ............................. 17
• Seat ........................................................... 17
• Fuel Tank .................................................. 17
• Subframe ................................................. 19
Maintenance Procedures ............................. 20
• Transmission Oil ................................... 20
• Coolant ................................................... 21
• Spark Plug .............................................. 22
• Ignition ................................................... 22
• Air Cleaner ............................................. 23
• Clutch ..................................................... 24
• RC Valve ................................................. 25
• Reed Valve ............................................. 28
2
2
• Cylinder Head/Cylinder/Piston ............. 29
3
3
• Nuts, Bolts, Fasteners ........................... 35
3
3
4
Bearings ................................................. 35
• Throttle Grip .......................................... 35
5
• Fuel Line ................................................. 35
5
• Carburetor .............................................. 36
5
• Front And Rear Wheels And Tires ....... 36
6
• Front Suspension .................................. 37
7
• Rear Suspension ................................... 38
7
• Brakes ..................................................... 39
7
• Drive Chain ............................................ 41
7
• Drive Chain Sliders ................................ 43
7
• Drive Chain Rollers ................................ 43
• Driven Sprocket ..................................... 43
8
• Expansion Chamber .............................. 44
9
• Control Cables ....................................... 44
10
• Torque Table .......................................... 45
5. CARBURETOR ADJUSTMENT ........................ 46
• Carburetor .............................................. 46
• Tuning For Special Conditions ............. 51
• Spark Plug Coloring Indications ........... 51
6. SUSPENSION ADJUSTMENT ......................... 52
• Race Sag ................................................ 52
• Rear Suspension ................................... 53
• Front Suspension .................................. 55
Specific Track Conditions ..................... 70
CONDITIONS .................................................... 74
• Rear End ................................................. 74
• Fork Height/Angle .................................. 74
• Wheelbase ............................................. 74
8. GEARING SELECTION ..................................... 74
9. TIRE SELECTION .............................................. 75
LOGBOOK ......................................................... 76
11. SPARE PARTS & EQUIPMENT ........................ 78
12. TROUBLESHOOTING ....................................... 79
Speeds .................................................... 79
• Poor Performance At High Speed ........ 79
13. CLEANING ........................................................ 80
29
14. STORAGE.......................................................... 81
30
Storage ................................................... 81
• Removal From Storage ......................... 81
15. WIRING DIAGRAM ............................................. 82
16. INDEX .................................................................. 83
17. AUTHORIZED MANUALS .................................. 84
1
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