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12
and close the throttle several times, allowing it to snap shut
under its own pressure. Ensure that it is able to shut off quickly
and fully at all handlebar positions, then check that there is 2 —
6 mm (0.08 - 0.24 in) of cable free play, measured in terms of
twistgrip rotation. If adjustment is necessary, use first the
adjuster which is set below the twistgrip. If there is an
insufficient range of adjustment the surplus free play can be
eliminated by peeling back the rubber cover and by using the
adjuster on the carburettor top.
7
Check the clutch adjustment
Fine adjustment is provided on the handlebar lever by way
of a threaded adjuster and lockring. Should this prove
insufficient, a second adjuster nut and locknut can be found at
the cable lower end. These should be set to give 1 0 - 2 0 mm
(0.4 — 0.8 in) movement at the lever end before the clutch
begins to lift.
8
Check the brakes
The brakes are adjusted by a nut at the end of the brake
cable or rod, as appropriate, with the front brake having an
additional fine adjuster at the cable handlebar end. To adjust the
brakes place the machine on its centre stand with the wheel to
be adjusted clear of the ground. Spin the wheel and tighten the
adjusting nut until a rubbing sound is heard as the shoes begin
to contact the drum, then unscrew the nut by \ - 1 turn until
the sound ceases. Spin the wheel hard and apply the brake
firmly to settle all components, then re-check the setting. This
procedure should give the specified setting of 20 - 30 mm (0.8
- 1.2 in) free play, measured at the lever or pedal tip. Check that
the stop lamp rear switch is set so that the lamp lights just as
pedal free play is taken up and the brake is beginning to engage.
At regular intervals the wheels should be removed so that
each brake assembly can be cleaned and checked for wear.
Renew any worn components and apply a smear of grease to
the camshaft bearing surfaces on reassembly. See Chapter 5.4.
9
Check the wheels
Referring to Chapter 5.2 check the wheel rims for runout,
the spokes for straightness, security and even tension, and the
bearings for signs of free play. Any faults found must be
rectified immediately.
Support the machine so that it is secure with the front
wheel clear of the ground, then grasp the front fork legs near
the wheel spindle and push and pull firmly in a fore and aft
direction. If play is evident between the top and bottom fork
yokes and the steering head, the steering head bearings are in
need of adjustment. Imprecise handling or a tendency for the
front forks to judder may be caused by this fault.
Bearing adjustment is correct when the lockring is
tightened until resistance to movement is felt and then
loosened by \ to \ of a turn. The lockring should be rotated by
means of a C-spanner after slackening the steering stem nut.
Front brake adjuster nut
Routine maintenance
Take great care not to overtighten the lockring. It is possible
to place a pressure of several tons on the head bearings by
over-tightening even though the handlebars may seem to turn
quite freely. Overtight bearings will cause the machine to roll at
low speeds and give imprecise steering. Adjustment is correct if
there is no play in the bearings and the handlebars swing to full
lock either side when the machine is supported with the front
wheel clear of the ground. Only a light tap on each end should
cause the handlebars to swing. Secure the lockring by
tightening the steering stem nut to a torque setting of 6.0 - 9.0
kgf m (43 - 65 Ibf ft) then check that the setting has not altered.
Examine closely the front and rear suspension. Ensure that
the front forks work smoothly and progressively by pumping
them up and down whilst the front brake is held on. Any faults
revealed by this check should be investigated further. Check
carefully for signs of leaks around the front fork oil seals. If any
damage is found, it must be repaired immediately as described
in the relevant Sections of Chapter 4.
To check the swinging arm place the machine on its centre
stand then pull and push horizontally at the rear end of the
swinging arm; there should be no discernible play at the pivot.
Main clutch cable adjuster is at lower end of cable
Annually, or every 7200 miles (12 000 km)
Repeat all
headings, then carry out the following:
7
Renew the spark plug
The spark plug should be renewed at this interval,
regardless of its apparent condition.
Rear brake adjuster nut
service
operations
listed
Clean out accumulated sediment from
housing
under previous
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