MAINTENANCE 1.7 COOLING SYSTEM 1.1 GENERAL Checking Coolant Level in Overflow Bottle.......................1-16 Check for Coolant in System............................................1-16 Servicing a New Motorcycle...............................................1-1 Safe Operating Maintenance..............................................1-1 Shop Practices...................................................................1-1 Repair Notes...............................................................1-1 Safety..........................................................................1-1 Removing Parts...........................................................1-1 Cleaning......................................................................1-1 Disassembly and Assembly........................................1-2 Checking Torques on Fasteners..................................1-2 Magnetic Parts Trays...................................................1-2 Repair and Replacement Procedures................................1-2 Hardware and Threaded Parts....................................1-2 Threadlocking Agents..................................................1-2 Wiring, Hoses and Lines.............................................1-2 Instruments and Gauges.............................................1-2 Bearings......................................................................1-2 Bushings.....................................................................1-2 Gaskets.......................................................................1-2 Lip Type Seals.............................................................1-2 O-Rings (Preformed Packings)....................................1-3 Gears..........................................................................1-3 Shafts..........................................................................1-3 Part Replacement........................................................1-3 Exhaust System Leakage............................................1-3 Cleaning.............................................................................1-3 Part Protection............................................................1-3 Cleaning Process........................................................1-3 Hammers.....................................................................1-4 Punches/Chisels..........................................................1-4 Screwdrivers................................................................1-4 Ratchets and Handles.................................................1-4 Sockets........................................................................1-4 Storage Units...............................................................1-4 1.8 ENGINE OIL AND FILTER Checking and Adding Oil..................................................1-17 Cold Engine Oil Level Check.....................................1-17 Hot Engine Oil Level Check.......................................1-17 Changing Oil and Filter.....................................................1-18 1.9 BATTERY MAINTENANCE General.............................................................................1-20 Disconnection/Removal....................................................1-21 Cleaning and Inspection...................................................1-21 Charging Battery..............................................................1-22 Safety Precautions....................................................1-22 Using a Battery Charger............................................1-22 Installation/Connection.....................................................1-23 Storage.............................................................................1-23 1.10 BRAKES Fluid Inspection................................................................1-25 Rear Brake Pedal.............................................................1-26 Pedal Adjustment......................................................1-26 1.11 BRAKE PADS AND DISCS Inspection.........................................................................1-27 Brake Pads................................................................1-27 Brake Disc Thickness................................................1-27 Brake Disc Lateral Runout and Warpage..................1-27 TABLE OF CONTENTS General.............................................................................1-31 Procedure.........................................................................1-31 1.13 TIRES AND WHEELS Tires.................................................................................1-33 Wheel Bearings................................................................1-33 1.2 MAINTENANCE SCHEDULE 1.14 CLUTCH General...............................................................................1-5 General.............................................................................1-34 Checking Clutch Fluid Level.............................................1-34 1.3 FUEL AND OIL Fuel....................................................................................1-8 Gasoline Blends.................................................................1-8 Engine Lubrication..............................................................1-8 Winter Lubrication..............................................................1-9 1.15 BLEEDING CLUTCH FLUID LINE Procedure.........................................................................1-35 1.16 REAR BELT DEFLECTION 1.4 BULB REQUIREMENTS Inspection.........................................................................1-37 General.............................................................................1-10 1.17 REAR BELT AND SPROCKETS General.............................................................................1-39 Cleaning...........................................................................1-39 Inspection.........................................................................1-39 Sprockets..................................................................1-39 Rear Belt...................................................................1-39 1.5 AIR CLEANER AND EXHAUST SYSTEM Removal...........................................................................1-11 Installation........................................................................1-12 Exhaust System Leak Check............................................1-13 1.6 RADIATOR SIDE COVERS 1.18 DRIVE BELT REPLACEMENT Replacement....................................................................1-41 Removal...........................................................................1-14 Installation........................................................................1-15 1.19 DRIVE SPROCKET FLANGE Replacement....................................................................1-43 III ............................
........................... ............................ ............................ ............................ ............................ Brake Disc Lateral ......1-3 Brake Pad Replacement ......1-3 Rear Brake Caliper. ......1-3 Front Brake Caliper ......1-3 .....1-3 1.12 BLEEDING B ......1-3