Chassis Maintenance | XJCD online

Submitted by xjcdadmin on Thu, 09/20/2018 - 10:55

Model(s)

700N (Maxim)

700NC (Maxim)

FINAL GEAR OIL

Oil Level Measurement

1. Place the motorcycle on a level area and place on its centerstand.

2 Remove:
• Oil filler cap

3. Observe:
• Oil level (2)

Low level— Add oil. (1) Oil

NOTE:
Oil level must be up to the brim of the filler hole.

CAUTION:
Be sure that no foreign material enters the final gear case.

Gear Oil Replacement

1. Place a receptacle under the final gear case.

2. Remove:
• Filler cap
• Drain plug (1) Drain final gear oil.

3. Install:
• Drain plug

23 Nm (2.3 m-kg, 17ftlb)

4. Fill
• Gear case (to specified level.)

Final Gear oil:
SAE80 API "GL-4" Hypoid

gear oil Oil Capacity:
0.20 / (0.18 imp qt, 0.21 qt)

NOTE:
If desired, an SAE 80W90 Hypoid gear oil may be used for all conditions.

5. Install:
• Filler cap

23 Nm (2.3 m-kg, 17 ft-lb)

AIR FILTER

1. Remove:
• Seat
• Fuel tank
• Rubber cover

2. Remove:
• Air filter cover (1)

3. Eliminate:
• Dust

Use compressed air

4. Inspect:
• Element Damage - Replace.

CAUTION:
The engine should never be run without the air/filter element installed; excessive piston and/or cylinder wear may result.

5. Install:
• Element

CAUTION:
Make sure the element cover fits into the corresponding filter case edge.

FRONT BRAKE

Brake Fluid Inspection

1. Check:
• Brake fluid level

Level low — Replenish.

NOTE:
Use only a designated, quality fluid.

DOT NO. 3

NOTE:

Be sure that:
• Water does not enter the master cylinder when refilling.
• Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding.

(1) Lower level

FRONT BRAKE/REAR BRAKE

Front Brake Lever Free Play Adjustment

1. Loosen:
• Adjuster lockout (1)

2. Adjust:
• Free play (3)

Turn the adjuster (2) until the free play (3) is within the specified limits.

Brake Lever Free Play:

2-5 mm (0.08 ~ 0.2 in)

CAUTION:
Proper level free play is essential to avoid excessive brake drag.

3. Tighten:
• Adjuster locknut

Brake Pad Inspection

1. Activate the brake lever

2. Inspect:
• Wear indicator (1) Indicator almost contacts disc (2) — Replace pads. Refer to CHAPTER 5, "CHASSIS."

REAR BRAKE

Rear Brake Pedal Height Adjustment

1. Loosen:
• Adjust locknut (1) .

2. Adjust:
• Brake pedal height (2).

Turn the adjuster (3) until the brake pedal position is at the specified height.

Brake Pedal Height: 10 mm (0.4 in) Below the Top of the Footrest

Adjust pedal height, then adjust brake pedal free play.

REAR BRAKE

Rear Brake Shoe Inspection

1. Depress brake pedal

2. Inspect:
• Wear indicator (2)

Indicator at wear limit line — Replace brake shoes.

(1) Wear limit line

Rear Brake Pedal Free Play Adjustment

1. Rotate:
• Adjuster nut (1)

Turn it clockwise or counterclockwise until proper brake pedal free play is attained.

Brake Pedal Free Play:
20-30 mm (0.8 -1.2 in)

Check to verify correct brake light operation after adjustment.

Brake Light Switch Adjustment

1. Hold the switch body (1) with your hand so that it does not rotate and turn the adjusting nut (2) .

CABLE INSPECTION AND LUBRICATION

Cable inspection and lubrication steps:
• Remove the two screws that secure throttle housing to handlebar.
• Hold cable end high and apply several drops of lubricant to cable.
• Coat metal surface of disassembled throttle twist grip with suitable all-purpose grease to minimize friction.
• Check for damage to cable insulation. Replace any corroded or obstructed cables.
• Lubricate any cables that do not operate smoothly.

SAE 10W30 Motor Oil

BRAKE AND CHANGE PEDALS/ BRAKE CLUTCH LEVERS

Lubricate pivoting parts of each lever and pedal.

CENTERSTAND AND SIDESTAND

Lubricate centerstand and sidestand at their pivot points.

SAE 10W30 Motor Oil

FRONT FORK OIL CHANGE

Securely support the motorcycle so there is no danger of it falling over.

1. Place a suitable stand under the engine to raise the front wheel off the ground.

2. Loosen:
• Inner tube pinch bolt (1)

3. Remove:
• Fork cap (2)
• Cap bolt (3)

Use the Front Fork Cap Socket (YM-01104) (4)

4. Remove:

• Drain screw (1) Drain the fork oil.

Do not allow any oil to contact the disc brake components. If oil is discovered, be sure to remove it, otherwise diminished braking capacity and damage to the rubber components of the brake assembly will occur.

7. Inspect:
• O-ring (1) (Cap-bolt)
• Gasket (Drain screw) Wear/Damage — Replace.

8. Install:
• Drain screw

9. Fill:
• Front fork

Each Fork:
383cm³(13.51 impoz, 12.95 USoz)

After filling pump the forks slowly up and down to distribute the oil.

10. Tighten:
• Cap-bolt
• Pinch bolt

Cap Bolt: 23 Nm (2.3 rrvkg, 17ftlb)
Pinch Bolt: 20 Nm (2.0 mkg, 14ft-lb)

11. Install:
• Fork cap

REAR SHOCK ABSORBER ADJUSTMENT

If the spring seat is raised, the spring becomes stiffer, and if lowered, it becomes softer.

Standard Position: B A. — Softest (1) E. — Stiffest (2)

Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability.

STEERING HEAD ADJUSTMENT

Steering Head Inspection

1. Place the motorcycle on its centerstand, then elevate the front wheel.

2. Check:
• Steering assembly bearings

Grasp the bottom of the forks and gently rock the fork assembly back and forth. Looseness — Adjust.

Adjustment

Steering head adjustment steps:
• Remove the handlebar securing bolts (1)
• Remove the handlebars .
• Remove the steering stem nut (2)
• Loosen the pinch bolts (3) .
• Remove the steering crown (4) .
• Remove the lock washer (5) .
• Loosen the ring nut (6) ,
• Tighten the ring nut (7) .

Ring Nut (Lower):
50 Nm (5.0 m-kg, 36 ft-lb)

The tapered side of ring nuts must face downward.

• Loosen the ring nut (7) completely and retighten it to specification.

Ring Nut (Lower):
6Nm(0.6 m-kg,4.3ft-lb)

• Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings 8 .

(See CHAPTER 5, STEERING HEAD for more details.)

• Hand-tighten the ring nut (6) , then align the slots of both ring nuts. If not aligned, hold the lower ring nut (7) and tighten the other until they are aligned.

• Install the lock washer (5) .

NOTE:
Make sure the lock washer tab is placed in the slots.

• Install the steering crown (4) and tighten the steering stem nut (2) to specification.

Steering Stem Nut:
110 Nm (11.0 m-kg, 80 ft*]

• Install the handlebar and torque the bolt 0 to specification.

Pinch Bolt: 20Nm(2.0m-kg, 14ft-lb)
Handlebar Bolt: 20 Nm (2.0 m-kg, 14 ft-lb)

WHEEL BEARINGS

Front Wheel Bearings

1. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fork while spinning the wheel-Excessive vibration — Replace bearings.

Rear Wheel Bearings

1. Remove:
• Rear wheel

2. Check:
• Bearing movement Rotate with the fingers. Roughness/Wear — Replace.

TUBELESS TIRES AND ALUMINUM WHEELS

• Always inspect aluminum wheels before a ride.
• Place the motorcycle on its centerstand and check for cracks, bends, or warpage of the wheels.
• Do not attempt any repairs to the wheel; replace any defective wheel.
• Do not attempt to use tubeless tires on a wheel designed for use with tube-type tire only. Tire failure and subsequent personal injury may result from sudden deflation.
• Be sure to install the proper tube when using tube-type tires.
• New tires have a relatively poor adhesion on the road surface so do not allow them to be subjected to high speed load from maximum speed until after a break-in run of approx. 100 km (60 mi).
• Always use the correct tire inflation pressure acording to the operating conditions.

Wheel	Tire
Tube type	Tube type only
Tubeless	Tube type or tubeless

A Tire	C Tubeless tire
B Wheel	D Tube type tire

(1) Air valve
(2) Aluminum wheel (Tubeless type)
(3) Tube
(4) Aluminum wheel (tube type)

Always perform the following steps to ensure safe operation, maximum tire performance, and long service. 1. Measure:

• Tire pressure Out of specification — Adjust.

Basic weight: With oil and full fuel tank	224 kg (494 lb)
Maximum load *	246 kg	542 lb)
Cold tire pressure	Front	Rear
Upto90kg(198lb) load"	177 kPa (1.8 kg/cm². 26 psi)	196 kPa (2.0 kg/cm². 28 psi)
90 kg (198 lb) load ~ 246 kg (542 lb) load-	196 kPa (2.0 kg/cm*, 28 psi)	275 kPa (2.8 kg/cm². 40 psi)
High speed riding	206 kPa (2.1 kg/cm? 30 psi)	225 kPa (2.3 kg/cm² 32 psi)