1. Brake adjustment
a. Front brake lever free play adjustment
The brake can be adjusted by simply adjusting the free play of the brake lever. The piston in the caliper moves forward as the brake pad wears out, automatically adjusting the clearance betweenthe brake pads and brake disc.
Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:
Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.
Inspect each shift fork signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.
2. Roll the guide bar across a surface place. If the bar is bent, replace.
3. Check the shift cam grooves for signs of wear or damage. If any profile has excessive wear and/or damage, replace cam.
1. Removal
a. Open the seat.
b. Remove the side cover (left).
c. Remove the air cleaner case cover by removing the four screws.
d. Pull out the element.
I. Air filter element
WARNING:
Securely support the motorcycle so there is no danger of it falling over.
1. Raise the motorcycle or remove the front wheel so that there is no weight on the front end of the motorcycle. Remove the handlebar if necessary.
2. Remove the rubber cap from the top of each fork.
1. Oil level measurement a. Place the motorcycle on the center stand, Warm up the engine for several minutes.
NOTE:
Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings.
b. With the engine stopped, check the oil level through the level window located at the lower part of the right side crank-case cover.
Cylinder head disassembly
1. Remove the valve lifters and pads. Be careful not to scratch the lifter bodies or lifter bores in the cylinder head. Be very careful to identify each lifters position so that it may be returned to its original place.
1. Valve filter 2. Adjusting pad
INTRODUCTION