Мануал kawasaki kle 500 на русском языке

Популярность:

33749 просмотры

Подсчет страниц:

401 страницы

Тип файла:

PDF

Размер файла:

6.3 Mb

Quick Reference Guide

Read OWNER’S MANUAL before operating.

Foreword

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the negative wire

(–) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (–) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and them remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Apply specified grease to lip of seal before installing the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.

1-6 GENERAL INFORMATION

Before Servicing

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

GENERAL INFORMATION 1-7

Model Identification

KLE500-B1 Left Side View

KLE500-B1 Right Side View

1-8 GENERAL INFORMATION

General Specifications

1-10 GENERAL INFORMATION

General Specifications

Specifications subject to change without notice, and may not apply to every country.

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

PERIODIC MAINTENANCE 2-5

Periodic Maintenance Chart

Periodic Replacement Parts

#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. A bolt or nut which is overtightened may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn and then tighten it to the specified torque.

Letters used in the «Remarks» column mean:

EO: Apply engine oil to the threads and seating surface.

L:Apply a non-permanent locking agent to the threads. LG: Apply liquid gasket to the threads.

Lh: Left-hand threads.

M:Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1)

R:Replacement parts.

S:Tighten the fasteners following the specified sequence.

SS:Apply silicone sealant to the threads.

St: Stake the fasteners to prevent loosening.

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent

The table relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

PERIODIC MAINTENANCE 2-11

Specifications

2-12 PERIODIC MAINTENANCE

Specifications

2-14 PERIODIC MAINTENANCE

Maintenance Procedure

Fuel System

Throttle Cable Inspection

Throttle Grip Free Play Inspection

•Check throttle grip play [A] by lightly turning the throttle grip back and forth.

If the free play is improper, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 3 mm (0.08 0.12 in.)

•Check that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

•Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle Grip Free Play Adjustment

If the free play is incorrect, loosen the locknut [A] and turn the adjuster [B] of the accelerator cable until the 2 3 mm (0.08 0.12 in.) of throttle grip play is obtained.

•Tighten the locknut against the adjuster securely.

•Check that the throttle pulley [A] stops against the idle adjusting screw [B] with the throttle grip closed.

2-16 PERIODIC MAINTENANCE

Maintenance Procedure

Idle Speed Adjustment

•Start the engine and warm it up thoroughly.

•Turn the adjusting screw [A] until idle speed is correct. ○Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if

necessary.

Carburetor Synchronization Inspection

Synchronization Inspection

•Situateground.the motorcycle so that it is perpendicular to the

•Remove the fuel tank and connect the auxiliary fuel tank to supply the fuel.

•Warm up the engine.

•Check idle speed and adjust if necessary.

•Pull the vacuum hoses off, and attach vacuum gauge [A] to the vacuum hose fittings on the carburetors.

Special Tool — Vacuum Gauge: 57001-1369

Synchronization Adjustment

○The pilot screw is set at the factory and should not be removed. But if necessary, check the pilot screw opening as follows.

•Turn in the pilot screw and count the number of turns until it seats fully but not tightly, and then remove the screw. This is to set the screw to its original (correct) position when assembling.

Special Tool — Pilot Screw Adjuster, C [A]: 57001-1239

NOTE

○Each carburetor has different opening of the pilot screw. When setting the pilot screw, do not refer to the specifications which show mean opening of the pilot screws.

PERIODIC MAINTENANCE 2-17

Maintenance Procedure

Coolant Filter Cleaning

○Before winter season starts, clean the coolant filter [A] in the carburetor system.

•Drain the coolant (see Coolant Draining).

•Remove the coolant filter from the cooling hoses in the carburetor system.

•Blow dirt and sediment off the filter with compressed air.

Fuel Hoses and Connections Check

○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

•Check that the hoses are securely connected and clamps are tightened correctly.

•When installing, route the hoses according to Cable, Wire, and Hose Routing section in the General Information chapter.

•When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

Air Cleaner Element Cleaning and Inspection

NOTE

○In dusty areas, the element should be cleaned more frequently than the recommended interval.

○After riding through rain or on muddy roads, the element should be cleaned immediately.

WARNING

Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.

2-18 PERIODIC MAINTENANCE

Maintenance Procedure

•Remove the element assembly from the air cleaner housing (see Air Cleaner Element Removal in the Fuel System chapter).

•Separate the element [A] from the element holders [B].

•Clean the element in a bath of high-flash point solvent, and then dry it with compressed air or by shaking it.

•Visually check the element for tear or breaks.

If any of the parts of the element are damaged, replace them with a new one.

•After cleaning of the element, saturate it with high quality form air filter oil and squeeze out excess oil.

•Wrap the element [A] in a clean rag [B] and squeeze it as dry as possible.

•Assemble the element with the holders, and install them into the air cleaner housing.

Cooling System

Coolant Level Inspection

•Situateground.the motorcycle so that it is perpendicular to the

•Check the level through the coolant level gauge on the reservoir tank [C]. The coolant level should be between the «H» (High) [A] and the «L» (Low) [B] level lines.

NOTE

○Check the level when the engine is cold (room or ambient temperature).

If the coolant level is lower than the «L» (Low) level line, add coolant to the «F» (Full) level line.

CAUTION

For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often, or the reserve tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks (see Visual Leak Inspection, and Cooling System Pressure Testing).

PERIODIC MAINTENANCE 2-19

Maintenance Procedure

Radiator Hoses and Connections Inspection

○The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.

•Check that the hoses are securely connected and clamps are tightened correctly.

Torque — Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)

Engine Top End

Air Suction Valve Inspection

The air suction valve is essentially a check valve which allows fresh air to flow from the air cleaner into the exhaust port. Any air that has passed the air suction valve is prevented from returning to the air cleaner.

•Remove the air suction valves.

•Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage.

If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly.

•Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder, or heat damage.

If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly.

•If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high flash-point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.

Valve Clearance Inspection

Valve Clearance Inspection

NOTE

○Valve clearance must be checked and adjusted when the engine is cold (room temperature).

•Remove the cylinder head cover (see Cylinder Head Cover Removal in the Engine Top End chapter).

•Remove the cylinder head oil pipes (see Cylinder Head Oil Pipe Removal in the Engine Top End chapter).

2-20 PERIODIC MAINTENANCE

Maintenance Procedure

•Unscrew the upper [A] and lower [B] caps on the alternator cover.

Special Tool — Filler Cap Driver: 57001-1454

•Check the valve clearance when the pistons are at TDC. ○The pistons are numbered beginning with the engine left

side.

•Using a wrench on the crankshaft rotation bolt [A], turn the crankshaft clockwise [B] until the «C» mark [C] on the rotor is aligned with the notch [D] in the edge of the upper hole in the alternator cover for #2 piston and «T» mark for #1 piston.

○Measure the valve clearance of the valves for which the cam lobe is pointing away from the rocker arm.

•Each piston has two inlet and two exhaust valves. Measure these two inlet or exhaust valves at the same crankshaft position.

Valve Clearance Measuring Position

#2 Piston TDC at End of Compression Stroke → Inlet valve clearances of #2 piston, and Exhaust valve clearances of #2 piston

NOTE

○Check the valve clearance using this method only. Checking the clearance at any other cam position may result in improper valve clearance.

Valve Clearance Measuring Position

#1 Piston TDC at End of Compression Stroke → Inlet valve clearances of #1 piston, and Exhaust valve clearances of #1 piston

2-22 PERIODIC MAINTENANCE

Maintenance Procedure

Clutch Lever Free Play Adjustment

•Slide back the dust cover [A].

•Loosen both adjuster nuts [B] at the right hand crankcase as far as they will go.

•Loosen the knurled locknut [A] at the clutch lever.

•Turn the adjuster [B] so that 5 6 mm (0.20 0.24 in.) [C] of threads are visible.

WARNING

Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into the place later, creating enough cable play to prevent clutch disengagement.

•After the adjustment is made, start the engine and check that the clutch does not slip and that it releases properly.

Wheels/Tires

Air Pressure Inspection/Adjustment

•Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3

hours).

Adjust the tire air pressure according to the specifications if necessary.

Air Pressure (when cold)

Tire Tread Wear Inspection

As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald.

•Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places.

PERIODIC MAINTENANCE 2-23

Maintenance Procedure

Wear Indicator [A]

Wear Indicator Position Mark [B]

If any measurement is less than the service limit, replace the tire.

Tread Depth

WARNING

To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.

Use the same manufacturer’s tires on both front and rear wheels.

NOTE

○Check and balance the wheel when a tire is replaced with a new one.

Wheel/Tire Damage Inspection

•Remove any imbedded stones [D], nail [C] or other foreign particles from the tread.

Wear Indicator [E]

•Visually inspect the tire for cracks [A] and cuts [B], and replace the tire if necessary. Swelling or high spots indicate internal damage, requiring tire replacement.

•Visuallyage. inspect the wheel for cracks, cuts and dents dam-

If any damage is found, replace the wheel if necessary.

Never attempt to repair a damaged wheel part. If the wheel part is damaged, it must be replaced with a new part.

PERIODIC MAINTENANCE 2-25

Maintenance Procedure

Final Drive

Drive Chain Slack Inspection

Drive Chain Slack Inspection

NOTE

○Check the slack with the motorcycle setting on its side stand.

○Clean the chain if it is dirty, and lubricate it if it appears dry.

•Check the wheel alignment (see Wheel Alignment Inspection/Adjustment).

•Rotate the rear wheel to find the position where the chain is tightest.

•Measure the vertical movement (chain slack) [A] midway between the sprockets.

If the chain slack exceeds the standard, adjust it.

Drive Chain Slack Adjustment

•Remove: Cotter Pin [A]

•Loosen: Axle Nut [B]

Chain Adjuster Locknuts [F] (both sides)

•Turn the chain adjusting nuts [C] forward or rearward until the drive chain has the correct amount of chain slack. To keep the chain and wheel properly aligned, the left adjuster mark [D] position should align with the same graduation that the right adjuster mark [E] position aligns with.

WARNING

Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition.

•Tighten both chain adjuster locknuts securely.

•Tighten the axle nut (see Front/Rear Wheel Installation in the Wheels/Tires chapter).

Torque — Rear Axle Nut: 108 N·m (11 kgf·m, 80 ft·lb)

•Insert a the new cotter pin [A].

NOTE

○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle shaft, tighten the nut clockwise [A] up to next alignment.

○It should be within 30 degree.

○Loosen once and tighten again when the slot goes past the nearest hole.

2-26 PERIODIC MAINTENANCE

Maintenance Procedure

•Bend the cotter pin [A] over the nut.

•Turn the wheel, measure the chain slack again at the tightest position, and readjust if necessary.

•Check the rear brake.

Wheel Alignment Inspection/Adjustment

•Check that the left adjuster mark [A] position should align with the same graduation [B] that the right adjuster mark

position aligns with.

If they do not, adjust the chain slack and align the wheel alignment.

NOTE

○Wheel alignment can also be checked using the straightedge or string method.

WARNING

Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition.

Drive Chain Wear Inspection

•Remove: Chain Cover

•Rotate the rear wheel to inspect the drive chain for damaged rollers, loose pins and links.

If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry.

•Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain.

•Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places.

If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced.

Drive Chain 20-link Length

PERIODIC MAINTENANCE 2-27

Maintenance Procedure

WARNING

If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.

For safely, use only the standard chain. It is an endless type and should not be cut for installation.

Drive Chain Lubrication

•If a special lubricant is not available, a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication.

•If the chain appears especially dirty, clean it before lubrication.

[A]Apply oil

CAUTION

The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules:

Use only kerosene or diesel oil for cleaning an O -ring drive chain.

Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring.

Blow the chain dry with compressed air immediately after cleaning.

Complete cleaning and drying the chain within 10 minutes.

•Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings. Apply the oil to the O-rings so that the O-rings will be coated with oil.

•Wipe off any excess oil.

Brakes

Brake Fluid Leak (Brake Hose and Pipe) Inspection

•Apply the brake lever or pedal and inspect the brake fluid leak from the brake hoses [A] and fittings.

If the brake fluid leaked from any position, inspect or replace the problem part.

2-28 PERIODIC MAINTENANCE

Maintenance Procedure

Brake Hose Damage and Installation Condition Inspection

•Inspect the brake hose and fittings for deterioration, cracks and signs of leakage.

○The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.

Replace the hose if any cracks [B] or bulges [C] are noticed.

Tighten any loose fittings and any banjo bolts.

Torque — Brake Hose Banjo Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)

•Inspect the brake hose routing.

If any brake hose routing is incorrect, route the brake hose according to Cable, Wire and Hose Routing Section in the Appendix chapter.

Brake Operation Inspection

•Inspect the operation of the front and rear brake by running the vehicle on the dry road.

If the brake operation is insufficiency, inspect the brake system.

WARNING

When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.

Brake Fluid Level Inspection

•Check that the brake fluid level in the front/rear brake reservoirs [A] is above the lower level line [B].

NOTE

○Hold the reservoirs horizontal by raising the motorcycle perpendicular to the ground when checking brake fluid level.

Special Tool — Jack: 57001-1238

•Remove the right side cover.

PERIODIC MAINTENANCE 2-29

Maintenance Procedure

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A] in the reservoir [B].

WARNING

Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter.

Recommended Disc Brake Fluid

Grade: DOT4

If the rear brake reservoir cap is open to fill the brake fluid, follow the procedure below to install the cap correctly.

○First, tighten the brake fluid reservoir cap [B] clockwise [C] by hand until the resistance is felt fully; then, tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir [A] body.

Brake Pad Wear Inspection

In accordance with the Periodic Maintenance Chart, in-

2-30 PERIODIC MAINTENANCE

Maintenance Procedure

Brake Light Switch Operation Inspection

Front Brake Light Timing Inspection

•Turn on the ignition switch.

•The brake light should go on when the brake lever is applied or after the tip of brake lever moves about 10 mm (0.39 in.) [A].

Rear Brake Light Timing Inspection

•Turn on the ignition switch.

•Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on as specified.

If it does not, adjust the brake light timing.

Brake Light Timing

Standard: On after about 15 mm (0.59 in.) pedal travel [A]

Rear Brake Light Timing Adjustment

Brake light timing is adjusted by changing the position of the rear brake light switch [A].

•Adjust the position of the switch so that the brake light goes on after the specified pedal travel by turning the adjusting nut [B].

[C]Lights sooner.

[D]Lights later.

CAUTION

To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.

Suspension

Front Forks/Rear Shock Absorber Operation

Inspection

•Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke.

If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).