TABLE OF CONTENTS 3
12 SERVICE WORK ON THE CHASSIS ............................... 45
12.1 Raising the motorcycle with a lift stand.............. 45
12.2 Removing the motorcycle from the lift stand...... 45
12.3 Bleeding the fork legs ......................................... 45
12.4 Cleaning the dust boots of the fork legs............. 45
12.5 Removing the fork protector............................... 46
12.6 Installing the fork protector................................. 46
12.7 Removing the fork legs ................................... 46
12.8 Installing the fork legs ..................................... 47
12.9 Removing the lower triple clamp .................... 47
12.10 Installing the lower triple clamp ...................... 48
12.11 Checking the play of the steering head
bearing................................................................ 50
12.12 Adjusting the steering head bearing play ....... 51
12.13 Lubricating the steering head bearing ............ 51
12.14 Removing the front fender .................................. 51
12.15 Installing the front fender.................................... 52
12.16 Removing the shock absorber ........................ 52
12.17 Installing the shock absorber .......................... 53
12.18 Removing the seat .............................................. 55
12.19 Mounting the seat............................................... 55
12.20 Removing the air filter box cover........................ 56
12.21 Installing the air filter box cover.......................... 56
12.22 Removing the air filter ..................................... 56
12.23 Installing the air filter ....................................... 57
12.24 Cleaning the air filter and air filter box ............ 57
12.25 Sealing the air filter box .................................. 58
12.26 Removing the right side cover ............................ 58
12.27 Installing the right side cover.............................. 58
12.28 Removing the main silencer................................ 59
12.29 Installing the main silencer.................................. 59
12.30 Changing the glass fiber yarn filling in the
main silencer ................................................... 59
12.31 Removing the fuel tank ................................... 60
12.32 Installing the fuel tank ..................................... 61
12.33 Checking for chain dirt accumulation................. 62
12.34 Cleaning the chain .............................................. 63
12.35 Checking the chain tension ................................ 63
12.36 Adjusting the chain tension................................. 64
12.37 Checking the chain, rear sprocket, engine
sprocket, and chain guide .................................. 65
12.38 Checking the frame ......................................... 66
12.39 Checking the swingarm .................................. 67
12.40 Checking throttle cable routing .......................... 67
12.41 Checking the rubber grip .................................... 67
12.42 Adjusting the basic position of the clutch
lever .................................................................... 68
12.43 Checking/correcting the fluid level of the
hydraulic clutch................................................... 68
12.44 Changing the hydraulic clutch fluid ................ 69
12.45 Removing the engine guard................................ 70
12.46 Installing the engine guard.................................. 70
13 BRAKE SYSTEM ............................................................. 71
13.1 Checking free travel of hand brake lever............ 71
13.2 Adjusting free travel of hand brake lever ............ 71
13.3 Checking the brake discs ................................... 71
13.4 Checking the front brake fluid level .................... 72
13.5 Adding front brake fluid .................................. 72
13.6 Checking the front brake linings ......................... 73
13.7 Changing the front brake linings ..................... 73
13.8 Checking the free travel of foot brake lever........ 75
13.9 Adjusting the basic position of the foot brake
lever ................................................................. 75
13.10 Checking the rear brake fluid level ..................... 76
13.11 Adding rear brake fluid .................................... 76
13.12 Checking the rear brake linings .......................... 77
13.13 Changing the rear brake linings ...................... 78
14 WHEELS, TIRES.............................................................. 80
14.1 Removing the front wheel ............................... 80
14.2 Installing the front wheel ................................. 80
14.3 Removing the rear wheel ................................ 81
14.4 Installing the rear wheel .................................. 82
14.5 Checking the tire condition................................. 83
14.6 Checking the tire air pressure............................. 83
14.7 Checking spoke tension ..................................... 84
15 ELECTRICAL SYSTEM.................................................... 85
15.1 Removing the battery ...................................... 85
15.2 Installing the battery ........................................ 85
15.3 Recharging the battery ................................... 86
15.4 Changing the main fuse...................................... 87
15.5 Changing the fuses of individual power
consumers .......................................................... 88
15.6 Removing the headlight mask with the
headlight ............................................................. 89
15.7 Installing the headlight mask with the
headlight ............................................................. 90
15.8 Changing the headlight bulb............................... 90
15.9 Changing the turn signal bulb............................. 91
15.10 Checking the headlight setting ........................... 91
15.11 Adjusting the headlight range ............................. 92
15.12 Changing the speedometer battery .................... 92
15.13 Diagnostics connector........................................ 93
16 COOLING SYSTEM......................................................... 94
16.1 Cooling system ................................................... 94
16.2 Checking the antifreeze and coolant level.......... 94
16.3 Checking the coolant level.................................. 95
16.4 Draining the coolant ........................................ 95
16.5 Refilling coolant ............................................... 96
17 TUNING THE ENGINE..................................................... 97
17.1 Checking the play in the throttle cable ............... 97
17.2 Adjusting the play in the throttle cable ........... 97
17.3 Setting the characteristic map of the throttle
response ......................................................... 98
17.4 Changing the mapping ....................................... 99
17.5 Adjusting the idle speed ................................. 99
17.6 Teaching the throttle valve position.................. 100
17.7 Checking the basic position of the shift
lever .................................................................. 100
17.8 Adjusting the basic position of the shift
lever ............................................................... 100
18 SERVICE WORK ON THE ENGINE ............................... 102
18.1 Changing the fuel screen .............................. 102
18.2 Checking the engine oil level ............................ 102
18.3 Changing the engine oil and oil filter,
cleaning the oil screens ................................ 103
18.4 Adding engine oil .............................................. 105
19 CLEANING, CARE......................................................... 106
19.1 Cleaning the motorcycle................................... 106
19.2 Checks and maintenance steps for winter
operation........................................................... 107
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