CONTENTS 2
CONTENTS
MEANS OF REPRESENTATION ............................................ 5
IMPORTANT NOTES............................................................ 6
MOTORCYCLE..................................................................... 7
Jacking up the motorcycle................................................ 7
Removing the motorcycle from the work stand.................... 7
Starting .......................................................................... 7
Vehicle level ................................................................... 8
01/FORK, TRIPLE CLAMP.................................................... 9
Cleaning dust boots of fork legs ........................................ 9
Removing the fork legs..................................................... 9
Installing the fork legs ................................................... 10
Servicing fork................................................................ 10
Disassembling the fork legs ............................................ 11
Checking the fork legs.................................................... 12
Assembling the fork legs ................................................ 13
Adjusting the fork overhang ............................................ 14
Removing the lower triple clamp ..................................... 15
Installing the lower triple clamp...................................... 16
Greasing the steering head bearing.................................. 17
Checking play of steering head bearing ............................ 18
Adjusting the play of the steering head bearing ................ 18
02/HANDLEBAR, CONTROLS AND INSTRUMENTS.............. 20
Checking the play in the throttle cable............................. 20
Adjusting the play in the throttle cable ............................ 20
Handlebar position ........................................................ 20
Adjusting handlebar position .......................................... 20
04/SHOCK ABSORBER, SWINGARM................................... 22
Adjusting the rebound damping of the shock absorber....... 22
Measuring rear wheel sag unloaded ................................. 22
Checking the static sag of the shock absorber .................. 22
Checking the riding sag of the shock absorber .................. 23
Adjusting the spring preload of the shock absorber ........... 23
Adjusting the riding sag ................................................. 24
Removing the shock absorber ......................................... 24
Installing shock absorber................................................ 24
Adjusting seat height ..................................................... 25
Servicing shock absorber................................................ 25
Removing the spring ...................................................... 25
Disassembling the damper ............................................. 26
Disassembling the piston rod .......................................... 27
Removing the heim joint ................................................ 28
Checking the damper..................................................... 29
Installing the heim joint ................................................. 30
Assembling the piston rod .............................................. 31
Assembling the damper (50 SX)...................................... 32
Assembling the damper (50 SX Mini) .............................. 33
Filling the damper with nitrogen ..................................... 34
Installing the spring (50 SX)........................................... 35
Installing the spring (50 SX Mini) ................................... 36
05/EXHAUST .................................................................... 38
Removing the exhaust manifold ...................................... 38
Installing the exhaust manifold ....................................... 38
Removing main silencer ................................................. 38
Installing the main silencer ............................................ 39
Removing the glass fiber yarn filling of the main
silencer ........................................................................ 39
Installing the glass fiber yarn filling of the main silencer ... 40
06/AIR FILTER.................................................................. 41
Removing the air filter ................................................... 41
Installing the air filter .................................................... 41
Cleaning air filter........................................................... 41
07/FUEL TANK, SEAT, TRIM.............................................. 42
Removing the seat ......................................................... 42
Mounting the seat ......................................................... 42
Removing the fuel tank .................................................. 42
Installing the fuel tank................................................... 43
08/MASK, FENDER ........................................................... 44
Dismounting the front fender .......................................... 44
Installing the front fender............................................... 44
Dismounting the start number plate ................................ 44
Installing the start number plate ..................................... 44
09/FRONT WHEEL ............................................................ 46
Removing front wheel .................................................... 46
Installing the front wheel................................................ 46
Checking the tire condition............................................. 47
Checking tire air pressure............................................... 47
Checking brake discs ..................................................... 47
Checking spoke tension.................................................. 48
10/REAR WHEEL .............................................................. 49
Removing rear wheel...................................................... 49
Installing the rear wheel................................................. 49
Checking chain dirt ....................................................... 49
Cleaning the chain......................................................... 50
Checking the chain tension ............................................ 50
Checking the chain tension - installing rear wheel............. 51
Checking rear sprocket / engine sprocket for wear ............. 51
Adjusting chain tension.................................................. 51
Adjusting chain tension - after checking .......................... 52
Adjusting chain tension - installing rear wheel.................. 52
Adjusting the chain guide............................................... 52
13/BRAKE SYSTEM........................................................... 53
Checking the play of the hand brake lever........................ 53
Adjusting the play of the hand brake lever........................ 53
Adjusting the basic position of the hand brake lever.......... 53
Checking the front brake fluid level ................................. 53
Adding front brake fluid ................................................. 54
Changing the front brake fluid ........................................ 55
Checking the front brake linings...................................... 56
Removing front brake linings .......................................... 56
Installing the front brake linings ..................................... 56
Changing the front brake linings ..................................... 57
Checking the free travel of the foot brake lever ................. 58
Adjusting the free travel of the foot brake lever................. 58
Adjusting the basic position of the foot brake lever ........... 58
Checking rear brake fluid level........................................ 59
Adding rear brake fluid .................................................. 59
Changing the rear brake fluid.......................................... 60
Checking the rear brake linings....................................... 61
Removing rear brake linings............................................ 61
Installing the rear brake linings....................................... 62
Changing the rear brake linings....................................... 62
30/ENGINE....................................................................... 64
Removing the engine ..................................................... 64
Installing the engine ...................................................... 65
30/DISASSEMBLING THE ENGINE..................................... 68
Clamping the engine into the engine work stand............... 68
Pulling off the spark plug connector ................................ 68
Draining the gear oil ...................................................... 68
Removing the cylinder head............................................ 68
Removing the cylinder ................................................... 69
Removing the piston ...................................................... 69
Removing the oil pump (50 SX Mini)............................... 69
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