TABLE OF CONTENTS
3
11.2 Removing the motorcycle from the
lift stand ......................................... 42
11.3 Bleeding the fork legs....................... 42
11.4 Cleaning the dust boots of the fork
legs ................................................ 43
11.5 Removing the fork protector .............. 44
11.6 Installing the fork protector............... 44
11.7 Removing the fork legs .................. 45
11.8 Installing the fork legs .................. 45
11.9 Removing the lower triple clamp .... 47
11.10 Installing the lower triple clamp ..... 47
11.11 Checking the steering head bearing
play ................................................ 50
11.12 Adjusting the steering head bearing
play ............................................ 51
11.13 Greasing the steering head
bearing ........................................ 52
11.14 Removing the fuel tank ................. 52
11.15 Installing the fuel tank .................. 53
11.16 Removing the start number plate....... 54
11.17 Installing the start number plate........ 54
11.18 Removing front fender ...................... 55
11.19 Installing front fender....................... 55
11.20 Removing the shock absorber ........ 56
11.21 Installing the shock absorber ......... 57
11.22 Removing the seat ........................... 58
11.23 Mounting the seat............................ 58
11.24 Removing the air filter .................. 58
11.25 Installing the air filter ................... 59
11.26 Cleaning the air filter and air filter
box ............................................. 59
11.27 Removing the main silencer .............. 60
11.28 Installing the main silencer............... 60
11.29 Changing the glass fiber yarn filling
of the main silencer ...................... 60
11.30 Removing the engine sprocket
cover ........................................... 61
11.31 Installing the engine sprocket
cover ........................................... 62
11.32 Checking the chain for dirt................ 62
11.33 Cleaning the chain ........................... 63
11.34 Checking the chain tension ............... 63
11.35 Adjusting the chain tension............... 64
11.36 Checking the chain, rear sprocket,
engine sprocket and chain guide ....... 65
11.37 Adjusting the chain guide .............. 67
11.38 Checking the frame ...................... 67
11.39 Checking the link fork ................... 68
11.40 Checking the throttle cable routing .... 68
11.41 Checking the rubber grip .................. 68
11.42 Additionally securing the rubber
grip ................................................ 69
12 BRAKE SYSTEM ......................................... 70
12.1 Checking play of handbrake lever ...... 70
12.2 Adjusting the play of the hand brake
lever ............................................... 70
12.3 Adjusting the basic position of the
hand brake lever .............................. 70
12.4 Checking the brake discs .................. 71
12.5 Checking the front brake fluid level ... 72
12.6 Adding the front brake fluid ........... 73
12.7 Checking the front brake linings ........ 74
12.8 Changing the front brake linings .... 74
12.9 Checking the free travel of the foot
brake lever ...................................... 77
12.10 Adjusting the free travel of the foot
brake lever ................................... 78
12.11 Adjusting the basic position of the
foot brake lever ............................ 78
12.12 Checking the rear brake fluid level..... 79
12.13 Adding rear brake fluid ................. 79
12.14 Checking the rear brake linings ......... 81
12.15 Changing the rear brake linings ...... 81
13 WHEELS, TIRES ......................................... 84
13.1 Removing the front wheel .............. 84
13.2 Installing the front wheel .............. 84
13.3 Removing the rear wheel ............... 85
13.4 Installing the rear wheel ................ 86
13.5 Checking the tire condition ............... 87
13.6 Checking tire pressure ...................... 88
13.7 Checking spoke tension .................... 88
14 COOLING SYSTEM ...................................... 89
14.1 Cooling system ................................ 89
14.2 Checking the antifreeze and coolant
level ............................................... 89
14.3 Checking the coolant level ................ 90
14.4 Draining the coolant ..................... 90
14.5 Refilling with coolant .................... 91
15 TUNING THE ENGINE................................. 93
15.1 Checking the installation position of
the throttle grip ............................... 93
15.2 Checking throttle cable play.............. 93
15.3 Adjusting the throttle cable play .... 94
15.4 Carburetor - idle (50 SX)................... 94
15.5 Carburetor - idle (50 SX Mini) ........... 95
15.6 Carburetor - adjusting the idle
speed (50 SX).............................. 95
15.7 Carburetor – adjusting the idle
speed (50 SX Mini) ...................... 96
15.8 Checking the clutch setting ........... 97
15.9 Removing the clutch cover ............ 98
15.10 Adjusting the clutch ..................... 98
15.11 Installing the clutch cover ............. 99
16 SERVICE WORK ON THE ENGINE .............. 100
16.1 Checking oil level (50 SX Mini) ....... 100
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