Final gear disassembly
1. Remove the nuts and bolts holding the bearing housing.
2. Remove the ring gear assembly and thrust washer from the final gear case.
3. Remove the self-locking nut from drive pinion by using the holding tool (special tool) and remove the coupling.
Steering head adjustment
1. Raise the front end of the motorcycle so that there is no weight on the front wheel.
WARNING: Securely support the motorcycle so there is no danger of it falling over.
2. Grasp the bottom of the forks and gently rock the fork assembly backward and forward, checking for looseness in the steering assembly bearings.
Clutch adjustment
This model has two clutch cable length adjusters. The cable length adjusters are used to take up slack from cable stretch and to provide sufficient free play for proper clutch operation. Normally, once the clutch cable length adjuster (crankcase) is properly set; the only adjustment required is maintenance of free play at the clutch cable length adjuster (handlebar lever).
Removal
1. Remove the rear wheel.
2. Remove the final gear case assembly.
3. Remove the drive shaft.
Final gear removal
1. Remove the rear axle and left shock absorber. Remove the rear wheel (see "REAR WHEEL" section in this chapter).
2. Remove the 4 nuts holding the final drive unit to the swing arm.
3. Remove the final gear assembly.
Front brake 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 between the brake pads and brake disc.
CAUTION: Proper lever free play is essential to avoid excessive brake drag.
To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure
Always check and adjust the tire pressures before operating the motorcycle.
The following special tools are not available but can be constructed for the final gear disassembly and assembly:
PRESS TOOL NO. 1
PRESS TOOL NO. 2
GEAR CASE HOLDING TOOL
Cable inspection and lubrication
WARNING: Damage to the outer housing of the various cables, may cause corrosion and often free movement will be obstructed. An unsafe condition may result so replace such cables as soon as possible.
Lubricate the inner cable and cable end. If they do not operate smoothly, replace them.
Recommended lubricant: SAE 10W30 motor oil
Inspection
1. Remove the rear wheel and both shock absorbers. Grasp the swing arm and try to move it from side to side as shown. There should be no noticeable side play.
