Date:

Odometer:                                   

by Flash #421 http://www.deathstar.org/~flash  

II - Service 6,000mi
10,000 km

III - Inspection 12,000 mi
20,000 km

IV
Annual
 

Page

Item

Tool / Part / Spec / Note

 c

 c

10

Valve Clearance c/Shims c   Rex:            
Lex:                   Lin:                   Rin:

0.10-0.15mm = 0.004-0.006" 
90 88 6 116 570 TDC Crank Stop Bolt

c

c

12

Replace Spark Plugs - NGK D8EA=#2120

20 Nm, gap :0.6-0.7mm, .024-.028"

c

c

12

Clean Air Filter c, Pull Airbox Drain Plug c

Washable Foam-type Air Filter Oil

c
c

c
c

12
n/a

Adjust Clutch Free Play
Lube Clutch & Brake Lever Pivots & Nipples

2mm at lever, lower arm: 2.75"
either powdered graphite or white lithium grease

c

c

c

13

Oil Change

2.2 qt w/ filter

c

c

14

Oil Filter Change c, Clean Oil Tank Screen c

11 00 2 317 015 oil chg. kit

c

15-16

Fork Oil Change

600cc per leg, 10 wt., 6x10 Cu washers, O-rings

c

c

17

Coolant Check

c

18

Change Coolant (non-nitride, non-silicate)

1.5qt: 50% mix, Loctite 243, 6x10 Cu washer

c

c

18

Clean Petcock Screens

c

c Replace

n/a

Fuel Filter  - Inspect c/Replace c 

c

c

19-20

Adjust Idle Speed c, CO c

1300-1400 rpm, CO: 2.5% -0.6%

c

c

21

Check Brake Lines & Fluid Level

DOT 4

c

c

22-23

Check Brake Pads c  (1.5mm min. thickness)
Replace Front c / Replace Rear c  

F:EBC209, Galfer172G1532-green, FerodoFDB2006
R:EBC213, Galfer165G1054-black, FerodoFDD2005

c

c

23

Brake Disks Thickness F:            R:

Min Thickness: 4.5mm, 0.177"

c

24

Change Brake Fluid

DOT 4

c Check

   c Check
   c Replace

24
 

Inspect Front & Rear Wheel Bearings
Replace at 24k-mi/40k-km multiples

6203-2RS: 2 per Wheel,1:30x40x7 Rear Seal
6204-2RS: Carrier, Seal 30x47x7.  1:40.x50x4 Frt. Seal

c

n/a

Lube Speedo & Tachometer (RPM) Cables

Moly-Grease

c

c

25

Check Spoke Tension            

Runout Limit = 2mm, 0.078"

c

 

c

 

25

 

Chain & Sprockets  Check c /Renew c
16/47 520-110, 30mm socket, Loctite 243,
Front sprocket O-ring, 18x3.5,  23 00 2 343 260

F:100Nm, Fr. Lock Washer: 23 00 2 343 472.
R:25Nm, 6 ea.: M8x30 bolts: 36 31 2 345 496,
M8 Nylock nuts: 36 31 2 345 495

c

c

26

Chain Tension  Check c /Adjust c 

20 - 30mm, 1" +/- 0.25", Axle:100Nm

c

c Lube

27

Steering Head Bearings  Check c/Adjust c 

100Nm,  30mm Socket = 1 3/16"

c

c

c

28

Battery - Refill c, Lube Terminals c

Distilled Water, YB12AL-A

c

c

29

Lube: Standsc Brake Pedalc Chain Rollersc

Multi-Purpose Grease

c
c
c Tighten
c Tighten

c
c
c Lube
c Lube

c
c
c
c

29
 

Check/Tighten: Engine Mount Bolts
Check/Tighten: Exhaust Mount Bolts
Swing-arm Pivot Bolt/Bearings
Shock & Linkage Bolts/Bearings

50Nm

Two: 22mm sockets = 7/8"
10mm Allen