To maximize the service life of the motorcycle, and gain maximum safety and performance, it is necessary to perform periodic inspections and maintenance. Minor problems found during routine service can be corrected before they develop into major ones. Harder than normal use and exposure to mud, water or high humidity indicates the need for more frequent servicing of most part or parts. Record all service and repairs in a maintenance log for a future reference.
A running record will make it easier to evaluate future service & maintenance requirements and maintain the motorcycle in top condition. Refer to your service manual for all maintenance intervals, capacities, recommendations, repair tips and specification for proper procedures
FUEL TYPE
Always check your service manual for the recommended pump octane number 87, 89, 91 or 93 as certain models and years may differ. Using fuel with a lower octane number can cause pinging or spark knock, and lead to engine damage. When choosing gasoline and filling the fuel tank, note the following:
1. When filling the tank, do not overfill it. There should be no fuel in the filler neck (tube located between the fuel cap and tank).
2. Because oxygenated fuels can damage plastic and paint, do not spill fuel onto the fuel tank during filling.
3. DO NOT use gasoline containing methanol (methyl or wood alcohol).
4. DO NOT use gasoline containing more than 10% of ethanol (ethyl or grain alcohol).
MAINTENANCE SCHEDULE
Refer to your service manual for a recommended maintenance schedule. If the motorcycle is operated under extreme conditions, perform the appropriate maintenance more frequently. Maintenance and service procedures are described in each manual with a step-by-step easy to understand outline. Some procedures, which require more than minor disassembly or adjustment, are covered in the appropriate chapter.
ROUTINE SAFETY CHECKS
Pre-ride Inspection
1. Check wheel and tire condition. Check tire pressure. Refer to your manual to find the recommended tire pressure for your model motorcycle
2. Make sure all lights work. Refer to the lights/horn or electrical
3. Check engine, transmission for oil leaks. If necessary, add oil as described in your manual.
4. Check brake fluid level and condition. If necessary, add fluid as described in the factory service manual.
5. Check the operation of the front and rear brakes.
6. Check clutch operation. If necessary, follow service manual guideline if it is necessary to adjust.
7. Check the throttle operation. The throttle should move smoothly and return quickly when released. If necessary make adjustments.
8. Inspect the front and rear suspension. They should have a solid feel with no looseness.
9. Check the exhaust system for leaks or damage.
10. Inspect the fuel system for leaks.
11. Check the fuel level in fuel tank.
12. If equipped with a drive chain, check chain free play as described in its appropriate chapter.
13. If equipped with a drive belt, check drive belt tension as described in its appropriate chapter.
Tire Inspection
Inspect the tires periodically for excessive wear, deep cuts and embedded objects such as stones or nails. If a nail or other object is found in a tire, mark its location with a light crayon prior to removing it. This will help locate the hole for repair.
Tire Pressure
Check the tire pressure often to maintain tire profile, traction and handling, and to get the maximum life out of the tire. Carry a tire gauge in the motorcycle’s tool kit. Check the cold tire pressures for the original equipment tires.
Lights and Horn
Turn the ignition switch on, and check the following:
1. Pull the front brake lever and make sure the brake light works.
2. Push the rear brake pedal down and verify the brake light operation.
3. Make sure the headlight and taillight work.
4. Move the dimmer switch between the high and low positions, and make sure both headlight elements are working.
5. Push the turn signal switch to the left and right positions, and make sure all four turn signal lights are working.
6. Make sure all accessory lights work properly, if so equipped.
7. Check the horn button operation.
8. If the horn or any light fails to work properly, refer to your service manual.
Rim Wheels Inspection
Check the rims for cracks and other damage. Refer to your service manual for rim & wheel service.
PERIODIC LUBRICATION
Before inspecting the oil level, inspect the oil tank for cracks or other damage. If oil leaks are evident on or near the oil tank, locate and repair the problem. Check the oil tank mounting bolt for loose or missing fasteners; replace or tighten all fasteners. Check all oil line connections on the tank and the engine crankcase, see diagrams in your manual. Replace damaged oil lines as described promptly.
Engine Oil Level Check
Run the engine until normal operating temperature is reached then stop the engine and allow the oil to settle in the oil tank. Place the motorcycle on a level surface and hold the motorcycle upright so it is not resting on the sidestand, allowing the motorcycle to rest on the side stand will result in an incorrect oil level reading. Wipe the area around the oil filler cap with a clean rag and then remove the cap by pulling it up, wipe the dipstick with a clean rag and reinstall the oil filler cap but be sure the cap is fully seated. Next remove the filler cap and check the oil level on the dipstick The oil level should be between the full (upper) and fill (lower) indicator grooves on the dipstick. Always add the recommended engine oil listed in your manual. Inspect the oil filler cap O-ring for cracks or other damage and replace the O-ring if necessary. Next reinstall the oil filler cap and be sure the cap is fully seated.
Engine Oil and Filter Change
Check your service manual for the recommended oil and filter change intervals for motorcycles operated in moderate climates. If the motorcycle is operated in heavy dust, mud, water or other
conditions, the oil should be changed more frequently. If manufacturer recommend brand oils are not available then use manufacturer recommended oil alternatives.certifications. Follow the viscosity recommendations applicable to your model oil. Always try and use the same brand of oil at each change and check your service manual for the correct oil viscosity to use in anticipated ambient temperatures, not engine oil temperature. Using oil additives.
Transmission Oil
Overfilling may cause clutch malfunctioning. The transmission oil also lubricates the clutch, primary drive chain and sprockets. Your manual will list the recommended transmission oil inspection intervals. When checking the transmission oil level, do not allow any dirt or debris to enter the transmission case opening. If the motorcycle has been operated recently, wait approximately ten minutes before checking the oil to allow the oil to settle in the case. Park the motorcycle on a level surface and have an assistant support it so that it is standing straight. up.
Fork Oil Change
This procedure is for a fork oil change. If the fork has been disassembled for service, refer to correct chapter for fork oil refilling and specifications and the lists of recommended fork oil change intervals.
Control Cables (Non-Nylon Lined Cables)
Lubricate the control cables with a cable lubricant at the intervals in your manual or when they become stiff or sluggish. When lubricating the control cables, inspect each cable for fraying and cable sheath damage. Always Replace damaged cables promptly.
Throttle Control Grip Lubrication
To remove and install the throttle grip, refer to the Throttle and Idle Cable Replacement section in your manual book. Lubricate the throttle control
grip where it contacts the handlebar with graphite.
Front Brake Lever Pivot Pin Lubrication
Inspect the front brake lever pivot pin (see diagrams for help) at the intervals in service maintenance section. If the pin is dry, lubricate it with a lightweight oil. To service the pivot pin, refer to the Front Master Cylinder in appropriate chapter.
Other lubrication points are: Clutch Lever Pivot Pin, Drive Chain (on appropriate models), Sidestand, Steering Head and Speedometer Cable (on older models).
PERIODIC MAINTENANCE
Perform the services listed at the intervals section in your motorcycle manual. If the motorcycle is exposed to harsh conditions then perform the services more frequently.
Primary Chain Adjustment (if applicable)
Drive Chain (Models So Equipped)
Check and adjust the drive chain at the intervals specified in your manual. If the motorcycle is operated at sustained high speeds or if it is repeatedly accelerated very hard, inspect the drive chain adjustment more often. When adjusting the chain, check the free play at several places along its length by rotating the rear wheel. The chain rarely wears uniformly and as a result will be tighter at some places than others. Measure the chain free play halfway between the sprockets. Make sure the chain free play at the tightest place on the chain is not less than the specs or specifications given.
Final Drive Belt Deflection
Check drive belt deflection to see if the drive belt is severely worn, or if it is wearing incorrectly, if after inspection you find sever wear or damage then follow the replacement procedures.
Brake Pad Inspection
1. Inspect the brake pads for damage.
2. Measure the thickness of each brake pad lining on the front caliper(s) and rear caliper. Replace the brake pad if its thickness is worn to the minimum thickness as listed in your specifications. Replace the brake pads following the service & repair procedures in the brakes section.
NOTE: It may be necessary to dismount the caliper in the following steps if there is not sufficient access to the brake pads.
Brake Fluid Level Inspection (Front brake, Rear brake).
Brake Disc Inspection
Inspect the front and rear brake discs for scoring, cracks or other damage. Measure the brake disc thickness and service the brake discs as described in your repair guide.
Brake Lines and Seals Inspection
Check the brake lines between each master cylinder and each brake caliper. If there are any leaks, tighten the connections and bleed the brakes as described in the book.
Brake Fluid Change
To change brake fluid, follow the brake bleeding procedure in and continue adding new fluid to the master cylinder until the fluid leaving the caliper is clean and free of contaminants and air bubbles.
Front Brake Adjustment - The front brake does not require periodic adjustment on most motorcycles.
Rear Brake Adjustment
Clutch Adjustment
Shift Lever Adjustment
Throttle Cables Inspection
Inspect the throttle cables from the grip to the carburetor. Make sure they are not kinked or chafed and replace them if necessary. Make sure the throttle grip rotates smoothly from fully closed to fully open. Check with the handlebar at the center, full left and full right positions. There are two different throttle cables. At the throttle grip, the front cable is the throttle control cable and the rear cable is the idle control cable. Label the cables before removal. This is only needed on Models So Equipped.
