CHAPTER 2: Inspection and Adjustment

2-1	Maintenance Schedule	2-9	Electrical System
2-3	Steering and Brakes	2-10	Maintenance Items
2-3	Brake Fluid Reservoir	2-14	Cooling System
2-4	Brake Discs and Pads	2-14	Lighting System
2-5	Suspension	2-15	RC Valve
2-5	Transmission

Maintenance Schedule

To use, find the part you wish to perform maintenance on, and look right for the dot. No dot means that there is no need to perform maintenance on that specific part, unless the part is obviously in need of repair.					Look here for special notes and instructions on items that only require maintenance at longer intervals.
Handlebar play
Handlebar damage
Left and right movement
Fork spindle installation					Tighten steering stem
Fork spindle movement					Tighten steering stem
Brake pedal/lever play					Play: 10-20mm pedal, 20-30mm lever
Lever or pedal noise
Brake disc or pad noise
Damage or leakage from  brake system
Brake hose replacement					Every 4 years
Brake fluid capacity					Fluid levels on reservoirs
Master cylinder damage or wear
Master cylinder, cap, dust seal,  calipers					Every 2 years, depending on wear
Disc to pad clearance
Pad wear					Observe indicator on pads
Disc wear and damage					Min disc thickness: 3.5mm front, 4mm rear
Brake fluid replacement
Tyre pressure
Tyre wear and damage
Tyre tread depth
Foreign objects in tire tread
Wheel nut and bolt
Rim and side rim damage
Front and rear wheel bearings
Swing-arm and swing-arm bushing  damage
Shock absorber damage
Shock absorber bushing damage
Clutch lever play					Play: 10-20mm lever
Transmission leakage, oil capacity
Gear movement
Transmission oil replacement					Every 2 years
Chain slack
Sprocket wear, damage and  installation

 

Spark plug performance					Plug gap 0.7-0.8mm
Spark plug replacement					Every 5000km
Battery terminal connections
Wire connections and damage
Body twisting, foreign sounds
Low and high speed performance					Idle speed 1200rpm +/- 100rpm
Exhaust gas
Air cleaner filter
Oil Leakage and capacity					Check that oil light does not illuminate
Oil leakage
Oil capacity
Oil cleaner and filter clogging
Oil pump performance
Fuel leakage
Carburetor linkage
Throttle and choke cable
Fuel filter clogging
Fuel capacity
Fuel hose replacement					Every 4 years
Radiator capacity					Observe levels in reserve tank
Water leakage
Radiator cap
Cooling agent replacement					Every 2 years
Radiator hoses and fittings
Horn
Labels and stickers
Gauges
Exhaust pipe, silencers

Many thanks to Joe Lippo for the translation of the NSR250 Maintenance Schedule.