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Comprehensive Online Parts Manual - MC16 | MC21 | MC28
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Maintenance Schedule
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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 & swing-arm bushing damage
 
 
 
 
 Shock absorber damage
 
 
 
 
 Shock absorber bushing damage
 
 
 
 
 Clutch lever play
 
 
 Play: 10-20mm lever
 Transmission leakage, oil capacity
 
 
 Click for diagram...
 Gear movement
 
 
 
 
 Transmission oil replacement
 
 
 
 
 Every 2 years
 Chain slack
 
 
 Sprocket wear, damage and installation
 
   
   
 Click for diagram...
 
 
 
 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