1. Stand the vehicle on a level surface.
WARNING Securely support the vehicle so that there is no danger of it falling over. |
2. Install:
NOTE:
Install the brake master cylinder holder with the arrow mark "a" pointing forward.
3. Install:
NOTE:
Before fully installing the front brake light switch, be sure to completely install the rubber cover over the switch. Also, be sure not to twist the front brake light switch lead when screwing in the switch.
4. Install:
NOTE:
5. Install:
NOTE:
There should be 1-3 mm (0.04-0.12 in) of clearance "a" between the throttle grip and the right grip end.
6. Install:
NOTE:
Align the mating surfaces of the clutch lever holder with the punch mark "a" on the left handlebar.
7. Install:
NOTE:
Align the projection "a" on the clutch switch with the slit "b" in the clutch lever holder.
8. Connect:
NOTE:
Lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease.
9. Install:
NOTE:
Align the projection "a" on the left handlebar switch with the hole "b" in the left handlebar.
10.Connect:
11.Install:
a. Apply a thin coat of rubber adhesive onto the end of the left handlebar.
b. Slide the handlebar grip over the end of the left handlebar.
c. Wipe off any excess rubber adhesive with a clean rag.
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
NOTE:
There should be 3 mm (0.12 in) of clearance "a" between the handlebar grip and the grip end.
12.Check:
NOTE:
Make sure the main switch lead, brake hose, throttle cable, clutch cable, and handlebar switch leads are routed properly. Refer to "CABLE ROUTING" on page 2-33.
13.Adjust:
14.Adjust:
Checking the drive chain
1. Measure:
15-link section "a" of the drive chain
Out of specification Replace the drive
chain.
a. Measure the length "a" between the inner
sides of the pins and the length "b" between
the outer sides of the pins on a 15-link section
of the drive chain as shown in the illustration.
...
Troubleshooting
The starter motor fails to turn.
NOTE:
Before troubleshooting, remove the following part(s):
1. Seats
2. Fuel tank
3. Left lower side cowling
4. Left upper side cowling
...
Installing the throttle body
1. Install:
Throttle body joint clamps
NOTE:
Align the projections "a" on the throttle body joint
with the slot "b" in each throttle body joint clamp.
2. Install:
Throttle body joint
NOTE:
Align the projection "a" on the throttle body joint
with the slot "b" in the intake mani ...