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:
Assembling the water pump
1. Install:
Water pump seal "1"
(into the water pump housing "2")
CAUTION:Never lubricate the water pump seal
surface
with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Install the water pump seal with the special
tools to the specifi ...
Checking the rear brake caliper
1. Check:
Brake caliper piston "1"
Rust/scratches/wear Replace the
brake
caliper piston.
Brake caliper cylinder "2"
Scratches/wear Replace the
brake caliper
assembly.
Brake caliper body "3"
Cracks/damage Replace the
brake caliper
assembly.
Brake fluid deli ...
Disassembling the front wheel
1. Remove:
Oil seal
Wheel bearings
a. Clean the surface of the front wheel hub.
b. Remove the oil seal "1" with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag "2"
between the screwdriver and the wheel surface.
c. Remove the wheel bearings "3" with a ge ...