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 cylinder head breather hose
1. Remove:
Left side panel
Refer to "GENERAL CHASSIS" on page 4-1.
2. Check:
Cylinder head breather hose "1"
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:Make sure the cylinder head
breather hose is
routed correctly.
...
Adjusting the clutch cable free play
1. Check:
Clutch cable free play "a"
Out of specification Adjust.
2. Adjust:
Clutch cable free play
a. Pull back the rubber cover "1"
b. Loosen the locknut "2".
c. Turn the adjusting bolt "3" in direction "a" or
"b" until the specified clutch cable free play is
obtained.
...
Installing the fuel hose
1. Install:
Fuel hose
Fuel hose connector cover
CAUTION:When installing the fuel hose, make sure
that
it is securely connected, and that the fuel
hose connector cover is in the correct position,
otherwise the fuel hose will not be properly
installed.
NOTE:
W ...