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 rear brake master cylinder
1. Check:
Brake master cylinder
Damage/scratches/wear Replace.
Brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with
compressed air.
2. Check:
Brake master cylinder kit
Damage/scratches/wear Replace.
3. Check:
Brake fluid reservoir
Cracks/ ...
Installing the drive chain
1. Lubricate:
Drive chain
Master link
2. Install:
Drive sprocket
Drive sprocket retainer bolts
3. Install:
Master link
O-rings
Master link plate
Master link clip "1"
CAUTION:
The closed end of the master link clip must
face in the direction of drive ch ...
Introduction
WARNINGDisc brake components rarely require
disassembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components unless
absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
sy ...