© Right handlebar switch lead © Clutch cable
@ Main switch lead and left handlebar switch lead © Throttle cable (return side) © Throttle cable (pull side) © Front brake hoses © Throttle cables ©Joint
© Under bracket
[A Pass the right handlebar switch lead inside the front brake hoses and over the throttle cables.
[B Install the throttle cables to the hook so that the pulling side of the throttle cables is routed downward.
O Pass the clutch cable through the guide.
[0 Plastic locking tie shall be positioned at 10 mm (0.39 in.) below from the upper bracket.
IE Clamp the left handlebar switch lead to the front fork with the plastic locking tie and cut the tip of the tie. Clamp it to the protector section.
F Pass the horn lead by the outside of the throttle cables and clamp it to the forefront of upper face of the under bracket. And then route it under the front brake hose and clamp it to the pawl of the under cover.
[G Clamp it at the position of 40 - 60 mm (1.57 - 2.36 in) from the upper face of the under bracket with the plastic locking tie. Cut the surplus part of the clamp tip leaving 2 - 4 mm (0.08 - 0.16 in). Point the tip of the clamp to the outside of vehicle. Pass the throttle cables inside the front brake hoses.
\T\ Set in the coupler between the head light's hollow section and the duct.
J Install the relay to the rib of the headlight.
(Location for the left and right relays is alternative.)
[K To the wire harness
[p To the front turn signal/position light (right)
M Set the sub wire harness in the joint.
[N Do not catch the sub wire harness when the duct is assembled.
[O To the front turn signal/position light (left)
[0 Point the tip of the plastic locking tie to the front side of the vehicle. Cut the tip leaving 2 - 10 mm (0.08 - 0.39 in).
[Q Point the tip of the plastic locking tie under the under bracket and rear side of the vehicle. Cut the tip leaving 2 - 10 mm (0.08 - 0.39 in).
1 Throttle stop screw © Coolant reservoir tank hose © Crankshaft position sensor lead @ Rear brake light switch lead © Water pump inlet hose ® Clutch cable @ Coolant hose protector ® Hose clamp assembly @ Hose clamp
[A Pass the rear brake light switch lead outside of rear engine mount bolt. [B Pass the ignition coil lead outside of the radiator hose.
O Pass the coolant reservoir tank hose under the frame and right side of the throttle body.
[0 Pass the clutch cable inside of the coolant reservoir tank hose and radiator return hoses.
[0 The punch mark starting point should be lower than the clamp's top end.
However, the aiming position of the punch mark starting point should be 5 mm (0.20 in) below the clamp's bottom end.
[0 Pass the clutch cable inside of the radiator hose.
[G Assemble as " (a)" shown below when clamping.
[0 Tip of the plastic locking tie shall be pointed to the inner side at the rear part of the vehicle.
HI Clamp the clutch cable so that it is positioned in this range.
J Clamp the clutch cable by routing the upper end of the clamp along with the bottom end of the hose clamp assembly.
[0 Put and apply the hose clamp to it. [0 Pass the crankshaft position sensor lead over the throttle stop screw.
1 Throttle cable (return side)
2 Throttle cable (pull side)
@ Canister hose (for CAL) 5 Balance hose (for CAL) ® Canister (for CAL) @ Coolant reservoir tank breather hose @ Oil level switch lead ® Sidestand switch lead
10 A.C. magneto lead
11 Radiator fan motor lead
12 Coolant reservoir tank
13 Coolant reservoir tank cover
14 Fuel tank drain hose
15 Fuel tank breather hose
16 Drive sprocket cover
[A Pass the main switch lead under the left handlebar switch lead and then to the right side of the vehicle.
[0 Pass the throttle stop cable by the left side of the sidestand switch lead, oil level switch lead, A.C. magneto lead, fuel tank drain hose and fuel tank breather hose, and then to the right side of the vehicle.
O Pass the fuel tank drain hose and fuel tank breather hose inside of the reservoir tank breather hose and reservoir tank hose, wire harness and throttle stop cable and then route it by the out side of the starter motor lead.
[0 To the throttle body.
[0 Route the coolant reservoir tank hose by the outside of the fuel tank drain hose and the fuel tank breather hose.
[0 Pass the fuel tank drain hose and fuel tank breather hose through the clamp of the coolant reservoir tank.
[G Projection allowance from the coolant reservoir tank cover shall be 30 - 50 mm (1.18 - 1.97 in).
\T\ Fasten the sidestand switch lead and oil level switch lead with a clamp.
J Pass the coolant reservoir tank breather hose, oil level switch lead and sidestand switch lead through the clamp.
[K Pass the sidestand switch lead, oil level switch lead and A.C. magneto lead between the engine stay and the engine.
[p To the radiator fan motor relay and fuse box
M Route it above the radiator hose.
[N Pass the throttle cable between the guide of the cover 2 and the frame.
0 Pass the radiator fan motor lead through the hole of the frame to the inner side of the vehicle.
[Q Route it below the coolant reservoir tank.
[0 Pass the coolant reservoir tank breather hose through the hole of the coolant reservoir tank cover.
[S Order of ups and downs means no object.
I Right handlebar switch lead @ Sub wire harness
@ Cover 8 @ Ignition coil lead © Throttle position sensor coupler © Coolant reservoir tank hose @ Throttle stop cable © Speed sensor lead coupler @ Crankshaft position sensor lead coupler
10 Fuel tank breather hose (except for CAL)
II Fuel tank drain hose © Fuel hose (return side) © Fuel pump 2 coupler © Fuel pump 1 coupler
@ Starter motor lead (16 Fuel hose (feed side) © Canister hose (for CAL) © Crankcase breather hose (19 Air vent hose (20 Fuse box (21 Cover 7
222 Radiator fan motor relay (23 Radiator fan motor lead (24 Left handlebar switch lead (25 Main switch lead
26 Wire harness
27 Throttle cables
28 Throttle sub-lead 1 (white 6 poles)
Throttle sub-lead 2 (black 6 poles)
Oil level switch lead coupler (white 1 pole)
Sidestand switch lead coupler (blue 2 poles)
) A.C. magneto lead coupler (white 3 poles)
) Rear brake light switch lead coupler (brown 2 poles) Neutral switch lead coupler (connector 1 pole)
[A To the headlight
[0 Make sure not to drop the headlight sub wire harness beneath the projection of the duct. Check it when installing the side cowling.
O Clamp the plastic locking tie to the cover 8. Place the coupler at the rear side of the vehicle against the plastic locking tie. Point the tip of the plastic locking tie to the downward in the inner side of the vehicle.
[D Route the head light and meter leads under the frame's lower part from the hollow section of the cover 2.
[0 Pass the left and right handlebar switch leads outside of the air filter case air vent hose.
[0 Connect the couplers (4 units) at the frame side hole. Do not catch each lead and wire harness when the cover 8 is attached.
G From the radiator
[0 Pass the coolant reservoir tank hose through forward the starter motor lead and speed sensor lead.
|T| Pass the speed sensor lead coupler and crankshaft position sensor lead coupler over the throttle stop cable.
J Pass the fuel tank breather hose and fuel tank drain hose under the fuel hose.
[K To the rear brake light switch lead.
[0 To the neutral switch
M Insert the wire harness wrapping clamp to the frame hole.
[N Pass the battery negative lead over the wire harness.
[O There should be no interference between the wire harness and the tip of the rear frame attaching bolts.
P To the coolant reservoir tank
[Q To the intake air temperature sensor (air filter case)
[0 To the oil level switch, sidestand switch and A.C. magneto
[S Install the wire harness wrapping clamp to the stay of the throttle body.
[T Pass the wire harness over the throttle air vent hose.
[U Pass the wire harness between frame and coolant hose.
W Pass it through the frame hole.
W Do not catch the coupler when the air filter case is assembled.
[X Clamp the wire harness, left and right handlebar switch leads and main switch lead. Align the tapping positions of three leads except the wire harness. Point the tip of the clamp to the front side of the vehicle.
[Y Sealing set of the cover can be either upper or lower against the frame lower end. However, it should not be caught.
[Z Clamp the wire harness, main switch lead branch section and radiator fan motor lead.
AA Branching leads to the fuse box and radiator fan motor relay shall pass through the guide section of the cover 2 under the wire harness and then to the outside of the frame.
AB AC AD
To the fuse box and fan motor relay Pass the throttle cables over the cover 2. Point the tip of the plastic locking tie to the rear side of the vehicle. To the main switch lead coupler Tip of the plastic locking tie should point to the downward outside of the vehicle. Use the plastic locking tie to clamp the starter motor lead at the protector section. Branching harness from the wire harness.
2 Battery positive lead
3 Starter relay
© Turn signal relay © Pressure sensor ©Tail/brake light © Tool kit
© Starting circuit cut-off relay
© Battery box
© Wire harness
12 Battery negative lead
13 Battery band
[A Push the starter motor lead in the clamping sections (two points) or the battery box assembly and secure it.
IB Fit the plastic cover in the starter relay after the flange bolts are installed.
O Make sure to clamp the wire harness. (Tighten it until the clamp latchet stops.)
[0 Install to the deepest position of the rib of the battery box assembly.
IE When installing the ECU, make sure to hook the pawls of the battery box assembly (at four points).
IE Hook of the battery box assembly shall hook on the upper face of the fuse box. (It should not be put on the side face.)
[G Install the pin of the battery box assembly to its base.
[H The knob section should be positioned in this area.
ED Pass the turn signal lead by the outside of the right side attaching boss of the tail/brake light.
J Pass the turn signal light and license light leads between the rear side ribs of the battery box assembly and to the rear part of the vehicle.
[0 Connect the turn signal lead couplers.
[p Connect the license light leads.
M Route the branching lead to the license light behind the tail/brake light left side attaching boss.
[N Route the tail/brake light lead under the projection part.
[O Route the tail/brake light lead above the projection part.
[H There should be no significant difference between right and left side of the tension rate on the band.
[Q Point the opening to the rear side of the vehicle.
[B Connect the tail/brake light lead coupler.
[S Install the starting circuit cut-off relay to the deepest position after placing the tail/brake light lead and turn signal lead in the guide.
[T The hook of the battery box assembly should hook on the surface.
[U Route the fuse box lead under the ECU connection coupler.
W Install the wrapping clamp of the wire harness to the hole of the battery box assembly.
W Connect the negative lead and the wire harness.
© Fuel pump assembly
© Canister hose
© Breather hose
© Blance hose
® Fuel tank drain hose
Install the O-ring with its lip pointed upward. Install the clip with its tab pointed in the upward direction.
Install the breather hose without projecting canister nipple out of the breather hose.
Install the clip with its tab pointed in the downward direction.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM/GENERAL MAINTENANCE AND
PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
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