EAS00035

CABLE ROUTING

1 Hose3

2 ECU

3 Ignition coil

4 Sidestand switch lead

5 Main switch

6 Hose

7 Coolant temperature sensor

8 Wiring harness

9 Throttle cable kit

0 Rear brake cable q AC magneto lead w Hose5 e Starter motor lead

CABLE ROUTING

SPEC 0 * r t

A

B

C

D

E

Battery positive lead

Wire lead cover

Assemble cramp on the Tstud at the right of back stay.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of box bracket 1 .

Install crap on the hols of stay 1 .

Penetrate thermo unit lead through the rear of hose 3.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of down tube 1 .

F Fix connector cover on the head light stay.

G Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of fuel tank bracket 2.

H Connect AC magnet lead on the cramp of fan case

1.

D-D

6

E-E

2-29

F-F G-G

CABLE ROUTING

SPEC 0 *

1 Speedometer A

2 Rectifier/Regulator cover the coupler.

3 Turn signal relay B

4 Throttle cable Ass’y C

5 Holder

6 Cable holder

7 Rear brake cable

8 Speedometer cable cable, fix crank case 1 .

When locking, make sure that the stopper at the front of holder touches the posi-

9 Front brake cable tion of crank case 1 .

0 Headlight D q Horn cable, install the protruding w Starting circuit cut-off relay part of cramp on the hole of under cover.

E Install the horn of coupler accotding to the direction shown in the drawing, and make sure that it is not loosen easily.

F Penetrate through the speed meter cable.

2-30

CABLE ROUTING

SPEC 0 *

1 Fuel pump i Rear fender

2 FI diagnostic tool conneco Fuel injector lead tor

3 Fuse box

4 Battery negative lead

5 ECU lead

6 Battery positive lead

7 Starter relay p s

A

B

Sub-wire harness lead valve lead

Crankcase2

Enter slant angle of sensor.

Enter tail/brake light.

E Put the idle speed control lead and wire sub lead in, and then close the cramp. a ISC(idle speed control) F Wire the starting device of the rear fender of rear motor lead and crank case 2.

Do not clip the lead in.

8 AC magneto lead

9 Tail/brake light lead

0 Starter motor lead q Holder w Cable holder

C

D

Fix throttle cable Ass’y. Install the protruding part of cramp on the hole of fuel tank bracket.

Fix throttle cable Ass’y. Ine Lean angle cut-off switch r Ignition coil t Throttle cable Ass’y y Rear brake cable u Wiring harness stall the protruding part of cramp on the hole of foot rest bracket. dx

©©

D

©

C © ® © © ©

5

A-A u o t

D-D E-E

B-B p a

2-31

E

F-F

C-C s F y

G-G

1 Speedometer

2 Rectifier/Regulator

3 Horn

4 Turn signal relay

5 Front brake cable

6 Rear brake cable

7 Throttle cable Ass’y

8 Speedometer cable

9 Rectifier/Regulator lead

0 Wiring harness q Main switch lead w Horn lead

CABLE ROUTING

SPEC 0 *

A Penetrate the rear brake D Penetrate the main switch cable and throttle cable Comp. Lead into the conthrough the left side of car body.

B Make sure to install the cramp on the head light

E nector cover.

Penetrate horn cable through the connector cover without sticking out stay. horn cable.

C Install the protruding part of F Enter rectifier and regulator cable strap of electrical wire harmess Ass’y on the hole of head light stay.

Ass’y.

1

2

G-

®-

-©

C

B

C xi)

-©

C

A

F

XD

-©

®

0

A-A B-B

2-32

G Let the left and right flasher lights, meter, and right lead wire of handle bar switch to face upward, let the main switch, front and rear brake switchand left lead wire of handle bar switch to face downward, connect to the coupler, and then store in the connector cover.

CABLE ROUTING

SPEC 0 *

1

2 m-

®-

C

-©

C

B

C-

F

A-A B-B

0

2-33

CABLE ROUTING

SPEC 0 *

1 Turn signal light lead(right) A Penetrate the rear brake

2 Handlebar switch lead(right)

3 Front brake light switch lead

4 Turn signal light lead(left)

B through the left side of car body.

Make sure to install the cramp on the head light

5 Handlebar switch lead(left)

6 Rear brake light switch

7 Throttle cable Ass’y

8 Front brake cable

9 Rear brake cable

0 Backward screw q Forward screw

C

D stay.

Install the protruding part of cable strap of electrical wire harmess Ass’y on the hole of head light stay.

Penetrate the main switch

Comp. Lead into the connector cover.

E Penetrate horn cable through the connector cover without sticking out horn cable.

F Enter rectifier and regulator

Ass’y.

G First, tighting the backward screw and tighting the forward screw.

2-34

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

CHK

ADJ

< &

INTRODUCTION 3-1

PERIODIC MAINTENANCE AND MINOR REPAIR 3-2

PERIODIC MAINTENANCE CHART FOR THE EMISSION CON-

TROL SYSTEM 3-2

GENERAL MAINTENANCE AND LUBRICATION CHART 3-3

COVER AND PANEL 3-5

SIDE COVERS AND TAIL/BRAKE LIGHT 3-5

SINGLE SEAT AND TRUNK 3-7

LEG SHIELD1,2 3-8

FOOTREST BOARD AND INNER FENDER 3-9

ENGINE 3-10

ADJUSTING THE VALVE CLEARANCE 3-10

CHECKING THE ENGINE IDLING SPEED 3-16

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-17

CHECKING THE SPARK PLUG 3-18

CHECKING THE IGNITION TIMING 3-20

MEASURING THE COMPRESSION PRESSURE 3-22

CHECKING THE ENGINE OIL LEVEL 3-24

CHANGING THE ENGINE OIL 3-25

CHANGING THE TRANSMISSION OIL 3-27

MEASURING THE ENGINE OIL PRESSURE 3-28

REPLACING THE AIR FILTER ELEMENT 3-30

CHECKING THE THROTTLE BODY JOINT AND INTAKE

MANIFOLD 3-32

CHECKING THE FUEL HOSE 3-32

CHECKING THE BREATHER HOSES 3-33

CHECKING THE EXHAUST SYSTEM 3-34

CHECKING THE COOLANT LEVEL 3-35

CHECKING THE COOLING SYSTEM 3-36

CHANGING THE COOLANT 3-37

CHASSIS 3-40

ADJUSTING THE FRONT BRAKE 3-40

ADJUSTING THE REAR BRAKE 3-40

CHECKING THE FRONT AND REAR BRAKE SHOES 3-41

CHECKING AND ADJUSTING THE STEERING HEAD 3-42

CHECKING THE FRONT FORK 3-44

CHECKING THE TIRES 3-45

CHK

ADJ

< &

CHECKING THE WHEELS 3-48

CHECKING AND LUBRICATING THE CABLES 3-48

LUBRICATING THE LEVERS AND PEDALS 3-49

LUBRICATING THE CENTERSTAND 3-49

ELECTRICAL SYSTEM 3-50

CHECKING AND CHARGING THE BATTERY 3-50

CHECKING THE FUSE 3-56

REPLACING THE HEADLIGHT BULB 3-58

ADJUSTING THE HEADLIGHT BEAM 3-59