Page 82 of 457
3-5
FUEL TANK
CHK
ADJ
CAUTION:
NOTE:
NOTE:
CAUTION:
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
fuel hose connector cover
fuel return hose
fuel hose
fuel sender coupler
fuel pump coupler
fuel tank breather hose
fuel tank over flow hose
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remain-
ing in it.
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:
fuel tank
Do not set the fuel tank down so that the installa-
tion surface of the fuel pump is directly under the
tank. Be sure to lean the fuel tank in an upright
position.
REMOVING THE FUEL PUMP
1. Remove:
fuel pump
Do not drop the fuel pump or give it a
strong shock.
Do not touch the base section of the fuel
sender.
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Page 83 of 457
3-6
FUEL TANK
CHK
ADJ
4 Nm (0.4 mkg, 2.9 ftlb)
NOTE:
CAUTION:
INSTALLING THE FUEL PUMP
1. Install:
fuel pump
Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
Always use a new fuel pump gasket.
Install the fuel pump as shown in the illustra-
tion.
Tighten the fuel pump bolts in stages in a criss-
cross pattern and to the specified torque.
INSTALLING THE FUEL TANK
1. Install:
fuel hose
fuel return hose
fuel hose connector cover
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
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Page 87 of 457
3-10
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the air filter case
Rider sear
Fuel tank
Plug
Air temperature sensor lead coupler
Spacer
Air temperature sensor
Air filter case cover
Air filter
Funnel
Air filter case
Air induction system hose
Crankcase breather hose1
1
1
1
1
1
2
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “FUEL TANK”.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
2 Nm (0.2 mkg, 1.4 ftlb)
3.4 Nm (0.34 mkg, 2.5 ftlb)
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
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Page 88 of 457
3-11
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
NOTE:
EAS00045
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
air filter case
Refer to “AIR FILTER CASE”.
bottom cowlings
side cowlings
Refer to “COWLINGS”.
throttle body assembly
Refer to “THROTTLE BODIES” in chapter 7.
air cut-off valve
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
radiator
radiator fan motor
Refer to “RADIATOR” in chapter 6.
2. Remove
ignition coils
spark plugs
cylinder head cover
cylinder head cover gasket
Refer to “CAMSHAFT” in chapter 5.
3. Remove
pickup rotor cover
1
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Page 94 of 457
3-17
ADJUSTING THE VALVE CLEARANCE /
SYNCHRONIZING THE THROTTLE BODIESCHK
ADJ
NOTE:
NOTE:
NOTE:
7. Install:
all removed parts
For installation, reverse the removal procedure.
SYNCHRONIZING THE THROTTLE BODIES
Prior to synchronizing the throttle bodies, the
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the motorcycle on a level surface.
Place the motorcycle on a suitable stand.
2. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
3. Remove:
synchronizing hoses
1
4. Install:
vacuum gauge
1
(onto the synchronizing hose)
digital tachometer
(near the spark plug)
Vacuum gauge
90890-03094, YU-08030
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Page 95 of 457
3-18
SYNCHRONIZING THE THROTTLE BODIES
CHK
ADJ
NOTE:
CAUTION:
NOTE: 5. Install:
fuel tank
Refer to “FUEL TANK”.
6. Start the engine and let it warm up for several
minutes.
7. Measure:
engine idling speed
Out of specification Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”.
Engine idling speed
1,150 1,250 r / min
8. Adjust:
throttle body synchronization
a. With throttle body #3 as standard, adjust
throttle bodies #1, #2, and #4 using the air
screws
1.
After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
If the air screw is removed, turn the screw 3 / 4
turn in and be sure to synchronize the throttle
body.
Do not use the throttle valve adjusting
screws to adjust the throttle body synchro-
nization.
Vacuum pressure at engine
idling speed
22 kPa
(165 mmHg, 6.5 inHg)
The difference in vacuum pressure between
two throttle bodies should not exceed 1.33 kPa
(10 mmHg, 0.39 inHg).
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Page 96 of 457
3-19
SYNCHRONIZING THE THROTTLE BODIES /
ADJUSTING THE EXHAUST GAS VOLUMECHK
ADJ
NOTE:
NOTE: 9. Measure:
engine idling speed
Out of specification Adjust.
Make sure that the vacuum pressure is within
specification.
10. Stop the engine and remove the measuring
equipment.
11. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3 5 mm (0.12 0.20 in)
13. Install:
synchronizing hoses
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
ADJUSTING THE EXHAUST GAS VOLUME
Be sure to set the carbon monoxide density to
standard, and then adjust the exhaust gas.
1. Turn the main switch to “OFF” and engine
stop switch “ON”.
2. While keeping the “SELECT” and “RESET”
buttons pressed simultaneously, turn “ON”
the main switch (keep them pressed for 8 se-
conds or more).
All indications on the meter disappear except
the clock and trip indications.
Letters “dIAG” appear on the clock LCD.
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Page 109 of 457
3-32
ADJUSTING THE CLUTCH CABLE FREE PLAY /
REPLACING THE AIR FILTER ELEMENTCHK
ADJ
a
b
NOTE: Engine side
a. Loosen the locknut
1.
b. Turn the adjusting nut
2 in direction a or b
until the specified clutch cable free play is ob-
tained.
Direction
Clutch cable free play is
increased.
DirectionClutch cable free play is
decreased.
c. Tighten the locknuts.
Lock nut
7Nm (0.7 mkg, 5.1 ftlb)
EAS00086
REPLACING THE AIR FILTER ELEMENT
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Remove:
air filter case cover
1
3. Check:
air filter element
1
Damage Replace.
Replace the air filter element at periodic inter-
vals of 40,000 km travel.
The air filter needs more frequent service if you
are riding in unusuallu wet or dusty areas.
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