Page 110 of 457
3-33
REPLACING THE AIR FILTER ELEMENT /
CHECKING THE FUEL AND BREATHER HOSESCHK
ADJ
CAUTION:
NOTE:
NOTE: 4. Install:
air filter case cover
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle bodies tuning, leading to poor
engine performance and possible overheat-
ing.
When installing the air filter element into the air
filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
5. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
EAS00096
CHECKING THE FUEL AND BREATHER
HOSES
The following procedure applies to all of the fuel
and breather hoses.
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Check:
breather hose
1
fuel hose 2
Cracks / damage Replace.
Loose connection Connect properly.
Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
ProCarManuals.com
Page 111 of 457
3-34
CHECKING THE FUEL AND BREATHER HOSES /
CHECKING THE CRANKCASE BREATHER HOSECHK
ADJ
CAUTION:
CAUTION:
CAUTION:
3. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
rider seat
Refer to “SEATS”.
fuel tank
Refer to “FUEL TANK”.
2. Check:
crankcase breather hose
1
Cracks / damage Replace.
Loose connection Connect properly.
Make sure the crankcase breather hose is
routed correctly.
3. Install:
fuel tank
Refer to “FUEL TANK”.
rider seat
Refer to “SEATS”.
To install the fuel tank, check that the breath-
er hose is not folded or pinched by the fuel
tank.
ProCarManuals.com
Page 135 of 457
3-58
CHECKING THE TIRES
CHK
ADJ
WARNING
WARNING
EAS00162
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
tire pressure
Out of specification Regulate.
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic
weight
(with oil
and a full
fuel tank)
193 kg (425 lb)
194 kg (428 lb) for CAL
Maximum
load*202 kg (445 lb)
201 kg (443 lb) for CAL
Cold tire
pressureFrontRear
Up to
90 kg
load*250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
90 kg
maximum
load*250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
High-
speed
riding250 kPa
(2.5 kgf / cm2,
2.5 bar,
35.6 psi)
290 kPa
(2.9 kgf / cm2,
2.9 bar,
41.3 psi)
* Total weight of rider, passenger, cargo and ac-
cessories
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
ProCarManuals.com
Page 145 of 457
3-68
CHECKING THE FUSES
CHK
ADJ
WARNING
Pocket tester
90890-03112, YU-3112
b. If the pocket tester indicates “∞”, replace the
fuse.
3. Replace:
blown fuse
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
Fuses
Amperage
ratingQ’ty
Main50 A1
Fuel injection
system15 A1
Headlight25 A1
Signaling
system10 A1
Ignition15 A1
Backup fuse
(odometer
and clock)
10 A1
Radiator
fan motor15 A2
Reserve25 A, 15 A,
10 A1
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
front cowling inner panel (left)
Refer to “COWLINGS”.
rider seat
Refer to “SEATS”.
ProCarManuals.com
Page 224 of 457
5-2
5
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10Removing the exhaust pipe
Rider seat and passenger seat
Fuel tank
Side cowlings and bottom cowlings
EXUP pulley cover
EXUP cable
Exhaust pipe assembly
Exhaust pipe gasket
Exhaust valve pipe gasket
Exhaust valve pipe assembly
Catalyst pipe assembly
Gasket
Muffler
Gasket1
2
1
4
1
1
1
1
2
2Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
ENGINEENG
EXHAUST PIPE
ProCarManuals.com
Page 227 of 457
5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
ProCarManuals.com
Page 233 of 457
5-11
Order Job / Part Q’ty Remarks
1
2
3
4Removing the cylinder head cover
Fuel tank
Side and bottom cowlings
Throttle body assembly
Radiator assembly
Air cut-off valve
Ignition coil
Spark plug
Cylinder head cover
Cylinder head cover gasket4
4
1
1Remove the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “RADIATOR” in chapter 3.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
13 Nm (1.3 mkg, 9.4 ftlb)
8 Nm (0.8 mkg, 5.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
CAMSHAFTENG
EAS00194
CAMSHAFT
CYLINDER HEAD COVER
ProCarManuals.com
Page 257 of 457
5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 mkg, 7.2 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
14 Nm (1.4 mkg, 10 ftlb)
22 Nm (2.2 mkg, 16 ftlb)
22 Nm (2.2 mkg, 16 ftlb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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