Page 80 of 457
3-3
Order Job / Part Q’ty Remarks
1
2Removing the seats
Rider seat
Passenger seat1
1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
7 Nm (0.7 mkg, 5.1 ftlb)
SEATS
CHK
ADJ
EAS00039
SEATS
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Page 81 of 457
3-4
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the fuel tank
Rider sear
Fuel tank side cover
Fuel hose connector cover
Fuel hose
Fuel return hose
Fuel sender coupler
Fuel pump coupler
Fuel tank over flow hose
Fuel tank breather hose
Fuel tank
Fuel tank cover
Fuel pump2
1
1
1
1
1
1
1
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
4 Nm (0.4 mkg, 2.9 ftlb)
4 Nm (0.4 mkg, 2.9 ftlb)
FUEL TANK
CHK
ADJ
EAS00040
FUEL TANK
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Page 84 of 457
3-7
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13Removing the front cowling and
side cowlings
Rider seat
Side cowling
Front turn signal light lead coupler
Side cowling inner panel
Bottom cowling
Bottom cowing front cover
Frame side cover
Frame side panel
Headlight panel
Front cowling
Rear view mirror
Windshield
Air intake duct
Air intake duck mount2
2
2
2
1
2
2
2
1
2
1
2
2Remove the parts in the order listed.
Refer to “SEATS”.
Disconnect.
For installation, reverse the removal
procedure.
7 Nm (0.7 mkg, 5.1 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
16 Nm (1.6 mkg, 12 ftlb)
COWLINGS
CHK
ADJ
COWLINGS
FRONT COWLING AND SIDE COWLINGS
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Page 85 of 457
3-8
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the rear cowling
Rider seat and passenger seat
Muffler
Rear cowling (upper)
Tail / brake light lead coupler
Rear turn signal light lead coupler
Tail / brake light
License plate bracket assembly
Rear cowling (lower)1
1
4
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “EXHAUST PIPE” in chapter 5.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4 Nm (0.4 mkg, 2.9 ftlb)10 Nm (1.0 mkg, 7.2 ftlb)
COWLINGS
CHK
ADJ
REAR COWLING
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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
ProCarManuals.com
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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