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ENGRADIATOR
EC455000
ASSEMBLY AND INSTALLATION
EC445344
Radiator
1. Install:
9Radiator breather hose 1
9Radiator hose 3 2
9Radiator hose 1 3
To radiator (right) 4.
NOTE:
Clamp the radiator hose in the direction as
shown.
2. Install:
9Radiator (right) 1
9Plain washer 2
9Bolt [radiator (right)] 3
9Radiator hose 4 4
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
3. Install:
9Radiator (left) 1
9Plain washer 2
9Bolt [radiator (left)] 3
9Radiator hose 2 4
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
4. Tighten:
9Clamp (radiator hose 1, 3) 5
5. Install:
9Panel 1
9Bolt (panel) 2
NOTE:
Fit the hook aon the inner side first into the
radiator.
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1C3-9-30-4A 25/5/04 7:23 PM Page 12
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ENGCARBURETOR AND REED VALVE
2. Tighten:
9Bolt (air filter joint) 1
9Bolt (carburetor joint) 2
3. Clamp:
9Air vent hose 1
9Overflow hose 2
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
4. Adjust:
9Idle speed
Refer to “IDLE SPEED ADJUSTMENT”
section in the CHAPTER 3.
2 Nm (0.2 m•kg, 1.4 ft•lb)
2 Nm (0.2 m•kg, 1.4 ft•lb)
1C3-9-30-4A 25/5/04 7:23 PM Page 32
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ENGCDI MAGNETO
7. Connect:
9CDI magneto lead 1
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
8. Install:
9Gasket [crankcase cover (left)]
9Crankcase cover (left) 1
9Screw [crankcase cover (left)] 2
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
5 Nm (0.5 m•kg, 3.6 ft•lb)
1C3-9-30-4C 25/5/04 7:18 PM Page 38
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6-1
ELECELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1“ENGINE STOP” button
2CDI unit
3Ignition coil
4CDI magneto
5Spark plug
EC612000
WIRING DIAGRAM
COLOR CODE
B...................Black
O ..................Orange
Y...................Yellow
B/R ...............Brack/Red
B/W ..............Black/White
G/L ..............Green/Blue
G/W ..............Green/White
W/L...............White/Blue
W/R ..............White/Red
1C3-9-30-6 14/5/04 5:47 PM Page 2
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