ANUAL SERVICE M

CARBURETOR INSTALLATION

Connect the throttle cables to the throttle drum but do not tighten the adjuster and lock nut yet.

Tighten the throttle bolt to the specified torque.

TORQUE: 4 N m (0.4 kgf m, 3.0 lbf-ft)

Install the throttle drum cover and bolt. Tighten the bolt to the specified torque. TORQUE: 3.4 Nm (0.3 kgf m, 2.5 Ibf ft)

Install the valve spring over the hot start cable and connect the cable end to the hot start valve.

Install the hot start valve to the carburetor body, and tighten the lock nut to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 lbf-ft)

Align the lug on the carburetor with the groove in the carburetor insulator.

Tighten the insulator band screw (page 1-17).

Connect the throttle position sensor 3P (Black) con­nector.

Install the shock absorber upper mounting bolt and nut.

Tighten the upper mounting nut to the specified torque.

TORQUE: 44 N m (4.5 kgf-m, 32 Ibf-ft)

NUT/BOLT

Lower the sub-frame and connect the air cleaner connecting boot securely.

Tighten the sub-frame mounting bolts to the speci­fied torque.

TORQUE ( 05 - '07):

Upper: 30 N m (3.1 kgf m, 22 Ibf-ft)

Lower: 49 N-m (5.0 kgf-m, 36 Ibf-ft)

TORQUE (After 07):

Upper/lower: 49 N m (5.0 kgf-m, 36 Ibf-ft)

LOWER MOUNTING BOLTS

Tighten the air cleaner connecting boot band screw

securely.

Install the following:

- Muffler ('05 - '07: page 3-9, After '07: page 3-11)

- Fuel tank (page 3-8)

- Seat (page 3-3)

After installation, check the following:

- Secondary air leak around the insulator and con­necting boot

- Fuel leaks around the fuel hose and carburetor

- Route the overflow hose, air vent hoses and fuel hose properly (’05 - '07: page 1-25, After '07: page 1-32).

- Throttle operation (page 4-9)

- Hot start lever (page 4-10)