ANUAL SERVICE M

COMPONENT LOCATION

'05 - '07 shown:

SERVICE INFORMATION

GENERAL

• Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control.

• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.

• Before disassembling the carburetor, place an approved gasoline container under the carburetor drain plug, remove the drain plug and drain the carburetor.

• When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassem­bly.

• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carbure­tor.

• If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor driveability.

SPECIFICATIONS

TORQUE VALUES

Rear fender mounting bolt

Sub-frame upper mounting bolt ('05 - '07)

Sub-frame lower mounting bolt ('05 - '07)

Sub-frame upper/lower mounting bolt (After '07)

Shock absorber upper mounting nut

Throttle drum cover bolt

Needle jet

Main jet

Slow air jet ('05-'07)

Starter jet Slow jet

Acc. pump bypass Carburetor top cover bolt Float chamber screw Carburetor drain plug

Carburetor drain screw (After '05)

Choke valve lock nut Throttle bolt (carburetor side)

Throttle shaft screw ('05, '06)

Throttle shaft torx screw (After '06)

Needle holder

Accelerator pump cover screw Hot start valve lock nut

Throttle position sensor torx screw ('05, '06)

Throttle position sensor bolt (After '06)

PAIR control valve mounting nut 13 N m (1.3 kgf-m, 10 Ibf ft)

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

49 N-m (5.0 kgf-m, 36 Ibf-ft) 49 N m (5.0 kgf-m, 36 Ibf-ft) 44 N-m (4.5 kgf-m, 32 Ibf-ft)

3.4 N-m (0.3 kgf-m, 2.5 Ibf-ft)

1.8 N-m (0.2 kgf-m, 1.3 Ibf-ft)

1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

0. 9 N-m (0.1 kgf-m, 0.7 Ibf-ft)

1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

0. 3 N-m (0.03 kgf-m, 0.2 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf ft)

4.9 N-m (0.5 kgf-m, 3.6 Ibf-ft)

1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

4 N-m (0.4 kgf-m, 3.0 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

3.4 N-m (0.3 kgf-m, 2.5 Ibf-ft)

3.4 N-m (0.3 kgf-m, 2.5 Ibf-ft) 13 N-m (1.3 kgf-m, 10 Ibf-ft)

U-nut

Apply locking agent to the threads

Apply locking agent to the threads

TOOLS

TROUBLESHOOTING

Engine will not start

• Too much fuel getting to the engine

- Air cleaner clogged

- Flooded carburetor

• Intake air leak

• Fuel contaminated/deteriorated

• No fuel to carburetor

- Fuel filter clogged

- Fuel line clogged

- Fuel valve stuck

- Float level misadjusted

- Fuel tank breather hose clogged

• Slow circuit clogged

• No spark at plug (faulty spark plug or ignition system malfunction) (page 4-12)

Lean mixture

• Fuel jets clogged

• Fuel tank breather hose clogged

• Fuel filter clogged

• Fuel hose restricted

• Float valve faulty

• Float level too low

• Air vent hose clogged

• Intake air leak

Misfiring during acceleration

• Ignition system faulty (page 18-5)

• Lean mixture

Afterburn during acceleration

• Ignition system faulty (page 18-5)

• Lean mixture

• Accelerator pump faulty

Rich mixture

• Choke valve in the "ON" position

• Float valve faulty

• Float level too high

• Air jets clogged

• Air cleaner element contaminated

• Flooded carburetor

Engine stalls, hard to start, rough idling

• Fuel line restricted

• Ignition system malfunction (page 18-5)

• Low cylinder compression

• Fuel mixture too lean/rich

• Fuel contaminated/deteriorated

• Intake air leak

• Float level misadjusted

• Fuel tank breather hose clogged

• Pilot screw misadjusted

• Slow circuit or starting enrichment circuit clogged

• Idle speed misadjusted

• Air cleaner clogged

Poor performance (driveability) and poor fuel economy

• Fuel system clogged

• Ignition system faulty (page 18-5)

• Air cleaner clogged

Afterfiring

• Ignition system malfunction (page 18-5)

• Carburetor malfunction

• Lean mixture

• Rich mixture