SERVICING INFORMATION 10-17
WIRING HARNESS, CABLE AND HOSE ROUTING
WIRING HARNESS ROUTING
*1
*2 Clamp
Wiring harness
Brake light switch
HO2 sensor (E-02, 19)
Wiring harness
Starter motor lead wire
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Clamp |
E |
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*2 |
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L |
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*3 |
P |
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M |
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A |
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*5 |
S |
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*4 |
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1 |
Integrated clamp |
8 |
Protector |
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2 |
Cooling fan relay |
*1 |
To ECT sensor |
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3 |
Fuel pump relay |
*2 |
Cut the tip after clamping. |
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4 |
Horn |
*3 |
To IAT sensor |
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5 |
Cooling fan motor |
*4 |
To CMP sensor |
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6 |
Left handlebar switch lead wire |
*5 |
Pass the lead wire through behind the frame and set it |
between the engine and frame. |
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7 |
Air intake (Frame) right inside |
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10-18 SERVICING INFORMATION
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6 N·m |
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Guide |
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(0.6 kgf-m, 4.5 lb-ft) |
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Handlebar switch (RH) |
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*1 |
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Iginition switch |
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Clamp |
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Wiring harness
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Battery - lead wire |
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E |
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L |
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P |
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M |
*3 |
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A |
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S |
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*4 |
Wiring harness
Position light (LH)
*2
Turn signal light (RH)
Clamp
1 |
Rear combination light |
8 |
Brake light switch |
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2 |
EXCVA |
9 |
Horn |
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3 |
AP sensor |
0 |
Regulator/rectifier |
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4 |
Starter relay |
*1 |
Lock part of the clamp should face inside. |
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5 |
Turn signal/side-stand relay |
*2 |
White marking. |
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6 |
TO sensor |
*3 |
Pass the lead wire through under the frame bridge. |
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7 |
Integrated clamp |
*4 |
To fan motor |
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10 N·m
6 N·m
5 N·m
7 N·m
14 N·m
10-20 SERVICING INFORMATION
HO2 SENSOR HARNESS ROUTING (For E-02, 19)
*4
*3
*2 |
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E |
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L |
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P |
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M |
48 N·m (4.8 kgf-m, 34.5 lb-ft) |
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A |
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S |
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*1 |
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1 |
HO2 sensor |
*2 |
Clamp the HO2 sensor lead wire so as not to over- |
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lap the oil inspection window. |
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2 |
Clutch cable |
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3 |
Oil pan |
*3 |
Pass the HO2 sensor lead wire through between |
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the frame and engine. |
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4 |
Under cowling |
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*1 |
Clamp the HO2 sensor lead wire so as not to |
*4 |
Pass the HO2 sensor lead wire through behind the |
contact with the under cowling. |
clutch cable. |
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SERVICING INFORMATION 10-21
CABLE ROUTING
*2
*1
E
L
P
M 0 mm
A
S
0 mm
0 mm
*3
1 |
Clutch cable |
*1 |
Clutch cable must be clamped on the grommet. |
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2 |
Throttle cable No.1 |
*2 |
Pass the throttle cables above the clutch cable. |
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3 |
Throttle cable No.2 |
*3 |
Pass the throttle cable No.2 outer from No.1. |
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10-22 SERVICING INFORMATION
FUEL TANK HOSE ROUTING
*1
*2
E
L
P
M
A
S
*3
1 |
Fuel tank water drain hose |
*1 |
Pass the fuel tank drain hose and breather hose |
through behind the PCV hose. |
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2 |
Fuel tank breather hose |
*2 |
Set the fuel tank drain hose and breather hose with |
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lengthwise backward. |
3 |
PCV (breather) hose |
*3 |
White marking |
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SERVICING INFORMATION 10-23
COOLING SYSTEM HOSE ROUTING
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90˚ |
90˚ |
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90˚ |
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*1 |
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*2 |
*2 |
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*2 |
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*4 |
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*3 |
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*5 |
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E |
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*5 |
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L |
*6 |
*4 |
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P |
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M |
*3 |
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A |
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*7 |
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S |
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*7 |
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*3 |
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*6 |
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*3 |
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*6 |
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*8 |
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*4 |
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*6 |
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1 |
Reservoir tank overflow hose |
*1 |
Clamp should face downward. |
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2 |
Reservoir tank inlet hose |
*2 |
Clamp should face right side. |
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3 |
Oil cooler outlet hose |
*3 |
Yellow marking |
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4 |
Clearance |
*4 |
White marking |
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5 |
Radiator inlet hose |
*5 |
Clamp should face backward. |
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6 |
Oil cooler inlet hose |
*6 |
Clamp should face left side. |
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7 |
Oil cooler |
*7 |
Clamp should face foreword. |
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8 |
Bypass hose |
*8 |
Red marking |
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9 |
Radiator outlet hose |
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0 |
Cylinder inlet hose |
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10-24 SERVICING INFORMATION
FRONT BRAKE HOSE ROUTING
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*1 |
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1 – 2 mm |
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(0.04 – 0.08 in) |
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*2 |
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*5 |
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*4 |
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*3 |
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*4 |
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E |
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L |
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P |
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14˚ |
M |
42˚ |
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42˚ |
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*3 |
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A |
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S*3 |
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*7 |
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*6 |
1 |
Brake hose guide |
*4 |
Clamp the brake hose firmly. |
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*1 |
Clamp should face downward. |
*5 |
After positioning the clamp with stopper, tighten |
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the clamp bolt. |
*2 |
Clamp should face backward. |
*6 |
Insert the clamp to the hole of the front fender |
fully. |
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*3 |
After the brake hose union has contacted the |
*7 |
The green paint is right side and face upside. |
stopper, tighten the union bolt. |
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SERVICING INFORMATION 10-27
COWLING INSTALLATION
Intake cover (RH)
To head light
Air intake pipe (RH)
Side cowling (LH)
Under cowling cover (RH)
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Intake |
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cover |
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E |
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(LH) |
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P |
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To frame |
To oil pan |
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LAir intakepipe (LH) |
Wind screen |
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M |
Under cowling |
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Side cowling (RH) |
A |
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cover (LH) |
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S |
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Under cowling (LH) |
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To |
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headlight |
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Heat shield |
Heat shield |
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Under cowling (RH) |
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Body cowling |
Cowling |
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Under inner |
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To |
brace |
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Under inner |
headlight |
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cowling (RH) |
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cowling (LH) |
Lower bracket cover |
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Body cowling cover |
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10-28 SERVICING INFORMATION
FRAME COVER INSTALLATION
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E |
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L |
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P |
SEAT LOCK CABLE ROUTING |
M |
A |
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S |
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40 N·m
50 N·m
SERVICING INFORMATION 10-31
FRONT FOOTREST INSTALLATION
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*1 |
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18 N.m (1.8 kgf-m, 13.0 lb-ft) |
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10 N.m (1.0 kgf-m, 7.0 lb-ft) |
E |
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P |
46 N.m (4.6 kgf-m, 33.5 lb-ft) |
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M |
L |
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A |
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S |
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*2 |
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*2 |
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23 N·m |
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23 N·m |
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(2.3 kgf-m, 16.5 lb-ft) |
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(2.3 kgf-m, 16.5 lb-ft) |
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1 |
Footrest |
7 |
Front footrest No. 2 bracket (RH) |
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2 |
Bank sensor |
8 |
Front footrest No. 2 bracket (LH) |
3 |
Holder |
9 |
Front footrest No. 1 bracket (RH) |
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4 |
Pin |
0 |
Front footrest No. 2 bracket (LH) |
5 |
Spring |
*1 |
Align the cutaway. |
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6 |
E-ring |
*2 |
Set this to shown position. |
*1
E
SERVICING INFORMATION 10-33
SPECIAL TOOLS
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09900-18740 |
09900-20101 |
09900-20202 |
09900-06107 |
09900-06108 |
Hexagon socket |
09900-20102 |
Micrometer |
Snap ring pliers |
Snap ring pliers |
(24 mm) |
Vernier calipers |
(25 – 50 mm) |
09900-20203 |
09900-20205 |
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09900-20602 |
09900-20605 |
Micrometer |
Micrometer |
09900-20508 |
Dial gauge |
Dial calipers |
(50 – 75 mm) |
(0 – 25 mm) |
Cylinder gauge set |
E |
(1/100 mm, 10 – 34 mm) |
(1/1000 mm, 1 mm) |
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L |
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A |
P |
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09900-20607 |
M09900-20803 |
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Dial gauge |
09900-20701 |
09900-20806 |
09900-20805 |
09900-21304 |
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S |
Thickness gauge |
Tire depth gauge |
V-block set (100 mm) |
(1/100 mm, 10 mm) Magnetic stand |
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09900-22301 |
09900-22401 (10 – 18 mm) |
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09900-25009 |
09900-28630 |
09900-22302 |
09900-22403 (18 – 35 mm) |
09900-25008 |
Needle pointed |
TPS test wire har- |
Plastigauge |
Small bore gauge |
Multi circuit tester set probe set |
ness |
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10-34 SERVICING INFORMATION
09910-20115 |
09913-10750 |
09913-50121 |
09913-70210 |
09915-40610 |
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Conrod stopper |
Adapter |
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Oil seal remover |
Bearing installer set |
Oil filter wrench |
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09915-64512 |
09915-74521 |
09915-74540 |
09915-77331 |
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Compression gauge |
Oil pressure gauge |
Oil pressure gauge |
Meter |
09916-10911 |
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set |
hose |
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attachment |
(for high pressure) |
Valve lapper set |
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E |
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L |
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P |
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09916-14530 |
09916-20640 |
09916-33210 |
09916-33320 |
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09916-14510 |
Valve lifter |
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Solid pilot |
Valve guide reamer |
Valve guide reamer |
Valve lifter |
attachment |
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M |
(4.5 mm) |
(9.8 mm) |
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(N-100-4.5) |
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A |
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S |
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09916-43211 |
09916-53310 |
09916-44930 |
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09916-34542 |
Valve guide |
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Valve guide |
09916-53330 |
09916-84511 |
Reamer handle |
remover/installer |
remover/installer |
Attachment |
Tweezers |
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SERVICING INFORMATION 10-35
09917-47011 |
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09920-34830 |
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09920-53740 |
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Vacuum pump |
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09919-28610 |
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Starter clutch |
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Clutch sleeve hub |
09921-20210 |
gauge |
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Sleeve protector |
holder |
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holder |
Bearing remover |
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09922-22711 |
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09921-20240 |
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Drive chain cutting |
09923-74511 |
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09924-84510 |
09924-84521 |
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Bearing remover set |
and joining tool |
Bearing remover |
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Bearing installer set |
Bearing installer set |
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E |
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L |
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09925-18011 |
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P |
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Steering bearing |
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09930-11930 |
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09930-11940 |
09930-11950 |
09930-30104 |
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installer |
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Torx bit JT30H |
M |
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Torx wrench |
Sliding shaft |
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Bit holder |
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A |
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S |
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09930-34980 |
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09930-44520 |
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09930-82720 |
09940-14911 |
09940-14960 |
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Rotor remover |
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Rotor holder |
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Mode selection |
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Steering stem nut |
Steering nut |
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switch |
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wrench |
wrench socket |
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10-36 SERVICING INFORMATION
09940-14940 |
09940-14990 |
09940-30221 |
09940-40211 |
09940-40220 |
Swingarm pivot |
Engine mounting |
Front fork assem- |
Fuel pressure |
Fuel pressure gauge |
thrust adjuster |
thrust adjuster |
bling tool |
gauge adaptor |
hose attachment |
socket wrench |
socket wrench |
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09940-52841 |
09940-52861 |
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09940-94922 |
09940-94930 |
Front fork inner |
Front fork oil seal |
09940-92720 |
Front fork spring |
Front fork spacer |
rod holder |
installer |
Spring scale |
E |
holder |
stopper plate |
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L |
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P |
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09941-34513 |
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M |
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09944-28320 |
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Steering race |
09943-74111 |
Hexagon socket |
09904-41010 |
99565-01010-007 |
installer |
Fork oil levelAgauge (19 mm) |
SDS Set |
CD-ROM Ver.7 |
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NOTE: |
S |
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When order the special tool, please confirm whether it is available or not.