Camshaft Installation
Remove the ignition pulse generator rotor cover cap. Align, the T mark notch mark with the index mark on the ignition pulse generator rotor cover by turning the crankShaft clockwise. Apply molybdenum disulfide oil a 50 50 mixture of engine oil and molybdenum disulfide grease to the cam shaft journals of the cylider head and camshaft holders. Install each camshaft to the correct side Each camshaft has an identification mark IN is for the intake side and EX is for the exhaust side Install the...
Requisite Service
Side fairing removal instalation page 2-3 Side fairing removal instalation page 2-3 Front turn signal connector 3P mini Align the basses on the headlight case with the grommets. Front turn signal connector 3P mini Instal the right seat rubber with the mark MT4-R facing in. Install the left seat rubber with the mark MT4-L facing in. Install the right plate with the marked side in and each arrow Install the left plate with the marked side out and each arrow Front cowl removal installation page...
Requisite Service Rxs
- Fuel tank removal installation page 2-11 Installation is in the reverse order of removal Before removing the air cleaner base, disconnect the cylinder head cover breather tube from the air cleaner When installing, align the boss on the front end of the air cleaner base with the hook on the frame. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area where gasoline is stored can cause a...
Requisite Service Erq
Side fairing removal page 2-3 Exhaust system removal installation page 2-10 Installation is in the reverse order of removal. Ignition pulse generator connector 2P mini 3P mini connector oil pressure switch wire neutral swich wire thermo sensor wire Refer to page 7-4 for removal and installation. Install the link with the punch marks on the link and gearshift spincfle. Disconnect the water hoses at the engine side. Install the long one to the left hanger arm and the short one to the right...
Pilot Screw Adjustment
If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Make sure the carburetor synchronization is within specification before pilot screw adjustment see page 1-6 . The pilot screws are factory pre-setand no adjustment is necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 rpm...
Requisite Service Vcy
Coolant draining page 5-3 Right side cover removal installation page 2-2 Shock absorber removal installation page 13-4 Coolant refill section 5 ot the Common Service Manual Installation is in the reverse order of removal. Release the hook on the reserve tank from the oval hole in the frame by pivoting the tank rearward.
Service Information Yml
Gasoline is extremely flammable and is explosive under certain conditions, KEEP OUT OF REACH OF Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. ________ Work in a well ventilated area. Smoking or allowing flames in the work or where gasoline is stored can cause a fire or explosion. Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might...
Requisite Service Wzg
Air cleaner housing removal installation page 6-3 Installation is in the reverse order of removal After removing the carburetor assembly, do not place it up side down or the air intake might be deformed Separate No3. No.4 carb. from No . No,2 carb. Carburetor connecting bolt nut 5mm Loosen each nut gradually and alternately. Carburetor connecting bolt nut 6mm Starting enrichment valve cable holder Vacuum chambers, float chambers and jets can be sen iced without separating the carburetors. Keep...
Side Cover RemovalInstallation
Unlock the quick release fasteners by aligning the long slot with the punch mark. Remove the side cover by releasing the bosses or the cover from the grommets. Be careful not to break the pins, tabs and slots in the side cower ant tail cowl when removing the side cover. Install the side cover signing its bosses with the grommets and engage the tabs with the slots, and pins with the holes securely as shown. Lock the clip by aligning the A mark with the punch mark. Do the same on the other side.
Requisite Service Bog
Side fairing removal installation page 2-3 Air cleaner housing removal installation page 6-3 Coolant refill section 5 of the Common Service Manual Installation is in the reverse order of removal. During removal and installation, be careful not to damage the radiator fins. When installing, align the grommet on the top of the radiator with the boss on the frame. Radiator removal installation page 5-5 Assembly is in the reverse order of disassembly. Remove the radiator grill by releasing the four...
Jet Needle Holder RemovalInstallation
Screw a proper 4 mm thread screw in the jet needle holder as shown and pull out the jet needle holder with a pliers. NOTE 3e careful not damage the diaphragm. Do not remove the jet needle holder by pushing in the jet needle. Install the jet needle holder In the reverse order of removal. NOTE Push the jet needle holder in until the 0-ring on the holder seats completely In the groove in the vacuum piston.
Shim Selection
Remove the valve lifter and shims page 8-2 . Do not allow shims to fall into the crankcase The shim s may occasionally stick to the valve lifter Mark the positions of all valve lifters and shims to ensure correct reassembly. It Is easy to remove the valve lifter with a valve lapping too or magnet. Remove the shims with tweezers or a magnet. Clean the valve lifter with compressed air. Measure the shim thickness with a micrometer and record it, Sixty-five different shims are available in...
Coolant Draining
Wait until the engine is cool before servicing the cooling system. Removing the radiator cap while the engine is hot and the coolant is under pressure may serious scalding. For coolant replacement, refer to section 5 of the Common Service Manual Remove the left side fairing page 2-3 . Remove the water pump drain bolt and sealing washer. Remove the radiator cap and drain the coolant. Place a suitable tray under the siphon tube joint of the reserve tank and disconnect the siphon tube from the...
Service Access Guide
The following shows the locations of the parts that must be removed for the maintenance items listed beiow. Refer to the Common Service Manual for items not included in this manual. Refer to section 2 Frame Body Panels Exhaust System for the parts that must be removed for service For exampleiAIR CLEANER Contamination, clogging, replacement Parts Fuel tank-------The parts must be removed for service- Reserve Tank Cap Coolant fiHingl Riylit side cover Level check, fluid replacement Right side...
Requisite Service Dys
Oil pump removal installation page 4-4 Oil pump cover bolt. Dowel pin Oil pump cover Thrust washer Drive pin Assembly is in the reverse order of disassembly. Install the drive pin into the hole in the pump shaft and align the pin with the groove In the inner rotor. Install the outer rotor with the punch mark facing the oil pump cover.
Carburetor Synchronization
Refer to section 2 of the Common Service Manual for carburetor synchronization procedure Synchronize the carburetors with the engine at normal operating temperature and the transmission in neutral. - No. 2 carburetor is the base carburetor. Disconnect the fuel valve vacuum tube from the No. 1 Remove the rubber cap from the No. 2 carburetor vacuum Remove the rubber cap by pinching the end of the cap. Do not pinch the cap body or it will be damaged. Remove the vacuum plugs from the No.3 and No.4...
Inspection
Adjust the valve clearance while the engine is cold below 35 C 95 F . Remove the air cleaner housing base page 6-3 . Remove the radiator mounting bolts and release the grommet on the radiator top from the boss on the frame. Move the radiator forward and secure it to the fork tubes with pieces of string as shown. Remove the ignition pulse generator rotor cover cap. Remove the cylinder head cover page 8-2 . Align the T mark notch mark with the index mark on the ignition pulse generator rotor...
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Spark Plug
Do not touch the exhaust system while it is hot. For detailed instructions, refer to section 2 of the Common Service Manual The No. 1 spark plug can be serviced from the right side, and the Mo. 2, No. 3 and No. 4 spark plugs can be serviced from the left side. Remove the maintenace lids by turning the quick screws counterclockwise. A spark plug wrench is included in the tool kit. Disconnect the spark plug caps and clean away dirt from around the spark plug bases. Remove the spark plugs using...