Removing the seats and battery Order Job/Parts to remove Quantity Remarks 1 Rider seat 1 2 Passenger seat 1 3 Battery negative lead 1 Disconnect. 4 Battery positive lead 1 Disconnect. 5 Tool band 1 6 Tool 1 7 Upper tail cover bracket 2 8 Battery cover 1 9 Battery 1 10 Battery...
Removing the side cowlings Order Job/Parts to remove Quantity Remarks 1 Front cowling inner panel 2 2 Side cowling 2 3 Front turn signal/position light coupler 2 Disconnect. 4 Front turn signal/position light 2 5 Lower cowling 2 6 Side cowling inner panel 2 For installation,...
Removing the ECU and rectifier/regulator Order Job/Parts to remove Quantity Remarks Side cowling Refer to " General chassis ". 1 ECU coupler 2 Disconnect. 2 ECU 1 3 Radiator fan motor relay coupler 1 Disconnect. 4 Radiator fan motor relay 1 5 ECU bracket 1 6 Rectifier/regulator coupler 1...
Removing the air ducts Order Job/Parts to remove Quantity Remarks Side cowling Refer to " General chassis ". ECU and rectifier/regulator Refer to " General chassis ". 1 Air chamber cover 2 2 Air chamber 2 3 Air chamber bracket 2 4 Air intake air duct cover 2 5 Rear intake...
Removing the front cowling assembly Order Job/Parts to remove Quantity Remarks Side cowling Refer to " General chassis ". ECU and Rectifier/regulator Refer to " General chassis ". Air duct Refer to " General chassis ". 1 Intake air temperature sensor coupler 1 Disconnect. 2 Auxiliary...
Removing the meter and headlight Order Job/Parts to remove Quantity Remarks Side cowling Refer to " General chassis ". ECU and Rectifier/regulator Refer to " General chassis ". Air duct Refer to " General chassis ". Front cowling assembly Refer to " General chassis ". 1 Rear view...
Disassembling the headlight assembly Order Job/Parts to remove Quantity Remarks 1 Auxiliary light socket 2 2 Auxiliary light bulb 2 3 Headlight bulb cover 2 4 Headlight bulb 2 5 Headlight harness 1 6 Headlight grille 2 For installation, reverse the removal procedure.
Removing the rear fender Order Job/Parts to remove Quantity Remarks Rider seat Refer to " General chassis ". Passenger seat Refer to " General chassis ". Upper tail cover bracket Refer to " General chassis ". 1 Upper tail cover 1 2 Muffler 2 Refer to " Engine removal ". 3...
Disassembling the license plate/turn signal light assembly Order Job/Parts to remove Quantity Remarks 1 License plate/turn signal light stay 1 2 License plate/turn signal light stay plate 1 3 Cover 1 4 Rear turn signal light 2 5 License plate light 1 6 Rear reflector 1 7 Side reflector bracket 1 8 Side...
Installing the quick fastener (screw type) To install the quick fastener, turn its screw counterclockwise so that it protrudes from the fastener head, then insert the fastener into the cover and turn the screw "a" clockwise in with a screwdriver. Make sure that the screw is flush with the...
Installing the quick fastener (push type) To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin "a" in with screwdriver. Make sure that the pin is flush with the fastener's head.
Installing the quick fastener (pull type) To install the quick fastener, pull the pin, then insert the fastener into the cover and push the pin "a". Make sure to insert the fastener until it is locked.
Installing the passenger seat lock cylinder 1. Install: Seat lock key cylinder "1" Lock stay "2" Lock spring "3" Align the projection "a" of the passenger seat lock key cylinder "1" to the grooves "b" of the lower tail cover and lock stay "2" and install.
Removing the front turn signal/position lights 1. Remove: Stay "1" Front turn signal/position light "2" Remove the stay "1" first and then remove the front turn signal/position light "2" from the side cowling.
Nstalling the front turn signal/position lights 1. Install: Front turn signal/position light "1" Stay "2" Insert the flasher stay tabs "a" into the front turn signal/position light grooves "b".
Installing the lower cowlings 1. Install: Lower cowling "1" Insert the lower cowling tab "a" into the inner panel hole "b" and slide back.
Removing the side cowling inner panels 1. Remove: Side cowling inner panel "1" When removing the side cowling inner panel downward, pull out the side cowling inner panel hole from the projection "a" of the air chamber cover "2".
Installing the side cowling inner panels 1. Install: Side cowling inner panel "1" Install the grommet "2" to the side cowling inner panel and insert them into the projection "a" of the air chamber cover "3".
Removing the air chamber covers 1. Remove: Air chamber cover "1" Pull out the air chamber cover tab "a" upward from the hole "b" of the air chamber "2".
Installing the air chamber covers 1. Install: Air chamber cover "1" Insert the air chamber cover tab "a" downward into the hole "b" of the air chamber "2".
Removing the intake air duct covers 1. Remove: Intake air duct cover "1" Press the upper surface of the intake air duct cover tab "a" to inside of the vehicle and remove the intake air duct cover upward.
Installing the intake air duct covers 1. Install: Intake air duct cover "1" Align the intake air duct cover tabs "a" and the tab "b" of the front cowling "2" as shown in the illustration and install.
Installing the air intake ducts 1. Install: Rear air intake duct "1" (to front air intake duct "2") Insert the rear air intake duct tabs "a" into the front air intake duct grooves "b".
Installing the rear view mirrors 1. Install: Rear view mirror "1" Rear view mirror nut (along with the mirror base "2"). 7 Nm (0.7 mr·kgf, 5.1 ft·lbf). Install the mirror base to the rear view mirror first, then install the rear view mirror to the front cowling.
Removing the windshield 1. Remove: Windshield "1" Slide the windshield to the back and remove from the front cowling. Remove the rear view mirror and then remove the windshield.
Installing the windshield 1. Install: Windshield "1" Insert the windshield tabs "a" into the receptors of the front cowling "2".
Installing the mirror fitting plates 1. Install: Mirror fitting plate "1" (to meter bracket "2") Face the mirror fitting plate concave "a" up and install it to the meter bracket. A. Front side
Removing the upper tail cover 1. Remove: Rider seat Refer to " General chassis ". Passenger seat Refer to " General chassis ". 2. Remove: Upper tail cover "1" a. Remove the bolt on the upper tail cover. b. Remove the quick fasteners on the upper tail cover. c. Slide the upper...
Installing the upper tail cover 1. Install: Upper tail cover "1" a. Install the upper tail cover from the front of the lower tail cover "2" and slide to the back. b. Put the upper tail cover down, align the tabs "3" of the upper tail cover to the lower tail cover tabs, and then...
Installing the tail/brake light 1. Install: Tail/brake light "1" Fit the tail/brake light tabs "a" into the holes "b" of the lower tail cover "2".
Adjusting the rider footrests 1. Remove: Rider footrest (right and left) EWA14B1018 Warning: When removing the right rider footrest "1", be careful not to burn with the exhaust chamber "2". 2. Adjust: Rider footrest position (right and left) a. Remove the rider footrest bolts....