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Side cover mouldings and leg shield
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CHK
ADJ
| Order | Job/Part | Q’ty | Remarks |
| Removing the side cover mouldings | Removing the parts in the order listed. | ||
| and leg shield | |||
| Upper side cover mole (left and right) | |||
| Lower side cover mole (left and right) | |||
| Center cover | |||
| Hinge cover | |||
| Side cover (left and right) | |||
| Footrest board (left and right) | |||
| Coolant reservoir cap access panel | |||
| Meter assembly coupler | Disconnect. | ||
| Meter assembly | |||
| Leg shield | |||
| Inner fender | |||
| For installation, reverse the removal pro- | |||
| cedure. | |||
3 - 5
COVER AND PANEL
REAR COVERS AND TAIL/BRAKE LIGHT ASSEMBLY
CHK
ADJ
| Order | Job/Part | Q’ty | Remarks |
| Removing the rear covers and tail/ | Removing the parts in the order listed. | ||
| brake light assembly | |||
| Seat | Open. | ||
| Upper side cover mole (left and right) | Refer to “SIDE COVER MOULDINGS | ||
| AND LEG SHIELD”. | |||
| Grab bar | |||
| Rear cover | |||
| Rear side cover (left and right) | |||
| Tail/brake light assembly coupler | Disconnect. | ||
| Tail/brake light assembly | |||
| For installation, reverse the removal pro- | |||
| cedure. | |||
3 - 6
FUEL TANK
FUEL TANK
CHK
ADJ
| R. | 10 Nm (1.0 m | • | kg, 7.2 ft | • | Ib) |
| T. | |||||
21 
13 
| R. | 4 Nm (0.4 m | • | kg, 2.9 ft | • | Ib) | R. | 7 Nm (0.7 m | • | kg, 5.1 ft | • | Ib) | ||
| T. | T. | ||||||||||||
| R. | 10 Nm (1.0 m | • | kg, 7.2 ft | • | Ib) | ||||||||
| T. |
New 20 
7 
T.
R.
| 10 Nm (1.0 m•kg, 7.2 ft•Ib) |
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10 
6
5 8 
T.
R.
T.
R.
7 Nm (0.7 m •
16 Nm (1.6 m • kg, 11 ft • Ib)
kg, 5.1 ft • Ib)
| Order | Job/Part | Q’ty | Remarks |
| Removing the fuel tank | Remove the parts in the order listed. | ||
| Battery cover | |||
| Negative battery lead | Disconnect. | ||
| Positive battery lead | Disconnect. | ||
| Battery | |||
| Fuse box assembly coupler | Disconnect. | ||
| Fuse box assembly | |||
| ABS motor fuse box | (XP500A) | ||
| Storage box light connector | Disconnect. | ||
| Fuel tank cover | |||
| Storage box light | |||
| Storage box | |||
| Storage box light switch coupler | Disconnect. | ||
| Hinge/damper | 2/1 | ||
3 - 7
CHK
FUEL TANK ADJ
| R. | 10 Nm (1.0 m | • | kg, 7.2 ft | • | Ib) |
| T. | |||||
21
13
| R. | 4 Nm (0.4 m | • | kg, 2.9 ft | • | Ib) | R. | 7 Nm (0.7 m | • | kg, 5.1 ft | • | Ib) | ||
| T. | T. | ||||||||||||
| R. | 10 Nm (1.0 m | • | kg, 7.2 ft | • | Ib) | ||||||||
| T. |
New 20
7
T.
R.
| 10 Nm (1.0 m•kg, 7.2 ft•Ib) |
10 6
5 8
T.
R.
T.
R.
7 Nm (0.7 m •
16 Nm (1.6 m • kg, 11 ft • Ib)
kg, 5.1 ft • Ib)
| Order | Job/Part | Q’ty | Remarks | |||||
| Fuel pump coupler | Disconnect. | Refer to “REMOVING | ||||||
| Fuel hose connector cover | THE FUEL TANK” and | |||||||
| Fuel hose | “INSTALLING THE FUEL | |||||||
| Fuel tank breather hose | TANK”. | |||||||
| Fuel pump bracket | Refer to “REMOVING THE FUEL | |||||||
| Fuel pump | PUMP” and “INSTALLING THE FUEL | |||||||
| Fuel pump gasket | PUMP”. | |||||||
| Fuel tank cap | ||||||||
| Fuel overflow tray/fuel overflow hose | 1/1 | |||||||
| Fuel tank | Refer to “REMOVING THE FUEL TANK” | |||||||
| and “INSTALLING THE FUEL TANK”. | ||||||||
| For installation, reverse the removal pro- | ||||||||
| cedure. | ||||||||
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3 - 8
CHK
FUEL TANK ADJ
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the fuel tank cap with a pump.
2. Remove:
• fuel hose connector cover 1
3. Disconnect:
• fuel hose 2
• fuel pump coupler 3
• fuel tank breather hose 4
CAUTION:
• Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.
• Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remaining in it.
• Do not disconnect the fuel hose except the fuel hose connector of the fuel pump feeding side.
NOTE:
Before removing the hoses, place a few rags in the area under where it will be removed.
4. Remove:
• fuel tank
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump bracket
• fuel pump
• fuel pump gasket
CAUTION:
• Do not drop the fuel pump or give it a strong shock.
• Do not touch the base section of the fuel sender.
3 - 9
| a | ||
FWD
4
3
FWD
CHK
FUEL TANK ADJ
INSTALLING THE FUEL PUMP
1. Install:
• fuel pump gasket New
• fuel pump
• fuel pump bracket
| T.R. | 4 Nm (0.4 m · kg, 2.9 ft · lb) |
NOTE:
• Do not damage the installation surfaces of the fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Align the projection a on the fuel pump with the projection in the fuel tank.
• Tighten the bolts to the specified torque in the proper tightening sequence as shown.
• Install the fuel pump in the direction shown in the illustration.
INSTALLING THE FUEL TANK
1. Install:
| • fuel tank | T.R. | 10 Nm (1.0 m · kg, 7.2 ft · lb) |
NOTE:
Tighten the bolts to the specified torque in the proper tightening sequence as shown.
2. Connect:
• fuel hose
• fuel breather hose
• fuel pump coupler
CAUTION:
• Be sure to connect the fuel hose by hand. Do not forcefully connect the hose with tools.
• When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct posi-tion, otherwise the fuel hose will not be properly installed.
3. Install:
• fuel pump connector cover
3 - 10
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
1
EAS00045
ENGINE
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