Installing the hydraulic unit

 

Proceed in the reverse order of disassembly.

 

Pay attention to the following items.

 

1.	Install:
•	hydraulic unit	T.R.	16 Nm (1.6 m · kg, 11 ft · lb)

NOTE:

• When tightening the hydraulic unit nuts, first temporarily tighten the front nuts, and then tighten the rear nut and the front nuts to specification in the order given.

 

• Do not allow any foreign materials to enter the hydraulic unit or the brake hoses when installing the hydraulic unit.

CAUTION:

		Do not remove the rubber plugs or bolts
		(M10Ч1.25) installed in the union bolt
		holes before installing the hydraulic unit.
		2. Remove:
	• rubber plugs or bolts (M10 Ч 1.25)
		3. Install:
		• copper washers New
		• brake hose 1 (to the rear brake caliper)
	• brake hose 2 (from the rear brake master
		cylinder)

К • brake hose 3 (to the front brake caliper)

 

brake hose 4 (from the front brake master cylinder)

union bolts T. 30 Nm (3.0 m · kg, 22 ft · lb)

R.

WARNING

The brake hoses to the front and rear brake calipers can be distinguished by the rubber at the end of each hose. Be sure to connect each brake hose to the correct union bolt hole.

CAUTION:

To route the front and rear brake hoses, refer to “CABLE ROUTING” in chapter 2.

 

 

4 - 65

FRONT AND REAR BRAKES ^CHAS

 

Л Fill:

 

brake master cylinder reservoirs

Recommended brake fluid

DOT 4

 

М Bleed the brake system.

 

М Check the operation of the hydraulic unit according to the brake levers response. (Refer to “[D-6-3-1] Hydraulic unit operation test 1”.)

 

CAUTION:

Always check the operation of the hydrau-lic unit according to the brake levers response.

 

 

4 - 66

HANDLEBAR ^CHAS

HANDLEBAR

 

Order	Job/Part	Q’ty				Remarks
	Removing the handlebar		Remove the parts in the order listed.
	Upper handlebar cover
	Band
	Grip end
	Front brake light switch connector		Disconnect.
	Right handlebar switch
	Throttle cable		Disconnect.
	Throttle grip					Refer to “INSTALLING
	Front brake master cylinder holder					THE HANDLEBAR”.
	Front brake master cylinder
	Rear brake light switch connector		Disconnect.

 

 

4 - 67

HANDLEBAR ^CHAS

 

 

Order	Job/Part	Q’ty						Remarks
	Parking brake lever/holder	1/1
	Rear brake lock lever cable			Disconnect.
	Left handlebar switch							Refer to “INSTALLING
					THE HANDLEBAR”.
	Rear brake master cylinder holder
	Rear brake master cylinder
	Handlebar grip			Refer to “REMOVING THE HANDLE-
				BAR” and “INSTALLING THE HANDLE-
				BAR”.
	Upper handlebar holder				Refer to “INSTALLING THE HANDLE-
	Handlebar				BAR”.
	Lower handlebar cover
				For installation, reverse the removal pro-
				cedure.

 

4 - 68

HANDLEBAR ^CHAS

EAS00666

REMOVING THE HANDLEBAR

 

1. Stand the scooter on a level surface.

 

WARNING

Securely support the scooter so that there is no danger of it falling over.

 

 

Н Remove:

 

handlebar grip 1

NOTE:

Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

 

 

CHECKING THE HANDLEBAR

 

О Check:

 

handlebar

 

Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

 

 

EAS00671

INSTALLING THE HANDLEBAR

 

1. Stand the scooter on a level surface.

 

WARNING

Securely support the scooter so that there is no danger of it falling over.

 

 

4 - 69

 

 

b ¹

 

UP

a

 

HANDLEBAR ^CHAS

П Install:

 

handlebar 1

 

handlebar upper holders 2

 

T.R.	23 Nm (2.3 m · kg, 17 ft · lb)

WARNING

First, tighten the bolts on the front side of the handlebar holder, then on the rear side.

NOTE:

РThe upper handlebar holders should be installed with the arrow marks a facing for-ward И.

 

РAlign the match mark b on the handlebar with the upper surface of the lower handlebar holder.

 

С Install:

 

handlebar grip

 

grip end

 

▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼

 

У Apply a thin coat of rubber adhesive onto the left end of the handlebar.

 

У Slide the handlebar grip over the left end of the handlebar.

 

У Wipe off any excess rubber adhesive with a clean rag.

WARNING

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