Route the wife
harness properly
('05
- '07:
page
/.
25, After '07:
PBge
1-32).
ENGINE REMOVAl/INSTALLATION
Connect the alternator 4P (Black) and
ignition
pulse
r-
generator
2P
(Black) connectors.
Install the
wi
re band.
Connect
the
starter
motor
cable
and
tigh
ten
the
nut
~~~~~~
~
securely.
Connect the clutch cable to the clutch tifter lever.
Install the
cl
utch cable stay and
ground
cable and
tighten
the
bolts securel
y.
Connect
the
b
reather
hoses.
Install
the
following:
- Ignition
coi'
(page 18-8)
Radiator reserve tank (page 7-9)
Brake pedal (page 16-24)
Gearshift pedal
(page'
1-27)
Kickstarter pedal (page 11-7)
Drive sprocket (page 8-4)
Carburetor
(page
6-24)
Exhaust
system
(page
3-14)
Spark
plug
cap
(page
4-12)
Fuel tank (page 3-8)
Left/right/canter engine guards (page 3-5)
Seat (page 3-3)
'05 and '06 Install the
PA
IR
control
valve (page 6-
30
1.
callfom~
type.
After
'06'
Fill the system
with
the recommended coolant and
bleed the
ai
r (page 7-
71
.
Fill
the
engine
with
the r
ecommended
engine oil
(page
4-19).
Fi
ll the transmission
with
the r
ecommended
trans-
mission oil (page 4-23).
After installing the engine.
perform
the
following
inspections and adjustments:
-
Thronle
grip
freeplay (page 4-91
-
Drive chain slack (page 4-24)
- Clutch lever freeplay (page 4-31)
Check the exhaust system
fo
r leaks.
8-9
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