Frame and engine (left side view)
1. Engine stop switch lead
2. Throttle cable
3. Clutch cable
4. Ignition coil
5. High tension cord
6. Clamp
7. Air vent hose
8. Radiator breather hose
9. CDI magneto lead
10. YPVS breather hose
11. Cable guide
12. Frame (weld bead)
13.Sub-lead wire (throttle position sensor lead/solenoid valve lead)
14. Engine bracket (left)
15. Crankcase breather hose
16. Overflow hose
17. Rear shock absorber
18. Connector cover
A. Align the throttle cable locating tape with the cable guide. Fasten each part with the plastic locking tie.
B. From the outside of the vehicle, pass the engine stop switch lead, clutch cable and throttle cable.
C. Insert the fuel tank breather hose end into the steering shaft hole.
D. Pass the throttle cable, clutch cable and engine stop switch lead above the radiator hose.
E. Install the ignition coil and side core together to the frame.
F. Clamp the throttle cable, high tension cord and sub-lead wire (throttle position sensor lead/solenoid valve lead) to the frame. Position the lock portion under the frame. After tightening the clamp, cut off the end of the clamp so that the remaining end is 1–5 mm (0.04–0.20 in) in length.
G. Make sure the high tension cord does not contact with clutch cable. (It does not matter if the clutch cable contacts with the grommet.)
H. Clamp the clutch cable and sub-lead wire (throttle position sensor lead/solenoid valve lead) to the engine bracket (left). The lock portion should face the inner side of the vehicle, while the end should face the rear side of the vehicle. Make sure the connector cover does not contact with engine. Do not cut the end of the clamp.
I. Pass the air vent hose front of the throttle cable.
J. Pass the air vent hose, overflow hose and crankcase breather hose between the frame and connecting rod.
K. Pass the radiator breather hose and YPVS breather hose on the outside of the engine bracket and then inside of the down tube. Then pass the radiator breather hose inside the YPVS breather hose.
L. Clamp the CDI magneto lead, radiator breather hose and YPVS breather hose to the frame. Do not cut the end of the clamp.
Pay attention so that the YPVS breather hose is not crushed when installing the clamp.
M. Clamp the CDI magneto lead and radiator breather hose to the rear side of the frame. Pay attention so that the radiator breather hose is not crushed when installing the clamp. Position the end of the clamp inside the YPVS breather hose. Take care to clamp them above the projection on the frame. Do not cut the end of the clamp.
N. Do not clamp throttle cable and clutch cable.
O. Locate the clamp ends in the arrowed range.
P. 30° Tighten the clamp with its screw head in the arrowed range.
Q. Pass the throttle cable back of the air vent hose.
R. The position of the air vent hose (right) and overflow hose does not matter after passing the clamp.
S. Pass the air vent hoses, overflow hose and crankcase breather hose so that they do not contact the rear shock absorber.
T. Position the clip as shown in the illustration. Locate the clip in the arrowed range.
U. After connecting the coupler, make sure that the connector cover contacts the end of the coupler.
Frame and engine (right side view)
1. High tension cord
2. Clamp
3. Ignition coil lead
4. CDI unit
5. CDI unit band
6. Sub-lead wire (throttle position sensor lead/solenoid valve lead)
7. Joint connector
8. Engine stop switch lead
9. Radiator breather hose
10. CDI magneto lead
11. Throttle cable
12. Clutch cable
13. Connector cover
14. Frame (weld bead)
15. CDI unit stay
A. Pass the high tension cord to the left of the radiator hose.
B. No cable routing such as wire harness on the push pin of the frame.
C. Clamp the CDI magneto lead and ignition coil lead to the frame at its locating tape. After tightening the clamp, cut off the end of the clamp so that the remaining end is 1–5 mm (0.04–0.20 in) in length. The tightening direction does not matter.
D.Clamp to the frame the ignition coil lead. After tightening the clamp, cut off the end of the clamp so that the remaining end is 1–5 mm (0.04–0.20 in) in length. The tightening direction does not matter.
E. Clamp to the frame the throttle cable, clutch cable, ignition coil lead and engine stop switch lead. In so doing, clamp the ignition coil lead and engine stop switch lead at their protecting tubes.
Align the engine stop switch lead with the positioning tape portion, and then clamp the lead. The clamp position should be close to the damper.
After tightening the clamp, cut off the end of the clamp so that the remaining end is 1–5 mm (0.04–0.20 in) in length. The tightening direction does not matter.
F. Clamp to the frame the throttle cable, clutch cable and engine stop switch lead. In so doing, clamp the engine stop switch lead at its protecting tube. After tightening the clamp, cut off the end of the clamp so that the remaining end is 1–5 mm (0.04–0.20 in) in length. The tightening direction does not matter.
G. Pass the radiator breather hose under the clamp ends.
H. Face the CDI unit coupler projection outside of the vehicle when installing the CDI unit.
I. Face the joint connector with its open end downward, and there is no pinching with peripheral parts. Joint connection position does not matter.
J. Pass the CDI magneto lead and radiator breather hose between the frame and the radiator (right).
K. Place the clamp end so that it is located outside the vehicle beyond the ignition coil lead.
L. After connecting the coupler, make sure that the connector cover (throttle position sensor lead/solenoid valve lead) contacts the end of the coupler.
M. Clamp the wire harness with two white tapes.
N. Good
O. No good
P. Pass the throttle cable and clutch cable under the frame (weld bead).
Place the clamp end so that it is located under the clutch cable of the vehicle.
Q. Insert the CDI unit band until it stops at the CDI unit stay.
R. Pass the throttle cable, clutch cable and engine stop switch lead under the frame (weld bead).
S. After connecting the couplers, move the handlebar all the way to the right side and clamp the leads without applying too much power.
T. Pass the CDI magneto lead and radiator breather hose between the frame and the radiator hose so that they come within the arrow-indicated range. Also take care so that the CDI magneto lead passes on the left of the radiator breather hose.
Handlebar (front view)
1. Brake hose
2. Master cylinder
3. Engine stop switch lead
4. Engine stop switch
5. Throttle cable
6. Clutch cable
7. Clamp
8. Cable guide
A. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder, while the white paint side faces to the front of the vehicle.
B. Pass the engine stop switch lead in the middle of the clutch holder.
C. Pass the throttle cable upper side of the number plate.
D. Pass the clutch cable rear of the number plate band.
E. Clamp the engine stop switch lead to the handlebar. Do not cut the end of the clamp.
F. Pass the clutch cable through the cable guide on the number plate.
G. Pass the brake hose in front of the number plate and through the cable guide.
