CARBURETOR ASSEMBLY

NEEDLE

HOLDER

THROTTLE VALVE PLATE

FLOAT VALVE

After 06:

NEEDLE CLIP

FLOAT

FLOAT PIN

O-RING

FLOAT CHAMBER

V ^

JET NEEDLE

THROTTLE STOP SCREW

ACC. PUMP BYPASS

,• BAFFLE

1 Ц plate

NEEDLE CLIP

O-RING

DIAPHRAGM

O-RING

After ’07:

D-RING

ACCELERATOR PUMP COVER

NEEDLE HOLDER

PUSH ROD STARTER JET

NEEDLE JET

MAIN JET

SLOW JET

PILOT SCREW

Install the throttle position sensor by aligning the tabs of the throttle position sensor with the flat side of the shaft as shown.

THROTTLE POSITION SENSOR

CARBURETOR ASSEMBLY

Install the throttle position sensor to its original position as marked during removal.

Alter tightening the bolt to the specified torque, break the bolt head.

05, 06:

Tighten the torx screw to the specified torque. TORQUE: 3.4 N m (0.3 kgf-m, 2.5 Ibf-ft)

After 06:

Tighten the bolt to the specified torque.

TORQUE: 3.4 N m (0.3 kgf m, 2.5 Ibf-ft)

• The throttle position sensor is factory pre-set and no adjustment is necessary unless the throttle position sensor is replaced.

• For sensor inspection (page 18-9) and replace­ment (page 6-26).

MAIN JET BAFFLE PLATE

NEEDLE JET

STARTER JET

SLOW JET

PILOT SCREW

CARBURETOR ASSEMBLY

Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat

Install the O-ring, washer, spring and pilot screw.

Perform pilot screw adjustment if a new pilot screw is installed (page 6-27).

/

SLOW AIR JET

(’05 — ’07)

• Install the pilot screw and return it to its original position as noted during removal.

Install the slow jet, starter jet, baffle plate, needle jet and main jet.

TORQUE:

Slow jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

Starter jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf ft)

Needle jet: 1.8 N m (0.2 kgf m, 1.3 Ibf ft)

’05 — ’07 Shown:

CARBURETOR ASSEMBLY

Main jet: 1.5 N-m (0.2 kgf-m, 1.1 Ibf-ft)

’05- ’07:

Install and tighten the slow air jet to the specified torque.

TORQUE: 0.9 N m (0.1 kgf m, 0.7 Ibf-ft)

Install the float valve, float and float pin.

Set the float level gauge so it is perpendicular to the float chamber face and in-line with the main jet.

FLOAT LEVEL GAUGE

PUSH ROD

CARBURETOR ASSEMBLY

Set the carburetor so the float valve just contacts the float arm lip. Make sure the float valve tip is securely in contact with the valve seat.

Make sure the float is level with the float level gauge.

TOOL:

Carburetor float level gauge 07401-0010000 FLOAT LEVEL: 8.0 mm (0.31 in)

If the float level is out of specification, adjust it by bending the lip.

’05-’07 Shown: LINK LEVER

Install the push rod while holding the push rod link lever.

CARBURETOR ASSEMBLY

ACC. PUMP BYPASS

CARBURETOR ASSEMBLY

Install the acc. pump bypass into the float chamber and tighten it to the specified torque.

TORQUE: 0.3 N m (0.03 kgf-m, 0.2 lbf-ft)

^ O-RING

Install a new O-ring to the float chamber. Install the float chamber to the carburetor.

Install the hose guides and float chamber screws. Tighten the screws to the specified torque.

STAY

CARBURETOR ASSEMBLY

FLOAT CHAMBER SCREWS

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

Install the throttle stop screw stay and tighten the screw securely.

D-RING

O-RING

CARBURETOR ASSEMBLY

Install a new D-ring with it flat side facing forward the accelerator pump cover.

COVER

i

DIAPHRAGM

Install the diaphragm, spring, new О-rings and accelerator pump cover.

COVER

’05 — ’07 shown: SCREWS

CARBURETOR ASSEMBLY

Install and tighten the screws to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibfft)

CHOKE KNOB

CARBURETOR ASSEMBLY

Install the choke knob and tighten the lock nut to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

Assemble the roller and throttle valve plate on the throttle valve.

Note the installation direction of the throttle valve plate.

THROTTLE VALVE PLATE

THROTTLE VALVE

CARBURETOR ASSEMBLY

• Install the throttle valve plate with the seal side facing toward the throttle valve.

CARBURETOR ASSEMBLY

’05, ’06 shown:

THROTTLE SHAFT SCREW

CARBURETOR ASSEMBLY

Install the throttle valve assembly into the carbure­tor with the valve plate facing towards the engine side.

• Make sure the throttle valve moves smoothly.

Align the holes in the throttle shaft arm and throttle shaft.

’05. 06:

After 06:

’05. ‘06:

Apply locking agent to the screw threads.

Install and tighten the throttle shaft screw to the specified torque.

TORQUE: 2.1 Nm (0.2 kgf m, 1.5 Ibf ft)

Apply locking agent to the torx screw threads.

Install and tighten the throttle shaft torx screw to the specified torque.

TORQUE: 2.1 N m (0.2 kgf m, 1.5 lbf-ft)

CARBURETOR ASSEMBLY

’05, ’06:

NEEDLE CLIP

Install the jet needle clip to the jet needle.

STANDARD CLIP POSITION:

2nd position from the top

CARBURETOR ASSEMBLY

After 06:

Install the jet needle and needle holder into the throttle valve.

’05. ’06:

’05, ’06 shown:

needlTholder

THROTTLE VALVE

CARBURETOR ASSEMBLY

Tighten the needle holder to the specified torque. TORQUE: 2.1 N m (0.2 kgf m, 1.5 Ibf ft)

After ’06:

Install the jet needle/holder assembly into the throt­tle valve.

Tighten the jet needle/holder assembly to the speci­fied torque.

TORQUE: 2.1 N-m (0.2 kgf m, 1.5 Ibf ft)

Install a new O-ring and top cover.

TOP COVER

CARBURETOR ASSEMBLY

O-RING

WIRE

BOLTS

FUEL HOSE

OVERFLOW

HOSE

CARBURETOR ASSEMBLY

Install the clamp and bolts.

Tighten the bolts to the specified torque.

TORQUE: 2.1 N-m (0.2 kgf-m, 1.5 Ibf-ft)

Clamp the throttle position sensor wire as shown.

Route the hoses properly (’05 — ’07: page 1-25, After ’07: page 1-32).

Connect the overflow hose, air vent hoses and fuel hose.

THROTTLE CABLES

THROTTLE BOLT

ADJUSTER

CARBURETOR ASSEMBLY

LOCK NUT

THROTTLE DRUM

CARBURETOR ASSEMBLY

BOLT

THROTTLE DRUM COVER

CARBURETOR ASSEMBLY

VALVE SPRING

HOT START VALVE

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