Installation

5 Slide the clips onto the hose and then work the hose onto its respective union.

9.2b ... or a small socket

9.2c Clips on small-bore hoses can be released with pliers

Cooling system 3»9

9.4A Union on the front of the block is retained by three bolts .

9.4B ... And on the back of the head by two bolts

PWW5I If the hose is difficult to push

hint

imuaa _{on its uniorii} n _{can be}

softened by soaking it in very hot water, or

alternatively a little soapy water can be

used as a lubricant.

6. Rotate the hose on its unions to settle it in position before sliding the clips into place and tightening them securely.

7. If either the inlet union to the cylinder block or the outlet union from the cylinder head has

been removed, fit a new O-ring, then install the union and tighten the mounting bolts securely (see illustration). 8 Refill the cooling system (see Chapter 1).

9.7a Fit new O-rings to the front union

9.7B ... And the rear union before reassembly

4»1

^{Chapter 4}

Fuel and exhaust systems

Contents

Air filter - cleaning and renewal see Chapter 1

Air filter housing - removal and installation 12

Air/fuel mixture adjustment - general information 4

Carburettor overhaul - general information 5

Carburettor synchronisation see Chapter 1

Carburettors - removal and installation 6

Carburettors - disassembly, cleaning and inspection 7

Carburettors - reassembly, and float height check 8

Carburettors - separation and joining 9

Choke cable - removal and installation 11

Degrees of difficulty

Exhaust system - removal and installation 13

Fuel hoses - check and renewal see Chapter 1

Fuel system - check see Chapter 1

Fuel tank - cleaning and repair 3

Fuel tank and fuel tap - removal and installation 2

General information and precautions 1

Idle speed - check see Chapter 1

Sub-air cleaner see Chapter 1

Throttle and choke cables - check and adjustment ... .see Chapter 1 Throttle cables - removal and installation 10

Easy, suitable for novice with little experience

_I

Fairly easy, suitable J|x

for beginner with

some experience 3j|

Fairly difficult, suitableforcompetent J^ DIY mechanic JS	Difficult, suitable for experienced DIY	^ ^ ^ ^
	mechanic

Very difficult, ^

suitable for expert DIY 5j or professional JN

Specifications

Note: Where applicable, models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details.

Fuel

Grade Unleaded, minimum 91 RON (Research Octane Number)

Fuel tank capacity 18 litres

Carburettors

Type Keihin VP 34 mm

Pilot screw setting (turns out) 1 to 2 turns out

Float height 13.7 mm

Idle speed 1300 rpm (± 100 rpm)

Pilot jet 38

Main jet 122

Torque settings

Carburettor joining nut (upper) 10 Nm

Carburettor joining nut (lower) 5 Nm

Exhaust downpipe nuts 13 Nm

Exhaust and silencer mounting bolts 27 Nm

Silencer clamp bolt 21 Nm

4*2 Fuel and exhaust systems

1 General information am precautions

General information

The fuel system consists of the fuel tank, fuel tap, filter, carburettors, fuel hoses and control cables.

The fuel filter is part of the tap and is fitted inside the fuel tank.

The carburettors used on all models are CV types with one carburettor for each cylinder. For cold starting, a choke lever is mounted on the left-hand handlebar, and is connected to the carburettors by a cable. To prevent carburettor icing, coolant is routed via a small-bore hose from the union on the back of the cylinder head to the carburettor bodies and then back to the cooling system via a union on the water pump cover.

Air is drawn into the carburettors through an air filter which is housed under the carburettors.

The exhaust system is a two-into-one design.

Many of the fuel system service procedures are considered routine maintenance items and for that reason are included in Chapter 1.

Precautions