Service Manual
Table Of Contents
- GENERAL INFORMATION
- MAINTENANCE
- ELECTRONIC FUEL INJECTION
- SPECIAL TOOLS
- Part Numbers / Descriptions
- Fuel Pressure Gauge Kit - PU-43506-A
- Fuel Pressure Gauge Adaptor - PS-48762
- Throttle Position Sensor Tester Kit - 2201519
- Digital Wrench™ Diagnostic Software PU-47063
- Digital Wrench™ SmartLink Module Kit - PU-47471
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ - Download Website
- FUEL TANK
- FUEL LINE
- EFI SERVICE NOTES
- EFI SYSTEM LAYOUT
- EFI COMPONENTS
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- FUEL INJECTORS
- CRANKSHAFT POSITION SENSOR (CPS)
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- IDLE AIR CONTROL VALVE (IAC)
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- EFI DIAGNOSTICS
- FUEL SYSTEM TROUBLESHOOTING
- EFI SYSTEM BREAK-OUT DIAGRAMS
- Fuel Injector Circuit (PTO)
- Fuel Injector Circuit (MAG)
- Idle Air Control (IAC) Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Fuel Pump / Fuel Level Sensor Circuit
- Fuel Pump Circuit
- Fuel Gauge Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Throttle Position Sensor (TPS) Circuit
- Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit
- Diagnostic Connector Circuit
- Diagnostic Connector Circuit (EPS Models)
- SPECIAL TOOLS
- COOLING SYSTEM
- ENGINE
- GENERAL INFORMATION - ENGINE
- ENGINE ASSEMBLY VIEWS AND TORQUE VALUES
- Torque & Torque Sequence - Main Engine Components
- Valve Cover / Breather Valve
- Camshaft Carrier / Camshaft / Rocker Arm
- Cylinder Head / Valve / IAFM
- Valve & Spring Height Detail
- Piston / Connecting Rod
- Crankshaft
- Crankcase
- Crankcase - Upper
- Balance Shaft / Balance Shaft Timing
- Crankcase (Lower) With Oil Pump
- Water Pump Coupler
- Water Pump / Water Pump Coupler / Stator / Flywheel
- Drive Coupler (Rear) / Starter Gear
- ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Valve Cover / Breather Valve
- Rocker Carrier / Camshaft Removal
- Rocker Arm / Rocker Arm Shaft Inspection
- Camshaft / Camshaft Bore Inspection
- Cylinder Head Removal
- Cylinder Head Cleaning
- Cylinder Head Warp Inspection
- Cylinder Head
- Valve Inspection
- Combustion Chamber
- Valve Guide Removal / Installation
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Head Installation
- Camshaft / Carrier Assembly
- Camshaft / Camshaft Carrier Installation
- Camshaft Timing
- Cam Chain Tensioner Installation
- Camshaft Timing - Quick Reference
- Crankcase Disassembly
- Crankcase (Lower) / Oil Pump Disassembly
- Crankcase Disassembly (Upper)
- Piston / Connecting Rod Removal
- Counterbalance Shaft Removal / Inspection
- Counterbalance Split Gear Replacement
- Crankshaft / Cam Chain Removal
- Cam Chain / Sprocket Inspection
- Crankcase Inspection (Lower)
- Crankshaft Inspection
- Connecting Rod Inspection
- Connecting Rod Big End Bearing Selection
- Piston / Piston Ring Inspection
- Piston Ring Removal
- Piston Ring Installed Gap
- Piston Pin Bore Inspection
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Honing - Important Information
- ENGINE ASSEMBLY
- Crankcase Preparation - Upper
- Piston Ring Installation
- Piston / Connecting Rod Assembly
- Piston / Connecting Rod Installation
- Crankshaft Installation
- Oil Passage Tube
- Crankcase Assembly - Upper
- Balance Shaft Installation
- Balance Shaft Timing
- Crankcase Preparation (Lower)
- Crankcase Sealant and Torque Values
- Crankcase Assembly
- WATER PUMP
- TROUBLESHOOTING
- TRANSMISSION
- CLUTCHING (PVT)
- FINAL DRIVE
- BODY / FRAME
- STEERING / SUSPENSION
- BRAKES
10.9
STEERING / SUSPENSION
10
5. Install the (4) mounting fasteners and torque fasteners to
specification. Refer to “Steering Exploded View (EPS
Models)”.
6. Reconnect the (2) electrical harnesses to the power steering
unit.
7. Align the mark on the upper steering post with the skip
tooth spline on the upper power steering shaft upon
installation (see Figure 10-1).
8. Apply anti-seize to the shaft splines to aid assembly.
9. Position the upper steering post on the shaft so the pinch
bolt is aligned with the recess in the power steering shaft.
10. Install the pinch bolt and torque to specification. Refer to
“Steering Exploded View (EPS Models)”.
11. Install the fuel tank assembly, fuel line and reconnect the
fuel pump harness (see Chapter 3).
12. Reinstall the upper steering post bushing bracket and torque
the (2) fasteners to specification.
13. Turn the ignition key to the “ON” position and move the
handlebar from left to right several times to ensure the
power steering doesn’t bind. If binding occurs:
• Loosen the (4) mounting fasteners
• Move handlebars from left to right several times to
position the power steering unit
• Torque the (4) mounting fasteners to specification and
check the steering operation for binding again
• If no binding is present, proceed; if binding is still
present, repeat this procedure.
14. Install both front mud guards and right-hand footwell (see
Chapter 9).
15. Install the front rack and front cover (see Chapter 9).
CAUTION
The 8-way connector, two rows of four pins,
does not have a channeled lock on both sides,
allowing it to be installed 180° from its intended
position. The connector will not positively
engage or snap into place while in the wrong
position, but can still be installed.
If the connector is not installed correctly, the
Power Steering Unit will not function.
CAUTION
Striking the steering post can permanently
damage the EPS unit and cause
a Power Steering Fault.
Shaft
Recess
Pinch
Bolt
Upper
Steering Post
= T
Steering Post to Bulkhead Bolts:
20 ft. lbs. (27 Nm)
20 ft. lbs. (27 Nm)