NOTICE
The KIBS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface.
Be careful not to get water or mud on the KIBS hydraulic unit.
Drain the brake fluid through the bleed valve by pumping the brake lever and pedal.
Clear the projection [C] from the bracket.
NOTICE
Clean all fittings on the KIBS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.
Spread over a shop towel around the KIBS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts.
NOTICE
Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.
NOTE
Remove the brake hoses and pipes according to each assembly of the exploded view.
NOTICE
The KIBS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disassemble and repair the KIBS hydraulic unit.
Cylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting).
Remove the pistons (see Piston Removal).
Assemble the cylinder (upper crankcase) [A], the cylinder
head [B] and the cylinder head gasket [C].
Tighten the cylinder head bolts (see Cylinder Head Installation
in the Engine Top End chapter).
...
Fuel Tank Installation
Note the above WARNING (see Fuel Tank Removal).
Run the hoses correctly (see Cable, Wire, and Hose Routing
section in the Appendix chapter).
Check that the dampers [A] are in place on the fuel tank.
If the dampers are damaged or deteriorated, replace
them.
If the fuel tank brack ...
Starter Motor Assembly
Install the positive brush assy [A] and the starter motor
terminal [B] as shown in the figure.
Replace the O-ring [C] with a new one, and install it.
Install:
Brush Springs [A]
Negative Brush Assy [B]
Turn the stopper side [C] to inside.
Tighten:
Torque - Brush Holder S ...