CABLE ROUTING DIAGRAM

Clutch cable

Throttle cable (return)

Throttle cable (pull)

Handlebar switch lead (left)

Start switch lead

Cable holder

Handlebar switch coupler (left) (black, 6-pin)

Start switch coupler (black, 2-pin)

Rectifier/regulator coupler

Tension arm

Gear position switch lead

Crankcase cover bolt (left)

Radiator hose

Stator coil assembly lead

Gear position switch coupler (white, 3-pin)

Stator coil assembly coupler (gray, 2-pin)

Grommet

Crankcase breather hose

Lower engine bracket

Radiator breather hose

Holder

Bracket

Adjust slack in the handlebar switch lead (left) and start switch lead at the vehicle’s front side of the cable holder.

Pass the handlebar switch lead (left) and the start switch lead between the frame and the cable holder. Pass the handlebar switch lead (left) above the start switch lead.

Insert the handlebar switch 6-pin coupler (left) (black) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

Insert the rectifier/regulator 2-pin coupler (not colored) and rectifier/regulator 3-pin coupler (not colored) into the bracket and secure them. After securing, connect the coupler, and then install the cover.

Pass the rectifier/regulator lead (wire harness side) to the inside of the tension arm (the side of the vehicle).

Route the gear position switch lead along the crankcase cover while making sure that there is no looseness of the lead.

Fasten the clutch cable and stator coil assembly lead with a plastic locking tie. The fastening position should be between the crankcase cover bolt (left) and the crankcase cover bolt (left), as shown. Place the lock portion of the plastic locking tie to the outside of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

Bring the protector of the clutch cable into contact with the radiator hose, and pass it to the outside of the gear position switch lead and the stator coil assembly lead (the outside of the vehicle).

Pass the stator coil assembly lead behind the radiator. Be sure the lead will not be pinched between the radiator and the tension arm. Make sure that the stator coil assembly lead does not get caught between the radiator and the gear position switch 3-pin coupler (white).

After connecting the gear position switch 3-pin coupler (white), attach the coupler cover.

After connecting the stator coil assembly 2-pin coupler (gray), attach the coupler cover.

Fasten the clutch cable, gear position switch lead, and stator coil assembly lead over the grommet with the plastic locking tie. Place the lock portion of the plastic locking tie to the front of the vehicle, and then cut off the end of the remaining portion. (The direction of the end does not matter.)

Route the crankcase breather hose between the radiator and the frame, and in front of the lower boss of the radiator.

Route the crankcase breather hose at the rear of the vehicle where the radiator breather hose is located.

Route the radiator breather hose between the radiator hose and the crankcase breather hose. Then, route it inside the vehicle’s lower engine bracket.

Clamp the clutch cable at the front of the lead (the front of the vehicle).

Insert the clip portion of the clamp into the frame. The lock part should face toward the front of the vehicle. Cut off the end of the remaining portion. (The direction of the end does not matter.)

When installing the dampers and the lower handlebar holders in the front hole, be sure to route the handlebar switch lead (left) as shown in the illustration.

Wire harness

Rear frame

Plastic locking tie

Starter relay coupler (black, 4-pin)

Negative battery lead

Starter relay

Starter motor lead

Taillight lead

CCU (Communication Control Unit)

Taillight coupler

Starter relay cover

Diode

Engine mounting bracket boss

Wire harness (resistor lead)

Resistor

Rear fender (projection)

Positive battery lead

CCU coupler

Starter motor

Clamp

Fasten the resistor lead, starter motor lead, negative battery lead, and starter relay lead to the rear frame with the plastic locking tie between the branch of the wire harness and the battery bracket. Point the end of the lock portion and end of the plastic locking tie to the lower side of the vehicle.

Route the negative battery lead inside the vehicle along the starter motor lead.

Insert the starter relay into the battery bracket, and secure it.

Route the starter motor lead between the starter relay and the rear frame. Adjust any slack between the starter relay and the plastic locking tie of the rear frame.

No slack to the rear side of the vehicle.

Place the taillight coupler inside the frame.

Install the starter relay cover over the starter relay.

Route the starter motor lead through the inside of the engine mounting bracket boss and along the front side of the vehicle behind the engine mounting bracket boss.

Insert the clip of the clamp into the rear frame. Fasten the starter motor lead and wire harness at the green tape position of the wire harness. Place the starter motor lead under the vehicle’s wire harness. Place the lock portion of the plastic locking tie to the lower part of the vehicle, and then cut off the end by pointing it to the outside of the vehicle.

Point the lock portion of the plastic locking tie toward the lower side of the vehicle and the end toward the outside of the vehicle, and then cut off the end.

Point the starter motor lead to the outside, and then install it.

Insert the projection of the resistor rubber band into the battery bracket. Then, fasten the resistor securely by sliding it to the front side of the vehicle.

Route the positive battery lead on the outside of the projection on the rear fender (outside the vehicle).

Insert the clip of the CCU coupler into the battery bracket from the rear side of the vehicle. When doing so, fasten the CCU coupler so that it is positioned as shown.

Cylinder head breather hose

High tension cord

Radiator fan motor lead

Radiator fan motor lead coupler

Upper radiator boss

Throttle position sensor lead

Air filter breather hose

Clip

3-way joint

Crankcase breather hose

Lower radiator boss

Radiator breather hose

Throttle position sensor coupler (black, 3-pin)

Radiator hose

Tension arm

Route the cylinder head breather hose through the inside of the coolant temperature sensor lead.

Route the throttle position sensor lead on the outside of the air filter breather hose and cylinder head breather hose, inside the vehicle along the ignition coil.

Install the clips as shown in the illustration. Then install the lower clip above the radiator stay.

Align the red paint mark on the hose with the convex mark on the 3-way joint, and then install the cylinder head breather hoses.

The radiator breather hose should be routed in the following order and via each mentioned point. The upper radiator boss at the rear of the vehicle.
The lower radiator boss at the front of the vehicle.
Outside the vehicle past the cylinder head breather hose (when doing so, cross them at the bottom of the radiator).
For routing the remaining leads, refer to the diagram “Frame and engine (front left side view)”.

After connecting the throttle position sensor 3-pin coupler (black), install the cover over it.

Route the radiator fan motor lead inside the vehicle along the high tension cord.

Fuel pump coupler (black, 5-pin)

Coolant temperature sensor coupler (black, 2-pin)

High tension cord

ECU lead

Radiator fan motor relay lead

Taillight coupler

CCU sub-lead

CCU (Communication Control Unit)

Wire harness

Resistor coupler

Positive battery lead

Radiator fan motor fuse

ECU (Engine Control Unit)

Radiator fan motor relay

After connecting, install the cover over the fuel pump 5-pin coupler (black).

Route the engine ground lead outside the vehicle past the high tension cord. When installing the engine ground lead terminal, it can face either way. Point the engine ground lead to the upper side of the vehicle, and then install it.

Route the coolant temperature sensor lead outside the vehicle past the high tension cord. After connecting the coolant temperature sensor 2-pin coupler (black), install the cover over it.

Throttle cable

Plastic locking tie

Handlebar protector

Clutch cable

Handlebar switch lead (left)

Front brake hose

Headlight lead

Multi-function display coupler (black, 4-pin)

Speed sensor coupler (black, 3-pin)

Start switch lead

Speed sensor lead

Meter bracket

Wire harness

Fasten at the center of both sides of the clamps.

Secure the handlebar switch lead (left) to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle while pointing the end to the front side of the vehicle without cutting off it.

Pass the throttle cable, clutch cable, handlebar switch lead (left), start switch lead and speed sensor lead between the wire guide of the meter bracket and the handle crown (in no particular order).

Fasten the wire harness and speed sensor lead to the meter bracket using the plastic locking tie. When fastening, turn the steering to left and no slack. The speed sensor lead should be fastened at the gray tape. Face the end of the plastic locking tie to the right side of the vehicle. The excess should be cut.

Route the headlight lead left side of the vehicle.

Connect the headlight lead to the headlight.

Route the speed sensor lead in front of the vehicle’s wire harness.

Insert the multi-function display 4-pin coupler (black) into the bracket and secure them. After securing, install the cover over them.

Insert the speed sensor 3-pin coupler (black) into the bracket and secure them. After securing, install the cover over them.

After fastening the speed sensor lead, route it as U-letter and route along the start switch lead. Pass it through the bottom of the front brake hose.

Secure the start switch lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle while pointing the end to the front side of the vehicle without cutting off it.

Fasten the start switch lead and speed sensor lead with the plastic locking tie at the front side of the handlebar (front side of the vehicle). Place the start switch lead and speed sensor lead above the lower part of the handlebar.

Secure the start switch lead and speed sensor lead to the handlebar using the plastic locking tie. Point the lock portion of the plastic locking tie to the upper part of the vehicle while pointing the end to the front side of the vehicle without cutting off it.

Secure the handlebar and handlebar protector with the plastic locking tie. Point the lock portion of the plastic locking tie to the lower side of the vehicle. The direction of the end does not matter.

Fasten at the paint portion of the speed sensor lead. The place of the front brake hose does not matter.

70–110°

Vertical direction of vehicle

5 mm (0.20 in)

Fasten the paint portion of the speed sensor lead at the shrinking tube of the front brake hose.

Ignition coil lead

Coolant temperature sensor lead

Engine ground lead

Air filter breather hose

Intake air pressure sensor coupler (dark blue, 3-pin)

Fuel injector coupler (gray, 2-pin)

Intake air temperature sensor coupler (black, 2-pin)

Tank rail

Air filter case

Spark plug cap

Cylinder head cover

Damper

Fuel hose

Starter motor lead

Wire harness

Install the terminal so that the lead is positioned above the vehicle. Connect the black cover of the ignition coil lead to the black terminal of the ignition coil, and the white cover to the green terminal.

Route the coolant temperature sensor lead, engine ground lead, and high tension cord outside the vehicle past the air filter breather hose.

Insert the projection of the main harness into the hole in the tank rail.

±10°

Right side of the vehicle.

Insert the spark plug cap all the way into the cylinder head cover so that there is no clearance between the cap and the cover.

Place the fuel hose on the flat surface on the upper side of the damper.

Route the starter motor lead along the damper and clamp it.

Place the wire harness on the flat surface on the upper side of the damper.

Insert the clip portion of the clamp into the air filter case.

Radiator fan motor relay lead

ECU lead

Battery

Radiator fan motor fuse

Negative battery lead

CCU (Communication Control Unit)

Positive battery lead

ECU (Engine Control Unit)

Radiator fan motor relay

Holder

Rear frame

Radiator fan motor fuse lead

Wire harness (resistor lead)

Plastic locking tie

Install the radiator fan motor fuse to the battery bracket.

Point the terminal of the negative battery lead to the inside of the vehicle, and install it.

After connecting the positive battery lead in the direction shown in the illustration, put the cover over it.

After connecting the ECU coupler, put the coupler cover over it.

After connecting the radiator fan motor relay to the wire harness, install the cover over the radiator fan motor relay. Point the portion connected to the wire harness to the left side of the vehicle, and then secure the radiator fan motor relay to the holder.

Insert the holder with the ECU installed into the battery box bracket. When doing so, secure the ECU so that the connector of the ECU points to the left side of the vehicle.

Install the terminal in the direction shown.

Make sure that the radiator fan motor fuse lead has slack at the rear side of the vehicle past the plastic locking tie.

Route the positive battery lead under the lower part of the vehicle’s negative battery lead and over the resistor lead.

Make sure that the resistor lead has slack at the rear side of the vehicle past the plastic locking tie.

Rear side of the vehicle

Protector

Rear brake caliper

Bleed screw

Rear brake hose

Brake pedal

Rear brake master cylinder assembly

Swingarm

Rear shock absorber assembly

It does not matter whether the spring is installed upward or downward.

Pass the rear brake hose into the rear brake hose holders.

Route the rear brake hose so that it does not interfere with the spring of the rear shock absorber assembly.

Make sure that the rear brake hose is not excessively twisted.

Install the rear brake hose so that the bended portion of the metal part of the rear brake hose faces as shown in the illustration.

Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder.

Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake caliper.

Speed sensor lead

Front brake hose

Clamp

Protector

Speed sensor

Clamp the shrinking tube portion of the speed sensor lead.

Absorb the slack in this section.

Pass the front brake hose and speed sensor lead to the guide of the headlight body. Scratching during the work is accepted.

Install the front brake hose with its paint aligning with the upper end of the clamp. The circumference direction does not matter.

Make sure that the metal part of the front brake hose contacts the stopper of the front brake caliper.

Clamp securely the speed sensor lead to the hook of the protector. (three places)

Taillight lead

Taillight

Clamp

Rear fender (projection)

There should be no slack of the taillight lead.

Route the taillight lead inside the projection of the rear fender.

Insert the taillight lead all the way.