FULL POWER VERSION ONLY FOR COMPETITION PURPOUSE

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Janis Cain
5 years ago
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1 2014 FULL POWER VERSION ONLY FOR COMPETITION PURPOUSE

KIT FULL POWER SPARE PARTS DESCRIPTION QUANTITY SPARE PARTS P/N KIT FULL POWER, COMPLET 1 01840-NN4-405 CAP AIR/C CASE

0 5 18326-NN4-G10 PIPE COMP EXH 1 18330-NN4-G10 CAP COMP END 1 18338-NN4-G30 CHAIN DRIVE 1 40530-NN2-000 SPROCKET 41T

2 KIT FULL POWER SPARE PARTS DESCRIPTION QUANTITY SPARE PARTS P/N KIT FULL POWER, COMPLET NN4-405 CAP AIR/C CASE NN4-000 PROTECTOR EXH PIPE NN4-000 RIVET BLIND NN4-G10 PIPE COMP EXH NN4-G10 CAP COMP END NN4-G30 CHAIN DRIVE NN2-000 SPROCKET 41T FINAL DRIVEN NN4-J30 Air cleaner cover replacement. - Remove the rear fender. Remove the top and side screws. SUBSTITUTION PROCESS - Remove the air cleaner cover. 2

3 - Replace the air cleaner cover with the new cover (17212-NN4-000) supplied in the kit. - Fasten the cover with the same screws. Modifying the power curve - Remove the fuel tank. Remove the front screw. Do not lift the tank. - Remove the fuel injector holder. 3

4 - Disconnect the injector by pressing the clips on the sides. - Disconnect the suction hose from the cylinder head. Carefully lift the petrol tank, being careful not to pull abruptly as the fuel hoses are connected and could be damaged. - Disconnect the fuel pump black connector (2P). 4

5 - Remove the fuel tank. - Remove the connectors from the protective cable cover. - Disconnect the lights connector - Disconnect the WHITE / GREEN cable from the clamp. 5

- Remove the wire by pressing on the inside of the

6 - Remove the wire by pressing on the inside of the connector using a wire remover. - Completely remove the cable from the clamp and protect it with insulating tape (a). - Reconnect the lights connector (b). a b - Cover the connectors with the cable guard. Muffler terminal replacement. - Remove the protective cover from the muffl er. 6

terminal. Use a drill to remove the rivets.

7 - Remove the exhaust pipe clamp. - Remove the silencer attachment bolt (a). - Remove the muffl er. a - Remove the fi ve rivets on the muffl er terminal. Use a drill to remove the rivets. - Insert the new muffl er terminal ( NN4-G30) supplied in the kit. 7

- Rivet the new muffl er terminal with the fi ve

8 - Rivet the new muffl er terminal with the fi ve rivets (18326-NN4-G10) supplied in the kit. Removal of the exhaust pipe and O2 sensor - Remove the upper clamp on the O2 sensor from the left hand side of the engine. - Remove the coil to take off the O2 sensor cable - Remove the cable from the O2 sensor 8

9 - Refi t the coil. - Loosen the screw on the horn and move it to one side. Leave it in a vertical position. - Remove the nuts attaching the exhaust pipe to the cylinder head. - Remove the manifold from the exhaust pipe together with the O2 sensor 9

10 Removal of the fuel restriction washer - Disconnect the taillights connector - Loosen the fi lter casing intake fl ange. - Remove and extract the fi lter casing - Remove the breather hose from the fi lter casing. 10

- Disconnect the ECU connector wires. - Remove the insulator.

by carefully moving the injector casing.

connected to the injector casing. - Fit the insulator.

11 - Disconnect the ECU connector wires. - Remove the insulator. Loosen the screws on the fastening fl ange and remove the insulator by carefully moving the injector casing. - Remove the lock washer located on the insulator on the part connected to the injector casing. - Fit the insulator. - Fit the ECU casing - Connect the ECU connector. - Fit the fi lter casing. - Connect the breather tube in the fi lter casing. 11

- Tighten the fi lter casing intake fl ange. - Adjust the engine idle speed.

The engine must be warm for an accurate idle inspection and adjustment.

When fi tting the tank, be sure to place tubes and cables in the right places.

12 - Tighten the fi lter casing intake fl ange. - Adjust the engine idle speed. Turn the idle screw by approximately ¾ of a turn to the right. The engine must be warm for an accurate idle inspection and adjustment. Idle speed: 1,800 ± 100 min-1 (rpm) - Fit the fuel tank. When fi tting the tank, be sure to place tubes and cables in the right places. - Ensure the injection pump/tank suction hose passes properly under the gas wire. - Connect the fuel pump black connector 2P. - Fit the fuel holder (a). Torque: 8-12 N m (0,8-1,2 kgf m) b Ensure that the injector O-ring is in the correct position. - Fit the injector connector (b). a 12

- Position the wires and tubes correctly.

manifold (b) (18330-NN4-G10) supplied in the kit.

13 - Position the wires and tubes correctly. - Connect the suction hose to the cylinder head. Exhaust pipe and exhaust protector assembly. a - Replace the exhaust pipe manifold (a) with the new manifold (b) (18330-NN4-G10) supplied in the kit. b - Fit the manifold. Torque: N m (1-1,4 kgf m) - Fit the exhaust pipe manifold guard ( NN4-000) supplied in the kit. 13

14 - Place the horn in position (horizontal) and tighten the screw. - Fit the exhaust muffl er. - Fit the mounting bolt (a). a - Tighten the exhaust pipe bracket bolt (b). b - Remove the protective cover from the muffl er. - Fit the rear fender. 14

Replacement of the sprocket and drive chain. - Remove the rear wheel.

Torque: 30-35 N m (3-3,5 kgf m) - Change the position of the chain tensioner

15 Replacement of the sprocket and drive chain. - Remove the rear wheel. - Replace the rear wheel sprocket with the new sprocket (41202-NN4-J30) supplied in the kit. (ED-3E) Torx screw Torque: N m (2,4-3 kgf m) (2E-4E) Hexagonal screw Torque: N m (3-3,5 kgf m) - Change the position of the chain tensioner stopper. Initial position (a) a - Move the stopper to the middle hole. Final position (b) b ATTENTION Change the stopper position on both swing arm sides. 15

16 - Remove the drive chain pin. - Replace the drive chain with the new chain (40530-NN2-000) supplied in the kit. - Fit the rear wheel. - Tighten the drive chain by placing the two eccentrics (a) (on the right and left of the swing arm) in the same position. a - Tighten the rear wheel axle nut. Torque: 69 N m (7,0 kgf m) 16

FULL POWER VERSION ONLY FOR COMPETITION PURPOUSE

2015 FULL POWER VERSION ONLY FOR COMPETITION PURPOUSE KIT FULL POWER SPARE PARTS DESCRIPTION QUANTITY SPARE PARTS P/N KIT FULL POWER, COMPLET 1 01840-NN4-406 CAP AIR/C CASE 1 17212-NN4-000 PROTECTOR EXH