Disconnection and Removal
Before you can inspect or disconnect the battery you must read the section containing information about air cleaner removal.
| 1. | Remove the air cleaner. See Maintenance and Lubrication → Air Cleaner: VRSC Models. | |
| 2. | See Figure 1. Compress hose clamp with a needle nose pliers and remove rear breather hose from cam cover. | |
| 3. | See Figure 2. Slide the o-ring (4) up each velocity stack (1) body to reveal the three retaining fasteners (5). Unscrew the fasteners and lift off the velocity stacks. | |
NOTICE Cover the throttle body bores with duct tape to prevent objects from falling down the injector bores. Do NOT use shop cloths or objects that could damage the throttle plates. (00212d) | ||
| 4. | Carefully lift up the airbox bottom tray. Two breather hoses are attached to the underside of the airbox bottom tray. The front breather hose is a press-fit on a brass tube and will disconnect. The rear breather hose was disconnected in Step 2. |
Figure 1. Removing Rear Breather Hose Clamp
| 1 | Velocity stacks |
| 2 | Rear breather hose |
| 3 | Air-oil separator |
| 4 | O-rings |
| 5 | Retaining fasteners (6) |
Figure 2. Velocity Stacks
WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
- See Figure 3. Remove the battery negative cable from the negative (-) terminal of the battery.
- Remove the battery positive cable from the positive (+) terminal of the battery.
- See Figure 4. Stretch rubber hold-down strap over the airbox cover grommet bracket and remove battery.
NOTE
Do not remove battery hold-down strap clip from battery tray.
| 1 | Negative battery terminal bolt |
| 2 | Positive battery terminal bolt |
| 3 | Hold-down strap clip |
Figure 3. Battery (12 amp-hour): VRSC Models
Figure 4. Hold-down Strap Over Grommet Bracket: VRSCR Model
Installation and Connection
| 1. | See Figure 4. Slide the fully charged battery under hold-down strap, terminal side up, negative (-) battery terminal toward the left side of the motorcycle. | |
| 2. | Remove hold-down strap from grommet bracket. | |
| WARNING Never route throttle cable over the battery. Fire due to short circuit could occur and cause death or serious injury. Throttle cables must be routed alongside battery, between hold down strap and coolant overflow bottle. (00224a) NOTICE Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical system. (00215a) WARNINGConnect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) WARNINGDo not allow positive (+) battery cable to contact ground with negative (-) cable connected. Resulting sparks can cause a battery explosion, which could result in death or serious injury. (00069a) NOTICE Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a) | ||
| 3. | Insert a battery terminal bolt through the battery positive cable (+) (red), into the threaded hole of the battery positive (+) terminal. | |
| 4. | Tighten the bolt to 6.8–10.8 N·m (60–96 in-lbs). | |
| 5. | Insert the other battery terminal bolt through the battery negative cable (black), into the threaded hole of the battery negative (-) terminal. | |
| 6. | Tighten the bolt to 6.8–10.8 N·m (60–96 in-lbs). | |
NOTICE Keep battery clean and lightly coat terminals with petroleum jelly to prevent corrosion. Failure to do so could result in damage to battery terminals. (00217a) | ||
| 7. | Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals. | |
| 8. | Remove the duct tape from the injector intakes. | |
| 9. | See Figure 5. Inspect the gasket on the bottom of the airbox tray. The gasket is located by the three alignment pins on the mating surface. NOTE Replace the gasket if it is torn or damaged in any way. | |
| 10. | Place the airbox tray over the injectors. Make sure the taller slanted lip of the tray faces the front of the motorcycle. Slide the rectangular hole in the tray down over the threaded mounting stud. | |
| 11. | See Figure 1. Attach the rear breather hose to the fitting on the cam cover. Retain hose with the spring clamp. | |
| 12. | Align the front breather hose on the airbox tray with the brass tube and press the airbox tray down firmly. Make sure the tray sits flush on top of the injectors. NOTE In the next step, you will install the velocity stacks. Each velocity stack has an index mark. Align the index mark on the velocity stack with the corresponding index mark on the airbox tray. | |
| 13. | See Figure 6. Align the index marks and install the velocity stacks, the longest stack toward the front of the motorcycle. Start all fasteners by hand first, making sure none are cross-threaded. Tighten the three fasteners on each velocity stack to 6 N·m (53 in-lbs). | |
| 14. | Slide the o-ring down each velocity stack until it contacts the three fasteners. Slide the breather hose onto the rear breather hose fitting. | |
| 15. | Reinstall the air filter element, air cleaner cap, wing nut and airbox cover. | |
| 16. | Lower the seat back down and lock it in place. |
Figure 5. Air Cleaner Gasket and Alignment Pins
| 1 | Velocity stack index mark |
| 2 | Airbox tray index mark |
Figure 6. Velocity Stack and Airbox Tray Index Marks