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 maxi-fuse. See Maintenance and Lubrication → Electrical Protection: VRSC Models. | |
| 2. | Remove the air cleaner. See Maintenance and Lubrication → Air Cleaner: VRSC Models. | |
| 3. | See Figure 1. Disconnect rear breather hose (2). | |
| 4. | 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. | |
| 5. | 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 a previous step. | |
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) | ||
| 6. | See Figure 2. Cover injector intakes. |
| 1 | Velocity stacks |
| 2 | Rear breather hose |
| 3 | Air-oil separator |
| 4 | O-rings |
| 5 | Retaining fasteners (6) |
Figure 1. Velocity Stacks
Figure 2. Covering Injector Intakes
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.
- Stretch battery hold down strap and remove from tab to release tension on strap. Battery hold down strap will become free from lower tab and can be completely removed.
- Firmly pull battery out and slightly upward to remove battery from battery caddy.
| 1 | Positive battery terminal bolt (shown without boot) |
| 2 | Negative battery terminal bolt |
| 3 | Hold down strap |
| 4 | Tabs |
| 5 | Throttle cables |
Figure 3. Battery: VRSC Models
Installation and Connection
| 1. | Connect hold down strap to bottom of battery caddy. | |
| 2. | See Figure 3. Slide the fully charged battery into battery caddy, terminal side up, negative (-) battery terminal toward the right side of the motorcycle. NOTE Battery must sit flat on bottom of tray pad. Verify that battery does not sit on front edge of pad. | |
| 3. | See Figure 3. Verify proper routing of throttle cable. | |
| 4. | Stretch hold down strap over top of battery. Latch hold down strap to tab on top of battery. | |
| WARNING Never route throttle cable over the battery. Fire due to short circuit could occur and cause death or serious injury. (00494c) 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) | ||
| 5. | Insert a battery terminal bolt through the battery positive cable (+) (red), into the threaded hole of the battery positive (+) terminal. | |
| 6. | Tighten the bolt to 6–10 N·m (53–89 in-lbs). | |
| 7. | Insert the other battery terminal bolt through the battery negative cable (black), into the threaded hole of the battery negative (-) terminal. | |
| 8. | Tighten the bolt to 6–10 N·m (53–89 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) | ||
| 9. | Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals. | |
| 10. | Remove the covering from the injector intakes. | |
| 11. | See Figure 4. 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. | |
| 12. | 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. | |
| 13. | See Figure 1. Attach the rear breather hose. | |
| 14. | 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. | |
| 15. | See Figure 4. 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). | |
| 16. | Slide the o-ring down each velocity stack until it contacts the three fasteners. Slide the breather hose onto the rear breather hose fitting. | |
| 17. | Reinstall the air filter element, air cleaner cap, wing nut and airbox cover. Lower the seat down. | |
| 18. | Install the maxi-fuse. See Maintenance and Lubrication → Electrical Protection: VRSC Models. |
Figure 4. Air Cleaner Gasket and Alignment Pins
| 1 | Velocity stack index mark |
| 2 | Airbox tray index mark |
Figure 5. Velocity Stack and Airbox Tray Index Marks