2.
Shift transmission to neutral position, and verify that neu-
ADJUSTING HANDLEBAR
tral indicator lamp turns on.
CONTROLS
3.
Start engine; check operation of starter.
4.
Check that oil pressure indicator lamp (12) turns off
If handlebar controls and clutch and brake lever assemblies
when engine is running above 1200 RPM. Check that
are incorrectly positioned, they may be rotated slightly for
battery icon (4) turns off. Engine Coolant temperature
more comfortable riding position.
icon (1) must not illuminate.
5.
Check that tachometer is functioning.
CAUTION
6.
Disengage clutch (squeeze clutch lever), and verify that
neutral indicator lamp (11) turns off when transmission is
Do not rotate front brake lever assembly too far. Brake
shifted to any forward gear. Shift transmission to neutral
master cylinder fits into a machined relief in handlebar. If
position, and verify that neutral indicator lamp turns on
not properly located in the machined relief, master cylin-
again.
der can be damaged when clamp screws are tightened.
Handlebar surface contains range marks to properly
7.
Check horn operation.
locate brake and clutch master cylinder and control
8.
Check operation of all remaining lamps:
assemblies. These assemblies MUST be located within
● headlamp-low and high beams
that range.
● headlamp high beam indicator lamp (9)
To adjust handlebar controls, proceed as follows:
● left directional (turn signal) lamps-front and rear
1.
See Figure 7-3. Loosen (but do not remove) brake and
clutch lever assembly clamp screws (1) and handlebar
● Ieft directional (turn signal) indicator lamp (8)
switch housing screws (2).
● right directional (turn signal) lamps-front and rear
● right directional (turn signal) indicator lamp (13)
d0419x1x
● Ieft front running lamp
2
● right front running lamp
● tail lamp-running lamp and brake lamp filaments
9.
After engine has reached normal operating temperature,
turn engine off.
10.
Check engine oil level in manner previously specified.
This time, fill sump to upper mark on filler cap/dipstick.
1
CAUTION
1.
Front brake lever assembly clamp screw (2)
2.
Handlebar switch housing screw (2)
To avoid over-filling the oil sump, wait approximately
three minutes after adding oil before checking the oil
Figure 7-3. Handlebar Lever and Control
level with the dipstick. An over-filled sump can cause
Mounting Screws (Right Side Shown)
engine damage. (00188a)
2.
See Figure 7-4. Range marks (4) are located on bottom
of handlebar adjacent to brake lever clamp assembly.
ADJUSTING HANDLEBARS
Rotate right control and brake master cylinder assembly
(2) slightly for most comfortable position. Make sure
The VRSCSE is shipped with the handlebars adjusted to a
control assembly is positioned so that clamp mating sur-
standard riding position. If handlebars need to be adjusted for
face (3) is located in area between range marks.
more comfortable rider position, proceed as follows:
1. Loosen, but do not remove, all four handlebar riser clamp
screws.
2. Raise or lower handlebars to desired position. Make cer-
tain handlebars are centered side-to-side in risers.
3. Tighten two front handlebar clamp screws until top and
bottom risers meet (no gap in front). DO NOT tighten
screws to more than 20.3 Nm (15 ft-lbs).
4. Tighten rear handlebar clamp screws to 16.3-20.3 Nm
(12-15 ft-lbs).
5. Final tighten front handlebar clamp screws to 16.3-20.3
Nm (12-15 ft-lbs).
2005 PDI: CVO Models
7-3
Check Hose Clamps For Tightness
CAUTION
1.
See Figure 7-5. If necessary, remove four screws (1) and
Control wiring is routed inside handlebar and may be
decorative cover (2) from water pump hose.
pinched or cut if controls are rotated too far.
2.
Check the four hose clamps (two each on hoses) for
3. Beginning with top screw, tighten right lever assembly
tightness.
clamp screws to 6.8-9.0 Nm (60-80 in-lbs).
3.
If removed, install decorative cover with four screws.
4.
Beginning with lower screw, tighten right handlebar
Tighten screws to 1.1-1.4 Nm (10-12 in-lbs).
switch housing screws to 4.0-5.1 Nm (35-45 in-lbs).
4.
With a long bladed screwdriver check two hose clamps
one at top left and one at top right of radiator.
NOTE
pd0214a
The engine ends of the radiator hoses are secured with a
2
1
plastic “shrink” clamp and do not require checking.
3
10770
1
4
2
1. Handlebar
2. Right control and brake lever assembly
3. Control assembly clamp mating surface
4. Range marks
Figure 7-4. Right Handlebar Control Assembly
(Bottom View)
1.
Screw (4)
2.
Decorative hose cover
5.
Orient the left handlebar control assembly to match the
position of the right handlebar control assembly.
Figure 7-5. Coolant Hose Cover (Engine right side)
CAUTION
Control wiring is routed inside handlebar and may be
pinched or cut if controls are rotated too far.
6. Beginning with top screw, tighten left lever assembly
clamp screws to 6.8-9.0 Nm (60-80 in-lbs).
7.
Beginning with lower screw, tighten left handlebar switch
housing screws to 4.0-5.1 Nm (35-45 in-lbs).
8.
Test handlebar switches to make sure they are function-
ing properly and wiring has not become pinched or oth-
erwise damaged.
7-4
2005 PDI: CVO Models
-------------------------------------------------------------------------------------------------------------------------------------------------------------
CHECKING CLUTCH FLUID
8834
CAUTION
D.O.T. 5 silicone hydraulic brake fluid is used in the
hydraulic clutch. Do not use other types of fluids as they
are not compatible and could cause equipment damage.
(00204a)
CAUTION
Do NOT allow foreign matter to enter the clutch master
cylinder reservoir. dirt or debris in the reservoir may
cause improper operation of the clutch and equipment
damage.
1CAUTION
Figure 7-6. Clutch Master Cylinder Reservoir
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact.
1.
Stand the motorcycle upright (not leaning on the jiffy
In case of eye contact flush with large amounts of water
stand) on a level surface. Turn the handlebars to the right
and get medical attention. Swallowing large amounts of
if necessary, so the top of the clutch master cylinder res-
D.O.T. 5 brake fluid can cause digestive discomfort. If
ervoir is level.
swallowed, obtain medical attention. Use in well venti-
2.
View reservoir sightglass on reservoir cover and verify
lated area. KEEP OUT OF REACH OF CHILDREN.
fluid presence. Sightglass should appear dark if fluid is
(00144a)
present. If sightglass is not dark, add brake fluid. See
The clutch is hydraulically actuated. See Figure 7-6. The
Service Manual. Use only D.O.T. 5 SILICONE HYDRAU-
clutch master cylinder fluid reservoir is located on the left
LIC BRAKE FLUID (Part No. 99902-77: 12 oz., 99901-
handlebar.
77: 1 gal.).
2005 PDI: CVO Models
7-5
-------------------------------------------------------------------------------------------------------------------------------------------------------------
MIRRORS AND TURN SIGNALS
pd0208
10
The mirrors are enclosed in a box in the crate. Install mirrors
and adjust for proper rear view as follows:
11
13
1. See Figure 7-7. Place spacer (10) onto right side mirror
stem, slide mirror stem down through hole in front brake
13
master cylinder assembly and right turn signal bracket
6
2
(5). Install lockwasher (8) and screw on acorn nut (7) fin-
ger tight.
4
2. In the same fashion, install left side mirror assembly.
9
3. Adjust mirrors so a small portion of the rider’s shoulder is
10
visible in each mirror. This helps establish the relative
distance of vehicles to the rear of the motorcycle.
12
4. Tighten acorn nuts to 6.8-9.0 Nm (60-96 in-lbs).
3
5. To adjust turn signals:
a. Loosen set screws (9) approximately 1/8 turn.
5
8
NOTE
It is not necessary, nor desirable, to completely remove set
7
screw to re-adjust turn signal housing. It is only necessary to
1
loosen set screw 1/8 turn, adjust turn signal and re-tighten set
9
screw. Nylon lock pellet on set screw maintains locking ability
after many loosening/tightening cycles. If set screw is com-
8
4
pletely removed, it should be replaced.
b. Position front turn signal housings (1, 2) evenly with
3
7
lenses pointing straight ahead.
c. Tighten each set screw to 5.7-6.8 Nm (50-60 in-
1.
Right turn signal housing
lbs).
2.
Left turn signal housing
3.
Jam nut (2)
4.
Ball stud (2)
SEATS AND PASSENGER STRAP
5.
Right turn signal bracket
6.
Left turn signal bracket
Refer to VRSC Models Owner’s Manual for seat and passen-
7.
Acorn nut (2)
ger strap removal and installation instructions.
8.
Lockwasher (2)
9.
Set screw (2)
10.
Spacer (2)
11.
Clutch control housing
12.
Brake control housing
13.
Mirror stem (2)
Figure 7-7. Turn Signals
7-6
2005 PDI: CVO Models
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