Engine Removal / Installation

Table of Contents

Exploded View....................................................................................................................................... 7-2

Specifications........................................................................................................................................ 7-3

Engine Removal/Installation.................................................................................................................. 7-4

Engine Removal................................................................................................................................ 7-4

Engine Installation............................................................................................................................ 7-5

Exploded View

Engine Removal/Installation

Engine Removal • Remove:

Upper and Lower Fairings (see Frame chapter)

Engine Oil (Drain, see Engine Lubrication System chapter)

Coolant (Drain, see Cooling System chapter)

Clutch Slave Cylinder (see Clutch chapter)

Fuel Tank (see Fuel System chapter)

Air Cleaner Housing (see Fuel System chapter)

Ignition Coils (see Electrical System chapter)

Carburetors (see Fuel System chapter)

Fuel Pump (see Fuel System chapter)

Baffle Plate on the Cylinder Head Cover

Oil Cooler Hoses

Radiator (see Cooling System chapter) Muffler (see Engine Top End chapter) Shift Pedal

Engine Sprocket (see Final Drive chapter)

• Disconnect wiring from the engine and free them from the clamps. Pickup Coil Lead and Oil Pressure Switch Lead Connector [A] Battery Ground Lead [B] Starter Motor Lead [C] Side Stand Switch Connector Alternator Lead Connector [D] Neutral Switch Connector

•Support the rear part of the frame on the jack [А]. Special Tool - Jack: 57001-1238

• Squeeze the brake lever slowly and hold it with a band.

• Remove:

Front Engine Mounting Bolts [B] and Brackets [C] Down Tube Bolts [D] Down Tubes [E]

•Support the engine with a stand [А]. • Remove the nuts [B] from the rear engine mounting bolts.

• Loosen the engine mounting locknuts [A], using the socket wrench [В].

Special Tool - Socket Wrench: 57001-1347

• Screw back all the engine collar bolts [C] for clearance around the engine.

• Remove the rear engine mounting bolts.

NOTE

О The drive chain will be removed from the output shaft when removing the engine.

• Lift up the engine and move it to the right to free the output shaft from the drive chain.

• Remove the engien.

Engine Installation

• Before engine installation, install the collar bolts and then screw back them fully.

• Hang the drive chain over the output shaft just before moving the engine into its final position in the frame.

• Insert the rear mounting bolts from the left side of the engine. Leave them protruding about 55 mm [A] as shown.

[B] Collar Bolt

[C] Collar

[D] Rear Mounting Bolt (Upper)

[E] Rear Mounting Bolt (Lower)

[F] Engine

•Install:

Down Tubes

Front Engine Mounting Bolts, Nuts and Brackets (temporarily)

Torque - Down Tube Bolts and Nuts: 44 N-m (4.5 kg-m, 33 ft-lb) Engine Collar Bolts: 9.8 N-m (1.0 kg-m, 87 In-lb)

•Tighten the engine mounting locknuts, engine mounting bolts and nuts.

Special Tool - Socket Wrench: 57001-1347

Torque - Engine Mounting Locknuts: 49 N-m (5.0 kg-m, 36 ft-lb)

Rear Engine Mounting Bolts and Nuts: 59 N-m (6.0 kg-m, 43 ft-lb)

Front Engine Mounting Bolts and Nuts: 44 N411 (4.5 kg-m, 33 ft-lb)

• Install the removed parts (see appropriate chapters). •Adjust:

Throttle cables (see Fuel System chapter) Choke Cable (see Fuel System chapter) Drive Chain (see Final Drive chapter)