ENGINE REMOVAL

Removing the exhaust pipe

Order

Job/Parts to remove

Q’ty

Remarks

 

Side cover (right)

 

Refer to GENERAL CHASSIS.

1

Silencer clamp

1

Loosen.

2

Silencer

1

 

3

Exhaust pipe 2 clamp

1

Loosen.

4

Exhaust pipe 2

1

 

5

Exhaust pipe 1

1

 

6

Gasket

1

 

7

Exhaust pipe 1 protector

1

 

8

Gasket

1

 

9

Gasket

1

 

10

Silencer body

1

 

11

Silencer cap

1

 

Removing the electronic parts

Order

Job/Parts to remove

Q’ty

Remarks

 

 

 

Use a maintenance stand to raise the front wheel off the ground.

 

Seat

 

Refer to GENERAL CHASSIS.

 

Side cover (left)

 

Refer to GENERAL CHASSIS.

 

Shroud (left)

 

Refer to GENERAL CHASSIS.

Removing the electronic parts

Order

Job/Parts to remove

Q’ty

Remarks

1

Rectifier/regulator

1

 

2

Stator coil assembly coupler

1

Disconnect.

3

Crankshaft position sensor coupler

1

Disconnect.

4

Coolant temperature sensor coupler

1

 

5

Gear position switch

1

 

6

Starter motor lead

1

Disconnect.

7

Engine ground lead terminal

1

Disconnect.

Removing the engine

Order

Job/Parts to remove

Q’ty

Remarks

 

 

 

Use a maintenance stand to raise the front wheel off the ground.

 

Seat

 

Refer to GENERAL CHASSIS.

 

Side cover (left/right)

 

Refer to GENERAL CHASSIS.

 

Shroud (left/right)

 

Refer to GENERAL CHASSIS.

 

Fuel tank

 

Refer to FUEL TANK.

 

Exhaust pipe/Silencer

 

Refer to ENGINE REMOVAL.

 

Air filter case

 

Refer to THROTTLE BODY.

 

Throttle body

 

Refer to THROTTLE BODY.

 

Clutch cable

 

Refer to CLUTCH.

 

Shift pedal/Drive sprocket

 

Refer to SHIFT SHAFT.

Refer to CHAIN DRIVE.

Removing the engine

Order

Job/Parts to remove

Q’ty

Remarks

 

Starter motor

 

Disconnect.

Refer to ELECTRIC STARTER.

 

Spark plug cap

 

Disconnect.

Refer to THROTTLE BODY.

 

Radiator hose 1/3/4

 

Disconnect.

Refer to RADIATOR.

1

Engine guard

1

 

2

Brake pedal

1

 

3

Spring

1

 

4

Cylinder head breather hose

1

 

5

Upper engine bracket (right)

1

 

6

Upper engine bracket (left)

1

 

7

Lower engine bracket

4

 

8

Pivot shaft

1

 

9

Engine

1

 

REMOVING THE ENGINE

1.Remove:

  • Exhaust pipe 2

Put the exhaust pipe 2 into the state as shown by moving this, and then remove it.

2.Remove:

  • Pivot shaft “1”

If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.

3.Remove:

  • Engine “1”

    (from the right side)

  • Make sure that the couplers, the hoses, and the cables are disconnected.

  • Lift up the engine, and remove this from its lower part toward the right of the chassis.

INSTALLING THE ENGINE

1.Install:

  • Engine “1”

    (from the right side)

  • Pivot shaft “2”

  • Pivot shaft nut

    75 N·m (7.5 kgf·m, 55 lb·ft)

  • Engine mounting bolt (lower side) “3”

  • Engine mounting bolt (lower side)

    53 N·m (5.3 kgf·m, 39 lb·ft)

  • Lower engine bracket “4”

  • Engine bracket bolt (front side) “5”

  • Engine bracket bolt (front side)

    34 N·m (3.4 kgf·m, 25 lb·ft)

  • Engine mounting bolt (front side) “6”

  • Engine mounting bolt (front side)

    55 N·m (5.5 kgf·m, 41 lb·ft)

  • Upper engine bracket “7”

  • Engine bracket bolt (upper side) “8”

  • Engine bracket bolt (upper side)

    34 N·m (3.4 kgf·m, 25 lb·ft)

  • Engine mounting bolt (upper side) “9”

  • Engine mounting bolt (upper side)

    45 N·m (4.5 kgf·m, 33 lb·ft)

  • Apply molybdenum disulfide grease to the pivot shaft.

  • Apply lithium-soap-based grease onto the threads and contact surface of the pivot shaft nut.

INSTALLING THE EXHAUST PIPE AND MUFFLER

1.Install:

  • Gasket

  • Exhaust pipe 1 “1”

  • Exhaust pipe nut “2”

  • Exhaust pipe nut

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

First temporarily tighten all nuts to 7 N·m (0.7 kgf·m, 5.2 lb·ft). Then retighten them to 10 N·m (1.0 kgf·m, 7.4 lb·ft).

2.Install:

  • Exhaust pipe 2 clamp

  • Exhaust pipe 2 “1”

  • Exhaust pipe bracket bolt “2”

Make sure that the clamp “3” does not ride on the projection “a” on the exhaust pipe “4” or silencer “5”. Be sure to insert the projection “b” into the slot in the exhaust pipe (or silencer).

A.

Exhaust pipe 1 and exhaust pipe 2

B.

Exhaust pipe 2 and silencer

3.Install:

  • Silencer clamp

  • Silencer “1”

  • Silencer bolt “2”

  • Silencer bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

4.Tighten:

  • Exhaust pipe bracket bolt

  • Exhaust pipe bracket bolt

    20 N·m (2.0 kgf·m, 15 lb·ft)

  • Exhaust pipe 2 clamp

  • Exhaust pipe clamp bolt (exhaust pipe 2 clamp)

    12 N·m (1.2 kgf·m, 8.9 lb·ft)

  • Silencer clamp

  • Exhaust pipe clamp bolt (silencer clamp)

    12 N·m (1.2 kgf·m, 8.9 lb·ft)

Tighten while checking that their front and rear joints are inserted in position.