ENGINE REMOVAL

Removing the exhaust pipe

Order

Job/Parts to remove

Q’ty

Remarks

 

 

 

Refer to INSTALLING THE EXHAUST PIPE AND MUFFLER.

 

Side cover (right)

 

Refer to GENERAL CHASSIS.

 

Rear shock absorber assembly lower bolt

 

Refer to REAR SHOCK ABSORBER ASSEMBLY.

 

Connecting arm bolt (frame side)

 

Refer to REAR SHOCK ABSORBER ASSEMBLY.

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

3

 

7

Exhaust pipe 1 protector

1

 

8

Silencer body

1

 

9

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/right)

 

Refer to GENERAL CHASSIS.

 

Air scoop (left/right)

 

Refer to GENERAL CHASSIS.

 

Fuel tank

 

Refer to FUEL TANK.

 

Air filter case cover

 

Refer to CLEANING THE AIR FILTER ELEMENT.

 

Intake air temperature sensor coupler

 

Refer to THROTTLE BODY.

 

ECU (Engine Control Unit)

 

Refer to THROTTLE BODY.

 

Ignition coil

 

Refer to THROTTLE BODY.

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

 

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.

 

Air scoop (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 chain

 

Refer to SHIFT SHAFT.

Refer to CHAIN DRIVE.

1

Engine guard

1

 

2

Brake pedal

1

 

3

Spring

1

 

4

Cylinder head breather hose

1

 

5

Drive sprocket cover

1

 

6

Drive chain guide

1

 

7

Drive sprocket

1

 

Removing the engine

Order

Job/Parts to remove

Q’ty

Remarks

8

Upper engine bracket (right)

1

 

9

Upper engine bracket (left)

1

 

10

Lower engine bracket

2

 

11

Pivot shaft

1

 

12

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

      85 N·m (8.5 kgf·m, 63 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)

Install the lower engine brackets with their stamps facing outward.

Apply molybdenum disulfide grease to the pivot shaft.

INSTALLING THE EXHAUST PIPE AND MUFFLER

1.Install:

  • Gasket

  • Exhaust pipe 1 “1”

  • Nut (exhaust pipe 1) “2”

  • Nut (exhaust pipe 1)

    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:

  • Clamp

  • Exhaust pipe 2 “1”

  • Bolt (exhaust pipe 2) “2”

Install and temporarily tighten the exhaust pipe 2 and silencer with its end positioned as shown with respect to the exhaust pipe 1 and 2.

3.Install:

  • Clamp

  • Silencer “1”

  • Bolt (silencer) “2”

  • Bolt (silencer)

    30 N·m (3.0 kgf·m, 22 lb·ft)

Install and temporarily tighten the silencer so that its joint is positioned as shown with respect to the exhaust pipe 2.

4.Tighten:

  • Bolt (exhaust pipe 2)

  • Bolt (exhaust pipe 2)

    20 N·m (2.0 kgf·m, 15 lb·ft)

  • Clamp “1”

  • 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.

  • Make sure that the exhaust pipe clamp “1” does not ride on the projection “a” on the exhaust pipe “2” or silencer “3”. 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