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.

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 cap

1

 

9

Spark arrester

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.

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

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/Side cover (left/right)/Shroud (left/right)

 

Refer to GENERAL CHASSIS.

 

Fuel tank

 

Refer to FUEL TANK.

 

Exhaust pipe/Silencer

 

Refer to ENGINE REMOVAL.

 

Air filter case/Throttle body

 

Refer to THROTTLE BODY.

 

Clutch cable

 

Refer to CLUTCH.

 

Shift pedal/Drive chain

 

Refer to SHIFT SHAFT.

Refer to CHAIN DRIVE.

 

Starter motor lead

 

Disconnect.

Refer to ELECTRIC STARTER.

 

Spark plug cap

 

Disconnect.

Refer to THROTTLE BODY.

 

Radiator hose 1/3/4

 

Refer to RADIATOR.

Removing the engine

Order

Job/Parts to remove

Q’ty

Remarks

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

 

8

Upper engine bracket (right)

1

 

9

Upper engine bracket (left)

1

 

10

Lower engine bracket (outside)

2

 

11

Lower engine bracket (inside)

2

 

12

Pivot shaft

1

 

13

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 (inside) “4”

  • Lower engine bracket (outside) “5”

  • Engine bracket bolt (front side) “6”

  • Engine bracket bolt (front side)

    34 N·m (3.4 kgf·m, 25 lb·ft)

  • Engine mounting bolt (front side) “7”

  • Engine mounting bolt (front side)

    55 N·m (5.5 kgf·m, 41 lb·ft)

  • Upper engine bracket “8”

  • Engine bracket bolt (upper side) “9”

  • Engine bracket bolt (upper side)

    34 N·m (3.4 kgf·m, 25 lb·ft)

  • Engine mounting bolt (upper side) “10”

  • 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 “1”

  • Exhaust pipe 1 “2”

  • Nut (exhaust pipe 1) “3”

  • Nut (exhaust pipe 1)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

  • When installing the exhaust pipe 1 “2”, install the exhaust pipe 1 “2” until the starter motor lead “a” contacts the engine mounting bracket boss while keeping it pressed so that it does not come in contact with the flange portion.

  • 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

    16 N·m (1.6 kgf·m, 12 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