ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................ |
8-2 |
Special Tool ............................................................................................................................ |
8-4 |
Engine Removal/Installation................................................................................................... |
8-5 |
Engine Removal................................................................................................................ |
8-5 |
Engine Installation............................................................................................................. |
8-7 |
8 
8-2 ENGINE REMOVAL/INSTALLATION
Exploded View
ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Adjusting collar locknut |
49 |
5.0 |
36 |
S |
|
2 |
Upper engine mounting bolts |
44 |
4.5 |
33 |
S |
|
3 |
Rear engine bracket bolts |
25 |
2.5 |
18 |
S |
|
4 |
Front engine bracket bolts |
44 |
4.5 |
33 |
S |
|
5 |
Middle engine mounting nut |
44 |
4.5 |
33 |
S |
|
6 |
Lower engine mounting nut |
44 |
4.5 |
33 |
S |
|
7 |
Engine ground cable terminal bolt |
9.8 |
1.0 |
87 in·lb |
|
8.Adjusting Collar
9.Middle Engine Mounting Bolt
10.Lower Engine Mounting Bolt
S:Follow the specific tightening sequence.
8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Engine Mount Nut Wrench: 57001–1450
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine• Removal
•Support the rear part of the swingarm with a stand. Squeeze the brake lever slowly and hold it with a band [A].
WARNING
Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
CAUTION
Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
•Drain:Engine Oil (see Engine Lubrication System in the Periodic Maintenance chapter)
Coolant (see Cooling System in the Periodic Mainte-
• nance chapter) Remove:
Seats (see Frame chapter)
Fuel Tank (see Fuel System chapter)
Side Covers (see Frame chapter)
Frame Covers (see Frame chapter)
Clutch Cable Lower End (see Clutch chapter)
Exhaust Pipe Assy and Muffler Body (see Engine Top
End chapter)
Throttle Body Assembly (see Fuel System (DFI) chapter)
Shift Lever (see Crankshaft/Transmission chapter)
•Remove:Radiator Hose Clamps [A] (Loosen)
• Radiator Hoses [B]
Disconnect:
Crankshaft Sensor Lead Connector (see Electrical System chapter)
Stick Coil Harness Connector [C]
•Pull off the connectors from the engine and free the wiring
•from the clamps. Remove:
Starter Motor Lead (see Electrical System chapter) Alternator Lead Connector (see Electrical System chapter)
Neutral Switch Lead Connector [A]
Side Stand Switch Lead Connector [B]
• Speed Sensor Connector [C]
Remove:
Left Radiator Hose (see Cooling System chapter)
Engine Sprocket (see Final Drive chapter)
8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•Remove:Camshaft Position Sensor Connector [A]
• Injector Harness Connector [B]
Remove the vacuum switch valve hose from the air cleaner housing.
•Remove:Breather Hose End [A]
Engine Ground Cable Terminal Bolt [B]
•Support the engine with a suitable stand [A].
○Put a plank [B] onto the suitable stand for engine balance.
•Remove:
Right and Left Upper Engine Mounting Bolts [A] Front Engine Bracket Bolts [B]
Front Engine Bracket [C]
ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
•Remove the middle and lower engine mounting nuts [A]
•and bolts. Remove:
Rear Engine Bracket Bolts [B] Rear Engine Bracket [C]
•Using the nut wrench [A], loosen the locknut [B].
Special Tool - Engine Mount Nut Wrench: 57001–1450
•Using the Hexagon Wrench, turn the adjusting collar [A] counter clockwise to mark the gap between the engine and frame adjusting collar.
•Remove the drive chain [A] from the output shaft [B].
•Using the stand, take out the engine.
Engine• Installation
Support the engine [A] with a suitable stand [B].
○Put a plank onto the suitable stand for engine balance.
•Screw the adjusting collar fully by hand.
•Install the engine ground cable.
Torque - Engine Ground Cable Terminal Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
•Install the engine mounting bolts and nuts, following the specified installing sequence.
○First, hang the drive chain over the output shaft just before moving the engine into its final position in the frame.
○Second, insert the lower engine mounting bolt [A]. ○Third, insert the middle engine mounting bolt [B]. ○Fourth, install the rear engine bracket [C] temporarily.
○Fifth, install the left upper engine mounting bolt [A] and tighten it.
Torque - Left Upper Engine Mounting Bolt : 44 N·m (4.5 kgf·m, 33 ft·lb)
○Sixth, tighten the adjusting collar [A] until the clearance between the crankcase [B] and frame bracket [C] come to 0 mm [D].
○Seventh, tighten the collar locknut [E].
Torque - Adjusting Collar Locknut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Special Tool - Engine Mount Nut Wrench : 57001–1450
○Eighth, tighten the rear bracket bolts.
Torque - Rear Engine Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
○Ninth, tighten securely: Middle Engine Mounting Nut Lower Engine Mounting Nut
Torque - Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft·lb)
ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
○Tenth, temporarily install: Front Engine Bracket [C]
Right Upper Engine Mounting Bolt [A] Front Engine Bracket Bolts [B]
○Eleventh, tighten the right upper engine mounting bolt. ○Lastly, tighten the front engine bracket bolts.
Torque - Right Upper Engine Mounting Bolt : 44 N·m (4.5
kgf·m, 33 ft·lb)
Front Engine Bracket Bolts: 44 N·m (4.5 kgf·m, 33
• ft·lb)
Run the leads, cables and hoses correctly (see Cable,
•Wire and Hose Routing section in Appendix chapter).
•Install the removed parts (see appropriate chapters). Adjust:
Throttle Cables (see Fuel System (DFI) chapter)
Choke Cable (see Fuel System (DFI) chapter)
Clutch Cable (see Clutch chapter)
• Drive Chain (see Final Drive chapter)
Fill the engine with engine oil (see Engine Lubrication
•System in the Periodic Maintenance chapter).
Fill the engine with coolant (see Cooling System in the
Periodic Maintenance chapter).