6. ENGINE REMOVAL/INSTALLATION

Page 6-1

Service Information6-2
Engine Removal6-3
Engine Installation6-5

really big verson

Page 6-2

SERVICE INFORMATION

GENERAL

SPECIFICATIONS

Engine dry weight61 kg (134 lb)
Oil capacity2.8 lit (2.94 US qt, 2.46 Imp qt) at disassembly
Coolant capacity2.0 lit (1.89 US qt, 2.27 Imp qt) total

TORQUE VALUES

Muffler mounting bolt27 N.m (2.7 kg-m, 20 ft-lb)
Exhaust pipe joint nut27 N.m (2.7 kg-m, 20 ft-lb)
Gearshift arm bolt12 N.m (1.2 kg-m, 9 ft-lb)
Drive sprocket bolt10 N.m (1.0 kg-m, 7.2 ft-lb)
Swingarm pivot nut65 N.m (6.5 kg-m, 47 ft-lb)
Swingarm pivot lock nut65 N.m (6.5 kg-m, 47 ft-lb)
Swingarm pivot adjusting bolt15 N.m (1.5 kg-m, 11 ft-lb)
Front engine bracket bolt28 N.m (2.8 kg-m, 20 ft-lb)
Front engine mounting bolt40 N.m (4.0 kg-m, 29 ft-lb)
rear upper engine mounting bolt40 N.m (4.0 kg-m, 29 ft-lb)
--mounting bolt lock nut55 N.m (5.5 kg-m, 40 ft-lb)
--mounting bolt adjusting bolt11 N.m (1.1 kg-m, 8 ft-lb)
Fuel tank mounting bolt - front12 N.m (1.2 kg-m, 9 ft-lb)
Fuel tank mounting bolt - rear22 N.m (2.2 kg-m, 13 ft-lb)

TOOL

Special
Lock nut wrench07908-ME90000

Page 6-3


ENGINE REMOVAL

Place the motorcycle on its center stand.
Drain the engine oil (page 2-3).
Drain the coolant (page 5-3).
Disconnect the battery negative cable from the battery terminal.

Remove the following:


Remove the gearshift arm from the gearshift spindle.

Loosen the drive chain (page 3-12).
Remove the drive sprocket cover (page 8-2), then remove the sprocket from the drive chain by removing two sprocket bolts and the plate.

Disconnect the following electrical connections:


Disconnect the following cooling system connections:

Remove the thermostat housing with water hoses attached.

Disconnect the clutch cable from the clutch lifter arm by removing the holder bolt.


Remove the swingarm pivot nut.

Page 6-4


Place a floor jack or other adjustable support under the engine.

CAUTION


Remove the engine upper bracket bolts and bracket.


Remove the front engine lower mounting bolt.
Loosen the rear engine upper mounting bolt lock nut and remove the rear engine upper mounting and adjusting bolts.

Remove the swingarm pivot adjusting bolt lock nut.

TOOL:
Lock Nut wrench    07908-ME90000


Turn the pivot bolt with the adjusting bolt counterclockwise to release the engine mounting frame.


Pull the swingarm pivot bolt out to clear the engine mounting hole, but do not remove it.

Remove the engine from the frame.

Page 6-5


ENGINE INSTALLATION

Install the engine into the frame correctly.

Engine installation is essentially the reverse order of removal. Use a floor jack or other adjustable support to carefully manuever the engine into place.

CAUTION



Insert the swingarm pivot bolt while aligning the serrations of the pivot bolt and adjusting bolt.


Turn the pivot bolt with the adjusting bolt clockwise fully to seat the swingarm left pivot collar.
Tighten the bolt to the specified torque.

TORQUE:    15 N.m (1.5 kg-m, 11 ft-lb)


Install the lock nut onto the adjusting bolt.
Tighten the lock nut to the specified torque while holding the pivot bolt and adjusting bolt together.

TORQUE:
    Actual: 65 N.m (6.5 kg-m, 47 ft-lb)
    Indicated: 59 N.m (5.9 kg-m, 43 ft-lb)

TOOL:
Lock nut wrench     07908-ME9000O

Page 6-6


Install the swingarm pivot nut and tighten it to the specified torque.

TORQUE:  65 N.m (6.5 kg-m, 47 ft-lb)


Install the rear engine upper mounting adjusting bolt.
Turn the mounting adjust bolt clockwise fully to seat the engine mount.
Tighten to the specified torque.

TORQUE  11 N.m (1.1 kg-m, 8 ft-lb)

Install the lock nut onto the adjusting bolt.

TORQUE  55 N.m (5.5 kg-m, 40 ft-lb)


Install the rear engine upper mounting bolt and tighten it to the specified torque.

TORQUE:  40 N.m (4.0 kg-m, 29 ft-lb)


Tighten all the fasteners to the torques given on page 6-1 and 2.

NOTE