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really big verson

GENERAL

• Support the motorcycle using a houset, a floor jack or other adjustable support.
• The following parts can be serviced with the engine installed in the frame:
  • Clutch
  • Gearshift linkage
  • Camshafts
  • Cylinder head
  • Alternator
  • Starter motor
  • Carburetors
  • Water pump
• To service the crankshaft/transmission, oil pump, and cylinder the engine must be removeed from the frame.
• When using the lock nut wrench, use a 20 inch long deflecting beam type torque wrench.  The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut.

TOOL

Remove the following:

• fuel tank (page 4-3).
• air cleaner case (page 4-4).
• carburetor (page 4-5).
• radiator (page 5-5).
• exhaust pipe and muffler (page 13-24).

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:

• oil pressure switch wire.
• neutral switch wire.
• pulse generator wire.
• alternator wire.
• starter moter cable and ground cable.

Disconnect the following cooling system connections:

• water hoses to thermostat housing at the engine.
• siphon tube at the filler neck.

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

Remove the swingarm pivot nut.

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

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.

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.

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.

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)