8.

ENGINE REMOVAL/INSTALLATION

SYSTEM COMPONENTS 8-2 ENGINE REMOVAL 8-4

SERVICE INFORMATION 8-3 ENGINE

INSTALLATION 8-7..

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 ENGINE REMOV AL/INST ALLATION

SYSTEM COMPONENTS

9.8 N'm (to kgf.m, 7 IbHt)

54 N'm (5.5 kgf.m, 40 IbHt)

26 N.m 12.7k\m. 20 Ibl.ftl

31 N'm (3.1 kgf.m, 23 IbHt)

8-2

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 ENGINE REMOV AL/INST ALLA TION

SERVICE INFORMATION
GENERAL
··When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
The following components require engine removal for service:
- transmission (page 12-13)
- crankshaft (page 12-17)

SPCIFICA TIONS
ITEM SPECIFICATIONS
Engine dry weight 34.7 kg (76.8 Ibs)
Engine oil capacity After draining 0.78 liters (0.82 US qt, 0.67 Imp qt)
After filter change 0.82 liter (0.87 US qt, 0.72 Imp qt)
After disassembly 1.20 liters (1.27 US qt, 1.06 Imp qt)
Transmission oil capacity After draining 0.55 liters (0.58 US qt, 0.48 Imp qt)
After disassembly 0.65 liters (0.69 US qt, 0.57 Imp qt)
Coolant capacity (radiator and engine) 1.5 liters (1.6 US qt, 1.3 Imp qt)

TORQUE VALUES
Drive sprocket bolt 31 N.m (3.2 kgf.m, 23 Ibf.ft)
Upper engine hanger nut 54 N.m (5.5 kgf.m, 40 Ibf.ft)
Upper engine hanger plate bolt 26 N'm (2.7 kgf.m, 20 Ibf.ft)
Front engine hanger nut 54 N'm (5.5 kgf.m, 40 Ibf.ft)
Front engine hanger plate bolt 26 N'm (2.7 kgf.m, 20 Ibf.ft)
Lower engine hanger nut 74 N.m (7.5 kgf.m, 54 Ibf.ft)
Swingarm pivot nut 108 N'm (11.0 kgf.m, 80 Ibf.ft)
Parking brake cable clamp bolt 9.8 N'm (1.0 kgf.m, 7 Ibf.ft) ALOC bolt: replace with a new one.

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8-3
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 ENGINE REMOV AL/INST ALLATION
ENGINE REMOVAL
Drain the engine oil (page 4-12).
Drain the transmission oil (page 4-15).
Drain the coolant (page 7-7).
Remove the following:
exhaust system (page 3-7)
carburetor (page 6-6)
- heat guard plate (page 3-7)
- brake pedal (page 15-27)
Disconnect the alternator connectors.

Disconnect the spark plug cap and engine coolant

temperature (ECT) sensor connector.

Disconnect the crankcase breather hose from the 3-

way joint.
Loosen the hose band screw and disconnect the
lower radiator hose from the water pump cover.

Loosen the hose band screw and disconnect the

upper radiator hose from the thermostat cover.
Remove the two cable clips.

8-4

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 ENGINE REMOV AL/INST ALLATION
Remove the two bolts, oil cooler hose joints and 0-
rings.

Remove the bolt and parking brake cable clamp

from the stay.
Loosen the clutch cable lock nut and disconnect the
clutch cable from the lifter arm.
Remove the clutch cable adjusting nut and the
clutch cable from the cable holder.

Remove the pinch bolt and gearshift pedal from the

gearshift spindle.
Remove the two bolts, drive sprocket cover with the
carburetor drain hose, and the drive chain guide.

Turn the rear axle bearing holder to obtain maxi-

mum drive chain slack (page 4-18).
Remove the bolt, washer and drive sprocket from
the countershaft.
Remove the drive sprocket from the drive chain.

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 ENGINE REMOV AL/INST ALLATION
Remove the upper engine hanger nut, bolt, two col-
lars and crankcase breather hose clamp.
Remove the engine hanger plate bolts and hanger
plates.

Remove the front engine hanger nut, bolt and two

collars.
Remove the engine hanger plate bolts and hanger
plates.

Remove the lower engine hanger nut, bolt and two

collars.

Support the frame with a floor jack or other suitable

support.
Remove the rear brake light switch wire from the
clamp.
Remove the swingarm pivot nut and bolt.
Remove the engine out of the frame to the right
side.
Reinstall the swingarm pivot bolt and nut so the
chassis can be moved and stored safely.

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 ENGINE REMOVAL/INST ALLATION
ENGINE INSTAllATION
·
NOTE:
Route the wires, cables and hoses properly (page
1-17).
Before installing the Install the engine into the frame from the right side.
engine, make sure
that the pivot col-
Install the swingarm pivot bolt and nut.
lars are installed Install the rear brake light switch wire into the
into the swingarm clamp.
pivots.

Install the two collars, lower engine hanger bolt and

nut.

Install the front engine hanger plates and loosely

install the bolts.
Install the collars, front engine hanger bolt and nut.

The upper engine Install the upper engine hanger plates and loosely
hanger plates are install the bolts.
identified by the "L" Install the crankcase breather hose clamp, collars,
(left) and "R" (right) upper engine hanger bolt and nut.
marks on them.

8-7
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 ENGINE REMOV AL/INST ALLATION
Tighten the swingarm pivot nut, engine hanger nuts
and hanger plate bolts.
TORQUE:
Swingarm pivot nut:
108 N'm (11.0 kgf.m, 80 Ibf.ft)
Lower engine hanger nut:
74 N.m (7.5 kgf.m, 54 Ibf.ft)
Front engine hanger nut:
54 N.m (5.5 kgf.m, 40 Ibf.ft)
Front engine hanger plate bolt:
26 N.m (2.7 kgf.m, 20 Ibf.ft)
Upper engine hanger nut:
54 N.m (5.5 kgf.m, 40 Ibf.ft)
Upper engine hanger plate bolt:
26 N.m (2.7 kgf.m, 20 Ibf.ft)
Install the drive sprocket onto the drive chain.
Note the direction Install the drive sprocket onto the countershaft.
of the drive
sprocket as shown. Install the washer with the "OUT SIDE" mark facing
out and tighten the bolt.
TORQUE: 31 N.m (3.2 kgf.m, 23 Ibf.ft)

Install the drive chain guide and drive sprocket

cover with the carburetor drain hose, and tighten
the two bolt securely.
Install gearshift pedal onto the gearshift spindle by
aligning the slit with the punch mark.
Install the pinch bolt and tighten it securely.

Install the clutch cable into the cable holder.

Install the clutch cable adjusting nut onto the cable.
Connect the clutch cable to the lifter arm.
Install parking brake cable clamp onto the stay with
a new bolt and tighten the bolt.
TORQUE: 9.8 N.m (1.0 kgf.m, 7 Ibf.ft)

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 ENGINE REMOV AL/INST ALLATION
Coat new O-rings with oil and install them onto the
oil cooler hose joints.
Install the oil cooler hose joints onto the engine and
tighten the bolts securely.

Install the two cable clips.

Connect the upper radiator hose to the thermostat
cover and tighten the hose band screw securely.

Connect the lower radiator hose to the water pump

cover and tighten the hose band screw securely.
Connect the crankcase breather hose to the 3-way
joint.

Install the spark plug cap onto the plug and connect
the connector to the engine coolant temperature
(ECT) sensor.

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~ 8-9
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 ENGINE REMOV AL/INST ALLATION
Connect the alternator connectors.
Install the following:
brake pedal (page 15-27)
heat guard plate (page 3-7)
- carburetor (page 6-21)
- exhaust system (page 3-8)
Fill the crankcase with the recommended engine oil
(page 4-12).
Fill the transmission with the recommended trans-
mission oil (page 4-15).
Fill and bleed the cooling system (page 7-7).
Adjust the following:
drive chain slack (page 4-18)
parking brake lever free play (page 4-25)
- clutch lever free play (page 4-26)

8-.10