ENGINE REMOVAL/INSTALLATION 60 Nem (6.0 ka-m, 34 Nem (3.4 kgm, 25 feb) 43 feb) 40 Nem (4.0 kg-m, 28 feb) 60 Nem (6.0'kg-m, 43 feb)5. ENGINE REMOVAL/ INSTALLATION SERVICE INFORMATION 5-1 ENGINEINSTALLATION 53 ENGINE REMOVAL 52 SEVICE INFORMATION GENERAL ® During removal and installation, support the vehicle with suitable blocs, © Ports requiring engine removal for servicing Crankehatt Section 10 Crankease Section 10 Balancer Section 10 Transmission Section 11 SPECIFICATIONS Engine weicht 50 kg (110 1b) Oilcapacty 1.9 jiters {2.01 US gt, 1.67 Imp qt) st draining 2.3 liters (2.43 US at. 2.02 Imp at efter disassembly TORQUE VALUES Engine henger nut: 10 mm nut 60 Nem 16.0 ko-m, 43 ft} 8mm nut 84 Nem (3.4 ko-m. 25 ftbh Oilpipe flare nut 40 Nem {4.0 kg-mn, 29 fttb} Oilhose flare nut 40 Nem (4.0 kgm, 29 feb} 5-1ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the following: = s0at and side covare (pege 16.2) ~ fuel tank (page 4-3) right and left falrings (page 15-2! Disconnect the folowing: — cylinder head cover breather tube akemator connactor — pulse generator cornector Remove the following: = exhaust pipes ipsge 15-7) — brake pedal (oge 13-11) skid plate — brakelight switch Disconnect the Following: = clutch cable at the oluteh lifter arm ~ spark plug cap — starter motor cable Loosan the drive chain adjuster fully (page 3-8) Romove the following: = carburetor (page 4-7) ‘drive sprocket cover and drive sprocket gearshift pecal — tool box. oil cutlet pipe ff inlet hose — engine hangs nuts, volts and plates Remove the engine from the right side of the frema. Remove the retsining alate, oil joint hose and oil inlet pipe. (3) CARBURETOR (4) SPROCKET COVER’ SPROCKETENGINE REMOVAL/INSTALLATION INE INSTALLATION ence Tp clean engine cil to a new O-rings. the new O-rings, install the ol joint hese and of inlet pine the engine, Install the retsining plato and secure it with two belts Install the engine from the right side of the frame. Install the top engine hanger plates, and tighten the bolts and nuts. TORQUE: 10 mm nut: 60 Nem (6.0 kgm, 43 feb) 8 mm nut: 34.Nem (3.4 kgm, 25ftb) Insta the front engine hanger plates, and tighten the bolts and aut. Inctal tho front lowor hangor bolt with the collar and tighten she nut. TORQUE: 10 mm bolt: 60 Nem (6.0 ka-m. 43 ftb) 8 mm bolt: 24 Nem (3.4 kg-m, 25 feb) Install and tighten the rear lower engine hanger balt an¢ nut, 1) 8 mm BOLTS on Install the rear uppar engine hangor plato, and tighten the 8 mm bolts and ute loosely. Install the collars, 10 mm bolt and nut, then tighten the & mm bolts and 10 mm nut, TORQUE: 10 mm nut: 60 Nem (6.0 kg-m, 43 feb) 8 mm bolt: 34.Nem (3.4 kgm, 25 ft]ENGINE REMOVAL/INSTALLATION Install the of ouvet pipe, and tighten the oll pipe flare nut. {(4) OUTLET H Pie fT Pi our TORQUE: 40 Nem (4.0 kg-m, 29 ftb) Inatall the il pipe/pulse gerorator wiro clamp and fairing slays, and secure them with bolts. Connect the oil outlet pipe end joint hose, and the oil intet pip to the oil strainer nut. Tighten the flere nuts. TORQUE: 40 Nem (4.0 kg-m, 29 4b) Install the drive sprocket and retaining plate over the counter shaft, and tighten the bots, Install the drive sprocket cover and secure It with two bots. 4, BOLTS § In the gearshift pedal aligning the punch marke on tho U OF pedal and gearshift spincle, and tighten the bolt iENGINE REMOVAL/INSTALLATION all the toolbox, signing tha bose on the bottom ofthe toot [iy Sb SLATE ER 12 TOQE BOK with the gromet. Secure with a bol ll the skid plate and secure it with three bolts. Install the following perts in the ravarse ardar of removal = Starter motor cable = Spark plug cap = Clutch cable = Brakelight switch = Brake pedal (page 13-11) = Exhaust pipe (page 18-7) = Pulse generator connector = Alternator connector = Cylinder head cover breather tube (2) BOLTS: = Fadl tank toage 4-3) = Fight ond left farings (page 15-2) = Seat and side covers page 15-2) Adjust the followings: © Drive chain (page 3-8) = Brake pedel (page 3-10) Braketgnt switcn (page 3-11) = Clutch lever ree play (page 3-11) Start the engine and creck the fellowing: = Exhaust pipes ‘or leakage = Ol pipesinoses tor loskage