6. Engine Removal/Installation Service Information 6-1 Engine Removal/Installation 64 Drive Sprocket, ASV Removai/installation 6-2 Service Information A toor jack or other agjustable support is required to support and maneuver the engine When removing/installing the engine, tape the frame around the engine beforehand for frame protection The following components can be serviced with the engine installed in the frame, il pump (Section 4 ~ Carburetor (Section 5) Cluter/gearshitt cam (Section 7) Camshaft (Section 8) ~ Cylinder head (Section 8) Cylinder/pisten (Section 9) Alternator (Section 14) Pulse generator (Section 15) Starter clutch (Section 16) Starter motor (Section 16} The following components require engine removal for service. Transmissionishift forks/gearshift spindle, shift drum (Section 10) Crankshaftibslancer (Section 111 6-1Engine Removal/Installation Drive Sprocket, ASV Removal/Installation ‘QUT’ mark facing out 6-2.Engine Removal/lnstallation Requisite Service + Side cover removal/instaliation (page 2-2) Loosen the rear axle nut and drive chain in slack fully. Procedure TASV Removal Order (U.S.A. only) T Low Remarks | Installation is in the reverse order of removal. (1) AICV vacuum tube 1 | Remove from the tube joint. (2) | Air suction hose 1 (3) | Air injection pipe bolt a) (4) | ASV mounting nut 2) (S| ASVinose assembly 1 | Release the hose from the clamps. (61 | ASV stay bolt 2 | (7) | ASV stay 1 | Drive Sprocket Removal Order (8) | Gearshift pedal pinch bolt 1 19) | Gearshift pedal 1 | At installation, align the punch marks (10)| Drive sprocket cover bolt 2 | (11)] Drive sprocket cover 1 112)| Setting plate bolt 2) 113)| Drive sprocket setting plate 1 | At installation, install onto the countershaft and align the | bolt holes on the plate with the holes of the sprocket. 1141) Drive sprocket 1_| At installation, install with the OUT mark facing out 6-3Engine Removal/installation Engine Removai/Installation an Fes So 10 mm: 50 ( 6-4Engine Removal/Installation CAUTION Turn the ignition switch OFF and disconnect the battery ground [-) terminal, D vere a + Support the motorcycle using safety stand or @ hoist | During engine removai/nstallation. be careful not to pinch the wire harness between the engine and frame. + Install all engine mounting nuts and bolts loosely, then tighten them to the specified toraue > Requisite Service + Drive sprocket, ASV removaliinstallation Ipage 6-21 + Fuel tank removatiinstallation (page 2-3) Carburetor removaliinstallation (page 5-4) + Exhaust pipe, muffler removal/installation (page 2:6), + Engine guard removal/installation (page 2-8) + Rear brake pedal removaliinstallation Ipage 13-12) + PCV, PCV tube removalrinstallation (California type only! (page 5-12) Removal Order Installation is in the reverse order of removal. Altermator/noutral switch wire connector | 1/1 Release the wire from the wire bands and clamps. | | a (2 3) (4) | Clurch cable | (5) | Spark plug cap | 16) | Pulse generator wire connector | 17) | Cylinder head cover breather tube 1 Clutch cable clamp bolt 1 1 1 1 1 1 18) | Starter motor cable 1 1 1 i 2 5 Clute cable holder bott Release the wire from the clamp of the down tubs, (| ens {13)| Engine hanger bracket At installation, note the direction of the brackets and Right side Left side 6-5MEMO.