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15. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION······················ 15-2 ENGINE REMOVAL ····························· 15-4

COMPONENT LOCATION ····················· 15-3 ENGINE INSTALLATION ······················ 15-8

15

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ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
ENGINE REMOVAL/INSTALLATION

GENERAL
• A hoist or equivalent is required to support the motorcycle when removing and installing the engine.
• A floor jack or other adjustable support is required to support and maneuver the engine.

Do not use the oil filter as a jacking point.

• When removing/installing the engine, tape the frame around the engine beforehand for frame protection.
• When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If
you mistake the torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct
sequence.
• The following components can be serviced with the engine installed in the frame.
– Starter motor (page 6-6)
– Throttle body (page 7-13)
– air cleaner housing (page 7-11)
– Water pump (page 8-10)
– Oil pump (page 9-5)
– oil strainer (page 9-8)
– Camshaft (page 10-8)
– Rocker arm (page 10-13)
– Cam chain tensioner lifter (page 10-22)
– Clutch (page 11-7)
– Primary drive gear (page 11-14)
– Gearshift linkage (page 11-15)
– Stator/CKP sensor (page 12-5)
– Flywheel (page 12-5)
– Starter clutch (page 12-8)
• The following components require engine removal for service.
– Cylinder head/valves (page 10-15)
– Transmission (page 13-8)
– Crankshaft (page 14-4)
– Piston/cylinder (page 14-13)
– Balancer (page 14-17)

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ENGINE REMOVAL/INSTALLATION
COMPONENT LOCATION

39 N·m (4.0 kgf·m, 29 lbf·ft)

55 N·m (5.6 kgf·m, 41 lbf·ft)

37 N·m (3.8 kgf·m,

27 lbf·ft)
55 N·m
(5.6 kgf·m,
41 lbf·ft)
45 N·m (4.6 kgf·m,
33 lbf·ft)

45 N·m
(4.6 kgf·m, 12 N·m
33 lbf·ft) (1.2 kgf·m,
9 lbf·ft)

45 N·m
(4.6 kgf·m,
33 lbf·ft)

45 N·m (4.6 kgf·m, 33 lbf·ft)

54 N·m
(5.5 kgf·m,
40 lbf·ft)

2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)

37 N·m (3.8 kgf·m,

27 lbf·ft)

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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (page 3-10).
[2]
Fully slacken the drive chain (page 3-14).
Remove the following:
– drive sprocket cover (page 2-7)
– exhaust pipe (page 2-13)
– fuel tank under tray (page 2-8)
– starter motor (page 6-6)
– regulator/rectifier (page 20-7)
– radiator (page 8-7)
– left side footpeg bracket (page 11-5)
Remove the socket bolt [1] and clutch cable holder [2],
then disconnect the clutch cable [3] from the clutch lifter
arm [4]. [3] [1]

Disconnect the ECT sensor 2P (Black) connector [1].

[1]

Release the rubber cap [1] from the EOP switch [2].
[3] [4]
Remove the terminal screw [3] and disconnect the
switch wire [4].

[1] [2]

Remove the bolt [1] and wire harness stay [2].

[2]

[1]

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ENGINE REMOVAL/INSTALLATION
Disconnect the neutral switch 2P (Black) connector [1].
[1]

Remove the AC generator wire [1] out of the frame.

[1]

Disconnect the CKP sensor 2P (Red) connector [1].

[1]

Remove the wire band [1] and CKP sensor wire [2] out
of the frame.

[1]

[2]

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ENGINE REMOVAL/INSTALLATION
Disconnect the air supply hoses [1].

[1]

Disconnect the VS sensor 3P (Black) connector [1].

[1]

Remove the two socket bolts [1] and right rider footpeg
bracket [2]. [2]

[1]

Remove the cotter pin [1], joint pin [2].

[6]
Remove the master cylinder mounting bolts [3], master [5]
cylinder [4] switch spring [5] and rear brake light switch
[6]. [3]

[2]

[1]
[4]

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ENGINE REMOVAL/INSTALLATION
Remove the drive sprocket bolt [1], washer [2] and drive
[3]
sprocket [3].

[1] [2]

Support the motorcycle securely with a hoist or

Left side: [2]/[3] [2]
equivalent.
Do not use the oil Place a floor jack or other adjustable support under the
filter as a jacking engine. [2]
point.

• The jack height must be continually adjusted to

relieve stress for ease of bolt removal.
Disconnect the connectors [1] from the horn.
Remove the following:
– front engine hanger bolts [2]
– front engine hanger nuts [3]
– horn mounting stay [4] [1]
– right engine hanger [5]
– left engine hanger nuts [6] Right side: [5] [6] [2]
[2]

[2]/[3] [4]

Remove the rear lower engine hanger bolt [1] and nut
[2].

[1]/[2]

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ENGINE REMOVAL/INSTALLATION
Loosen the upper engine hanger stay bolt [1].
Remove the upper engine hanger stay bolt [2], upper [1]
engine hanger stay bolt [3] and nut [4].
During engine Carefully lower the jack or adjustable support, then
removal, hold the remove the engine from the frame.
engine securely and
be careful not to
damage the frame
and engine.

[2] [3/[4]]

ENGINE INSTALLATION
During engine Place the engine in the frame, then loosely install all the bolts, collars, washers and nuts.
installation, hold the
engine securely
and be careful not • Place the jack or other adjustable support under the engine.
to damage the • Do not use the oil filter as a jacking point.
frame and engine. • The jack height must be continually adjusted to relieve stress for ease bolt installation.
• Carefully align the mounting points with the jack to prevent damage to engine, frame, radiator hoses, wires
and cables.
Tighten the bolts and nuts to the specified torque in the specified sequence as shown.

4 55 N·m (5.6 kgf·m, 41 lbf·ft)

39 N·m (4.0 kgf·m,

28.8 lbf·ft)

1 45 N·m (4.6 kgf·m,

33 lbf·ft)

5 55 N·m (5.6 kgf·m,

41 lbf·ft)

2 45 N·m (4.6 kgf·m,

33 lbf·ft)

3 45 N·m (4.6 kgf·m,

33 lbf·ft)

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ENGINE REMOVAL/INSTALLATION
Install the removed parts in the reverse order of
[2] [1]
removal.

TORQUE:
Rider footpeg bracket bolt:
37 N·m (3.8 kgf·m, 27 lbf·ft)
Drive sprocket bolt:
54 N·m (5.5 kgf·m, 40 lbf·ft)
EOP switch terminal screw:
2.0 N·m (0.2 kgf·m, 1.5 lbf·ft)
Right crankcase cover bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Install the drive sprocket [1] with its "OUT" mark [2]
facing out.
• Align the clutch cable holder hole with the right
crankcase cover boss.
Adjust the following:
– throttle grip freeplay (page 3-4)
– clutch lever freeplay (page 3-21)
– drive chain slack (page 3-14)
Fill the engine with the recommended engine oil (page
3-10).
Fill and bleed the cooling system (page 8-5).
Check the exhaust system and cooling system for
leaks. Align

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