ENGINE REMOVAL/INSTALLATION 8-5

Engine Removal/Installation

Engine Removal

•Support the rear part of the swingarm with a stand.

•Squeeze the brake lever slowly and hold it with a band [A].

WARNING

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.

CAUTION

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.

•Drain:

Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)

Coolant (see Coolant Change in the Periodic Maintenance chapter)

•Remove:

Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter)

Coolant Reserve Tank (see Coolant Reserve Tank Removal in the Cooling System chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

Clutch Cable Lower End (see Cable Removal in the Clutch chapter)

Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter)

Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter)

Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter)

Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter)

•Remove the air switching valve [A] (see Air Switching Valve Removal in the Engine Top End chapter).

•Disconnect:

Stick Coil Connectors [B]

Water Temperature Sensor Connector (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter)

Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter)

Gear Position Switch/Sidestand Switch Lead Connector [C]

Crankshaft Sensor/Oil Pressure Switch Lead Connector [D]

•Turn up the front side of the heat insulation rubber plate [E].

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•Remove the clamp [A].

•Disconnect the sidestand switch lead connector [A].

•Remove the engine ground cable terminal bolt [A].

•Remove: Bolt [A]

Heat Insulation Plate [B]

○Clear the projections [C] from the frame [D].

•Support the engine with a suitable stand [A].

○Put a plank [B] onto the suitable stand for engine balance.

ENGINE REMOVAL/INSTALLATION 8-7

Engine Removal/Installation

•Remove the left front engine mounting bolt [A].

•Remove:

Right Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut

•Using the nut wrench [A], loosen the locknuts [B].

Special Tool - Engine Mount Nut Wrench: 57001-1450

•Using the Hexagon Wrench, turn the adjusting collars [A] counterclockwise to make the gap between the engine and adjusting collar.

•Turn the lower engine mounting bolt clockwise to make the gap between the adjusting collar and frame.

•Pull out the engine mounting bolts.

•Using the stand, take out the engine.

8-8 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

Engine Installation

•Install the adjusting collar [A] to crankcase backside until end of the threads.

•Install the adjusting collar [A] to the frame until end of the threads.

•Support the engine with a suitable stand.

○Put a plank onto the suitable stand for engine balance.

ENGINE REMOVAL/INSTALLATION 8-9

Engine Removal/Installation

•Install the engine mounting bolts and nuts, following the specified installing sequence.

○First, tighten the following bolts and nuts temporarily. Lower Engine Mounting Bolt [A] and Nut [B] Middle Engine Mounting Bolt [C] and Nut [D]

Left Front Engine Mounting Bolt [E]

Right Front Engine Mounting Bolt [F]

○Second, tighten the left front engine mounting bolt [A]. Frame [B]

Engine [C]

Torque - Left Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)

8-10 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

○Third, tighten the adjusting collar [A] with the lower engine mounting bolt [B] counterclockwise until the adjusting collar touches [C] the frame [D].

Torque - Adjusting Collars: 9.8 N·m (1.0 kgf·m, 87 in·lb)

○Fourth, tighten the adjusting collar [E] counterclockwise until the adjusting collar touches [C] the frame [D].

Torque - Adjusting Collars: 9.8 N·m (1.0 kgf·m, 87 in·lb)

○Fifth, tighten the adjusting collar locknut [F].

Special Tool - Engine Mount Nut Wrench: 57001-1450

Torque - Adjusting Collar Locknuts: 49 N·m (5.0 kgf·m, 36 ft·lb)

○Sixth, tighten the lower and middle engine mounting nuts.

Torque - Lower Engine Mounting Nut [G]: 44 N·m (4.5 kgf·m, 32 ft·lb)

Middle Engine Mounting Nut [H]: 44 N·m (4.5 kgf·m, 32 ft·lb)

○Seventh, remove the right front engine mounting bolt [A], and tighten the adjusting collar [B] counterclockwise until the clearance [C] between the engine [D] and collar come to 0 mm (0 in.).

○Eighth, tighten the adjusting collar locknut [E].

Special Tool - Engine Mount Nut Wrench: 57001-1450

Torque - Adjusting Collar Locknuts: 49 N·m (5.0 kgf·m, 36 ft·lb)

○Lastly, tighten the right front engine mounting bolt.

Torque - Right Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)

•Run the leads, cables and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Install the removed parts (see appropriate chapters). ○Insert the projections [A] into the holes [B].

○Apply a non-permanent locking agent to the threads of the heat insulation plate bolt [C] and tighten it.

Torque - Heat Insulation Plate Bolt: 3.9 N·m (0.40 kgf·m, 35 in·lb)

•Adjust:

Throttle Cables (see Throttle Control System Inspection in the Periodic Maintenance chapter)

Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter)

Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter)

•Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter).

•Fill the engine with coolant (see Coolant Change in the Periodic Maintenance chapter).