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Service Information 6-1 Engine Removal 6-2

The document provides instructions for removing the engine from a motorcycle. It lists removing parts like the luggage box, body cover, air cleaner and carburetor. It then instructs to disconnect the A/C generator connector, starter motor cable, and high-tension cord. Finally, it describes loosening bolts and removing the rear swing arm, rear wheel, and engine from the motorcycle.

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Omer
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117 views3 pages

Service Information 6-1 Engine Removal 6-2

The document provides instructions for removing the engine from a motorcycle. It lists removing parts like the luggage box, body cover, air cleaner and carburetor. It then instructs to disconnect the A/C generator connector, starter motor cable, and high-tension cord. Finally, it describes loosening bolts and removing the rear swing arm, rear wheel, and engine from the motorcycle.

Uploaded by

Omer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Engine Removal

6. Engine Removal

Service Information 6-1


Engine Removal 6-2

Service Information
General Safety
NOTE
ҮUse a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions
not to damage the frame, engine, cable or harness.

ҮAttach tape to the frame to protect it during the engine removal or installation.

ƃ The following works can be carried out without removing the engine from the vehicle body.
- Transmission (ਨ Section 11)
- A.C. generator (ਨ Section 8)
- Kick starter, continuously variable transmission(ਨ Section 7)
- Cylinder head, cylinder, and piston (ਨ Section 9 and 10)
- Carburetor (ਨ Section 5)
- Oil pump (ਨ Section 2)
ƃItems to be worked after removing engine
- Crankshaft, crankshaft bearing, crank case bearing
ƃ Engine oil capacity: 1.0ֹ-when disassembled

Torque values:
Engine hanger bolt (Front): 2.7kg-m(27N.m, 20ft-1b)
(Rear) : 3.5kg-m(35N.m, 25ft-1b)

6-1
Engine Removal

Engine Removal
ƃ Drain the engine oil. A.C.G connector
ƃ Remove the following parts.
- Luggage box (ऻ 4-5)
- Body cover (ऻ 4-6)
- Air cleaner (ऻ 5-4)
- Carburetor (ऻ 5-6)
ƃ Disconnect the A.C. generator connector and
starter motor cable cord.
ƃ Disconnect the high-tension cord from the engine.
ƃ Remove the negative pressure tube from the
caburetor insulator.
ƃ Remove the EX. muffler. (ऺ 4-9)
ƃ Remove the rear brake caliper.
ƃ Remove the L.floor side cover.(ऺ 4-5)
ƃ remove the radiator hose.

Rear caliper Muffler

ƃ Loosen the 3 rear mud-guard setting bolts.


ƃ Loosen the engine hanger mounting bolt.

Hanger bolt

ƃ Loosen the rear cushion lower bolt.

Lower bolt

6-2
Engine Removal

ƃ Remove the engine.


(with the rear swing arm and rear wheel attached)
ƃ Remove the rear swing arm.
ƃ Remove the rear wheel. (ऺ 13-3)

Rear swing arm

Engine Installation
ƃ Install in the reverse order of removal.

NOTE
Ү Take precautions not to damage wiring and cable.
Ү Take precautions not to damage the threaded part of
bolts.
Ү Arrange the cable, tubes and wiring in the right
positions.

Toque:
Engine hanger bolt:(Front)2.7kg-m(27N.m, 20ft-lb)
(Rear)3.5kg-m(35N.m, 25ft-lb)
ƃ Check the following after the engine is assembled.
- Engine oil
- Electric systems

6-3

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