Remounting the Engine

Submitted by xjcdadmin on Thu, 05/07/2009 - 16:38

1.  Refer to engine removal. Reverse those removal steps that apply.

2.  Tighten engine mounting bolts

Engine Mounting Bolt: Front 1: 42 Nm (4.2 m-kg, 30 ft-lb) 
Rear 2 : 90 Nm (9.0 m-kg, 65 ft-lb) 
Down Tube 3 , Bracket 4 : 33 Nm (3.3 m-kg, 24 ft-lb)

3. Connect:
• Pickup coil lead
• Generator lead
• Neutral switch lead
• Oil level switch lead
• Starter motor lead
• Crankcase ventilation hose
• Battery leads

NOTE:
•See CHAPTER 8 "Cable Routing" for proper cable, lead, and hose routing.
• Connect the battery positive lead first.
• Make sure that the cables are not twisted.
• Be careful not to pinch the leads.

4.  Install the Carburetors. Note: see Carburetor section for further details.

5.  Connect:
• Throttle cable
• Starter cable

6.  Tighten the air cleaner case mounting bolts

Air Cleaner Case: 10Nm{1.0m-kg, 7.2ft-lb)

7.  Install:
• Fuel tank 
• Seat

8.  Add: 
• Engine oil

Engine Oil: 3.5 L (3.1 Imp qt, 3.7 US qt)

• Coolant

Recommended Coolant: High Quality Ethylene Glycol Antifreeze Containing Anti-corrosion for Aluminum Engine Inhibitors Coolant and Water.
Mixed Ratio: 50%/50% 
Total amount: 2.4 L (2.11 Imp qt, 2.54 US qt) .
Reservoir Tank Capacity: 0.49 L (0.43 Imp qt, 0.52 US qt) 
From "LOW" to "FULL" Level: 0.14 L (0.12 Imp qt, 0.15 US qt)