Engine Removal

ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.

A. Preparation for removal

1. All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. This will help prevent and harmful foreign material from engine oil.

2.    Before the engine removal and disassembly, be sure that you have the proper tools and cleaning equipment so that you can perform a clean and efficient job.

3.    During disassembly of the engine, clean and place all of the parts in trays in order of disassembly. This will speed up assembly time and help insure correct reinstall-action of all the engine parts.

4.    Place the motorcycle on its center stand. Start the engine and allow it to warm up. Stop the engine and drain the engine oil.

5.    Remove the oil filter cover from the crankcase.

6.    Remove the left and right side covers.

B. Seat and fuel tank

1.    Turn the fuel petcock to "ON".

2.    Open the seat and the fuel tank holding bolt. Lift the rear end of the fuel tank and disconnect the fuel pipes and vacuum pipe from the petcock.

3.    Disconnect the fuel level switch lead wire.

4. Remove the tool tray.

C. Mufflers

1.    Remove the rear brake pedal and foot-rests (left and right).

2.    Remove the exhaust pipe holding nuts from the cylinder head.

3. Loosen the clamp bolts securing the muffler joints.

4. Remove the bolts holding the right and left mufflers to the muffler bracket and remove the left and right mufflers.

D. Battery case

1. Remove the battery cover then remove the negative battery cable from the battery terminal. Remove the battery.

2. Remove the battery case holding bolts and remove the battery case.

NOTE:
The engine ground wire is secured together with left side holding bolt.

1. Engine ground wire

E. Air cleaner case

1. Remove the clamps holding the carburetors to the air cleaner case and intake manifolds. Remove the crankcase ventilation hose at the right crankcase cover.

1. Crankcase ventilation hose

2.    Remove the bolts holding the air cleaner case to the frame.

3.    Remove the starter (CHOKE) cable from the carburetor.

4.    Remove the air cleaner joint rubbers and pull the carburetor assembly to the rear.

5.    Disconnect the throttle cable from the carburetor throttle lever and remove the carburetor assembly to the right.

1. Starter (CHOKE) cable 2. Throttle cable

F. Wiring and cables

1. Disconnect the clutch cable at the crankcase side.

2. Remove the spark plug lead wires and the tachometer cable.

3.    Disconnect the electric starter cable at the starter relay switch.

4.    Disconnect the pick-up coil and A.C.G. lead wire couplers.

Position the disconnect lead wires so that they can be safely removed. See page .

CAUTION:
The A.C.Generator lead, starter cable, and pick-up lead are clamped at the lower cross tube of the frame. Do not forget the remove this clamp before removing the engine.

5. Remove the flasher relay.

G. Change pedal and drive sprocket

1.    Remove the change pedal and left crank-case cover.

2.    Loosen the drive sprocket securing bolts and remove the sprocket holder.

3.    Remove the drive sprocket.

H. Engine removal

1. Remove the front engine mounting bolts and nuts. Remove the brackets.

NOTE:
It is advisable to hold the engine with a suitable garage jack before removing the engine mounting bolts and nuts.

2. Remove the rear engine mounting bolt.

3. Slide the engine forward slightly and remove the engine to the right.

NOTE:
Position a box or other support to the right side of the motorcycle for the assistance when removing the engine.