Engine Removal

Submitted by xjcdadmin on Wed, 06/10/2009 - 17:02


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 keep harmful foreign material from the 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 reinstallation 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 and middle gear oil.

5.    Remove the oil filter element from the crankcase.

6.    Remove the left and right side covers.

B.   Fuel Tank

1.    Turn the fuel cock to "ON".

2.    Open the seat and remove the fuel tank securing clamp and retainer. Lift the rear end of the fuel tank and disconnect the fuel pipe and vacuum pipe from the cock.

1. Clip 2. Retainer

3. Remove the tool tray.

C . Brake Pedal and Exhaust Pipe

1.    Remove the rear brake pedal.

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

3.    Loosen the clamp bolts securing the exhaust pipes to the right and left mufflers. Remove the exhaust pipes.

4. Remove the bolts holding the muffler bracket to the crankcase.

D. Battery Case

1. Remove the negative battery cable from the battery terminal then remove the positive battery plate. Remove the battery.

1. Positive battery plate

2. Remove the starter motor lead wire from the starter relay and disconnect the relay leads form the wire harness.

1.  Starter motor lead wire `2. Starter relay

3. Remove the battery case holding bolts and remove the battery case with the starter relay assembly.

E. Air Cleaner Case

1.    Remove the ignitor unit mounting board securing screw and disconnect all connectors. Remove the board assembly.

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

1. Crankcase ventilation hose

3. Remove the bolts holding the air cleaner case to the frame (left and upper)

1. Engine ground wire

4.    Remove the air cleaner joint rubbers.

5.    Remove the starter (CHOKE) and clutch cables from the carburetor assembly.

6.    Pull the carburetor assembly to the rear.

1. Starter (CHOKE) cable    2. Clutch cable

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

1. Throttle cable

F. Wiring and Cables

1.    Disconnect the clutch cable at the crank-case side.

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

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

Position the disconnected wires so they will not be damaged during engine removal.

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

G. Drive Shaft Joint

1.    Remove the coil spring holding the rubber boot.

2.    Pull the rubber boot from the drive shaft coupling to expose the joint bolts.

3.    Remove the joint bolts on the drive shaft coupling.

I. Engine Removal

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

1 Front engine mounting bolts

2. Remove the rear engine mounting bolts and right and left footrests.

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.