DRIVE SPROCKET
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iffll ADJUSTER |
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LOCK NUT |
Raise the rear wheel off the ground by placing a workstand or equivalent under the engine.
Loosen the axle nut.
Loosen the drive chain adjuster lock nuts and turn the adjusters clockwise fully.
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SPACER |
Remove the bolts, sprocket cover and spacer.
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BOLTS |
SPROCKET COVER
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WASHER |
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DRIVE SPROCKET |
Shift the transmission other than neutral position. Remove the bolt, collar, washer and drive sprocket.
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BOLT |
COLLAR
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DRIVE SPROCKET |
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OUT" MARK |
Install the drive chain to the drive sprocket.
Install the drive sprocket onto the countershaft with the "OUT" mark facing out.
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Install the washer and collar with their "OUT-SIDE" marks facing out.
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I "OUT-SIDE" MARKS |
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BOLT |
Tighten the drive sprocket bolt to the specified torque.
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SPACER |
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SPROCKET COVER |
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BOLTS |
TORQUE: 31 N m (3.2 kgf m, 23 Ibf ft)
Install the spacer, sprocket cover and tighten the bolts securely.
Adjust drive chain slack (page 4-24).
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CRANKCASE BREATHER HOSE |
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Drain the engine oil (page 4-20).
Drain the transmission oil (page 4-23).
Drain the coolant (page 7-7).
Remove the following:
- Seat (page 3-3)
- Left/right/center engine guards (page 3-5)
- Fuel tank (page 3-8)
- Spark plug cap (page 4-12)
- Ignition coil (page 18-8)
- Exhaust system (page 3-13)
- Carburetor (page 6-11)
- Drive sprocket (page 8-4)
- Kickstarter pedal (page 11-5)
- Gearshift pedal (page 11-24)
- Brake pedaHpage 16-24)
- Radiator reserve tank (page 7-9)
'05and 06 Remove the PAIR control valve (page 6-30).
California rype Disconnect the breather hoses.
After 06:
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STARTER MOTOR CABLE * |
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Remove the bolt and ground cable.
Remove the nut and starter motor cable.
Remove the bolt and clutch cable stay, then disconnect the clutch cable from the clutch lifter lever.
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Remove the wire band. Disconnect the alternator 4P (Black) and ignition pulse generator 2P (Black) connectors. |
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WIRE BAND |
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CONNECTORS |
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Loosen the hose band screws and disconnect the radiator hoses. Remove the bolt, water hose joint and O-ring from the cylinder head. |
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RADIATOR HOSES |
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WATER HOSE JOINT/O-RING |
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Remove the nut, bolts, fuel hose guide, clutch cable guide and engine hanger plates. |
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I BOLTS ENGINE HANGAR PLATES |
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CABLE GUIDE |
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BOLT/NUT |
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HOSE GUIDE |
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Loosen the swingarm pivot nut. Loosen the engine front and lower mounting nuts. Remove the swingarm pivot nut, washer and bolt. Remove the engine front and lower mounting nuts, washers and bolts. Remove the engine. • A workstand or equivalent is need to support the swingarm when removing the engine. |
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SWINGARM PIVOT NUT/WASHER/BOLT |
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During engine removal, hold the engine securely and be careful not to damage the frame and engine. |
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NUTS/WASHERS/ BOLTS |
Before engine Turn the engine 90 degrees in the frame so that the removal, tape the left crankcase cover is facing rearward using the fol - comers of the lowing procedures: cylinder head cover to protect it from damage
05' - '07 shown:
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NOTE ('05 - '07): Be careful not to damage the cylinder head cover with the ignition coil stays. |
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NOTE (After '07): Be careful not to damage the cylinder head cover with the ignition coil stay (upper only) |
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2. Move the rear end of the engine over 1. Position the water hose joint inside the swingarm pivot of the frame. of the front engine hanger. |
Remove the engine from the right side of the frame using the following procedures:
'05 - '07 shown:
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1. Lift the bottom of the engine and pass the water hose joint under the front engine hanger.
2. Pass the engine rear end over the right side of the frame, and then remove the engine. |
Note the direction of the engine hanger plates and mounting bolts.
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05- '07 shown: |
Temporarily install the swingarm pivot bolt so the chassis can be moved and stored safely.
