ENGINE INSTALLATION
Apply molybdenum disulfide paste to the engine contact area of the front engine hanger.
Carefully align the Install the engine in the frame.
mounting points to Apply thin coat of grease to the swingarm pivot bolt prevent damage to sliding surface.
engine, frame, wire Loosely install the swingarm pivot bolt, washer and and cables, nut.
Loosely install the engine mounting bolts, washers and nuts.
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• Route the wires and cables properly ('05 - '07: page 1-25, After '07: page 1-32). • Do not tighten the swingarm pivot nut and engine mounting nuts yet. Install the engine hanger plates, fuel hose guide, clutch cable guide, upper engine mounting bolt, washer, nut and engine hanger plate bolts. Tighten the engine mounting nuts, engine hanger plate bolts and swingarm pivot nut to the specified torque. TORQUE: Swingarm pivot nut: 88 N m (9.0 kgf-m, 65 Ibf ft) Engine hanger plate bolt: 26 N m (2.7 kgf-m, 19 lbf-ft) Engine mounting nut: (front): 54 N-m (5.5 kgf-m, 40 lbf-ft) (upper): 54 N-m (5.5 kgf-m, 40 lbf-ft) (lower): 54 N-m (5.5 kgf-m, 40 lbf-ft) |
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Install the water hose joint to the cylinder head. Connect the radiator hoses and tighten the band screws securely. |
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BOLTS/WASHERS/ NUTS |
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ENGINE HANGAR PLATES BOLTS /Ж JSmm |
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1 |
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CABLE GUIDE I |
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BOLT/NUT |
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HOSE GUIDE |
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RADIATOR HOSES |
WATER HOSE JOINT
Connect the alternator 4P (Black) and ignition pulse generator 2P (Black) connectors.
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Route the wire harness properly 105 - 07: page 125, After ’07: page 1-32). |
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WIRE BAND |
Install the wire band.
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CONNECTORS |
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STARTER MOTOR CABLE N |
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GROUND CABLE |
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CRANKCASE BREATHER HOSE |
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Connect the starter motor cable and tighten the nut securely.
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TRANSMISSION BREATHER HOSE |
Connect the clutch cable to the clutch lifter lever. Install the clutch cable stay and ground cable and tighten the bolts securely.
Connect the breather hoses.
Install the following:
- Ignition coil (page 18-8)
- Radiator reserve tank (page 7-9)
- Brake pedal (page 16-24)
- Gearshift pedal (page 11-27)
- Kickstarter pedal (page 11-7)
- Drive sprocket (page 8-4)
- Carburetor (page 6-24)
- Exhaust system (page 3-14)
- Spark plug cap (page 4-12)
- Fuel tank (page 3-8)
- Left/right/center engine guards (page 3-5)
- Seat (page 3-3)
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‘05 and 06 California type. After 06: |
Install the PAIR control valve (page 6-30).
Fill the system with the recommended coolant and bleed the air (page 7-7).
Fill the engine with the recommended engine oil (page 4-19).
Fill the transmission with the recommended transmission oil (page 4-23).
After installing the engine, perform the following inspections and adjustments:
- Throttle grip freeplay (page 4-9)
- Drive chain slack (page 4-24)
- Clutch lever freeplay (page 4-31)
Check the exhaust system for leaks.
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