nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Slide the water hose clamps [A].
Disconnect the water hoses [B].
Remove:
Oil Cooler Bolts [C]
Oil Cooler [D]

Oil Cooler Installation

the O-ring [A] with a new one.
• Replace
Apply
grease
to the O-ring and install it.
• Install the oil cooler.
• Apply a non-permanent locking agent to the threads of
• the oil cooler bolts.
• Tighten:
Torque - Oil Cooler Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

the water hoses [A] and clamps [B] as shown.
• Install
Pour:
• Engine Oil (see Engine Oil Change in the Periodic Main-

•

tenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
Install the lower fairings (see Lower Fairing Installation in
the Frame chapter).

ENGINE LUBRICATION SYSTEM 7-15
Oil Pressure Measurement
Oil Pressure Measurement

• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Oil Passage Plug [A]

• Attach the adapter [A] and gauge [B] to the plug hole.
Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Oil Pressure Gauge Adapter, PT3/8: 57001
-1233

the engine and warm up the engine.
• Start
Run
the
at the specified speed, and read the oil
• pressureengine
gauge.
Oil Pressure
Standard:

•
•

About 295 kPa (3.01 kgf/cm², 42.8 psi)
@4 000 r/min (rpm), oil temperature 50°C
(122°F)

If the oil pressure is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing insert
wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.
Stop the engine.
Remove the oil pressure gauge and adapter.

WARNING
Hot oil can cause severe burns. Beware of hot engine oil that will drain through the oil passage when
the gauge adapter is removed.
a non-permanent locking agent to the oil passage
• Apply
plug, and tighten it.
Torque - Oil Passage Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)

the right lower fairing (see Lower Fairing Installa• Install
tion in the Frame chapter).

7-16 ENGINE LUBRICATION SYSTEM
Oil Pressure Switch
Oil Pressure Switch Removal

the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
the left lower fairing (see Lower Fairing Removal
• Remove
in the Frame chapter).
the switch cover.
• Slide
• Remove:
Switch Terminal Bolt [A]
Oil Pressure Switch [B]

Oil Pressure Switch Installation

a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket to the threads of the oil pressure
switch and tighten it.
Sealant - Liquid Gasket, TB1211: 56019-120
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

the switch lead (see Cable, Wire, and Hose Routing
• Install
section in the Appendix chapter).
• Tighten:
Torque - Oil Pressure Switch Terminal Bolt: 2.0 N·m (0.20
kgf·m, 18 in·lb)

• Apply grease to the terminal.
NOTE

○Apply a small amount grease to the terminal so that
grease should not close two breather holes [A] for
switch diaphragm.

the switch cover.
• Install
Install
the
removed parts (see appropriate chapters).
•

ENGINE LUBRICATION SYSTEM 7-17
Oil Pipe
Oil Pipe Removal

• Remove:
Oil Pan (see Oil Pan Removal)
Oil Pipe [A]

Oil Pipe Installation

the O-rings [A] with new ones.
• Replace
grease to the O-rings, and install them.
• Apply
Install:
• Oil Pipe
Oil Pan (see Oil Pan Installation)

ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................

8-2
8-4
8-4
8-6

8

8-2 ENGINE REMOVAL/INSTALLATION
Exploded View

ENGINE REMOVAL/INSTALLATION 8-3
Exploded View
No.
1
2
3
4
5
6
7
8

Fastener
Upper Front Engine Bracket Bolts
Upper Front Engine Mounting Bolts
Upper Rear Engine Bracket Bolts
Upper Rear Engine Mounting Bolts
Middle Front Engine Mounting Bolts
Middle Engine Bracket Bolts
Middle Rear Engine Mounting Nut
Lower Engine Mounting Nut

S: Follow the specified tightening sequence.

N·m
29
59
25
44
44
25
44
44

Torque
kgf·m
3.0
6.0
2.5
4.5
4.5
2.5
4.5
4.5

ft·lb
21
44
18
32
32
18
32
32

Remarks
S
S
S
S
S
S
S
S

8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal

the rear part of the swingarm with a stand.
• Support
the brake lever slowly and hold it with a band
• Squeeze
[A].

WARNING
Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.

NOTICE
Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.

• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•

tenance chapter)
Coolant (see Coolant Change in the Periodic Maintenance chapter)
Remove:
Lower Fairings (see Lower Fairing Removal in the Frame
chapter)
Clutch Cable Lower End (see Clutch Cable Removal in
the Clutch chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Removal in the Cooling System chapter)
Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)

• Disconnect:
Stick Coil Connectors (see Stick Coil Removal in the
Electrical System chapter)
Alternator Lead Connector (see Alternator Cover Removal in the Electrical System chapter)
Crankshaft Sensor Lead Connector (see Crankshaft
Senor Removal in the Electrical System chapter)
Starter Motor Cable (see Starter Motor Removal in the
Electrical System chapter)

ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
the clamps [A].
• Slide
Disconnect:
• Air Bleeder Hose [B]
Water Hose [C]

the clamps [A].
• Open
Disconnect
pressure switch lead [B] and gear po• sition sensortheleadoil connector
[C].

• Remove the clamps [A].

• Remove the engine ground cable terminal bolt [A].

• Remove the drive chain [A] from the output shaft [B].

8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the engine with a suitable stand [A].
•○Support
Put a plank [B] onto the suitable stand for engine balance.

• Remove:
Upper Front Engine Mounting Bolt [A] (Both Sides)
Upper Front Engine Bracket Bolts [B] and Washers (Both
Sides)
Upper Front Engine Bracket [C] (Both Sides)

the crankshaft sensor lead [A] from the clamp.
• Free
Remove:
• Lower Fairing Bracket Bolts [B]
Lower Fairing Bracket [C]

• Remove:
Upper Rear Engine Mounting Bolt [A] (Both Sides)
Middle Front Engine Mounting Bolt [B] (Both Sides)
Upper Rear Engine Bracket Bolts [C] and Bracket (Both
Sides)
Middle Engine Bracket Bolts [D] and Bracket (Both
Sides)

• Remove:
Middle Rear Engine Mounting Nut [A] and Bolt
•

Lower Engine Mounting Nut [B] and Bolt
Using the suitable stand, take out the engine.

Engine Installation

the engine with a suitable stand.
•○Support
Put a plank onto the suitable stand for engine balance.

ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation
This page intentionally left blank.

8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the engine mounting bolts and nuts, following the specified installing sequence.
•○Install
First, hang the drive chain over the output shaft just before moving the engine into its final position
in the frame.

○Second, insert the lower engine mounting bolt [A] and middle rear engine mounting bolt [B] temporarily.
○Third, tighten the lower engine mounting nut [C] and middle rear engine mounting nut temporarily
by hand.
○Forth, install the following parts temporarily.
Upper Front Engine Brackets [E]
Upper Rear Engine Brackets [F]
Middle Engine Brackets [G]
○Fifth, tighten the following parts temporarily by hand.
Upper Front Engine Bracket Bolts [H]
Upper Rear Engine Bracket Bolts [I]
Middle Engine Bracket Bolts [J]
Upper Front Engine Mounting Bolts [K]
Upper Rear Engine Mounting Bolts [L]
Middle Front Engine Mounting Bolts [M]
○Sixth, temporarily tighten the lower engine mounting nut [C].
○Seventh, temporarily tighten the middle rear engine mounting nut [D].
○Eighth, tighten the following parts temporarily.
Upper Front Engine Mounting Bolts [K]
Upper Rear Engine Mounting Bolts [L]
Middle Front Engine Mounting Bolts [M]
○Ninth, tighten the following parts temporarily.
Upper Front Engine Bracket Bolts [H]
Upper Rear Engine Bracket Bolts [I]
Middle Engine Bracket Bolts [J]
○Tenth, by the following specified sequence [1  8], tighten the nuts and bolts.
Torque - Lower Engine Mounting Nut [C]: 44 N·m (4.5 kgf·m, 32 ft·lb)
Middle Rear Engine Mounting Nut [D]: 44 N·m (4.5 kgf·m, 32 ft·lb)
Upper Front Engine Bracket Bolts [H]: 29 N·m (3.0 kgf·m, 21 ft·lb)
Upper Rear Engine Bracket Bolts [I]: 25 N·m (2.5 kgf·m, 18 ft·lb)
Middle Engine Bracket Bolts [J]: 25 N·m (2.5 kgf·m, 18 ft·lb)
Upper Front Engine Mounting Bolts [K]: 59 N·m (6.0 kgf·m, 44 ft·lb)
Upper Rear Engine Mounting Bolts [L]: 44 N·m (4.5 kgf·m, 32 ft·lb)
Middle Front Engine Mounting Bolts [M]: 44 N·m (4.5 kgf·m, 32 ft·lb)

ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation

the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).
the removed parts (see appropriate chapters).
• Install
Adjust:
• Throttle Cables (see Throttle Control System Inspection

•
•

in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)
Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).
Fill the engine with coolant (see Coolant Change in the
Periodic Maintenance chapter).

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission
Table of Contents
Exploded View...................................
Specifications ....................................
Special Tools and Sealants ...............
Crankcase Splitting............................
Crankcase Splitting ......................
Crankcase Assembly ...................
Crankshaft and Connecting Rods......
Crankshaft Removal ....................
Crankshaft Installation .................
Connecting Rod Removal ............
Connecting Rod Installation .........
Crankshaft/Connecting Rod
Cleaning ....................................
Connecting Rod Bend Inspection
Connecting Rod Twist Inspection.
Connecting Rod Big End Side
Clearance Inspection ................
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection..................................
Crankshaft Side Clearance
Inspection..................................
Crankshaft Runout Inspection......
Crankshaft Main Bearing
Insert/Journal Wear Inspection .
Balancer ............................................
Balancer Removal........................
Balancer Installation.....................
Balancer Adjustment....................
Balancer Damper Inspection........
Starter Motor Clutch ..........................
Starter Motor Clutch
Removal/Installation..................
Starter Motor Clutch Disassembly

9-2
9-6
9-8
9-9
9-9
9-10
9-15
9-15
9-15
9-15
9-16
9-20
9-20
9-20
9-21

9-21
9-23
9-24
9-24
9-27
9-27
9-27
9-28
9-28
9-29
9-29
9-29

Starter Motor Clutch Assembly ....
Starter Motor Clutch Inspection ...
External Shift Mechanism..................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation .................................
External Shift Mechanism
Inspection..................................
Transmission .....................................
Transmission Shaft Removal .......
Transmission Shaft Installation ....
Transmission Shaft Disassembly .
Transmission Shaft Assembly......
Shift Drum and Fork Removal......
Shift Drum and Fork Installation...
Shift Drum Disassembly...............
Shift Drum Assembly ...................
Shift Fork Bending Inspection ......
Shift Fork/Gear Groove Wear
Inspection..................................
Shift Fork Guide Pin/Drum
Groove Wear Inspection ...........
Gear Dog and Gear Dog Hole
Damage Inspection ...................
Ball Bearing, Needle Bearing, and Oil
Seal.................................................
Ball and Needle Bearing
Replacement .............................
Ball and Needle Bearing Wear
Inspection..................................
Oil Seal Inspection .......................

9-29
9-29
9-30
9-30
9-30
9-31
9-31
9-32
9-34
9-34
9-34
9-34
9-35
9-40
9-40
9-40
9-41
9-41
9-41
9-41
9-42
9-43
9-43
9-43
9-43

9

9-2 CRANKSHAFT/TRANSMISSION
Exploded View

CRANKSHAFT/TRANSMISSION 9-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13

Fastener
Balancer Shaft Clamp Bolt
Balancer Shaft Clamp Lever Bolt
Connecting Rod Big End Nuts
Oil Jet Nozzle Bolt
Breather Side Plate Bolt
Breather Plate Bolts
Starter Motor Clutch Bolts
Oil Passage Plugs
Oil Passage Plug
Crankcase Bolts (M6)
Crankcase Bolts (M7)
Crankcase Bolts (M8)
Crankcase Bolts (M9)

Torque
N·m
kgf·m
9.8
1.0
25
2.5
see the text
←
6.9
0.70
5.9
0.60
9.8
1.0
12
1.2