the O-ring [A] with a new one.
• Replace
Apply
grease
to the new O-ring.
•

ENGINE LUBRICATION SYSTEM 7-15
Oil Cooler
the water hoses and hose clamps as shown.
• Install
Blue Paints [A]
the oil cooler [B].
• Install
Apply
a non-permanent locking agent to the oil cooler
• mounting
bolts.
Tighten
the
oil cooler mounting bolts by following the se• quence numbers
[1  4].
Torque - Oil Cooler Mounting Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)

the water hoses correctly (see Cable, Wire, and Hose
• Run
Routing section in the Appendix chapter).
• Pour:
Coolant (see Coolant Change in the Periodic Mainte-

•

nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
Install the removed parts (see appropriate chapters).

7-16 ENGINE LUBRICATION SYSTEM
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 90 kPa (0.92 kgf/cm², 13 psi) @4 000
r/min (rpm), Oil Temperature 90°C (194°F)

•
•

If the reading 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 (Tapered): 20 N·m (2.0 kgf·m,
15 ft·lb)

ENGINE LUBRICATION SYSTEM 7-17
Oil Pressure Switch
Oil Pressure Switch Removal

the engine oil (see Engine Oil Change in the Peri• Drain
odic Maintenance chapter).
• Remove:
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Switch Cover [A]
Switch Terminal Bolt [B]
Oil Pressure Switch [C]

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, TB1211F: 92104-0004
Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

the switch lead [A] as shown.
• Install
Clamp [B]
• Tighten:
Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15
kgf·m, 13 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 REMOVAL/INSTALLATION 8-1

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

8-2
8-4
8-5
8-5
8-8

8

8-2 ENGINE REMOVAL/INSTALLATION
Exploded View

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

Fastener
Right Front Engine Mounting Bolt
Adjusting Collar Locknut
Left Front Engine Mounting Bolt
Middle Engine Mounting Bolt
Lower Engine Mounting Bolt
Middle Engine Mounting Nuts
Lower Engine Mounting Nuts

M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
45
50
45
10
10
45
45

Torque
kgf·m
4.6
5.1
4.6
1.0
1.0
4.6
4.6

ft·lb
33
37
33
89 in·lb
89 in·lb
33
33

Remarks
S
S
S
S
S
R, S
R, S

8-4 ENGINE REMOVAL/INSTALLATION
Special Tool
Engine Mount Nut Wrench:
57001-1450

ENGINE REMOVAL/INSTALLATION 8-5
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:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Clutch Cable Lower End (see Cable Removal in the
Clutch chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Premuffler Chamber (see Premuffler Chamber Removal
in the Engine Top End chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Air Switching Valve (see Air Switching Valve Removal in
the Engine Top End chapter)

the clamp [A].
• Open
Disconnect
the stick coil connectors [B].
•

8-6 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation

• Disconnect:
Water Temperature Sensor Connector [A]
•
•

Crankshaft Sensor/Oil Pressure Switch Lead Connector
[B]
Remove the throttle body assy holder clamps [C].
Roll up the heat insulation rubber plate [D].

the starter motor cable [A] (see Starter Motor
• Disconnect
Removal in the Electrical System chapter).
• Remove the engine ground cable terminal bolt [B].

the gear position sensor lead connector [A].
• Disconnect
Remove
the
• bracket. gear position sensor lead connector from the

the side stand switch lead connector [A].
• Disconnect
• Free the side stand switch lead from the clamps [B].

• Open the clamp [A].

ENGINE REMOVAL/INSTALLATION 8-7
Engine Removal/Installation

• Remove:
Bolt [A]
Heat Insulation Plate [B]

○Clear the projections [C] from the frame.

• Disconnect the regulator/rectifier connector (gray) [A].

the engine with a suitable stand [A].
•○Support
Put the planks [B] onto the suitable stand for engine balance.

• Remove:
Left Front Engine Mounting Bolt [A]
Middle Engine Mounting Nut [B]
Lower Engine Mounting Nut [C]

• Remove:
Right Front Engine Mounting Bolt [A]

8-8 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
the engine mount nut wrench [A], loosen the locknut
• Using
[B].
Special Tool - Engine Mount Nut Wrench: 57001-1450

the Allen wrench, turn the adjusting collar [A] coun• Using
terclockwise to make the gap between the engine and adjusting collar.

the middle and lower engine mounting bolts clock• Turn
wise to make the gap between the adjusting collar and

•
•

frame.
Pull out the engine mounting bolts.
Using the stand, take out the engine.

Engine Installation

molybdenum disulfide grease to the threads of the
• Apply
adjusting collars [A].
the adjusting collars to crankcase backside until
• Install
end of the threads.

ENGINE REMOVAL/INSTALLATION 8-9
Engine Removal/Installation
the adjusting collar [A] to the frame until end of the
• Install
threads.

the engine mounting nuts with new ones.
• Replace
Support
the
with a suitable stand.
•○Put the planksengine
onto the suitable stand for engine balance.

○Support the engine until all bolts have been tightened.

the engine mounting bolts and nuts, following the
• Install
specified installing sequence.
install and tighten the following bolts temporarily.
• First,
Middle Engine Mounting Bolt [A]
Lower Engine Mounting Bolt [B]
Left Front Engine Mounting Bolt [C]
Right Front Engine Mounting Bolt [D]

8-10 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
tighten the left front engine mounting bolt [A].
• Second,
Frame [B]
Engine [C]
Torque - Left Front Engine Mounting Bolt: 45 N·m (4.6
kgf·m, 33 ft·lb)

insert the middle [A] and lower [B] engine mount• Third,
ing bolts to the adjusting collars [C], and tighten the bolts
counterclockwise.

NOTE

○Tighten the bolts until the clearance [D] between the
frame and collar come to 0 mm (0 in.).
Torque - Middle Engine Mounting Bolt: 10 N·m (1.0 kgf·m,
89 in·lb)
Lower Engine Mounting Bolt: 10 N·m (1.0 kgf·m,
89 in·lb)

tighten the middle [E] and lower [F] engine mount• Fourth,
ing nuts.
Torque - Middle Engine Mounting Nut: 45 N·m (4.6 kgf·m,
33 ft·lb)
Lower Engine Mounting Nut: 45 N·m (4.6 kgf·m,
33 ft·lb)

remove the right front engine mounting bolt [A].
• Fifth,
Sixth,
the adjusting collar [B] clockwise by hand
• until thetighten
clearance [C] between the engine [D] and collar

•

come to 0 mm (0 in.).
Seventh, tighten the adjusting collar locknut [E].
Special Tool - Engine Mount Nut Wrench: 57001-1450
Torque - Adjusting Collar Locknut: 50 N·m (5.1 kgf·m, 37
ft·lb)

• Lastly, tighten the right front engine mounting bolt.
Torque - Right Front Engine Mounting Bolt: 45 N·m (4.6
kgf·m, 33 ft·lb)

the leads, cables and hoses correctly (see Cable,
• Run
Wire, and Hose Routing section in the Appendix chapter).

ENGINE REMOVAL/INSTALLATION 8-11
Engine Removal/Installation
that the pad [A] is in place on the heat insulation
• Check
plate [B].
5 mm (0.20 in.) [C]

the projections [A] into the holes [B].
• Insert
Apply
locking agent to the threads of
• the heata non-permanent
insulation plate bolt [C] and tighten it.

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 .........................................
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 .
Pistons...............................................
Piston Removal............................
Piston Installation.........................
Cylinder (Upper Crankcase) Wear
Inspection..................................
Piston Wear Inspection ................
Piston Ring, Piston Ring Groove
Wear Inspection ........................
Piston Ring Groove Width
Inspection..................................
Piston Ring Thickness Inspection
Piston Ring End Gap Inspection ..
Balancer ............................................
Balancer Removal........................
Balancer Installation.....................
Balancer Adjustment....................
Balancer Damper Inspection........
Balancer Assembly ......................
Torque Limiter....................................

9-2
9-6
9-9
9-10
9-10
9-11
9-17
9-17
9-17
9-18
9-18
9-22
9-23
9-23
9-23

9-23
9-25
9-26
9-26
9-28
9-28
9-29
9-30
9-30
9-31
9-31
9-31
9-32
9-33
9-33
9-33
9-33
9-34
9-34
9-35

Torque Limiter Removal ...............
Torque Limiter Installation ............
Starter Motor Clutch ..........................
Starter Motor Clutch Removal......
Starter Motor Clutch Installation...
Starter Motor Clutch Disassembly
Starter Motor Clutch Assembly ....
Starter Motor Clutch Inspection ...
Transmission .....................................
Transmission Assy Removal........
Transmission Assy Installation.....
Transmission Assy Disassembly .
Transmission Assy Assembly ......
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/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 ...................
External Shift Mechanism..................
Shift Pedal Removal ....................
Shift Pedal Installation .................
External Shift Mechanism
Removal ....................................
External Shift Mechanism
Installation .................................
External Shift Mechanism
Inspection..................................
Ball Bearing, Needle Bearing, and Oil
Seal.................................................
Ball and Needle Bearing
Replacement .............................
Ball and Needle Bearing Wear
Inspection..................................
Oil Seal Inspection .......................

9-35
9-35
9-37
9-37
9-37
9-38
9-38
9-38
9-39
9-39