SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Note; In order to prevent scratching the frame, it is recommended that you place either duct tape or a length of garden hose split down the middle around the areas that are likely to be contacted by the engine.
Engine Removal
Drain the oil. See the Engine Oil topic for more information.
Remove the seat. See the Seat topic for more information.
Remove the side covers. See the Side Covers topic for more information.
Remove the fuel tank. See the Fuel Tank topic for more information.
Remove the exhaust system. See the Exhaust Removal topic for more information.
Remove the carburetor. See the Carburetor Removal topic for more information.
Remove the front sprocket. See the Front Sprocket topic for more information.
Drain the coolant. See the Coolant Replacement topic for more information.
Remove the radiator shrouds. See the Radiator Shrouds topic for more information.
Remove the radiator. See the Radiator topic for more information.
Remove the three bolts holding the coolant reservoir tank in place using an 8 mm wrench and pull off the reservoir tank.
Remove the coolant hose from the cylinder head using a #2 Phillips head screwdriver.
Remove the coolant hoses from the water pump using a #2 Phillips head screwdriver.
Remove the battery.
Remove the spark plug cap from the spark plug, unplug the ignition coil primary leads and unbolt the ignition coil using a 10 mm wrench.
Unplug the water temperature sensor lead.
Unplug the six pin white plastic coupler that has the three yellow stator coil leads and the red and white source coil leads. Also unplug the three pin white plastic coupler with the black and black/yellow pickup coil wires and the light green neutral switch wire.
Unplug the light green wire from the neutral switch.
Remove the left foot peg using a 12 mm wrench and remove the shift lever using a 10 mm wrench.
Loosen the two locknuts at the bottom of the clutch cable using two 12 mm wrenches.
Pull the clutch cable out of the bracket.
Remove the cable end from the clutch release arm.
Remove the skid plate bolts using a 10 mm socket.
Pull back the rubber cover and remove the starter motor cable using a 10 mm wrench. Be careful not to turn the starter motor terminal stud.
Remove the upper rear motor mounts using a 12 mm socket.
Remove the front engine mounts by holding the frame bolts with a 12 mm wrench and loosening the nuts with a 12 mm socket. Hold the engine bolt with a 14 mm wrench and loosen the nut with a 14 mm socket.
Remove the lower rear engine mounting bolt using two 14 mm wrenches.
Remove the swing arm pivot nut using a 22 mm wrench. Partially drive out the swing arm pivot bolt only far enough to release the engine.
Caution: Driving the swing arm pivot bolt partially out to release the engine will allow the engine to shift in the frame. Be careful not to get your hands caught between the engine and the frame.
Remove the engine from the left side of the frame.
Engine Installation
Installation is essentially the reverse of removal with the following notes.
The chain does not have a master link (if it is the original chain), so make sure the swing arm pivot bolt goes through the chain when it is driven back through the engine.
Install all of the engine mount bolts before torqueing any of them to specification. Always start with the largest diameter bolts and torque the smallest bolts last.
Torque the swing arm pivot bolt and nut to specification.
Swingarm pivot nut torque: 98 N-m or 72 ft-lb
Torque the 10 mm diameter lower rear motor mount nut and bolt and the front motor mount engine nut and bolt to specification using 14 mm wrenches.
10 mm diameter motor mount bolt torque: 44 N-m or 33 ft-lb
Torque the 8 mm diameter front motor mount frame nuts and bolts and the three upper rear motor mount bolts to specification.
8 mm diameter motor mount bolts: 24 N-m or 17.5 ft-lb