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Start switch ON: less than 1 V

Start switch OFF: more than 12 V

Out of specification → Replace the handle-bar switch.

8. If the above-mentioned checks are within specification, replace the ECU (ABS).

4 - 127

ENG ₅


		ENG

CHAPTER 5

ENGINE
ENGINE REMOVAL........................................................................................	5-1
MUFFLER ASSEMBLY.............................................................................	5-1
LEADS AND HOSES.................................................................................	5-2
ENGINE.....................................................................................................	5-5
INSTALLING THE ENGINE.......................................................................	5-6
CAMSHAFTS...................................................................................................	5-7
CYLINDER HEAD COVER........................................................................	5-7
CAMSHAFTS............................................................................................	5-8
REMOVING THE CAMSHAFTS................................................................	5-9
CHECKING THE CAMSHAFTS..............................................................	5-10
CHECKING THE CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES...............................................................	5-12
CHECKING THE TIMING CHAIN TENSIONER......................................	5-13
INSTALLING THE CAMSHAFTS............................................................	5-13
CYLINDER HEAD..........................................................................................	5-17
REMOVING THE CYLINDER HEAD.......................................................	5-18
CHECKING THE CYLINDER HEAD.......................................................	5-18
INSTALLING THE CYLINDER HEAD.....................................................	5-19
VALVES AND VALVE SPRINGS..................................................................	5-20
REMOVING THE VALVES......................................................................	5-21
CHECKING THE VALVES AND VALVE GUIDES..................................	5-22
CHECKING THE VALVE SEATS............................................................	5-24
CHECKING THE VALVE SPRINGS........................................................	5-26
CHECKING THE VALVE LIFTERS.........................................................	5-27
INSTALLING THE VALVES....................................................................	5-27
CYLINDER AND PISTON..............................................................................	5-30
REMOVING THE CYLINDERS AND PISTONS......................................	5-31
CHECKING THE CYLINDERS AND PISTONS......................................	5-32
CHECKING THE PISTON RINGS...........................................................	5-33
CHECKING THE PISTON PINS..............................................................	5-34
INSTALLING THE PISTONS AND CYLINDERS....................................	5-35
STARTER CLUTCH AND A.C. MAGNETO ROTOR....................................	5-37
REMOVING THE A.C. MAGNETO ROTOR............................................	5-39
CHECKING THE STARTER CLUTCH....................................................	5-40
INSTALLING THE A.C. MAGNETO ROTOR..........................................	5-40


		ENG

OIL PUMP......................................................................................................
5-42
CHECKING THE OIL PUMP...................................................................	5-45
CHECKING THE RELIEF VALVE...........................................................	5-46
CHECKING THE OIL DELIVERY PIPES................................................	5-46
CHECKING THE OIL STRAINER...........................................................	5-46
CHECKING THE OIL PUMP DRIVE CHAIN...........................................	5-46
ASSEMBLING THE OIL PUMP...............................................................	5-46
CLUTCH........................................................................................................	5-48
REMOVING THE CLUTCH.....................................................................	5-51
DISASSEMBLING THE CLUTCH...........................................................	5-51
CHECKING THE FRICTION PLATES.....................................................	5-52
CHECKING THE CLUTCH PLATES.......................................................	5-52
CHECKING THE CLUTCH SPRINGS
AND CLUTCH DAMPER SPRINGS.......................................................	5-53
CHECKING THE CLUTCH HOUSING....................................................	5-53
CHECKING THE CLUTCH BOSS...........................................................	5-54
CHECKING THE PRESSURE PLATE AND THRUST PLATE................	5-54
CHECKING THE WEIGHT......................................................................	5-54
ASSEMBLING THE CLUTCH.................................................................	5-54
INSTALLING THE CLUTCH....................................................................	5-56
V-BELT AUTOMATIC TRANSMISSION.......................................................	5-57
V-BELT CASE.........................................................................................	5-57
V-BELT AND PRIMARY/SECONDARY SHEAVE...................................	5-58
REMOVING THE PRIMARY SHEAVE ASSEMBLY,
SECONDARY SHEAVE ASSEMBLY AND V-BELT...............................	5-62
DISASSEMBLING THE PRIMARY SHEAVE..........................................	5-63
DISASSEMBLING THE SECONDARY SHEAVE....................................	5-63
CHECKING THE V-BELT........................................................................	5-63
CHECKING THE V-BELT CASE AIR DUCT...........................................	5-64
CHECKING THE PRIMARY SHEAVE....................................................	5-64
CHECKING THE WEIGHTS....................................................................	5-64
CHECKING THE SLIDERS.....................................................................	5-64
CHECKING THE SECONDARY SHEAVE..............................................	5-65
ASSEMBLING THE PRIMARY SHEAVE................................................	5-65
ASSEMBLING THE SECONDARY SHEAVE..........................................	5-66
INSTALLING THE PRIMARY SHEAVE ASSEMBLY,
SECONDARY SHEAVE ASSEMBLY AND V-BELT...............................	5-67
CRANKCASE AND CRANKSHAFT.............................................................	5-70
CRANKSHAFT ASSEMBLY....................................................................	5-70
CONNECTING ROD...............................................................................	5-72
DISASSEMBLING THE CRANKCASE....................................................	5-73
REMOVING THE CRANKSHAFT MAIN JOURNAL BEARINGS............	5-73
REMOVING THE CONNECTING RODS................................................	5-74
CHECKING THE CRANKCASE..............................................................	5-74
CHECKING THE TIMING CHAIN............................................................	5-74
CHECKING THE CRANKSHAFT AND CONNECTING RODS...............	5-74
INSTALLING THE CRANKSHAFT MAIN JOURNAL BEARINGS...........	5-80
INSTALLING THE CONNECTING RODS...............................................	5-80
INSTALLING THE CRANKSHAFT..........................................................	5-82
ASSEMBLING THE CRANKCASE..........................................................	5-82


		ENG

TRANSMISSION............................................................................................
5-84
REMOVING THE TRANSMISSION........................................................	5-85
CHECKING THE TRANSMISSION.........................................................	5-85
ASSEMBLING THE CRANKCASE..........................................................	5-86
CHAIN DRIVE................................................................................................	5-87
CHECKING THE SWINGARM................................................................	5-91
CHECKING THE CHAIN DRIVE ASSEMBLY.........................................	5-91
ASSEMBLING THE CHAIN DRIVE ASSEMBLY....................................	5-91
INSTALLING THE CHAIN DRIVE...........................................................	5-92

ENG

ENGINE REMOVAL ^ENG

ENGINE

ENGINE REMOVAL

MUFFLER ASSEMBLY

Order	Job/Part	Q’ty	Remarks

	Removing the muffler assembly		Remove the parts in the order listed.
	Right rear side cover/inner fender		Refer to “COVER AND PANEL” in chap-
			ter 3.
	O₂ sensor coupler		Disconnect.
	Protector 1
	O₂ sensor
	Protector 2
	Muffler assembly
	Gasket
			For installation, reverse the removal pro-
			cedure.

5 - 1

ENGINE REMOVAL ^ENG

LEADS AND HOSES

5 Nm (0.5 m • kg, 3.6 ft • Ib)

5 ⁴

23 Nm (2.3 m • kg, 17 ft • Ib)

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order	Job/Part	Q’ty	Remarks

	Disconnecting the leads and hoses		Disconnect the parts in the order listed.
	Leg shield/footrest board		Refer to “COVER AND PANEL” in chap-
			ter 3.
	Storage box/fuel tank		Refer to “FUEL TANK” in chapter 3.
	Engine oil		Drain.
			Refer to “CHANGING THE ENGINE OIL”
			in chapter 3.
	Coolant		Drain.
			Refer to “CHANGING THE COOLANT” in
			chapter 3.
	Chain drive oil		Drain.
			Refer to “CHANGING THE CHAIN
			DRIVE OIL” in chapter 3.
	Thermostat outlet hose/coolant pipe/oil		Refer to “RADIATOR AND OIL COOLER”
	filter cartridge		in chapter 6.

5 - 2

ENGINE REMOVAL

ENG

5 Nm (0.5 m

•

kg, 3.6 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

Order	Job/Part	Q’ty	Remarks

	V-belt case air filter element (left)/water		Refer to “WATER PUMP” in chapter 6.
	pump inlet pipe/water pump outlet pipe
	Throttle body/injector		Refer to “THROTTLE BODY” in chapter
			7.
	Muffler assembly		Refer to “ENGINE REMOVAL”.
	Rear shock absorber		Refer to “REAR SHOCK ABSORBER” in
			chapter 4.
	Chain drive assembly		Refer to “CHAIN DRIVE”.
	Spark plug cap		Disconnect.
	Starter motor lead		Disconnect.
	Battery negative lead		Disconnect.
	Coolant temperature sensor coupler		Disconnect.
	A.C. magneto lead		Disconnect.

5 - 3

ENGINE REMOVAL

ENG

5 Nm (0.5 m

•

kg, 3.6 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

Order

Job/Part

Q’ty

Remarks

Intake air pressure sensor hose

Disconnect.

Right passenger footrest

For installation, reverse the removal pro-cedure.

5 - 4

ENGINE REMOVAL

ENG

ENGINE

87 Nm (8.7 m

•

kg, 63 ft

•

lb)

48 Nm (4.8 m

•

kg, 35 ft

•

Ib)

•

48 Nm (4.8 m

kg, 35 ft

Ib)

Order	Job/Part	Q’ty		Remarks

	Removing the engine		Remove the parts in the order listed.
	Front lower mounting bolt/washer	4/4

	Spacer			Refer to “INSTALLING THE ENGINE”.
	Front upper mounting bolt/nut	1/1


	Rear mounting bolt/nut	1/1

	Engine
			For installation, reverse the removal pro-
			cedure.

5 - 5

	ENGINE REMOVAL	ENG
	INSTALLING THE ENGINE
	1. Install:
• rear mounting bolt/nut 1

	• front upper mounting bolt/nut 2
• washers

	• spacer 3
	• front lower mounting bolts 4
	NOTE:
	Do not fully tighten the bolts.
	2. Tighten:
• rear mounting nut 1

	T.R.87 Nm (8.7 m · kg, 63 ft · lb)
	• front upper mounting nut 2
	T.R.87 Nm (8.7 m · kg, 63 ft · lb)
	• front lower mounting bolts 4
T.R.48 Nm (4.8 m · kg, 35 ft · lb)

5 - 6

CAMSHAFTS ^ENG

CAMSHAFTS

CYLINDER HEAD COVER

Order	Job/Part	Q’ty	Remarks

	Removing the cylinder head cover		Remove the parts in the order listed.
	Engine		Refer to “ENGINE REMOVAL”.
	Intake manifold		Refer to “THROTTLE BODY” in chapter
			7.
	Spark plug
	Cylinder head cover
	Cylinder head cover gasket
	Dowel pin
			For installation, reverse the removal pro-
			cedure.

5 - 7

					CAMSHAFTS		ENG
CAMSHAFTS
					T.			•	•	Ib)
T.	•	kg, 7.2 ft	•	Ib)	R.7 Nm (0.7 m	kg, 5.1 ft
R.	10 Nm (1.0 m
				T.	•	kg, 7.2 ft	•	Ib)
				R.	10 Nm (1.0 m
				M
E

					New 2				New
E



				M

Order	Job/Part	Q’ty			Remarks

	Removing the camshafts		Remove the parts in the order listed.
	Timing chain tensioner

	Timing chain tensioner gasket
	Camshaft cap
	Dowel pin		NOTE:						Refer to “REMOV-

			During	removal,				ING THE CAM-
			the dowel	pins
						SHAFTS” and

			may still be con-				“INSTALLING THE
			nected	to	the				CAMSHAFTS”.
			camshaft cap.

	Intake camshaft

	Exhaust camshaft
	For installation, reverse the removal pro-

			cedure.

5 - 8

CAMSHAFTS ^ENG

REMOVING THE CAMSHAFTS

Б Remove:

timing plug 1

Л Align:

“I” mark a on the A.C. magneto rotor

(with the stationary pointer b on the A.C. magneto cover)

▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼

М Turn the crankshaft counterclockwise.

М When piston #1 is at TDC on the compres-sion stroke, align the “I” mark a on the A.C. magneto rotor with the stationary pointer b on the A.C. magneto rotor cover.

NOTE:

Н TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.

Н In order to be sure that the piston is at TDC, the alignment mark c on the intake cam-shaft sprocket and the alignment mark d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration.