Engine Removal
Fragment manuala — str. 302–308
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ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the exhaust pipe assembly
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
6 New
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib) (8)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib) 2 T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS” on page
Left side cowling/Right side cowling/T-bar 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-25.
Radiator Refer to “RADIATOR” on page 6-1.
1 O2 sensor coupler 1 Disconnect.
2 O2 sensor 1
3 Left muffler 1
4 Right muffler 1
5 Exhaust pipe assembly 1
6 Gasket 4
For installation, reverse the removal proce-
dure.
5-1
ENGINE REMOVAL
Disconnecting the leads and hoses (FJR13A)
9 3
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5 7
Order Job/Parts to remove Q’ty Remarks
Front fender Refer to “FRONT WHEEL” on page 4-17.
Refer to “GENERAL CHASSIS” on page
Air filter case 4-1.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-5.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve/Reed valves page 7-11.
Thermostat/Thermostat inlet pipe 1 Refer to “THERMOSTAT” on page 6-6.
Drain.
Engine oil/Oil filter cartridge Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Oil cooler Refer to “OIL COOLER” on page 6-4.
Water pump Refer to “WATER PUMP” on page 6-10.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-40.
Left footrest assembly/Sidestand Refer to “SHAFT DRIVE” on page 4-95.
1 Clutch release cylinder 1
2 Dowel pin 2
3 Crankcase breather hose 1
4 Stator coil coupler 1 Disconnect.
5-2
ENGINE REMOVAL
Disconnecting the leads and hoses (FJR13A)
9 3
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5 7
Order Job/Parts to remove Q’ty Remarks
5 Oil level switch coupler 1 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 Gear position switch coupler 1 Disconnect.
8 Ground lead 1 Disconnect.
9 Spark plug cap 4
For installation, reverse the removal proce-
dure.
5-3
ENGINE REMOVAL
Disconnecting the leads and hoses (FJR13AE)
12 .
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9 10
11 LT
LT
2 1
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Order Job/Parts to remove Q’ty Remarks
Front fender Refer to “FRONT WHEEL” on page 4-17.
Refer to “GENERAL CHASSIS” on page
Air filter case 4-1.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-5.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve/Reed valves page 7-11.
Thermostat/Thermostat inlet pipe 1 Refer to “THERMOSTAT” on page 6-6.
Drain.
Engine oil/Oil filter cartridge Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Oil cooler Refer to “OIL COOLER” on page 6-4.
Water pump Refer to “WATER PUMP” on page 6-10.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-40.
Refer to “SHIFT ACTUATOR AND SHIFT
Left footrest assembly/Sidestand ROD (FJR13AE only)” on page 5-67.
Refer to “SHIFT ACTUATOR AND SHIFT
Gear position sensor cover ROD (FJR13AE only)” on page 5-67.
1 Gear position sensor coupler 1 Disconnect.
2 Gear position sensor 1
5-4
ENGINE REMOVAL
Disconnecting the leads and hoses (FJR13AE)
12 .
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
9 10
11 LT
LT
2 1
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)
Order Job/Parts to remove Q’ty Remarks
3 Clutch release cylinder 1
4 Dowel pin 2
5 Crankcase breather hose 1
6 Stator coil coupler 1 Disconnect.
7 Oil level switch coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Neutral switch coupler 1 Disconnect.
10 YCC-S speed sensor coupler 1 Disconnect.
11 Ground lead 1 Disconnect.
12 Spark plug cap 4
For installation, reverse the removal proce-
dure.
5-5
ENGINE REMOVAL
Removing the engine
. 49 Nm (4.9 m • kg, 35 ft • Ib)
T
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib) T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
R.
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib) 15 1
E
T.
R.
49 Nm (4.9 m • kg, 35 ft • Ib) 12
11 .
R.
T 49 Nm (4.9 m • kg, 35 ft • Ib)
17 E
10 14
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib) 11
13 19
7 T.
R.
37 Nm (3.7 m • kg, 27 ft • Ib)
16 6
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)
4 T.
R.
37 Nm (3.7 m • kg, 27 ft • Ib)
32 Nm (3.2 m • kg, 23 ft • Ib)
2 T.
R.
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) T. 16 Nm (1.6 m • kg, 11 ft • Ib)
R.
Order Job/Parts to remove Q’ty Remarks
NOTE:
Place a suitable stand under the engine.
1 Brake pedal 1
2 Engine mounting bolt (left rear side) 2
3 Engine bracket bolt (left rear side) 1
4 Engine bracket (left rear side) 1
5 Engine bracket bolt (top) 4
6 Engine mounting bolt (top) 2
7 Engine bracket (top) 2
8 Pinch bolt (rear side) 2
9 Pinch bolt (front side) 2
10 Engine mounting bolt (right front lower side) 1
11 Spacer 2
12 Engine mounting bolt (right front upper side) 1
13 Engine mounting bolt (left front lower side) 1
14 Engine mounting bolt (left front upper side) 1
15 Engine mounting nut (rear upper side) 1
5-6
ENGINE REMOVAL
Removing the engine
. 49 Nm (4.9 m • kg, 35 ft • Ib)
T
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib) T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
R.
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib) 15 1
E
T.
R.
49 Nm (4.9 m • kg, 35 ft • Ib) 12
11 .
R.
T 49 Nm (4.9 m • kg, 35 ft • Ib)
17 E
10 14
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib) 11
13 19
7 T.
R.
37 Nm (3.7 m • kg, 27 ft • Ib)
16 6
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)
4 T.
R.
37 Nm (3.7 m • kg, 27 ft • Ib)
32 Nm (3.2 m • kg, 23 ft • Ib)
2 T.
R.
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) T. 16 Nm (1.6 m • kg, 11 ft • Ib)
R.
Order Job/Parts to remove Q’ty Remarks
16 Spacer bolt 1 Loosen.
17 Engine mounting bolt (rear lower side) 1
18 Spacer 1
19 Engine mounting bolt (rear upper side) 1
20 Engine 1
For installation, reverse the removal proce-
dure.
5-7