3-10
INSTALLING THE ENGINE
ENGINE CRANKCASE INSTALLATION
1. See Figure 3-2. Place engine crankcase on supports so
frame may be installed over the top of the engine.
2. See Figure 3-3. If removed, attach swingarm mount block
to engine. Install upper bolts (3), washers and locknuts
finger tight. Install lower bolts (4), washers and locknuts
finger tight. Tighten upper bolts to 41-45 ft-lbs (55.6-61.0
Nm) and lower bolts to 68-75 ft-lbs (92.2-101.7 Nm).
3. If removed, install swingarm. Adjust swingarm bearing
preload. See SWINGARM in Section 2.
4. Remove oil filter (if installed). Walk frame over powertrain.
5. See Figure 3-4. Install front isolator bolt. Attach front iso-
lator mount with bolt (6), washers (7), D-washer (8) and
locknut (9). Tighten bolt finger tight.
1
CAUTION
Isolator bolts must be tightened within 30 minutes of
applying LOCTITE THREADLOCKER. Failure to tighten
bolts within 30 minutes may cause LOCTITE to set.
6. See Figure 3-3. Apply LOCTITE THREADLOCKER 262
(red) to side isolator bolts (7). Align pins on frame into
holes in rubber isolators. Install bolts (7) and lockwash-
ers (6) finger tight.
1
CAUTION
Do not adjust tie bar assemblies. Tie bar tension is set at
the factory. Any attempt at adjusting tension will cause
damage to tie bars. Damaged tie bars must be replaced.
7. See Figure 3-3. Attach rear tie bar assembly (2). Install
bolt, lockwasher, and washer on swingarm mount block.
Install bolt and locknut on frame. Tighten bolts to 30-33
ft-lbs (40.7-44.7 Nm).
8. Attach top center tie bar assembly. Install bolt, washer,
front tie bar spacer and locknut on ignition mount. Install
bolt and locknut on frame. Tighten bolts to 30-33 ft-lbs
(40.7-44.7 Nm).
9. See Figure 3-4. Attach front tie bar assembly to engine.
Install bolt (5), lockwasher (4), washer (3) and front tie
bar spacer (2).
10. See Figure 3-3. Tighten the two side isolator bolts (7) to
100-110 ft-lbs (135.6-149.1 Nm).
11. See Figure 3-4. Tighten front isolator bolt (6) to 100-110
ft-lbs (135.6-149.1 Nm).
12. Connect feed, return and vent lines to oil tank. See OIL
HOSE ROUTING on page 3-29. Use
new
hose clamps.
13. Attach battery ground strap to swingarm mount block.
14. Attach clutch cable to handlebar lever.
15. Remove strap from between engine cylinders. Using a
floor hoist, lift motorcycle by the frame and remove the
wooden cradle from underneath the crankcase.
16. Install rear shock. See REAR SHOCK ABSORBER,
INSTALLATION in Section 2. Remove floor hoist straps.
17. Install rear wheel and attach secondary drive belt. See
REAR WHEEL, INSTALLATION in Section 2.
18. Install rear brake caliper. See REAR BRAKE CALIPER in
Section 2.
19. Attach disconnected wires. See Section 7.
a. Connect 18-gauge green wire to starter motor.
b. Plug ignition switch assembly into main harness
plug.
c. Plug regulator/rectifier into stator connection.
d. Attach ignition sensor to wire harness.
e. Connect V.O.E.S. to ignition module.
f. Connect neutral switch.
g. Connect oil pressure switch wire.
20. Install REAR FENDER/LOWER BELT GUARD and
SPROCKET COVER. See Section 2.
21. Install footrests. See FOOTRESTS in Section 2.
22. Continue with the steps listed below.
ENGINE INSTALLATION AFTER
CYLINDER HEAD REPAIR
1. Install
new
oil filter, engine oil, and primary chaincase
lubricant as necessary. See Section 1.
2. Install carburetor with intake manifold. See CARBURE-
TOR, INSTALLATION in Section 4.
3. Install exhaust system as described under EXHAUST
SYSTEM in Section 2.
4. Install air cleaner assembly. See AIR CLEANER,
INSTALLATION in Section 4.
5. If removed, install horn and ignition coil. See Section 7.
6. Connect spark plug cables. See SPARK PLUG CABLES
in Section 7.
1
WARNING
Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion producing personal injury.
1
CAUTION
Hold battery cable when tightening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
7. Install battery. Connect battery cables, positive first.
8. Install tail section, fuel tank and seat. See TAIL SEC-
TION in Section 2.
9. If engine crankcase installation was performed:
a. Adjust belt according to REAR BELT DEFLECTION
in Section 1.
b. Adjust rear shock spring preload. See REAR PRE-
LOAD ADJUSTMENT in Section 1.
c. Adjust clutch lever. See CLUTCH in Section 1.
d. Check rear brake pedal freeplay. See BRAKES in
Section 1.
10. Check all electrical components for proper operation.
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