3.13REMOVING ENGINE FROM CHASSIS
PROCEDURE
NOTE
Removal begins on the RIGHT SIDE of the motorcycle.
1. Position motorcycle on a suitable lift.
2. Remove seat.
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
3. Disconnect battery cables, negative cable first.
4. Remove air cleaner cover and backplate. See 4.4 AIR
CLEANER ASSEMBLY.
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)
5. Cut hose clamp and remove fuel feed line (large O.D.)
and vacuum line (small O.D.) from throttle body.
6. Drain fuel from fuel tank into suitable container. Remove
fuel tank. See 4.5 FUEL TANK.
7. Loosen and remove throttle control cables from induction
module. See 4.9 INDUCTION MODULE.
8. Remove heat shields and exhaust. See 4.16 EXHAUST
SYSTEM.
9. Using a 5/16 in. Allen bit, remove two screws and rear
brake pedal and right footpeg bracket. Remove cotter pin
and clevis pin and disconnect assembly from master cyl-
inder actuator lever.
10. Disconnect the following connectors.
a. Crank position sensor connector [79].
b. Stator/voltage regulator connector [46].
c. Oil pressure sending unit connector [140].
11. Drain oil from primary chaincase. See 1.9 PRIMARY
CHAIN.
12. Loosen pinch bolt and remove shifter foot lever from
primary chaincase.
13. Using a 5/16 in. Allen bit, remove two screws and left side
footpeg and bracket.
14. Remove primary chaincase cover and primary chaincase.
See 6.4 PRIMARY CHAINCASE HOUSING.
15. Remove spark plug cables from spark plugs. Remove
spark plugs to avoid damaging them.
16. Remove right side stabilizer link nut, Allen bolt and spacer
from frame tab. Remove two bolts from horn bracket and
cylinder heads. Remove stabilizer link and horn bracket
as an assembly.
17. Remove MAP sensor connector [80] from MAP sensor.
18. Note routing of clutch cable before removing. Disconnect
clutch cable from clutch lever. Unclip cable at left side
frame downtube and pull cable through chassis to right
side of motorcycle. Leave cable installed on transmission.
See 2.24 CLUTCH CONTROL.
19. Place wire loom or other protective material on both front
downtubes to prevent damage.
20. Position jack under transmission. Place a block of wood
between jack and oil pan to prevent damage to oil pan
and raise jack just enough to support transmission.
21. Using a ratchet and ratchet strap, secure transmission to
chassis (vertically) to prevent transmission from shifting
position.
22. Remove four bolts and washers that connect engine to
transmission.
23. Remove two bolts and washers that secure engine to front
engine mount bracket.
24. Remove engine oil dipstick.
25. Using a suitable hoist, remove engine from chassis from
the right side.
NOTE
The engine is positively located to the transmission with two
dowels that fit in the lower mounting bolt holes and extend out
approximately 0.5 in. (12.7 mm) from the transmission. The
engine may have to be rotated counterclockwise slightly to
disengage the locating dowels.
2008 Dyna Service: Engine 3-23
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