3-3 ENGINE
ENGINE REMOVAL AND REINSTALLATION
ENGINE REMOVAL
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Bafore taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The proce-
dure of engine removal is sequentially explained in the following steps.
1. Remove the oil drain plug to drain out engine oil.
2. Remove the frame head cover and radiator cap.
3. Remove the water drain plug to drain out coolant.
4. Remove the seat.
5. Disconnect the battery 0 and 0 lead wires from the battery terminals, remove the battery.
CAUTION: Be
sure to disconnect the @ lead wire first.
6. Remove all the frame covers.
7. Turn the fuel cock “OFF” position and remove the fuel tank mounting bolts, remove the fuel tank by
disconnecting the fuel hose.
8. Remove the left and right mufflers.
9. Disconnect the following lead wires.
* Side stand switch
* Starter motor
* Cooling fan motor lead
* Generator
* Starter relay
* Neutral indicator
* Pick-up coil
* Water temperature gauge * Ground lead
* Oil pressure indicator
10. Remove the secondary bevel gear case cover.
11. Remove the clutch release cam assembly.
12. Remove the radiator by removing the radiator protector, radiator hose clamps and radiator cooling
fan.
13. Remove the left-footrest.
14. Remove the gearshift lever.
15. Remove the water pump case.
16. Loosen the shaft drive boot clamp.
17. Remove the coolant reservoir tank.
18. Disconnect the choke cables and throttle cables.
19. Disconnect the rear carburetor fuel hose.
20. Disconnect the breather hose from the rear cylinder head.
21. Disconnect the fuel pump vacuum hose from the front carburetor intake pipe.
22. Loosen the front and rear carburetor clamps.
23. Remove the rear carburetor air cleaner mounting bolts and slide the air cleaner backward.
24. Remove the front and rear carburetors.
25. Remove the rear brake pedal mounting bolts and rear brake master cylinder mounting bolts, remove
the brake pedal and master cylinder.
26. Support the engine with a proper jack.
27.
Remove the engine mounting bolts, nuts, spacer, brackets and right frame down tube securing bolts.
CAUTION: When holding the engine with a jack, place a wooden piece on a jack or oil pan may be
damaged.
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28. Dismount the engine by pulling slightly forward and to right-side.
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