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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
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.
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.
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
HOSE ROUTING
on
page
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
INSTALLATION
in Section 2. Remove floor hoist straps.
17. Install rear wheel and attach secondary drive belt. See
REAR WHEEL, INSTALLATION
3-10
INSTALLING THE ENGINE
in Section 2.
OIL
3-29. Use new hose clamps.
REAR SHOCK ABSORBER,
in Section 2.
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18. Install rear brake caliper. See
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
SPROCKET
COVER. See Section 2.
21. Install footrests. See
FOOTRESTS
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
TOR, INSTALLATION
in Section 4.
3.
Install exhaust system as described under
SYSTEM
in Section 2.
4.
Install air cleaner assembly. See
INSTALLATION
in Section 4.
5.
If removed, install horn and ignition coil. See Section 7.
6.
Connect spark plug cables. See
in Section 7.
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.
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
TION
in Section 2.
9.
If engine crankcase installation was performed:
a.
Adjust belt according to
in Section 1.
b.
Adjust rear shock spring preload. See
LOAD ADJUSTMENT
c.
Adjust clutch lever. See
d.
Check rear brake pedal freeplay. See
Section 1.
10. Check all electrical components for proper operation.
REAR BRAKE CALIPER
in
and
in Section 2.
CARBURE-
EXHAUST
AIR CLEANER,
SPARK PLUG CABLES
TAIL SEC-
REAR BELT DEFLECTION
REAR PRE-
in Section 1.
CLUTCH
in Section 1.
BRAKES
in
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