2. Raise the engine, looping the drive chain over the output sprocket as it is raised.
Caution! Unless the following engine mounting bolt installation/tightening sequence is precisely followed, severe frame damage can occur.
3. Align the engine to the frame.
4. Lubricate the threads of the mounting bolts for the cylinder head rear mountings only with a smear of proprietary high temperature copper based grease.
5. Fit the right hand front engine mounting bolt (located at the front of the cylinder head) and fit a new nut. Do not tighten at this stage.
6. Fit the right hand centre engine mounting bolt (located at the rear of the cylinder head) ensuring the engine is still adequately and securely supported. Do not tighten the bolt at this stage.
Note: The frame is fitted with four frame adjuster sleeves, located on the left hand side of the frame, as shown below.
1. Front frame adjuster position; 2. Centre frame adjuster position; 3. Rear upper frame adjuster position; 4. Rear lower frame adjuster position
7. Align the left hand centre engine mounting and using T3880103 - Engine Mounting Adjuster, tighten the frame adjuster to 3 Nm.
1. T3880103 - Engine Mounting Adjuster; 2. Centre frame adjuster
8. Fit the left hand centre engine mounting bolt but do not fully tighten at this stage.
9. Insert the lower and upper rear (gearbox) bolts from the right hand side, ensuring the spacer is installed as noted during removal.
1. Nut; 2. Washer; 3. Spacer
10. Using T3880103 - Engine Mounting Adjuster, tighten the rear upper frame adjuster sleeve to 10 Nm.
11. Using T3880181 - Wrench Frame Adjuster, tighten the rear lower frame adjuster sleeve to 10 Nm.
1. T3880103 - Engine Mounting Adjuster; 2. Rear upper frame adjuster; 3. T3880181 - Wrench Frame Adjuster; 4. Rear lower frame adjuster
12. Tighten the right hand front engine mounting bolt (located at the front of the cylinder head) to TBA.
13. Tighten the right hand centre engine mounting bolt to 48 Nm.
14. Tighten the left hand centre engine mounting bolt to 48 Nm.
15. Fit the washer and a new nut to the lower rear (gearbox) bolt and tighten the bolt to 48 Nm.
16. Using T3880103 - Engine Mounting Adjuster, tighten the front frame adjuster to 3 Nm.
1. T3880103 - Engine Mounting Adjuster; 2. Front frame adjuster
17. Fit the washer and a new nut to the upper rear (gearbox) bolt and tighten the bolt to 48 Nm.
18. Fit the left hand front engine mounting bolt and fit a new nut. Tighten the bolt to 48 Nm.
19. Tighten the right hand front engine mounting bolt (located at the front of the cylinder head) to 48 Nm.
20. Remove the support from beneath the engine.
21. Refit the cover to the gearbox upper mounting on the left hand side of the frame.
1. Cover; 2. Gearbox upper mounting
22. Connect the clutch cable to the clutch (see Clutch cable - installation).
23. Connect the crankshaft position sensor to the main harness.
1. Crankshaft position sensor connector
24. Route the alternator harness as noted for removal and connect it to the regulator/rectifier.
1. Grey connector; 2. Regulator/rectifier
25. Attach the ground cables to the engine and tighten the fixing to 10 Nm. Refit the rubber boot over the ground cables.
26. Attach the two harness brackets and purge valve bracket to the engine breather cover and tighten the fixings to 10 Nm.
1. Harness brackets; 2. Fixings; 3. Rubber boot; 4. Ground cable fixing; 5. Purge valve bracket (purge valve shown removed for clarity)
27. Connect the gear position sensor to the main harness.
28. Reconnect all electrical connections to the engine.
29. Align the split line on the gear pedal crank to the alignment mark on gear change shaft. Tighten the pinch bolt to 9 Nm.
1. Alignment mark; 2. Split line; 3. Pinch bolt
30. Set the drive chain adjustment (see Final drive chain Free-Movement Adjustment).
31. Route the side stand switch down to the side stand as noted for removal.
32. If drained, refill the engine oil (see Oil and oil filter change).
Perform the following operations:
- Exhaust Header Pipe - Installation, Exhaust Silencer - Installation
- Coolant expansion tank - installation
- Radiator - installation
- Side stand switch - installation
- Front sprocket cover - installation
- Side panel - installation
- Throttle bodies/injectors - installation
- Airbox - installation
- Fuel tank - installation
- Battery - installation
- Seat - installation