Removing the drive sprocket
Order | Job/Parts to remove | Quantity | Remarks |
1 | Locknut | 2 | |
2 | Shift rod | 1 | |
3 | Shift arm | 1 | |
4 | Drive sprocket cover | 1 | |
5 | Drive sprocket nut | 1 | |
6 | Lock washer | 1 | |
7 | Drive sprocket | 1 | |
8 | Plate | 1 |
For installation, reverse the removal procedure.
Removing the exhaust pipe
Order | Job/Parts to remove | Quantity | Remarks |
Rider and passenger seat | Refer to «General chassis». | ||
1 | EXUP pulley cover | 1 | |
2 | EXUP servo motor cover | 1 | |
3 | EXUP cables | 2 | |
4 | EXUP servo motor | 1 | |
5 | O2 sensor | 1 | |
6 | Exhaust pipe assembly | 1 | |
7 | Exhaust pipe gasket | 4 | |
8 | Muffler | 1 | |
9 | Muffler gasket | 1 | |
10 | Muffler cover | 1 | |
11 | Muffler end cover | 1 |
For installation, reverse the removal procedure.
Disassembling the exhaust valve pipe
Order | Job/Parts to remove | Quantity | Remarks |
1 | Nut | 1 | |
2 | Pulley | 1 | |
3 | Spring | 1 | |
4 | Spring seat | 1 |
For assembly, reverse the disassembly procedure.
Disconnecting the leads and hoses
Order | Job/Parts to remove | Quantity | Remarks |
Fuel tank | Refer to «Fuel tank». | ||
Air filter case | Refer to «General chassis». | ||
Throttle body assembly | Refer to «Throttle bodies». | ||
Engine oil | Drain. Refer to «Changing the engine oil». | ||
Oil cooler | Refer to «Oil cooler». | ||
Air cut-off valve | Refer to «Air induction system». | ||
Starter motor | Refer to «Electric starter». | ||
1 | Battery negative lead | 1 | |
2 | Battery positive lead | 1 | |
3 | Clutch cable | 1 | |
4 | Ground lead | 2 | |
5 | Stator coil assembly coupler | 1 | Disconnect. |
6 | Crankshaft position sensor lead coupler | 1 | Disconnect. |
7 | Oil level switch connector | 1 | Disconnect. |
8 | Neutral switch connector | 1 | Disconnect. |
9 | Cylinder identification sensor coupler | 1 | Disconnect. |
10 | Speed sensor coupler | 1 | Disconnect. |
Removing the engine
Order | Job/Parts to remove | Quantity | Remarks |
1 | Right front engine mounting bolt 1 | 1 | |
2 | Left front engine mounting bolt | 1 | |
3 | Upper self-locking nut | 1 | |
4 | Upper engine mounting bolt | 1 | |
5 | Lower self-locking nut | 1 | |
6 | Lower engine mounting bolt | 1 | |
7 | Engine mounting adjust bolt | 2 | |
8 | Engine | 1 |
For assembly, reverse the removal procedure.