Notice

Be sure lu lighten all engine mounting fasteners to the specified torque in the specified sequence described following page. If you make a mistake during the tightening torque or sequence, loosen oil mounting fasteners, then tighten them again to the specified torque in the specified sequence.

Install the engine hanger adjusting bolts fully in from the inside of the frame.

REAR HANGER BOLT*

ADJUSTING BOLT

Carefully install the engine into the frame. Install the left side of the center hanger bolt.

CENTER HANGER BOLT

CENTER HANGER BOLT

REAR HANGER BOLT"*

Install the front hanger distance collar and hanger bolt on both sides.

Tighten the left side center hanger bolt to the specified torque.

Install the rear engine hanger distance collars and temporarily install the rear engine hanger bolt from the left side.

REAR HANGER BOLT"*

Tighten the left side front engine hanger bolt to the specified torque.

Tighten the right side front engine hanger bolt to the specified torque.

FRONT HANGER BOLT

iliF^MSu DISTANCE COLLAR

CENTER HANGER BOLT

CENTER HANGER BOLT

Tighten the right side center hanger adjusting bolt to the specified torque.

Turn the adjusting bolt out 180r and check that there is no clearance between the adjusting bolt and the engine.

Tighten the right side rear hanger adjusting bolt to the specified torque.

Turn the adjusting bolt out 180c and check that there is no clearance between the adjusting holt and the distance collar.

Install and lighten lire right side center hanger adjusting holt lock nut to the specified torque, while holding the adjusting bolt.

TOOL:

Lock nut wrench 07VMA-MBB0100 or

07VMA-MBB0101

TORQUE:

Actual: 54 N-m (5.5 kgf-m, 40 lbf-ft) Indicated: 49 N-m (5.0 kgf-m, 39 lbf«ft)

Install and tighten the right side rear hanger adjusting bolt lock nut to the specified torque, while holding the adjusting bolt.

TOOL:

Lock nut wrench 07VMA-MBB0100 or

07VMA-MBB0101

TORQUE:

Actual: 54 N-m (5.5 kgf-m. 40 lbf-ft) Indicated: 49 N-m (5.0 kgf-m, 39 lbf-ft)

" LOCK NUT WRENCH"

" LOCK NUT WRENCH"

LOCK NUT WRENCH

LOCK NUT WRENCH

Install and tighten the right side center hanger bolt to the specified torque.

Fully install the rear engine hanger bolt.

Install and tighten the rear engine hanger nut to the specified torque.

REAR HANGER NUT

Install the swingarm between the engine and frame, install and tighten the pivot components (page 14-22).

Install the drive sprocket with the drive chain onto the countershaft with the "MT4F" mark facing out. Install the washer and bolt, tighten the bolt to the specified torque.

CENTER HANGER BOLTjr

REAR HANGER NUT

.SHER

DRIVE SPROCKET

.SHER

DRIVE SPROCKET

Connect the clutch cable to the clutch lifter lever.

Install the clutch cable guide to the right crankcase cover and tighten the mounting bolts securely.

CLUTCH CABLE

CABLE GUIDE

CLUTCH CABLE

CABLE GUIDE

LIFTER LEVER

BOLT

LIFTER LEVER

BOLT

Install the cam chain tensioner lifter onto the cylinder head.

Install the sealing washers and bolts, tighten the bolts to the specified torque.

TENSIONER LIFTER

SOCKET BOLTS

TENSIONER LIFTER

SOCKET BOLTS

Sfti GASKET

SEALING WASHERS

Sfti GASKET

SEALING WASHERS

Route the alternator wire properly, connect the alternator 3P (White) connector.

Connect the engine sub-harness 12P (Gray) connector and cam pulse generator 2P (Natural) connector.

Connect the starter motor ground cable and install and tighten the starter motor mounting bolt. Connect the starter motor cable to the motor terminal, tighten the terminal nut to the specified torque.

Install a new O-ring into the thermostat housing groove.

Install the thermostat housing to the cylinder head.

THERMOS I AI

Install and tighten the thermostat housing mounting bolts.

Install the thermostat and thermostat housing cover fe^

Install the lower cowi brackets onto the oil pan, tighten the bolts.

Install the radiator lower bracket to the cylinder blor.k, tighten the bolts securely.

LOWER COWI BRACKETS

Install the radiator assemhly (page 6 11).

Connect the air bleed hose and upper radiator hose to the thermostat housing cover and tighten the hose band screw.

Connect the oil cooler water hose to the oil cooler, tighten the hose band screw securely.

COOLER WATER HOSE , j

COOLER WATER HOSE , j

OIL COOLER i

OIL COOLER i

AIR BLEED HOSE

UPPER RADIATOR HOSE

THERMOSTAT HOUSING COVER

Connect the lower radiator hose to the water pump cover and tighten the hose band screw securely.

Connect the rear brake light switch 2P (Black) connector.

Clamp the brake light switch wire with the wire band.

Install the direct ignition coils into the spark plug holes and connect the ignition coil connectors. Connect the PAIR air suction hoses to the reed valve covers.

Install the fuel tank (page 5-57).

Add the recommended engine oil to the proper level (page 3-14).

Fill the cooling system with the recommended coolant and bleed any air (page 6-4).

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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