Removal
CAUTION
Yamaha recommends removing the
alternator cover before removing the
engine from the frame. Though this is
necessary, it also exposes the alterna
tor cover mating surface on the
crankcase, which could be damaged
during engine removal. If this surface
is marred and leaks oil, the crank
cases will have to be replaced. Use an
old coolant hose to protect this mating
surface as described in Step 15.
Refer to
Figure 1
.
1. Securely support the motorcycle in an upright
position with the rear wheel off the ground.
2. Drain the engine oil and remove the oil filter as
described in Chapter Three.
3. Remove the battery cover (Chapter Fourteen).
Disconnect the negative lead (A,
Figure 2
) from the
battery and disconnect the ground connector (B)
from its harness mate.
CAUTION
Stuff clean shops rags into the intake
manifold openings to prevent the en
try of foreign matter into the cylinder
head.
4. Refer to Chapter Eight and remove the fuel tank,
air filter housing, surge tank, carburetor assembly
and exhaust system.
5. Remove the brake pedal/footrest assembly
(Chapter Thirteen).
6. Remove the right and left side covers, toolbox
panel, frame neck covers and the sidestand as de-
scribed in Chapter Fourteen.
7. Follow the oil level switch wire (A,
Figure 3
)
and disconnect the bullet connector from its harness
mate.
8. Remove the starter, speed sensor and horn
(Chapter Nine).
9. Remove the shift pedal/footrest assembly
(Chapter Seven).
NOTE
Before removing the spark plug caps,
twist the caps from side to side to
break the mating seal. Also label each
spark plug wire if the original labels
are no longer in place.
10. Disconnect the spark plug cap from each spark
plug.
11. Remove the cylinder head covers from each
cylinder head (Chapter Four).
12. Remove the external oil pipes, so they will not
be damaged during engine removal, as follows:
a. Pull the clip (A,
Figure 4
) from the oil pipe
damper (B) on the front cylinder. Remove the
damper from the cooling fins.
ENGINE LOWER END
135
5
2
3
4