f. Torque the front frame member bolts (
Figure
13
) and rear frame member bolts (B,
Figure
3
) to 48 N•m (35 ft.-lb.).
g. Torque the front engine bracket bolts (A, B
and C,
Figure 12
and
Figure 11
) to 48 N•m
(35 ft.-lb.).
15. Pull the coolant hose from the left side of the
frame and install the alternator cover as described in
this chapter.
16. Connect the clutch cable as described in
Clutch
Release Mechanism
in Chapter Six.
17. Install the external oil pipes as follows:
a. Set the oil pipes into place on the engine.
b. Loosely install the oil pipe banjo bolt (
Figure
7
) that secures the oil pipe to the crankcase.
Use three new copper washers.
NOTE
Two types of rocker arm bolts are used
in the cylinder head: one with a single
oil hole (A,
Figure 5
) and one with
two oil holes (B). The bolt with two oil
holes (B,
Figure 5
) secures the oil
pipe to the cylinder head.
c. Loosely install the rocker arm bolt (
Figure 6
)
that secures an oil pipe to each cylinder head.
Use two new copper washers on each bolt;
one washer on either side of the pipe fitting.
d. Hand tighten the bolts, and torque the oil pipe
banjo bolt (
Figure 7
) and the intake rocker
arm bolts (
Figure 6
) to 20 N•m (15 ft.-lb.).
18. Install the cylinder head covers (Chapter Four).
19. Connect each spark plug cap to the spark plug
in its respective cylinder.
20. Install the shift pedal/footrest assembly (Chap-
ter Seven).
21. Install the starter, speed sensor and horn (Chap-
ter Nine).
22. Route the oil level switch wire (A,
Figure 3
)
along the path noted during removal and connect
the bullet connector to its harness mate.
23. Install the right and left side covers, toolbox
panel, frame neck covers and the sidestand (Chapter
Fourteen).
24. Install the brake pedal/footrest assembly
(Chapter Thirteen).
25. Install the carburetor assembly, exhaust sys-
tem, surge tank, air filter housing and fuel tank
(Chapter Eight).
26. Install the battery (Chapter Three), connect the
ground lead connector (B,
Figure 2
) to its harness
mate, and install the battery cover (Chapter Four-
teen).
27. Fill the crankcase with the recommended type
and quantity of oil as described in Chapter Three.
28. Adjust throttle cable and clutch cable free play
as described in Chapter Three.
29. Start the engine and check for oil and exhaust
leaks.
ALTERNATOR COVER
Removal/Installation
Refer to
Figure 17
.
1. Drain the engine oil as described in Chapter
Three.
2. Remove the battery cover and disconnect the
electrical lead from the negative battery terminal
(A,
Figure 2
).
3. Remove the shift pedal/footrest assembly
(Chapter Seven).
4. Disconnect the clutch cable from the clutch re-
lease lever as follows:
a. Remove the mounting bolts (A,
Figure 18
),
and pull the clutch adjuster cover (B) from the
alternator cover.
b. At the handlebar, slide the clutch lever boot
(A,
Figure 19
) away from the adjuster.
Loosen the clutch cable locknut (B,
Figure
19
) and rotate the adjuster (C) to provide
maximum slack in the cable.
c. Disconnect the clutch cable (
Figure 20
) from
the clutch lever. Pull the clutch cable from the
fitting on the alternator cover.
ENGINE LOWER END
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