Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 9

CLUTCH 6-13

Clutch

•

Install the friction plates [A] and steel plates [B] alternately
as shown.

Thick Steel Plate [C]

NOTICE

If new dry friction plates and steel plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.

○

Install the last friction plate and steel plate later with the
clutch pressure plate.

•

Apply molybdenum disulfide grease to the pusher end [A].

•

Install the washer [B], spring [C], bearing [D] and shim [E]
to the pusher.

•

Install the pusher to the drive shaft [F] direction as shown.

•

Put the last friction plate [A] and steel plate [B] on the
clutch pressure plate [C] and install them.

•

Install the last friction plate so that the tangs [A] fit into the
grooves in the housing as shown.

NOTE

○

Make sure that the clutch pressure plate is installed
without a gap.

6-14 CLUTCH

Clutch

•

Be sure to install the spring seats on the clutch pressure
plate.

•

Install:

Clutch Springs
Clutch Stopper Plate [A]

•

Tighten the clutch stopper bolts by hand.

○

Hold the clutch pressure plate by hand while tightening
the clutch stopper bolts.

•

Check the clutch stopper bolts position is correct (see
Clutch Removal).

•

Set the special tools.

○

Refer to the Clutch Removal for setting the special tools.

Special Tools - Crankcase Splitting Tool Assembly: 57001

-1362

Clutch Plate Holder: 57001-1788

•

To press the clutch springs, tighten the center bolt [A] of
the crankcase splitting tool assembly until the clutch stop-
per plate stops.

○

The clutch stopper plate stops in contact with the boss of
the clutch hub.

NOTICE

Tightening the center bolt of the crankcase splitting
tool assembly too much may damage the special
tools.

•

Tighten:

Torque - Clutch Stopper Bolts [A]: 8.8 N·m (0.90 kgf·m, 78

in·lb)

•

Remove the crankcase splitting tool assembly and clutch
plate holder.

•

Install:

Clutch Cover (see Clutch Cover Installation)

CLUTCH 6-15

Clutch

Clutch Plate Assembly Length Measurement

•

Assemble the following parts.

Clutch Hub [A]
Friction Plates [B]
Steel Plates [C]
Clutch Pressure Plate [D]
Spring Seats [E]
Clutch Springs [F]
Clutch Stopper Plate [G]
Clutch Stopper Bolts [H]

Torque - Clutch Stopper Bolts: 8.8 N·m (0.90 kgf·m, 78

in·lb)

•

Measure the clutch plate assembly length [I].

Clutch Plate Assembly Length

40.5

∼

41.3 mm (1.59

∼

1.63 in.)

NOTE

○

The length of the clutch plate assembly changes by the
steel plate thickness.

Clutch Plate, Wear, Damage Inspection

•

Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.

•

Measure the thickness of each friction plate [A] at several
points.
If any plates show signs of damage, or if they have worn
past the service limit, replace them with new ones.

Friction Plate Thickness

Standard:

2.72

∼

2.88 mm (0.107

∼

0.113 in.)

Service Limit:

2.5 mm (0.098 in.)

Clutch Plate Warp Inspection

•

Place each friction plate or steel plate on a surface plate
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.

Friction and Steel Plate Warp

Standard:

0.15 mm (0.0059 in.) or less

Service Limit:

0.3 mm (0.012 in.)

6-16 CLUTCH

Clutch

Clutch Spring Free Length Measurement

•

Measure the free length of the clutch springs [A].
If any spring is shorter than the service limit, it must be
replaced.

Clutch Spring Free Length

Standard:

48.38 mm (1.905 in.)

Service Limit:

46.3 mm (1.82 in.)

Clutch Housing Finger Inspection

•

Visually inspect the clutch housing fingers [A] where the
friction plate tangs [B] hit them.
If they are badly worn or if there are groove cuts where the
tangs hit, replace the housing. Also, replace the friction
plates if their tangs are damaged.

Clutch Housing Spline Inspection

•

Visually inspect where the teeth [A] on the steel plates
wear against the sub clutch hub splines [B].
If there are notches worn into the splines, replace the sub
clutch hub. Also, replace the steel plates if their teeth are
damaged.

Clutch Pressure Plate and Clutch Hub Inspection

•

Visually inspect the contact areas [A] of the clutch pres-
sure plate [B] and clutch hub [C] for damage.
If the contact areas are damaged replace them with new
ones.

ENGINE LUBRICATION SYSTEM 7-1

Engine Lubrication System

Table of Contents

Exploded View........................................................................................................................

7-2

Engine Oil Flow Chart.............................................................................................................

7-4

Specifications .........................................................................................................................

7-7

Special Tools and Sealant ......................................................................................................

7-8

Engine Oil and Oil Filter..........................................................................................................

7-9

Oil Level Inspection...........................................................................................................

7-9

Engine Oil Change............................................................................................................

7-9

Oil Filter Replacement ......................................................................................................

7-9

Oil Pan....................................................................................................................................

7-10

Oil Pan Removal ...............................................................................................................

7-10

Oil Pan Installation ............................................................................................................

7-10

Oil Pressure Relief Valve........................................................................................................

7-11

Oil Pressure Relief Valve Removal ...................................................................................

7-11

Oil Pressure Relief Valve Installation ................................................................................

7-12

Oil Pressure Relief Valve Inspection.................................................................................

7-13

Oil Pump.................................................................................................................................

7-14

Oil Pump Removal ............................................................................................................

7-14

Oil Pump Installation .........................................................................................................

7-15

Oil Pump Drive Gear Removal..........................................................................................

7-16

Oil Pump Drive Gear Installation.......................................................................................

7-16

Oil Pump Drive Gear Shaft Removal ................................................................................

7-16

Oil Pump Drive Gear Shaft Installation .............................................................................

7-17

Oil Cooler................................................................................................................................

7-18

Oil Cooler Removal...........................................................................................................

7-18

Oil Cooler Installation........................................................................................................

7-18

Oil Cooler/Oil Filter Case Removal ...................................................................................

7-19

Oil Cooler/Oil Filter Case Installation ................................................................................

7-19

Oil Pressure Measurement.....................................................................................................

7-21

Oil Pressure Measurement ...............................................................................................

7-21

Oil Pressure Switch ................................................................................................................

7-22

Oil Pressure Switch Removal ...........................................................................................

7-22

Oil Pressure Switch Installation ........................................................................................

7-22

7-2 ENGINE LUBRICATION SYSTEM

Exploded View

ENGINE LUBRICATION SYSTEM 7-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Air Bleed Bolt

9.8

1.0

87 in·lb

Oil Cooler/Oil Filter Case Mounting Bolts

2.0

Oil Cooler Mounting Bolts

2.0

Oil Filter Holder Bolt

2.5

Oil Filter

1.7

G, R

Oil Filter Guard Bolts

4.0

0.41

35 in·lb

Oil Jet Nozzles

2.9

0.30

26 in·lb

Oil Passage Plugs (Taper)

2.0

Oil Pressure Switch Terminal Bolt

1.5

0.15

13 in·lb

10 Oil Pressure Switch

1.5

11 Water Pump Cover Bolts

1.2

106 in·lb

12 Oil Pump Drive Gear Bolt

9.8

1.0

87 in·lb

13 Oil Passage Plug

1.7

14 Impeller Bolt

9.8

1.0

87 in·lb

15 Engine Oil Drain Bolt

3.0

16 Oil Pressure Relief Valve

1.5

17 Oil Pan Bolts

9.8

1.0

87 in·lb

EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R: Replacement Parts

S: Follow the specified tightening sequence.

SS: Apply silicone sealant.

W: Apply water.

7-4 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

ENGINE LUBRICATION SYSTEM 7-5

Engine Oil Flow Chart

1. Intake Camshaft
2. Exhaust Camshaft
3. Camshaft Oil Passage
4. Oil Filter
5. Oil Cooler
6. Oil Jet
7. Oil Pressure Switch
8. Drive Shaft Oil Passage
9. Output Shaft Oil Passage

10. Oil Screen

11. Oil Pressure Relief Valve

12. Oil Pump
13. Main Oil Passage
14. Crankshaft Oil Passage
15. Alternator Oil Passage

7-6 ENGINE LUBRICATION SYSTEM

Engine Oil Flow Chart

1. Blowby Gas

ENGINE LUBRICATION SYSTEM 7-7

Specifications

Item

Standard

Engine Oil

Type

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

Viscosity

SAE 10W-40

Capacity

2.8 L (3.0 US qt) (when filter is not removed)

3.1 L (3.3 US qt) (when filter is removed)

3.6 L (3.8 US qt) (when engine is completely dry)

Level

Between upper and lower level lines (Wait 2

∼

3 minutes after

idling or running)

Oil Pressure Measurement

Oil Pressure

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

18 psi) at 4 000 r/min

(rpm), Oil Temperature 90°C (194°F)

7-8 ENGINE LUBRICATION SYSTEM

Special Tools and Sealant

Outside Circlip Pliers:
57001-144

Oil Pressure Gauge, 10 kgf/cm²:
57001-164

Oil Pressure Gauge Adapter, PT3/8:
57001-1233

Liquid Gasket, TB1211:
56019-120

ENGINE LUBRICATION SYSTEM 7-9

Engine Oil and Oil Filter

WARNING

Vehicle operation with insufficient, deteriorated,
or contaminated engine oil will cause accelerated
wear and may result in engine seizure, accident,
and injury. Check the oil level before each use and
change the oil and filter according to the periodic
maintenance chart.

Oil Level Inspection

•

Check that the engine oil level is between the upper [A]
and lower [B] levels in the oil level inspection window.

NOTE

○

Situate the motorcycle so that it is perpendicular to the
ground.

○

If the motorcycle has just been used, wait several min-
utes for all the oil to drain down.

○

If the oil has just been changed, start the engine and
run it for several minutes at idle speed. This fills the oil
filter with oil. Stop the engine, then wait several minutes
until the oil settles.

NOTICE

Racing the engine before the oil reaches every part
can cause engine seizure.
If the engine oil gets extremely low or if the oil pump
or oil passages clog up or otherwise do not func-
tion properly, the red warning indicator light (LED)
and oil pressure warning symbol will light. If this
light stays on when the engine is running above
idle speed, stop the engine immediately and find the
cause.

If the oil level is too high, remove the excess oil, using a
syringe or some other suitable device.
If the oil level is too low, add the correct amount of oil
through the oil filler opening. Use the same type and
make of oil that is already in the engine.

NOTE

○

If the engine oil type and make are unknown, use any
brand of the specified oil to top off the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.

Engine Oil Change

•

Refer to the Engine Oil Change in the Periodic Mainte-
nance chapter.

Oil Filter Replacement

•

Refer to the Oil Filter Replacement in the Periodic Main-
tenance chapter.

7-10 ENGINE LUBRICATION SYSTEM

Oil Pan

Oil Pan Removal

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)

•

Remove:

Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Oil Pan Bolts [A]
Clamps [B]
Oil Pan [C]
Front [D]

Oil Pan Installation

•

Replace the oil pan gasket [A] with a new one.

•

Install the dowel pins [B] and clamps [C] as shown.

•

Tighten the oil pan bolts [D] as shown sequence [1

∼

21].

Torque - Oil Pan Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

ENGINE LUBRICATION SYSTEM 7-11

Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal

•

Remove:

Oil Pan (see Oil Pan Removal)
Oil Screen [A]

•

Remove the oil pressure relief valve [A].

7-12 ENGINE LUBRICATION SYSTEM

Oil Pressure Relief Valve

Oil Pressure Relief Valve Installation

•

Apply a non-permanent locking agent to the threads of
the oil pressure relief valve [A], and tighten it.

NOTICE

Do not apply too much non-permanent locking
agent to the threads. This may block the oil pas-
sage.

Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11

ft·lb)

•

Clean the oil screen [B] with a high flash-point solvent and
remove any particles stuck to them.

○

Blow away the particles by applying compressed air from
the inside to the outside (from the clean side to the dirty
side).

WARNING

Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the screen in a well-ventilated area,
and take care that there are no sparks or flame
anywhere near the working area; this includes any
appliance with a pilot light. Do not use gasoline or
a low flash-point solvent to clean the screen.

NOTE

○

While cleaning the oil screen, check for any metal par-
ticles that might indicate internal engine damage.

•

Check the screen carefully for any damage, holes, broken
wires.
If the screen is damaged, replace it.

•

Replace the O-ring [C] with a new one.

•

Apply grease to the O-ring.

•

Install the O-ring and damper [D] to the oil screen.

•

Install the oil screen so that the crankcase rib [E] and relief
valve fits the oil screen.

•

Install the oil pan (see Oil Pan Installation).

ENGINE LUBRICATION SYSTEM 7-13

Oil Pressure Relief Valve

Oil Pressure Relief Valve Inspection

•

Remove the oil pressure relief valve (see Oil Pressure
Relief Valve Removal).

•

Check to see if the valve [A] slides smoothly when push-
ing it in with a wooden or other soft rod, and see if it comes
back to its seat by spring [B] pressure.

NOTE

○

Inspect the valve in its assembled state. Disassembly
and assembly may change the valve performance.

If any rough spots are found during above inspection,
wash the valve clean with a high flash-point solvent and
blow out any foreign particles that may be in the valve with
compressed air.

WARNING

Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns.

Clean the oil pressure relief valve in a

well-ventilated area, and take care that there are no
sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Do
not use gasoline or a low flash-point solvent to
clean the oil pressure relief valve.

If cleaning does not solve the problem, replace the oil
pressure relief valve as an assembly. The oil pressure
relief valve is precision made with no allowance for re-
placement of individual parts.

7-14 ENGINE LUBRICATION SYSTEM

Oil Pump

Oil Pump Removal

•

Drain:

Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)

•

Remove:

Water Pump Cover Bolts [A]
Water Pump Cover [B]

•

Loosen the water hose clamp screw [C].

•

Disconnect the water hose [D].

•

Loosen the water hose clamp screw [A].

•

Disconnect the water hose [B].

•

Remove:

Impeller Bolt [C] and Washer
Impeller [D]

•

Install the impeller bolt [A] temporary.

•

Using the impeller bolt [A], remove the oil (water) pump
[B] as an assembly.

•

Remove the outer rotor [C] and impeller bolt.

•

Remove:

Water Pump Body [A]
Oil Pump Cover [B]
Inner Rotor [C]
Pin [D]
Oil (Water) Pump Shaft [E]

ENGINE LUBRICATION SYSTEM 7-15

Oil Pump

Oil Pump Installation

•

Install the outer rotor [A] into the crankcase.

•

Install the pin [B] and inner rotor [C] to the oil (water) pump
shaft [D], and install the assy.

○

Turn the pump shaft so that the slot [E] in its shaft fits onto
the projection [F] of the pump drive gear shaft.

•

Fit the pin [A] of the oil pump cover [B] into the hole [C] in
the crankcase.

•

Replace the O-ring [A] with a new one.

•

Install the dowel pins [B].

•

Fit the dowel pins of the crankcase into the holes [C] in
the water pump body [D].

•

Apply coolant to the seating surface [A] on the impeller.

•

Install the impeller, washer and bolt.

•

Tighten:

Torque - Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install the water hose [A] and hose clamp [B] as shown.

White Mark [C]

•

Tighten:

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

•

Replace the O-ring [D] with a new one.

•

Install the dowel pins [E] and water pump cover.

•

Apply a non-permanent locking agent to the threads of
the water pump cover bolts, and tighten them.

Torque - Water Pump Cover Bolts: 12 N·m (1.2 kgf·m, 106

in·lb)

7-16 ENGINE LUBRICATION SYSTEM

Oil Pump

•

Align the line [A] of the water pump cover and the white
mark [B] of the water hose [C].

•

Install the water hose clamp [D] as shown.

•

Tighten:

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

Oil Pump Drive Gear Removal

•

Remove the clutch (see Clutch Removal in the Clutch
chapter).

•

Fit the suitable tool into the hole of the oil passage plug
[A].

•

Hold the oil pump drive gear [A] steady with the suitable
tool [B], and remove the oil pump drive gear bolt [C].

•

Remove the oil pump drive gear.

Oil Pump Drive Gear Installation

•

Align the groove [A] of the oil pump drive gear to the oil
pump drive gear shaft [B] to install the oil pump drive gear.

•

Apply a non-permanent locking agent to the threads of
the oil pump drive gear bolt.

•

Hold the oil pump drive gear steady with the suitable tool,
and tighten the bolt.

Torque - Oil Pump Drive Gear Bolt: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Oil Pump Drive Gear Shaft Removal

•

Remove:

Oil Pump Drive Gear (see Oil Pump Drive Gear Re-
moval)
Oil Pan (see Oil Pan Removal)
Oil Screen (see Oil Pressure Relief Valve Removal)
Circlip [A]
Washer [B]
Oil Pump Drive Gear Shaft [C]

Special Tool - Outside Circlip Pliers: 57001-144

ENGINE LUBRICATION SYSTEM 7-17

Oil Pump

Oil Pump Drive Gear Shaft Installation

•

Apply molybdenum disulfide grease [A] to the oil pump
drive gear shaft.

•

Apply molybdenum disulfide oil solution [B] to the
crankcase.

•

Install the oil pump drive gear shaft and washer [C] as
shown.

•

Install the new circlip [D] into the groove of the oil pump
drive gear shaft.

Special Tool - Outside Circlip Pliers: 57001-144

7-18 ENGINE LUBRICATION SYSTEM

Oil Cooler

Oil Cooler Removal

•

Drain:

Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)

•

Remove:

Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)

•

Loosen the water hose clamp screw [A].

•

Disconnect the water hose [B].

•

Loosen the water hose clamp screw [A].

•

Disconnect the water hose [B].

•

Remove:

Oil Cooler Mounting Bolts [C]
Oil Cooler [D]

Oil Cooler Installation

•

Replace the O-ring [A] with a new one.

•

Install the oil cooler [A].

•

Tighten:

Torque - Oil Cooler Mounting Bolts [B]: 20 N·m (2.0 kgf·m,

15 ft·lb)

•

Install the water hoses and hose clamps (see Cable, Wire,
and Hose Routing section in the Appendix chapter).

•

Tighten:

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,

27 in·lb)

•

Install the removed parts (see appropriate chapters).

•

Pour:

Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)
Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)

ENGINE LUBRICATION SYSTEM 7-19

Oil Cooler

Oil Cooler/Oil Filter Case Removal

•

Remove:

Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)
Oil Cooler (see Oil Cooler Removal)
Oil Filter Guard Bolts [A]
Oil Filter Guard [B]

•

Remove:

Oil Cooler/Oil Filter Case Mounting Bolts [A]

•

Remove:

Oil Cooler/Oil Filter Case Mounting Bolts [A]
Oil Cooler/Oil Filter Case [B]

○

Remove the oil filter holder bolt [C] as necessary.

Oil Cooler/Oil Filter Case Installation

If the crankcase was disassembled, pour the engine oil
into the oil passage [A] until O-ring insert portion [B] of
the upper crankcase.

7-20 ENGINE LUBRICATION SYSTEM

Oil Cooler

If the oil filter holder bolt [A] was removed, install it.

○

Apply a non-permanent locking agent to the threads of
the oil filter holder bolt, and tighten it.

Torque - Oil Filter Holder Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Replace the O-rings [A] with new ones.

•

Apply grease to the new O-rings.

•

Install the oil cooler/oil filter case.

•

Apply a non-permanent locking agent to the threads of the
oil cooler/oil filter case mounting bolts, and tighten them.

Torque - Oil Cooler/Oil Filter Case Mounting Bolts: 20 N·m

(2.0 kgf·m, 15 ft·lb)

•

Install the oil filter guard.

•

Apply a non-permanent locking agent to the threads of
the oil filter guard bolts, and tighten them.

Torque - Oil Filter Guard Bolts: 4.0 N·m (0.41 kgf·m, 35

in·lb)

•

Install:

Oil Cooler (see Oil Cooler Installation)
Oil Filter (see Oil Filter Replacement in the Periodic
Maintenance chapter)

ENGINE LUBRICATION SYSTEM 7-21

Oil Pressure Measurement

•

Remove:

Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Oil Passage Plug [A]

•

Attach the adapter [A] and gauge [B] to the plug hole.

Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164

Oil Pressure Gauge Adapter, PT3/8: 57001

-1233

•

Start the engine and warm up the engine.

•

Run the engine at the specified speed, and read the oil
pressure gauge.

Oil Pressure

Standard:

∼

123 kPa (0.95

∼

1.25 kgf/cm², 13

∼

psi) at 4 000 r/min (rpm), Oil Temperature
90°C (194°F)

If the reading is much lower than the standard, check
the oil pump, relief valve, and/or crankshaft bearing in-
sert wear immediately.
If the reading is much higher than the standard, check the
oil passages for clogging.

•

Stop the engine.

•

Remove the oil pressure gauge and adapter.

WARNING

Hot oil can cause severe burns. Beware of hot en-
gine oil that will drain through the oil passage when
the gauge adapter is removed.

•

Apply a non-permanent locking agent to the oil passage
plug, and install it.

Torque - Oil Passage Plug (Taper): 20 N·m (2.0 kgf·m,

15 ft·lb)

7-22 ENGINE LUBRICATION SYSTEM

Oil Pressure Switch

Oil Pressure Switch Removal

•

Drain the engine oil (see Engine Oil Change in the Peri-
odic Maintenance chapter).

•

Remove the right lower fairing (see Lower Fairing Re-
moval in the Frame chapter).

•

Slide the switch cover [A].

•

Remove:

Switch Terminal Bolt [B]
Oil Pressure Switch [C]

Oil Pressure Switch Installation

•

Using a high flash-point solvent, clean off any oil or dirt
that may be on the liquid gasket coating area. Dry them
with a clean cloth.

•

Apply liquid gasket to the threads of the oil pressure
switch, and tighten it.

Sealant - Liquid Gasket, TB1211: 56019-120

Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

•

Install the switch lead [A] as shown.

Front View [B]

•

Apply grease to the terminal.

•

Tighten:

Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15

kgf·m, 13 in·lb)

•

Install the switch cover.

•

Install the removed parts (see appropriate chapters).

ENGINE REMOVAL/INSTALLATION 8-1

Engine Removal/Installation

Table of Contents

Exploded View........................................................................................................................

8-2

Special Tool ............................................................................................................................

8-4

Engine Removal/Installation ...................................................................................................

8-5

Engine Removal................................................................................................................

8-5

Engine Installation.............................................................................................................

8-7

8-2 ENGINE REMOVAL/INSTALLATION

Exploded View

ENGINE REMOVAL/INSTALLATION 8-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Adjusting Collar Locknuts

5.0

Right Front Engine Mounting Bolt

4.5

Left Front Engine Mounting Bolt

4.5

Adjusting Collars

9.8

1.0

87 in·lb

S, (M)

Middle Engine Mounting Nut

4.5

R, S

Lower Engine Mounting Nut

4.5

R, S

S: Follow the specified tightening sequence.

M: Apply molybdenum disulfide grease.

8-4 ENGINE REMOVAL/INSTALLATION

Special Tool

Engine Mount Nut Wrench:
57001-1450

ENGINE REMOVAL/INSTALLATION 8-5

Engine Removal/Installation

Engine Removal

•

Support the rear part of the swingarm with a stand.

•

Squeeze the brake lever slowly and hold it with a band
[A].

WARNING

Motorcycle may fall over unexpectedly resulting in
an accident or injury. Be sure to hold the front brake
when removing the engine.

NOTICE

Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)
Coolant (see Coolant Change in the Periodic Mainte-
nance chapter)

•

Remove:

Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Re-
moval in the Cooling System chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Clutch Cable Lower End (see Cable Removal in the
Clutch chapter)
Radiator (see Radiator and Radiator Fan Removal in the
Cooling System chapter)
Heat Insulation Plate (see Heat Insulation Plate Re-
moval in the Cooling System chapter)
Exhaust Pipe (see Exhaust Pipe Removal in the Engine
Top End chapter)
Shift Lever (see Shift Pedal Removal in the Crank-
shaft/Transmission chapter)
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)

•

Remove the air switching valve [A] (see Air Switching
Valve Removal in the Engine Top End chapter).

•

Disconnect:

Stick Coil Connectors [B]
Water

Temperature

Sensor

Connector

(see

Wa-

ter Temperature Sensor Removal/Installation in the
Self-Diagnosis System chapter)
Starter Motor Cable (see Starter Motor Removal in the
Electrical System chapter)
Gear Position Switch/Sidestand Switch Lead Connector
[C]
Crankshaft Sensor/Oil Pressure Switch Lead Connector
[D]

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•

Free the lead from the clamps [A].

•

Disconnect the sidestand switch lead connector [B].

•

Remove the engine ground cable terminal bolt [A].

•

Remove:

Bolt [A]

•

Support the engine with a suitable stand [A].

○

Put a plank [B] onto the suitable stand for engine balance.

•

Remove:

Left Front Engine Mounting Bolt [A]

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