Engine - Installation

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.Do not support the motorcycle on any ancillary component, the exhaust system or any other non structural parts of the motorcycle frame.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall resulting in motorcycle damage, serious injury or death.

Engine Install LG1; LGX

  1. Position the engine beneath the frame.
  2. Make sure the alternator regulator/rectifier harness is routed as noted during removal.
  3. Raise the engine, looping the drive chain over the output sprocket as it is raised.
    4. caution
    Unless the following engine mounting bolt installation/tightening sequence is precisely followed, severe frame damage can occur.
  4. Align the engine to the frame.
  5. Loosely assemble the left hand side front cylinder head bolt and a new lock nut.
  6. Loosely assemble the right hand side front cylinder head bolt and a new lock nut.
  7. Thoroughly clean the threaded part of the left hand side rear cylinder head bolt and smear the first four threads with a proprietary copper based grease
  8. Loosely assemble the left hand side rear cylinder head bolt.
  9. Loosely assemble the right hand side rear cylinder head bolt and a new lock nut.
  10. Using service tool T3880166 tighten the upper crankcase frame adjuster to 3 Nm.
  11. Loosely assemble the upper crankcase bolt, washer and a new lock nut.
  12. Using service tool T3880166 tighten the lower crankcase frame adjuster to 3 Nm.
  13. Loosely assemble the lower crankcase bolt, washer and a new lock nut.
  14. Whilst holding the lock nut, tighten the upper crankcase bolt to 48 Nm.
  15. Whilst holding the lock nut, tighten the lower crankcase bolt to 48 Nm.
  16. Whilst holding the lock nut, tighten the left hand side front cylinder head bolt to 48 Nm.
  17. Tighten the left hand side rear cylinder head bolt to 48 Nm.
  18. Whilst holding the lock nut, tighten the right hand side front cylinder head bolt to 48 Nm.
  19. Whilst holding the lock nut, tighten the right hand side rear cylinder head bolt to 48 Nm.
    20. LG1 Engine Fixings (RHS)

    1. Lower crankcase bolt (and frame adjuster)

    2. Upper crankcase bolt (and frame adjuster)

    3. Right hand side rear cylinder head bolt

    4. Right hand side front cylinder head bolt

    LG1 Engine Fixings_1 (LHS)

    1. Left hand side front cylinder head bolt

    2. Left hand side rear cylinder head bolt

    3. Upper crankcase bolt

    4. Lower crankcase bolt

  20. Attach the MAP sensor hose (engine end) to its four way connector.
    21. Detatch MAP hose from 4 way connector clhj_1

    1. MAP sensor hose (throttle body removed for clarity)

    2. Four way connector

  21. Reconnect the gear position sensor to the main harness.
  22. Reconnect the engine subharness to the main harness.
  23. Reconnect the engine ground lead to the crankcase with a new lock nut and tighten to 10 Nm.
    24. Ground Lead LG1_Subharness (ckxw)

    1. Engine subharness connector

    2. Engine ground lead

  24. Reconnect the following components to the main harness:
    25. * ignition coils
    * fuel rail (injectors)
    * coolant temperature sensor
    * secondary air injection valve.
  25. Reconnect the grey alternator regulator/rectifier electrical connection.
  26. Refit the gear change bracket and side stand switch to the frame with two fixings and tighten to 24 Nm.
  27. Set the drive chain adjustment (see Drive Chain Free Movement - Adjustment).
  28. If drained, refill the engine oil (see Oil and Oil Filter Change).

Perform the following operations

Perform the following operations:

Exhaust - Installation L Series

Radiator - Install L Series

Coolant Expansion Tank - Installation L Series

Front Sprocket Cover - Install L Series

Throttle Body - Install L Series

Purge Valve - Install L Series

Airbox - Install L Series

Fuel Tank - Install L Series

Battery - Install L Series

Seat - Install L Series