HOME 2.7 ENGINE REPLACEMENT GENERAL Removal and replacement of the engine may be required for either replacement engines or for engine overhaul. sm01963 REMOVAL TOOL NAME PART NUMBER ENGINE ASSEMBLY SUPPORT FIX- TURE HD-43517 ENGINE ASSEMBLY SUPPORT FIX- TURE HD-45317 1. See Figure 2-6 . On a table lift with a LIFT SIDE EXTEN- SION, position a scissors jack under the fuel tank. NOTE To provide clearance and alignment, locate a scissors style jack under the fuel tank frame extensions to raise or lower the motorcycle throughout the procedure. Figure 2-6. Lift Side Extension (typical) 9. Remove air filter top, air filter, breather hose, velocity stacks, and air filter bottom.
Unscrew threaded air filter hold down rod from throttle body. See 1.5 AIR CLEANER AND EXHAUST SYSTEM . To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 10. At the fuel rail, disconnect pressure fuel line and return fuel line by pressing blue buttons with thumb and first finger. 2. Allow engine to cool. 11. See Figure 2-8 . Disconnect copper L-bracket (1) with negative battery cable from front cylinder head. 3. Open seat. 12. Remove fastener on rear cylinder head and remove GND 1 (8), GND 2 (9) and horn ground wire (10).
Replace fastener. 4. Purge fuel supply line of high pressure gasoline. a. Disconnect fuel module connector from top plate. b. In neutral, start engine and allow engine to run. 13. Remove fastener on front cylinder head and remove reg- ulator ground (3). Replace fastener. c. When engine stalls, operate starter for 3 seconds to remove any remaining fuel from fuel lines. 14. Separate wiring connectors from horn. Unbolt and remove horn from rubber grommet on frame. See 7.27 HORN . 5. Place a suitable container under engine, loosen oil drain plug and drain oil. 15. Separate: 6. Install and tighten oil drain plug to 35 Nm (25 ft-lbs). a. Front (2) and rear coil connectors [83F, 83R]. a.
For replacement engines, leave oil filter threaded into its mounting plate. b. Main engine connector [45] (7). c. Throttle position sensor [88] (4). b. For engine overhaul, remove oil filter as necessary. d. Idle air control actuator [87] (5). NOTE Dispose of oil in accordance with local regulations. 16. For a California model, pull the purge solenoid hose (6) off throttle body. 7. Remove right side cover and maxi-fuse. See 7.4 MAXI- FUSE . 17. Perform throttle body procedure: a. For a replacement engine, loosen throttle cable adjustor jam nuts. Turn throttle cable adjuster until cable is as short as possible. Remove throttle cable 8. battery. See ental veh s injury, ceeding.
( negative a 1.9 BATTE icle start-up, which could cause housings from guides at the disconnect negative (-) battery cable barrels from throttle 00048a) b. See Figure 2-7. For engine nd positive battery cables from at each intake and lift thro RY MAINTENANCE. throttle cables attached, w body for protection and s Cover intake openings to p into intake bore. 2009 VRSC