Awarning

To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury.

5. Disconnect negative battery cable.

6. See Figure 2-3. Remove two cross member bolts (5) and washers (4). Pull bottom of radiator assembly forward with cross member or remove the radiator assembly as required. See 6.8 RADIATOR/OIL COOLER.

7. Remove shift lever linkage, right foot rest axle and foot shift lever from frame rail. See 2.11 FOOTRESTS/FOOT CONTROLS.

8. Remove left foot rest axle. See 2.11 FOOTRESTS/FOOT CONTROLS.

9. Remove rear brake master cylinder and rear brake pedal. See 2.19 REAR BRAKE MASTER CYLINDER/ RESERVOIR.

10. Remove clutch fluid line from clips on right lower frame rail. See 2.15 CLUTCH FLUID LINE.

11. Remove starter solenoid bracket nuts and remove starter solenoid from right lower frame rail. See 5.5 STARTER SOLENOID.

12. Remove engine mount tie link from frame rail bracket. See 2.5 FRONT ENGINE MOUNT.

NOTE

Maintain tie link length for reinstallation. Do not loosen jam nuts on tie link.

13. Remove bolts (7) holding on the right and left lower frame rails (2 & 3). Remove the frame rails.

1. See Figure 2-3. Install left and right lower frame rails (2 & 3) and finger tighten mounting bolts (7).

2. Using clips, attach clutch fluid line to right lower frame rail. See 2.15 CLUTCH FLUID LINE.

3. Attach the engine mount tie link to the frame rail bracket. Tighten to 34-41 Nm (25-30 ft-lbs). See 2.5 FRONT ENGINE MOUNT.

4. Attach starter solenoid bracket to right lower frame rail with nuts. Tighten to 6-10 Nm (53-88 in-lbs).

5. Attach right foot rest axle and foot shift lever to frame rail. Attach shift lever linkage. See 2.11 FOOTRESTS/FOOT CONTROLS.

6. Attach rear brake master cylinder to bracket on left lower frame rail. See 2.19 REAR BRAKE MASTER CYLINDER/RESERVOIR.

7. Install left foot rest axle with rear brake pedal. Attach rear brake pedal master cylinder to brake pedal. See 2.11 FOOTRESTS/FOOT CONTROLS.

8. Replace radiator/oil cooler assembly as required or pull radiator/oil cooler assembly into position and install and finger tighten cross member mounting bolts (5) and washers (4). Tighten cross member bolts (5) to 20-26 Nm (15-19 ft-lbs). See 6.8 RADIATOR/OIL COOLER.

9. Tighten lower frame rail bolts (7) to 61-75 Nm (45- 55 ft-lbs).

10. Fill and bleed rear brake. See 1.9 BLEEDING BRAKES.

11. Connect negative battery cable. Tighten to 6.8-10.8 Nm (60-96 in-lbs).

12. Replace airbox cover.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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