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5. ENGINE REMOVAL/INSTALLATION

5-0

PEOPL E 25 0

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ENGINE REMOVAL/INSTALLATION

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SERVICE INFORMATION -------------------------------------------- 5-1

ENGINE REMOVAL --------------------------------------------------- 5-2

ENGINE INSTALLATION -------------------------------------------- 5-5

ENGINE HANGER REMOVAL --------------------------------------- 5-4

Summary of content (7 pages)

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5.
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5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. • Drain the coolant before removing the engine. • After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the water jacket.
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5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 ENGINE REMOVAL Drain the coolant. (!3-9) Remove the met-in box, carrier. (!2-6) Remove the frame body cover, center cover and rear fender A together. (!2-6) Remove the exhaust muffler. (!2-10) Disconnect all of the A.C. generator. A.C. Generator Wire Connectors Nut Starter Motor Wire Remove the nut to disconnect the starter motor wire that goes to the starter relay.
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5. ENGINE REMOVAL/INSTALLATION Disconnect the engine oil pressure switch wire. Loosen the water hose bands to disconnect water hoses from the water ducts. Disconnect the secondary air tube from the secondary air inlet tube. PEOPL E 250 Engine Oil Pressure Water Hoses Switch Wire Water Ducts Secondary Air Tube Water Hose Bands Disconnect the breather hose (air cleaner) from cylinder head cover. Disconnect the spark plug cap from cylinder head.
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. ENGINE REMOVAL/INSTALLATION Remove the left rear shock absorber. Remove the right rear shock absorber lower mount bolts. Remove the right rear shock absorber. Remove the rear wheel nut. Disconnect the rear brake fluid tube from the guide. Remove the four bolts on the rear fork to remove rear brake caliper and rear fork. PEOPL E 250 Rear Shock Absorber Bolt Nut Bolts Rear Fork Brake Fluid Tube Remove the bolt to disconnect the engine negative cable.
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5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 Remove the engine mounting bolt and pull out the engine. ENGINE INSTALLATION Reverse the “REMOVAL” procedures. ＊ Apply grease onto the O-rings, oil seals and bush). Engine Mounting Bolt Nuts ENGINE HANGER REMOVAL Nuts Remove met-in box and carrier. (!2-6) Remove the body cover, center cover and rear fender A together. (!2-6) Remove air cleaner. (!5-3) Remove the two nuts of the right and left step bar. Remove the right and left step bar.
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5. ENGINE REMOVAL/INSTALLATION Inspect the engine hanger bushings and stopper rubber for wear or damage. PEOPL E 250 Bushing INSTALLATION Reverse the “REMOVAL” procedures. ＊ Apply grease onto the bush.