B
ENGINE
SECTION
BI
REMOVING
AND
REPLACING
THE
ENGINE
UNIT
.
Open
the
twlnseac, remove
the
large
screw
securing
the
left side
battery
cover, and pull
the
panel off
the
tWO
locating pegs on the rear frame.
Disconnect
the
fuse bolder, which
Is
fitted
In
the
negative lead
from
the
battery, and remove
the
petrol
tank
(Section E1). Take off the leads from
the
spark
plugs. Remove the all cooler (Section AS), and
disconnect
the
rocker
feed pipe
by
removing
the
two
domed nuts from
the
right side
of
the
rocker
boxes. Slide
the
banJ~
connections
over
the
rocker
spindles, retaining the four
copper
washer,.
Take
off
the
ground connections, which
are
attached
to
long engine studs, on
top
of
the
unit. It
Is
advisable,
at
this stage,
to
remove
the
small
right
side panel,
located
In
front
of
the oil tank,
to
prevent
damage.
This
Is
held
In
position
by
three
cross-head screws.
Unscrew
the
oil tank drain plug, and allow
the
011
to
drain
Into a suitable receptacle. Remove
the
011
cartridge
filter end plug from beneath
the
front
of
the
gearbox outer cover
,
and
allow the
compart~
ment
to
drain. Unscrew
two
clips retaining
the
oil
pipes
to
the
crankcase stubs, and Withdraw
both
pipes, allowing any all
to
drain Into a suitable
container.
The
oil pipe stubs
are
situated beneath
the
left
side
of
the
centre crankcase
section.
Remove
the
gearbox
drain plug from below
the
centre
crankcase section,
and
allow
the
oil
to
drain Into a
suitable
container. Refer
to
Fig.
A6
for
the
position
of
the
drain plug. The chaincase drain plug should
be
removed, and the chalncase allowed
to
drain.
The
drain plug
Is
situated below
the
centre
of
the
Inner chaincase. DIsconnect
the
tachometer
cable
from Its drive box, located
at
the
front
left
side
of
the
crankcase.
Remove
five cross
head
screws from
the
clutch
release
mechanism Inspection
cover.
The
coYer can
then
be removed, and the cable detached from
the
mechanism.
The
most satisfactory
method
of
disconnecting
the
clutch cable
Is
co
slacken
the
lock
nut
and adjuster
on
the cenCre clucch pull
rod,
thereby
producing the reqUired
amount
of slack
In
the
cable.
The
nipple
can
then
be removed from
the
slotted
roller. Retain
the
cable
abutment
as
the
cable
Is
withdrawn. The
carburetors
and
air
cleaner
body can be
taken
off
as
one unit. First, release
the
screw
at
the
end
of
the air cleaner container,
on
the
right
side. This
will
allow
the
outer
cover
and
filter
element
of
the
air
cleaner
to
be
removed.
The
throttle
cable should be removed from
the
B4
carbu retor
linkage
by;first
unscrewing
the adJuster,
and withdrawing the cable from the table stop.
The
nipple
can
be removed from the
throttle
by
turning
It through
90
degrees,
and
sliding
the
cable
and
the
nipple
out
of
the
lever Sideways. Slacken
the
six worm drive clips securing the inlet manifold
connection
hoses,
and
also remove
the
rubber
buffer from
the
bottom air filter support lug. The
rubber
1~'Just
a push-In fit
In
the casting. Remove
the
air
filter
to
crankcase breather pipe,
When
the
whole
assembly
can
be .pulled off the connection
hoses, and withdrawn from the left side of
the
machine, complete with choke operating lever and
cables.
Disconnect
the
two
stator
snap connectors
(Green/
White
and Green/Yellow), which are located
at
the
rear
of
the
engine unit, above the transmission
(gearbox). Then disconnect the
three
contact
breaker
snap connectors (Yellow/Black,
White/
Black, and Red/Black), situated at the top, front,
of
the
011
tank, beneath
the
twlnseat.
Next,
take off
the
silencers, which are held
by
two
bolts
to
a bracket on
either
side of the machine,
and
by
a clip
at
their
forward end. Slacken
the
exhaust
pipe clips on the two
outer
pipes, and also
the
clips at
the
Joints between the four pipes and
the
collector box. The tie bolt for
the
Inner
exhaust
pipes can then be taken
off,
which should
enable
the
complete assembly
to
be
removed
as
a
unit.
Disconnect the oil pressure switch wire,
the
switch
being located to the right of
the
011
pipe
stubs
beneath
the
crankcase,
and
also
the
neutral
Indicator switch wires, at the snap connectors,
in
the
same vicinity. Disconnect the
two
wires from
the
footbrake stoplight switch, mounted on
the
right
side engine plate. Withdraw
the
all tank
oreather
pipe from
Its
hollow stub
on
the
chalncase
vent
chamber Inspection cover. Remove
the
rear
chain spilt link, and take off
the
chain.
Take
off
the
left side engine plate, complete
With
footrest,
by
removing four bolts and nuts, with
distance
spacers etc., and one bolt
In
the
middle
of
the
plate. Remove the bolts holding
the
right side
engine
plate and footrest. It
will
be
found
that
the
bottom
one of
the
two bolts holding
the
engine
Itselfwill
not
withdraw completely, being restricted
by
the
footbrake pedal, but It must be withdrawn
as far as possible.
Note
that
a ground (earth) cable
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