Removal - refitting of the engine assembly

1 -	Removal - refitting of the engine assembly

Plug

Bolt

Nut

4	Special nut

5	Swingarm pivot shaft

Parts catalogue


FRAME
SWINGARM

Important

Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.

Removal of the engine

In order to remove engine you must first remove a series of other components from the motorcycle.

Most of these removal procedures are described in the relative sections of this manual.

The following flow chart illustrates the logical sequence in which the parts are to be removed from the motorcycle and a reference to the section where the removal procedure is described. This section describes only the operations to be carried out after having removed all the parts listed in the flow chart.


Operation	Section reference
Remove the seat	E 3, Removal of the seat
Remove the side fairings	E 2, Removal of the side fairings
Remove the battery	P 2, Removal of the battery
Remove the starter contactor	P 3, Starter contactor
Remove the fuel tank	L 2, Removal of the fuel tank
Disconnect the HT leads	M 3, Spark plug
Remove the airbox	L 7, Removal of the airbox
Disconnect the throttle cables from the throttle body	F 1, Removal of the throttle twistgrip
Remove the throttle body	L 6, Removal of the throttle body
Drain the oil from the lubrication system	D 4, Changing the engine oil and filter cartridge
Remove the oil cooler hoses from the engine block	N 2.2, Removal of the oil cooler
Remove the gearchange control	F 5, Removal of the gearchange control
Remove the footrest brackets	H 4, Removal of the footrest brackets
Remove the sidestand	H 5, Removal of the sidestand
Disconnect the exhaust pipes from the cylinder heads	L 8, Removal of the exhaust system
Remove the clutch slave cylinder	F 2, Removal of the clutch slave cylinder
Slacken off the drive chain	D 4, Adjusting the chain tension
Remove the front sprocket	G 8, Removal of the front sprocket
Disconnect the wiring connectors on the engine block	P 1, Routing of wiring on frame

Place a service stand beneath the engine to support it during removal from the frame.

Remove the plugs (1) from the frame tubes at the engine mounting points.

Unscrew the nuts (3) on the right-hand side of the frame, on the two upper engine mounting bolts (2).

Restrain the swingarm pivot shaft (5) on the right-hand side of the motorcycle while unscrewing the nut (4) on the left-hand side:

Using drift 88713.1074, fully extract the swingarm pivot shaft. This frees the swingarm from the engine and therefore it can be left attached to the frame.

Remove the two upper bolts (2).

Withdraw the complete engine assembly from the frame by lowering it and pushing it forwards.

Refitting the engine

Refitting is the reverse of removal.

In particular, lubricate the nuts (3), nut (4) and the swingarm pivot shaft (5).

Tighten the nuts (3) and the nut (4) to the specified torque (Sect. C 3, Frame torque settings).


Operation	Section reference
Reconnect the wiring connectors on the engine block	P 1, Routing of wiring on frame
Refit the front sprocket	G 8, Refitting the front sprocket
Adjust the drive chain tension	D 4, Adjusting the chain tension
Refit the clutch slave cylinder	F 2, Refitting the clutch slave cylinder
Reconnect the exhaust pipes to the cylinder heads	L 8, Refitting the exhaust system
Refit the sidestand	H 5, Refitting the sidestand
Refit the footrest brackets	H 4, Refitting the footrest brackets
Refit the gearchange control	F 5, Refitting the gearchange control
Refit the oil cooler hoses to the engine block	N 2.2, Refitting the oil cooler
Fill the lubrication system	D 4, Changing the engine oil and filter cartridge
Refit the throttle body	L 6, Refitting the throttle body
Reconnect the throttle cables to the throttle body	F 1, Refitting the throttle twistgrip
Refit the airbox	L 7, Refitting the airbox
Reconnect the HT leads	M 3, Spark plug
Refit the fuel tank	L 2, Refitting the fuel tank
Refit the starter contactor	P 3, Starter contactor
Refit the battery	P 2, Refitting the battery
Refit the side fairings	E 2, Refitting the side fairings
Refit the seat	E 3, Refitting the seat