Frame and Ancillaries

F

SECTION F1
REMOVAL OF POWER UNIT
In some types of repair, for example, during an accident repair, where the frame must be changed, it is desirable to remove the engine/gearbox/primary drive and engine plates as a group. To remove this assembly, proceed as below:
1	Release the large side knobs and lift the seat off upwards and to the rear (Fastback seats lift straight upwards).
2	Turn the ring of the twist fastener to release the forward end of the accessory cover and lift the cover forward off the rear mounting pegs.
3	Disconnect the battery by removing the fuse from the fuseholder adjacent to the battery.
4	Remove the right side panel which is secured by two screws at the top and a peg and rubber at the bottom.
5	Remove the fuel tank (Section F9).
6	Remove both exhaust pipes with mufflers by il releasing the tab washers at the finned lockrings and unscrewing the lockrings using service tool 063968. Remove the nuts and washers holding the muffler bracket to the two mounting rubber studs and lift each system away in turn.
7	Disconnect the rear chain at the split link and remove the chain completely.
8	Disconnect the rear brake cable from the expander lever by removing the adjuster nut completely and depressing the rear brake pedal so that the end of the cable clears the trunnion. Collect the trunnion.
The swinging arm must now be removed. The pivot is lubricated by SAE 140 oil and provision must be made to collect the oil released as the end cap is removed. Proceed as follows:
9	Unscrew the pivot end cap screw and lift the end cap, washers and long screw away together.
10	Whilst allowing oil to drain from the pivot, remove the rear wheel (see Section H1). Pre1971 models may have the wheel removed complete with sprocket and brake. On 1971 and later models remove the wheel only, leaving the sprocket and brake assembled to the swinging arm.

11	Lift away the right footrest complete after removing two set screws or nuts of the same length, and one bolt, the nut for which secures also the ground (earth) tag for the Zener diode.
12	Disconnect the flexible rear chain oiler tobe from the metal oiler pipe at the swinging arm.
13	Remove the suspension unit bottom bolts.
14	Take out the swinging arm pivot spindle. This is an easy sliding fit but is secured by a lock screw on top of the pivot tube which must be removed. It will be noted that the pivot spindle is threaded internally to aid removal. Screw a bolt with locking nut into the thread (the main front mounting bolt will be ideal) tighten the nut and twist and pull the spindle gently out.
15	Lift away the swinging arm complete with chainguard. Collect the left end plate and 'O' rings.
16	Disconnect the tachometer cable (at the top front of the crankcase).

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