SECTION F4
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REFITTING POWER UNIT
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Prior to refitting the power unit, if any major
mechanical attention has been given, wash the oil
tank and oil pipes out very thoroughly to remove
dirt and foreign matter. As with dismantling,
protect the lower frame rails against damage.
Proceed as follows:
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1
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Pass the power unit into the frame from the
right side, raising the front slightly and lowering
the rear to clear the airbox.
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2
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With the power unit loosely in position, move
the rear end as far as possible to the right side
of the frame to facilitate assembly of the rear
mounting.
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Engine mountings are covered in detail in
Section F12-17.
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However, if the mountings have merely been
dismantled and are to be reassembled without
varying the shimming, proceed as follows:
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3
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Grease using silicone grease (such as Releasil
No. 7) and place in position the shims and left
side end cap (the shims should be divided equally
between left and right).
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4
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Grease using a silicone grease and insert as a
group the left side gaiter, collar and polyurethane
washer with the gaiter held back for maximum
clearance. Note that the gaiter should be greased
inside to slide easily over the cap and mounting.
The order of assembly and method of holding the
gaiter back on the edge of the polyurethane washer
are seen respectively in Figs. F14 and F5.
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5
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Position the spacer between the left hand alloy
footrest mounting plate and battery tray bracket
and slide in the mounting stud from the left side,
moving the power unit as necessary to align the
stud holes.
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6
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Grease using a silicone grease and fit the right
side shims and cap.
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7
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Grease (including inside the gaiter) and fit the
gaiter, spacer collar and polyurethane washer (see
Figs. F14 and F5).
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8
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Tap the main stud right through aligning with
the right frame bracket, insert the footrest plate
spacer, then fit the washer and nut. Tighten to 25
Ibs./ft. (3~456 Kg/m).
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9
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Fit the front engine mounting plates to the
crankcases, sliding the long end of the mounting
over the lower crankcase bosses. With the stud or
bolt fitted, pivot the mounting up into position to
insert the second stud or bolt. Almost certainly
the power unit will need to be lifted to insert the
crankcase studs (or bolts).
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10
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Grease the components with a silicone grease and
reassemble the front mounting as in Section C32.
Tighten the centre bolt to a torque of 25 Ibs./ft.
(3 456 Kg/m).
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11
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Refit the oil pipe junction block, using a new
gasket if necessary and securing with the single
bolt which must not be overtightened.
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12
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Prior to refitting the carburetors and spacers,
grease the manifold scrows lightly and run them
into the cylinder holes to ensure that they can be
tightened by finger pressure only when the
carburettors and manifolds are assembled. During
this operation and before attempting to fit the
engine to the frame block the inlet ports with
clean non-fluffy cloth to prevent a screw dropping
down one of the ports. Remember to remove the cloth
before fitting the carburetors.
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13
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Holding the Tuffnol insulating block in place
(some models use blocks with one flat edge which
must fit inboard) fit the air hose to the airbox
using a screwdriver blade to enter the lip, then
assemble the right carburetor and manifold to the
head tightening the socket screws completely.
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14
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Fit the air hose to the airbox, then offer the
insulatin block, carburetor and manifold to the
cylinder head tightening the socket screws as far
as possible with the fingers. When locking up the
screws an abbreviated socket key is essential.
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