Engine - Removal

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.Do not support the motorcycle on any ancillary component, the exhaust system or any other non structural parts of the motorcycle frame.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall resulting in motorcycle damage, serious injury or death.

Perform the following operations

Perform the following operations:

Seat - Remove L Series

Battery - Remove L Series

Fuel Tank - Remove L Series

Airbox - Remove L Series

Purge Valve - Remove L Series

Throttle Body - Remove L Series

Front Sprocket Cover - Remove L Series

Coolant Expansion Tank - Removal L Series

Radiator - Remove L Series

Exhaust - Removal L Series

Engine Remove LG1; LGX

  1. If required, drain the engine oil (see Oil and Oil Filter Change).
  2. Remove the two fixings and remove the gear change bracket and side stand switch from the frame.
  3. Note the routing of the alternator regulator/rectifier harness for installation. Release the grey alternator regulator/rectifier electrical connection and route the harness back to the engine.
  4. Disconnect the harness from the following components:
    5. * ignition coils
    * fuel rail (injectors)
    * coolant temperature sensor
    * secondary air injection valve.
  5. Remove and discard the lock nut securing the engine ground lead to the crankcase. Remove the engine ground lead.
  6. Disconnect the engine subharness from the main harness.
    7. Ground Lead LG1_Subharness (ckxw)

    1. Engine subharness connector

    2. Engine ground lead

  7. Disconnect the gear position sensor from the main harness.
  8. Detach the MAP sensor hose (engine end) from its four way connector.
    9. Detatch MAP hose from 4 way connector clhj_1

    1. MAP sensor hose (throttle body removed for clarity)

    2. Four way connector

  9. Set the drive chain adjustment to allow maximum free play in the chain (see Drive Chain Free Movement - Adjustment).
  10. Place a support beneath the engine and ensure that the frame is still adequately and securely supported.
    11. note
    The frame is fitted with two frame adjuster sleeves, located on the right hand side of the frame in the upper and lower crankcase bolt positions.
  11. Remove the lower crankcase bolt, washer and lock nut. Discard the lock nut.
  12. Remove the upper crankcase bolt, washer and lock nut. Discard the lock nut.
  13. Using service tool T3880166, loosen the frame adjusters and unscrew them fully to allow clearance between the frame and engine.
  14. Remove the right hand side rear cylinder head bolt and lock nut. Discard the lock nut.
    15. caution
    When removing/installing the frame to cylinder head left hand mounting bolt, power/air tools must not be used. Hand tools must only be used.Damage to the cylinder head threads can occur if power/air tools are used.
  15. Remove the left hand side rear cylinder head bolt.
  16. Remove the right hand side front cylinder head bolt and lock nut. Discard the lock nut.
  17. Remove the left hand side front cylinder head bolt and lock nut. Discard the lock nut.
    18. LG1 Engine Fixings (RHS)

    1. Lower crankcase bolt (and frame adjuster)

    2. Upper crankcase bolt (and frame adjuster)

    3. Right hand side rear cylinder head bolt

    4. Right hand side front cylinder head bolt

    LG1 Engine Fixings_1 (LHS)

    1. Left hand side front cylinder head bolt

    2. Left hand side rear cylinder head bolt

    3. Upper crankcase bolt

    4. Lower crankcase bolt

    caution
    To prevent damage to components, lower the engine very carefully.
  18. Lower the engine sufficiently to allow the drive chain to be detached from the front sprocket.
  19. Remove the engine.