Service Manual
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*NOTE* This service manual is for a NON EN10 modified engine. Whilst most of the information is relevent, there are some critical differences.
For more information on EN10 modified engines, please contact
Mick Broom at Broom Development Engineering on +44 (0)1327 353023

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Timing Cover Removal

For attention to parts within the timing side the oil should be drained from the front drain plug (Alternatively, lean the machine over about 20° to the left). If the timing case is to be removed it is not necessary to remove the fuel tank, silencers, exhaust pipes etc., but the seat should be unlocked, and the right hand side cover detached.

Remove the right footrest and brake pivot bolts; slacken the pillion footrest bolt allowing the foot rest to hang down. If the timing cover is to be removed completely, the clutch hydraulic hose must be detached. To avoid losing hydraulic fluid the pipe banjo can be blocked off, using a 10mm bolt and nyloc nut. Alternatively the clutch lever may be held to the handlebar with a rubber band. In the latter case, take care when removing the banjo bolt as the fluid will be under slight pressure.

NOTE: Use new copper washers when refitting hydraulic unions.

If the timing cover is not to be removed completely, it may be swung to one side without disturbing the hydraulic connection. To help prevent damage, pass a length of string through one of the screw holes in the cover and attach it to the passenger grab rail.

When removing the cover it is not necessary to disturb the oil filter cover or clutch hydraulic cylinder. Remove the timing side cover screws; as the cover is removed a small amount of oil will be released. Lift off the cover and allow the oil to drain out from the oil cooler pipes in the crankcase.

NOTE: The two dowels on the joint face will normally remain in the timing cover.

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