Service Manual
Page 39 of 50

*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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REMOVAL OF THE ENGINE FROM THE FRAME

In order to remove the engine from the frame the following operations must first be performed:

Lift the motorcycle onto the centrestand. Pull off the plug leads from both sparking plugs. Unscrew the tachometer drive cable from the engine.
Unscrew the jubilee clip from the front air box connector rubber and detach the connecting pipe from the front carburettor.
Push the rear air box connector rubber back into the rear air box.
Remove the front air box. Separate the fuse-box from the rear air box and allow it to hang from the harness; remove the rear air box.
Disconnect the engine breather pipe from the camchain case. Remove both oil cooler pipes from the oil cooler end.
Cut all the ties retaining the oil cooler hoses. Remove the exhaust system complete.
Note: The exhaust clamps are held tight with stainless steel fastenings. Do not confuse these with similar nonstainless fixings elsewhere on the machine.
Disconnect the gear change linkage. and foot rest assembly.
Remove the foot brake pedal and pivot bolt, allowing it to hang. Take particular care not to loose the bronze bearing.
Slacken the clutch hydraulic bolt on the timing cover.
Pull back the clutch lever, tying it back to the handlebars with. tape or a rubber band. A small amount of fluid will be ejected around the banjo bolt when this is done.
Remove the banjo bolt from the clutch pipe and collect the copper washers. Loosely refit the banjo bolt to avoid any damage to the sealing face.
Disconnect the neutral light and oil pressure switch wires. Remove the lower cable (starter motor) from the solenoid. Disconnect the alternator leads adjacent to the solenoid.
Remove the front bolt on the rear brake torque stay. Release the stay and refit the bolt to the centre stand; do not tighten the bolt excessively at this stage as the outer crankcase lug is unsupported.
Disconnect the chain link and remove the drive chain.
Remove the screws from the front carburettor manifold, collecting the insulator bushes and gaskets.
Slacken the pinch bolt on the rear carburettor and slide it from the stub.
Place a jack or suitable block under the front of the sump, to support the engine. If using a jack ease it up until the three engine mounting studs slide out. Alternatively they may be driven out with a soft metal drift, taking care not to damage the threads. Note that the front engine bolt is the shortest of the three.
If no assistance is available, the wheels and front mudguard should first be removed to enable the frame assembly to be lifted from the engine. Alternatively it is possible to support the engine on wood strips front and rear (not the centre stand) and remove the strips one at a time, allowing the engine to drop gradually until it is at ground level. Whatever method is used, there is a danger of damage to the surface finish of both frame and engine unless great care is taken. The risk of damage is reduced if the V1000 covers and the ignition housing are removed from the engine whilst it is in the frame.
Note: It is more convenient before refitting the engine to remove the chain guard from the swinging arm to avoid damaging the front end of the guard.

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