Casing unit: outer components

9.1 -

2	Timing gear pair

3	Safety washer

4	Hexagon nut

Key

6	Aluminium gasket

Screw

8	Aluminium gasket

9	Blanking plug

10	Breather valve

O-ring

12	Head stud bolt

13	Locating dowel

14	Blanking plug

15	Blanking plug

16	Seal, thk. 2

Nipple

18	Mesh filter

19	Neutral switch

Gasket

Gear pin

Washer

23	Intermediate gear

Washer

Circlip

Screw

27	Blanking plug

Gasket

Spare parts catalogue


Timing
Filters and oil pump
Half crankcases
Electric starter and ignition

Caution

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the outer components


Operations	Reference See Section
Remove the engine from the frame	N 1, Removing the engine
Remove the lubrication system	N 2.1, Removing the oil pump
Remove the complete head unit with timing system	N 4.2, Cylinder heads: side covers / timing system
Remove the complete cylinder/piston unit	N 5, Removing cylinder / piston assy

Note

The removal procedure described is only necessary when changing or cleaning the casings. If the original casings are reused, the components may be left in place.

Remove oil breather valve (10) and O-ring (11) from the engine block.

Undo and remove the two plugs (14) and seals (8) from the clutch-side casing.

Undo and remove the oil cartridge filter (Sect. D 4, Changing the engine oil and filter cartridge).

Undo and remove oil filter support nipple (17).

Undo and remove the screw (7) with gasket (6) to check engine timing sensor air gap.

Remove mesh filter (18) and seal from the clutch-side casing as described under Sect. D 4, Changing the engine oil and filter cartridge.

Remove the plug (27), collect the seal.

Remove drain plug (9) with seal (28).

Remove neutral light switch (19) with seal (20).

Using the special tool, remove head stud bolts (12).

Remove gear selector ratchet and gear stopper as described in Sect. N 7.1, Removing the gear stopper and ratchet.

Reassembling the outer components

Check O-ring (11) for wear. Change, if necessary.

Fit oil breather valve (10) with O-ring (11) inside engine block and tighten to the specified torque (Sect. C 3, Engine torque settings).

Tighten both plugs (14) and seals (8) to the specified torque (Sect. C 3, Engine torque settings).

Tighten oil filter cartridge support nipple (17) to the specified torque (Sect. C 3, Engine torque settings).

Tighten the drain plug (9) with seal (28) to the specified torque (Sect. C 3, Engine torque settings) after applying the recommended threadlocker.

Refit the neutral light switch (19) with seal (20) and tighten to the specified torque (Sect. C 3, Engine torque settings).

Apply threadlocker to the plug (27), fit the seal, start it in its thread and tighten it to the specified torque (Sect. C 3, Engine torque settings).

Refit mesh filter (18) with seal, as described in Sect. D 4, Changing the engine oil and filter cartridge.

Refit the ratchet and gear stopper (Sect. N 7.1, Reassembling gear stopper and ratchet).

To refit stud bolts (12) on casing, apply speed bond on threads and tighten to the specified torque (Sect. C 3, Engine torque settings). Use the suitable tool (shown).


Operations	Reference See Section
Refit the cylinder-piston assemblies	N 5, Refitting cylinder / piston assy
Refit complete head assembly and timing system parts	N 4.2, Cylinder heads: side covers / timing system
Refit the lubrication system	N 2.1, Refitting the oil pump
Refit the engine to the frame	N 1, Reassembling the engine