Forum

[Alan R]

Hello all ----- my turn not to be "in the know" now. Can a Classic 500 engine be removed from the frame with the 4-speed gearbox left attached ?? Or is it better to remove them as a 1-piece unit THEN unbolt. In both cases I would assume to remove alternator, clutch, etc. beforehand. Bike is on an hydraulic table. I have trolley jacks and a couple of "mates" standing by. Thanks ------------

[Norm]

Hi Alan,
I always remove the primary and head and then lift it out as a complete unit.
I would put the bike back on the ground, on the centre stand and once unbolted lift it out throught the right hand side. There is a pinch bolt under the gearbox, loosen that, doesn't need to be removed, lift the grarbox up, front of the motor down and twist the whole lot to the right. Before refitting I cut the bottom of the front down tube off at 45degrees so the motor is easier to lift back in.Good luck

[Jack]

I removed the engine 3 times in 50,000 miles and never removed the gearbox.This is how i do it.It's admittedly a little fiddly,loosen the back nut on the triangulated plate up top and slip the mudguard bracket out of the way,if you've got a socket set,preferably 3/8",use an extension and universal to remove the 4 large nuts on the gearbox and apply some loctite and spin the large studs out..Head and barrel off,primary too then loosen the nut at back bottom of sump.Remove front plates and let crankcase rest forward taking the weight on that rear bottom bolt.Engine can be lifted out with one hand,so bike can be wheeled around even with the rear chain left on.None of my gearbox bolts have been disturbed since it left the factory.

[Alan R]

Thanks chaps----------have printed that out, enlarged onto A4 and is now hanging on my clipboard in the workshop. Best wishes-------------- Alan R