Removal–refitting of the engine assembly

1 -	Removal–refitting of the engine assembly

Screw

Nut

Screw

4	Swingarm pivot shaft

Screw

Washer

Spare parts catalogue


1200 ABS	Frame
1200 ABS	swingarm
1200 S ABS	Frame
1200 S ABS	swingarm

Important

Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.

Removal of the engine

In order to remove engine you must first remove a series of other components from the motorcycle.

Most of these removal procedures are described in the relative sections of this manual.

The following flow chart illustrates the logical sequence in which the parts are to be removed from the motorcycle and a reference to the section where the removal procedure is described.

This section describes only the operations to be carried out after having removed all the parts listed in the flow chart.


Operation	Section reference
Remove the saddles	5 - 3, Removal of the seat
Remove the side fairings	5 - 3, Removal of the side panels and seat cowling
Remove the front half-fairings	5 - 2, Removing the front half-fairing
Remove the half-fairings	5 - 2, Removal of the fuel tank fairings
Remove the oil sump guard unit	5 - 4, Removing the undersump
Remove the instrument panel internal bulkheads	5 - 1, Removing the panel
Remove the fuel tank	8 - 2, Removal of the fuel tank
Remove the air filter	8 - 7, Removal of the air filters
Disconnect the throttle cable	7 - 8.1, Removal of the throttle twistgrip
Remove the airbox, the throttle body, the blow by and the oil breather tube	8 - 6, Removal the airbox and throttle body
Remove the fuel system and the injectors from the intake manifolds	8 - 6, Removal of the fuel injectors
Disconnect the cables from the coils	6 - 8, Ignition coils
Remove the exhaust unit	8 - 8, Removal of the exhaust system
Bleed the lubrication system	4 - 3, Changing the engine oil and filter cartridge
Remove the oil pipes of the oil radiator from the engine block	9 - 2.2, Removal of the lubrication system
Empty the coolant out of the cooling system	4 - 3, Changing the coolant
Remove the pipes and the cooling system joints from the engine block	9 - 3.2, Removal of the cooling system hoses and unions
Remove the water radiator lower retainer from the engine	9 - 3.2 Removal of the radiator
Connect the starter motor/solenoid cable	6 - 3, Removing the starter motor
Remove the gearchange control	7 - 9, Removal of the gearchange control
Remove the clutch transmission unit	7 - 8.2, Removal of the clutch transmission unit
Remove the front sprocket	7 - 14, Removing of the front sprocket
Remove the side stand	7 - 16, Removing of the side stand
Disconnect wiring connectors on the engine block	6 - 1, Routing of wiring on frame

Place a stand beneath the engine to support it during removal from the frame.

Loosen the nuts (2) on the right side of the frame, in reference to the engine upper supporting screws (1) and (6).

Loosen the screws (5).

Block the screw (3) of the swingarm shaft on the left side of the frame and at the same time undo the screw (3) on the right side.

Using the drift 88713.1074, fully extract the swingarm shaft: from the LH side and recover the washer (7).

In this way the swingarm is not fixed to the engine any more, leave it connected to the frame.

Remove the upper supporting screws (1) and (6).

Withdraw the complete engine assembly from the frame by lowering it and pushing it forwards.

Refitting the engine

Refitting is the reverse of removal.

Important

Tighten the screws (3) to the torque of 48 Nm ± 5% (Sect. 3 - 3, Frame torque settings).

Tighten the screws (5) to the torque of 42 Nm ± 5% (Sect. 3 - 3, Frame torque settings).

Refit the removed parts by performing the steps shown in the table and in the specific sections of the manual in reverse order.


Operation	Section reference
Connect wiring connectors on the engine block	6 - 1, Routing of wiring on frame
Refit the side stand	7 - 16, Refitting the side stand
Refit the front sprocket cover	7 - 14, Refitting the front sprocket
Refit the clutch transmission unit	7 - 8.2, Refitting the clutch transmission unit
Refit the gearchange control	7 - 9, Refitting the gearchange mechanism
Connect the starter motor/solenoid cable	6 - 3, Refitting the starter motor
Refit the lower retainer of the water radiator on the engine block	9 - 3.2 Refitting the radiator
Refit the pipes and the cooling system joints on the engine block	9 - 3.2, Refitting the cooling system hoses and unions
Refill the cooling system	4 - 3, Changing the coolant
Refit the oil pipes of the oil radiator on the engine block	9 - 2.2, Refitting the lubrication system
Refill the lubrication system	4 - 3, Changing the engine oil and filter cartridge
Refit the exhaust unit	8 - 8, Refitting the exhaust system
Connect the cables of the coils	6 - 8, Ignition coils
Refit the oil breather pipe, the blow by, the throttle body and the airbox	8 - 6, Refitting the airbox and throttle body
Connect the throttle cable	7 - 8.1, Refitting the throttle twistgrip
Refit the air filter	8 - 7, Refitting the air filters
Refit the fuel tank	8 - 2, Refitting the fuel tank
Refit the instrument panel internal bulkheads	5 - 1, Refitting the panel
Refit the oil sump guard unit	5 - 4, Refitting the undersump
Refit the side fairings	5 - 2, Refitting the fuel tank fairings
Refit the front half-fairings	5 - 2, Refitting the front half-fairing
Refit the side fairings	5 - 3, Refitting the side panels and seat cowling
Refit the saddles	5 - 3, Refitting the seat