Some 500 dismantling advice needed please.

[McCabe-Thiele (Ted)]

Just a couple of quick questions as I've started the dismantling of my 500.
I've not managed to find what I need to know on my first trawl through a CD manual.

1.) How do I disconnect the clutch cable from the hole it disappers into seemingly in the middle of the engine unit?

(its so different from the 400)

2.) To remove the engine will it come out as is or is it a sump & cam cover removal first?

[gary123]

The side cover has to come off to disengage the clutch cable.
Re taking the engine, out I think its easier if you remove as much weight as poss.
Carbs off
Drain oil
Remove sump. This also gives more clearance.
Remove filter housing and filter, breather cover. cam cover, Cylinder head, not sure about barrels but if you can do.
Remove alternator and all covers.

Youll still need two people and with the sump removed I would use a piece of wood and a scissor jack to support the engine while you get all the bolts out.

Good luck

[Bryanj]

Sprocket cover off, top breather cover off, sump off, oil filter housing off.
If you are stripping right down its worth removing generator cover and rotor so you aint chasing it round the bench, similarly head and barrels in case head nuts are tight, all this makes it lighter and easier to handle

[McCabe-Thiele (Ted)]

Thanks Guys that will come in handy tomorrow

[gary123]

AND starter motor, oil pump, sprocket and clutch any weight reduction is helpful.

[McCabe-Thiele (Ted)]

Wendy has gone to bed early as she is doing the Flu clinic admin in the morning so managed to sneak out and do another half hour on the 500 this evening.

Side cover off and clutch cable disconnected - wow half a cup of water came out!

As cable out of ther way the carbs pulled off pretty easily in my gloved hands - I have learnt how to minimise the blood letting when they let go - 74 year old skin is like paper when it comes to bruises & blood letting.

Removed the clocks ready for posting out to Pater H.

A very satisfying day.

PS: when I removed the three multi plugs from bracket on the left side I noticed they are not only yellow but very brittle and the clip bits are broken. The loom seems pretty good but........

Can anyone point me in the right direction for replacement multi plugs please?

[Johnny4428]

Kojaycat Ted.

[McCabe-Thiele (Ted)]

Kojaycat Ted.

Thanks Johnny - never thought of them even though I had some 4 way connectors from them some time ago!