Engine Assembly; Engine Removal And Installation - TGB EST 1000 Service Manual

Engine Removal and
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Air Intake System
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Exhaust System

ENGINE REMOVAL AND INSTALLATION

WARNING
To avoid potential burns, let engine and exhaust system cool down before servicing.
During assembly/installation, use the torque Values and service products as in the exploded view.
Clean thread before applying a thread locker.
WARNING
Torque wrench tightening specifications must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin,
etc.) must be installed or replaced with new one where specified. If the efficiency of a
locking device is impaired, it must be renewed.
ENGINE REMOVAL
Preparation
1. Place vehicle on a workstation that will have
access to an engine-lifting hoist.
2. Safely lift and support the vehicle.
3. Disconnect BLACK (-) cable from battery,
then the RED (+) cable.
WARNING
Always disconnect battery cables exactly in
the specified order, the BLACK (-) cable
first. It is recommended to disconnect
electrical connections prior to
disconnecting fuel lines.
4. Remove seat and seat steady.
5. Remove the following plastic parts:
- Upper cover.
- LH and RH side covers and footrest.
- Heat isolation.
6. Remove air cleaner and the rear bracket.
7. Remove the throttle body,air intake manifold.
8. Drain engine oil.
NOTE: Drain engine oil and gearbox oil only if
engine overhaul and gearbox need to repair is
necessary.
8. Drain engine coolant.
9. Remove footrest bracket.
10. Remove the front and rear exhaust head
pipes and muffler.
Installation·············· 5-1

5-1. ENGINE ASSEMBLY

Cooling System········································5-9
AC Generator System
11. Remove the shift connecting rod.
12. Disconnect the CVT inlet duct from the CVT
cover.
13. Remove the CVT outlet duct.
14. Disconnect the coolant hose at water pump
and thermostat cover.
15. Disconnect the crankcase vent hose.
16. Disconnect the gearbox vent hose.
17. Unplug and remove the ETS (engine
temperature sensor).
18. Unplug all remaining connectors and
remove cables from engine. Cut all
necessary locking ties.
- Spark plug cables.
- Starter cable (retaining nut on starter body).
- Gear Position Switch.
- Vehicle speed sensor.
- Oil Pressure Sensor.
- Crankshaft Position Sensor.
- Engine ground cable.
- ACG connector.
19. Remove the bolts of the front and rear
universal joint.
20. Remove CVT assy. and crankcase cover
LH.
21. Remove bracket and cushion bush at
cylinder head.
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5-1