Reliant Rebel 700 1967, Руководство по ремонту

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Description
The 700cc and 750cc engines are both four cylinder in line units
having a die-cast aluminium cylinder head with cast iron valve guides
and sintered steel valve seats. The cylinder block is also made from
cast aluminium and incorporates removable wet cast iron liners. The
forged steel crankshaft is mounted in three main bearings.
Engine service operations
The following service operations give detailed instructions for
servicing and dismantling all the major engine assemblies. Where it is
necessary to remove ancillary components and parts please refer to
the appropriate sections of the document.
Before reassembling, during any operation, all components should be
thoroughly cleaned, paying particular attention to joint faces and
bearing surfaces. High spots ot burrs should be removed carefully.
Ensure that gasket fragments or dirt in blind tapped holes is removed.
Awhen tightening a bolt in to a contaminated thread a characteristic
springiness will be felt. If this occurs remove the bolt and clean the
hole.
Operation 1 Engine removal and installation
To remove
1. Disconnect battery.
2. Drain cooling system.
3. Drain engine oil.
4.
Remove radiator complete with hoses (Section E).
5. Disconnect the heater hoses from the engine and
heater and remove.
6. Disconnect wiring from dynamo/alternator, starter
motor, oil and temperature senders
7. Remove the air cleaner body and element.
8. Disconnect the fuel pipe from the tank at the pump
and plug to avoid ingress of dirt.
9. Remove the High and low tension leads from the coil.
10. Disconnect throttle and choke cables from
carburettor.
11. Disconnect Clutch. On 700cc engines uncouple the
clutch rod assembly from the clutch arm. On 750cc
engines disconnect the clutch slave cylinder hydraulic
pipe and plug the end to avoid dirt ingress. Remove
the clutch return spring.
12. Remove the engine stabiliser rod from the rear engine
plate and chassis. Note position of rubber grommets
(700cc engines only).
13.
Remove exhaust downpipe from manifold.
14. Disconnect the centre tie rod from the steering drop
arms.
15. Remove the nut and washer securing the exhaust
support bracket to the bell housing allowing the
exhaust system to hang clear of the engine.
16. Remove oil filter.
17. Remove starter motor.
18. Use a jack placed beneath the gearbox to support the
unit during engine removal.
19. Unscrew the two 5/16” UNC bolts and six 5/16”UNF
nuts securing the rear engine plate to the gearbox.
20. Sling the engine from a suitable lifting hoist and take
the weight of the engine.
21.
Remove the front engine mounting brackets and
rubbers (Figure 3).
22. Draw engine forwards to disengage from gearbox,
then carefully lift it out through the bonnet aperture
and clear of the vehicle. Lower it on to a suitable base.
23. Remove ancillary components (see appropriate
sections) then carry out the necessary service works.
To replace
1. Refit all ancillary components.
2. Refit front engine mount brackets.
3. Fit engine mounting rubbers to engine mount
brackets.
4. Attach suitable lifting tackle and suspend the assembly
over the engine compartment.
5. Carefully lower the engine into place and manoeuvre
to connect fully with the gearbox. Locate the front
engine mounting lugs on to the front engine
mountings in the frame.
6. Attach the nuts and washers on the front engine
mountings and leave loose.
7. Fit the two 5/16”UNC bolts and six 5/16”UNF nuts to
the fix the rear engine plate to the gearbox bell
housing.
8.
Tighten front engine mounting nuts.
9. Refit the starter motor.
10. Refit the oil filter and fill engine with the correct oil.
11. Reconnect the centre tie bar to the steering drop
arms.
12.
Refit the exhaust pipe to the manifold with a new
gasket and secure with new brass nuts. Refit the bell
housing exhaust bracket.