Removing the engine

Finally I found the time to get the engine out, and fortunately it went without a hitch and took about an hour, which is a lot quicker than I recall the last one taking. More often than not things get stuck and require a bit of creativity to get them out, but this time every nut and bolt came out a treat.

First of all you need to disconnect the following: Gear (x2), clutch, brake, choke, throttle cables, HT lead, wiring (I just chopped mine as its all being replaced) and fuel pipe and air filter and hose (if you're bringing the carburettor with you). My air filter had seen better days! This red dust is common on Lambrettas from this part of India:

The engine hinges on the frame by a shaft secured by a 24mm nut at each end. To remove this undo the nuts (the largest socket in my set!) and then hammer it through with a heavy mallet and a steel bar of some sort. Make sure the steel bar is a good few mm narrower than the shaft so that you don't damage the threads and it easily slides through the frame. I used an extender bar from my socket set:

 

At the rear the engine is supported on the shock/spring unit. 

Undo both 24mm nuts on this and remove the unit completely, levering it away with a large flat screwdriver or old chisel. You'll probably be replacing the bushes here - if you aren't then be careful not to damage them. The bike will now sit right down on the rear wheel and the engine will only be loosely attached by your steel bar at the front. Now if you support the frame and pull out the bar the engine will drop out to the floor, or to whatever support or cushioning you have provided.

I have to admit I cut a corner and didn't remove the footboards - the engine does drop between them, but if you care for your footboards and your paint job you'd best remove them.

And there you have it, simple as that. I now have the engine in my workshop (shed) which gives me the chance to do the next few hours of work in the dry and relative warmth.