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generator components. The central retaining nut should be
temporarily refitted so that it is flush with the shaft end. Do not
place undue strain on the assembly using this method. If
removal proves difficult, abandon the attempt and obtain the
proper service tool.
3
With the flywheel/rotor removed as described above,
release the three countersunk screws which secure the
generator stator. It will also be necessary to release the output
leads from beneath the guide before lifting the assembly clear.
There is no need to mark the stator position as this is not vari-
able.
9
Dismantling the engine/gearbox unit: removing the cam
gear and shaft
1
If this job is being tackled with the engine in the frame, it is
first necessary to remove the cylinder head and pushrods, the
cylinder barrel and cam followers and the generator assembly.
Refer to the preceding Sections in this Chapter for details.
2
The cam gear takes the form of a skew-cut gear driven by
the crankshaft and producing rotation at half engine speed. The
cam lobe is retained on the gear by a circlip, and the assembly
runs on a special shaft which is retained by the generator stator.
When the latter is removed, the small thrust spring in the end of
the shaft will probably fall away. A screwdriver can be used to
lever the head of the shaft gently outwards against the
resistance of the 0 ring seal. The gear and cam assembly will be
freed as the shaft is withdrawn, and can be lifted out through
the aperture adjacent to the crankcase mouth.
10 Dismantling the engine/gearbox unit: removing the
centrifugal oil filter
1
If the engine is in the frame the oil must be drained, the
clutch cable must be disconnected and the exhaust system and
footrest assembly must be removed first. Remove its pinch bolt
and pull the kickstart pedal off its shaft, then remove all the
screws around the outer edge of the crankcase right-hand
/
Oil pump assembly
2
Pinion casing
3
Inner casing half
4
5
Gasket
6
Drive pinion
Chapter 1 Engine, clutch and gearbox
Fig. 1.3 Oil pump and centrifugal filter - component parts
7
Pump spindle
Inner rotor
9
Outer rotor
cover. Tap the cover smartly with a soft-faced mallet to break
the seal and withdraw the cover, noting the two locating dowels
in the mating surface, also the pushrod in the centre of the
clutch. Peel off the cover gasket.
2
Slacken and remove the three screws which secure the oil
filter cover. As the cover is lifted away, place some rag beneath
the unit to catch the residual oil which will be caught inside the
filter assembly.
3
The inner half of the filter housing is retained by a slotted
nut which will require the use of a peg spanner to release it. This
tool is available as a Honda service tool, part number:
fabricate a suitable tool from a length of thick-walled tubing.
Refer to the accompanying photograph for details, cutting away
the segments shown with a hacksaw to leave four tangs. If the
machine is to be regarded as a long term purchase, it may be
considered worthwhile spending some time with a file to obtain
a good fit. The end can then be heated to a cherry red colour
and quenched in oil to harden the tangs. An axial hole can be
drilled to accept a tommy bar.
4
Lock the crankshaft either by selecting top gear and
applying the rear brake (engine in frame) or by passing a bar
through the small end eye and resting the ends on a wooden
block placed each side of the crankcase mouth. The securing
nut can then be removed, and the inner housing pulled off the
crankshaft. Note that the special washer, fitted behind the nut,
is marked outside' for reference during reassembly.
11 Dismantling the engine/gearbox unit: removing the oil
pump
1
The oil pump is retained by two screws which pass through
the inner pinion casing into the crankcase. It will be noted that
the front half of the pinion casing has two holes in it. A
screwdriver can be passed through these, and the correspond-
ing holes in the pinion in order to release the retaining screw.
The pump can then be lifted away as an assembly.
17 Nut
18 0 ring - 2 off
23
20 Screw - 2 off
21 Screw - 2 off
22 Screw - 3 off
23 R pin
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