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DISMANTLING THE KICKSTARTER
When the gear box cover is removed, the kickstarter mechanism will come out with
the cover.
The face ratchet pinion is under tension of the ratchet spring, to remove this pinion
temporarily fit the kick-starter crank and relieve the spring tension, the pinion will then
be released.
Remove the circlip located in the kick-starter shaft if fitted.
To remove the kick-starter shaft prise out the end of the return spring from its anchorage,
the shaft can then be extracted.
REFITTING T H E GEAR BOX END COVER
W i t h the kick-starter mechanism assembled the end plate can be refitted in the reverse
order described for dismantling.
The gasket must be undamaged to avoid oil leakage. The only necessary precaution is to
ensure that the foot change operating parts are in correct order by first fitting the thin
washer with the largest diameter hole over the shaft for the foot change spindle before
the gear box end cover is fitted.
the spindle followed by the foot change ratchet, the washer for the pawl spring and finally
the foot change ratchet and shaft nut.
particular note should be made of the pawl spring location.
The outer pawl spring washer is shaped to hold it in position, whilst the cover is refitted.
When the assembly is completed, ensure the gear box drain plug is firmly tightened and
refill with 3 pints of S.A.E. 50 oil, as shown in the list of recommended lubricants.
Allow time for the oil to seep through.
TO REMOVE THE SLEEVE GEAR SPROCKET
It is preferable to remove this sprocket with the end plate in position.
instructions to dismantle the clutch.
Take off the rear portion of the primary drive cover, after removing the six fixing screws.
The nut securing the sleeve gear sprocket is firmly tightened and has a LEFT HAND
thread.
A well fitting ring spanner is required to release it after turning back the tab washer.
Engaging top gear and pressing the rear brake pedal will prevent the gear sprocket
turning, whilst the nut is unscrewed.
Disconnect the rear chain, the sprocket is on a splined gear and can be extracted without
difficulty.
REFITTING THE SLEEVE GEAR SPROCKET
As this sprocket is part of the transmission and subjected to reversal loads, the importance
of firmly tightening the fixing nut cannot be too highly stressed. Turn down the tab
washer and assemble in the reverse order given for dismantling.
TO REMOVE GEAR B O X INTERNALS
If the gear box is to be completely dismantled, remove parts in the following order:—
the clutch, sleeve gear sprocket and the gear box end cover.
With the gears exposed unscrew the selector fork shaft, using a spanner on the two flats
machined on it, the gears, shafts and operating mechanism can then be withdrawn.
The spring loaded plunger and cam plunger bolt are situated immediately below the
sleeve gear sprocket.
TO ASSEMBLE GEAR BOX INTERNALS
Fit the mainshaft with gears in the sequence shown in the illustration.
plunger and spring for the cam segment are in position, then insert the cam segment
assembly.
Take up the selector fork with the projection at three o'clock and put the fork in the
slot for the slider gear with the projection in the profiled slot in the cam segment.
Fit the layshaft with gears, i.e., fixed and free pinion. Take up the sliding gear, fit the
remaining selector fork into the sliding gear, slip the gear on the layshaft and engage the
projection in the cam segment slot.
tighten.
Fit the low gear pinion to complete the assembly.
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After fitting the end cover the thick washer goes over
The assembly is clearly shown in the illustration,
Line up the selector forks and refit the shaft and
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Follow the
Ensure the
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