Instruction manual

TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY

To remove outer half of front chaincase

Place tray under chaincase to catch oil.

Remove exhaust pipe and silencer, as one unit.

Remove nut on left end of footrest rod, push rod towards the right hand side of machine

sufficiently to allow footrest for left foot to be disengaged.

Slide footrest arm to one side or completely take away.

Remove screw binding chaincase metal band at its rear.

Remove metal band.

Remove rubber band.

Remove nut and washer, in centre of chaincase front.

Take away outer half of chaincase.

To remove front driving chain and clutch assembly

Engage top gear, apply rear brake, and unscrew engine sprocket nut.

Unscrew the nuts retaining the clutch springs.

Take away the clutch spring pressure plate with the clutch springs and clutch spring cups,

and flatten the turned up part of the lock washer that is under the large central nut.

Remove front chain connecting link and take away chain.

Engage top gear, apply rear brake, and unscrew nut retaining the clutch centre to the

gear box mainshaft.

Remove the lock and plain washers from gear box mainshaft.

Remove complete clutch assembly by pulling it away, as one unit from gear box mainshaft.

Take care not to lose any of the twenty-four clutch sprocket bearing rollers which may

be displaced when the clutch centre and sprocket assembly is withdrawn from the main-

shaft. The clutch centre is a sliding fit on the mainshaft and an extractor should not be

required.

To remove dynamo chain and back half of chaincase

Remove the spring lock ring on dynamo sprocket retaining nut.

Take away lock washer surrounding dynamo sprocket nut.

Apply spanner (017254, included in tool kit) to the two flats on the back of the dynamo

sprocket and, holding same, unscrew the nut retaining the dynamo sprocket.

Release dynamo sprocket with suitable extractor.

Take away, as one assembly, the dynamo sprocket, dynamo chain and engine shock

absorber assembly. (The dynamo chain is " endless.")

Straighten tabs on lock washers under the three bolts retaining the back half of chaincase

to the boss on the crankcase and remove the three bolts.

Remove the long headed bolt (under battery carrier) fixing rear chain guard to front

chaincase.

Remove nut on centre fixing bolt, and spacer behind it, and back half of chaincase can be

taken away.