TO RE-ASSEMBLE
If gears have been disturbed insert them in their proper order with slider shafts in
correct location and apply end plate with paper joint gasket in position.
Re-fit the three cheese head screws and firmly tighten down with a stout screwdriver-
Then insert conical ended plunger and spring and apply the gear selection cam barrel
with anyone of the depressions on its underside engaging with the conical end of the
spring loaded plunger.
Next insert the selector shaft pins and secure each in position with its split pin.
Complete the assembly in reverse order of dismantling ascertaining, before applying the
K.S. case cover, that the ball is inserted in the end of the mainshaft.
Fill to correct level with one of the recommended oils and lastly re-fit the gear indicator
disc and adjust its position to give correct indication of gears.
TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY
To remove outer half of front chaincase
Place tray under chaincase to catch oil.
Remove left side footrest arm.
Remove screw binding chaincase metal band at its rear.
Remove metal band.
Remove endless 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 COMPLETE
Unscrew the nuts retaining the clutch springs, using end of spanner Part No. 017254.
Take away the clutch spring pressure plate with the clutch springs and clutch spring cups,
and flatten the turned up part of the lock plate 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 sleeve.
Remove the lockplate and plain washer 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be displaced when the clutch centre and sprocket assembly is withdrawn from the main-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 sleeve and an extractor should
not be required.
TO REMOVE DYNAMO CHAIN AND BACK HALF OF
CHAINCASE
Remove engine sprocket nut and withdraw shock absorber spring, cupped washer and
cam.
Remove the spring lock ring on dynamo sprocket retaining nut.
Take away lock washer surrounding dynamo sprocket nut.
Apply spanner (017254, included in too! kit) to the two flats on the back of the dynamo
sprocket and, holding same, unscrew the nut retaining the dynamo sprocket. Holding
sprocket thus relieves the dynamo shaft of bending strain.
Release dynamo sprocket with suitable extractor.
Take away, as one assembly, the dynamo sprocket, dynamo chain and engine sprocket
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 wide nut and washer on centre fixing bolt, when back half of chaincase can be
taken away.
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