rear engine plate with distance pieces behind it. Release the two clamp
nuts then take away the plate and the gear box.
Take out the engine by:
Removing five studs passing through the crankcase and frame.
Raise the rear end of the crankcase—pull it back and out of the frame.
If difficulty exists, take the machine off the central stand the frame will
open and let the engine come out.
Dismantling the engine. Before dismantling, study the exploded view of
the engine.
Special tools required.
(1) Extractor bolt for automatic ignition device 042247.
(2) Small timing pinion extractor 043332.
(3) Clutch withdrawal tool 040449—only required when clutch is a
tight fit on the shaft.
With engine removed from frame.
Remove drain plugs from crankcase and oil reservoir.
Remove contact breaker base plate—use tool 042247.
Remove four bolts for cam housing—gently tap it to remove,
Remove nine bolts for reservoir, it will then come away.
Remove small timing pinion nut RIGHT HAND THREAD then strip
down the timing gear in the following order.
(1) Camshaft.
(2) Camshaft distance piece—wide,
(3) Camshaft follower exhaust.
(4) Camshaft distance piece—narrow.
(5) Camshaft follower, inlet.
Warning. An attempt to separate the crankcase halves, without first
removing the oil pump plunger 042178 will result in serious damage, by
making the crankcase beyond further use.
Remove oil pump guide pin 010079 and sleeve 010138.
Remove screwed plug and 'O' ring 042178,
Remove oil pump plunger 042104—insert a piece of rod in the spindle
hole to extract it.
Remove felt filter cap 042058, take out the filter.
Remove six crankcase bolts 042035, one bolt 042036, also stud 016103
—the timing case half can now be separated from drive side.
Remove the breather stator fixing tube at the rear of the crankcase.
On engines after number 8979 the stator is fixed by a bolt below the drive
side bearings.
The crankcase must be heated to relieve the interference fit of the
bearings in the crankcase—not above 200 centigrade, when the crankcase
will come away leaving the ball bearing in the case.
Re-heat the case—use a drift to drive out the ball bearing,
Take off the breather stator from the shaft, watch for the key which
must be removed before taking off the inner bearing.
Dismantling the flywheels. A flywheel separating tool is shown in Fig. 7,
With one crank pin nut removed place the tool over the flywheels as
shown—position the draw bolt. By screwing in the bolt the flywheel will
come away from the crank pin.
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