pinions is clearly illustrated. Ensure the plunger and springs are in posi-
tion in the gear box shell.
For clarity, assemble in the following order:
(1) Fit footchange spindle and quadrant.
(2) Take up the main shaft fit first, second and third gear, enter shaft
through sleeve gear.
(3) Fit mainshaft selector fork and locate it in quadrant.
(4) Take up layshaft fit second and third gear, enter shaft in bush.
(5) Fit layshaft selector fork and locate.
(6) Pass selector fork shaft through both selectors and screw home.
(7) Fit low gear pinion.
Precautions during assembly of gear box.
(1) Make sure the selector forks 041341/3 are correctly indexed.
(2) If the end cover does not go back properly, do not use force, take
off the cover and find out what is wrong.
(3) Make sure all gaskets are undamaged, stick them on to the gear box
and covers some time before they are refitted.
(4) Make sure the small peg inside the ball race housing has not fallen
out. This locates the clutch operating body,
(5) Insert the pin 042143 for clutch body from the top end. If this pin
is a loose fit, give the top end a few light blows with a hammer to deform
it and make it fit tight.
(6) Put a little clean oil on all moving parts.
DO NOT OMIT TO FILL THREE PINTS (1.8 LITRES) OF SAE 50 OIL.
The kickstarter axle. Should it be necessary to dismantle the kickstarter,
take off the gear box end cover as described elsewhere. The ratchet pinion
041300 is in tension by the ratchet spring 041358. To relieve this tension
temporarily, fit the kickstarter crank, and depress it which will release
the pinion and enable it to be taken away.
Remove the circlip encircling the shaft, should one be fitted, prise out
the end of the return spring 040045, the shaft can now be extracted.
CSR Models. The gear box for the CSR model is identical to the standard
machines, with the exception of the clutch, which is the same as used on
the 350 lightweight. See technical data for gear ratios.
CLUTCH—LIGHTWEIGHT
To dismantle the clutch, remove outer portion of front chain case (see
ENGINE SERVICE).
Remove the three clutch spring adjusters, take out the springs and cups.
Take out the clutch plates, noting the order in which they are removed.
Remove the clutch body from the mainshaft. Use a box spanner F"
across the flats. Engage top gear, use the tool to stop the clutch from
rotating whilst the nut is unscrewed as shown in Fig. 8. Alternatively press
hard on the rear brake lever to hold the clutch stationary.
Usually the clutch will came off the shaft splines without the use of an
extractor tool.
Friction material is bonded to the plate. When new the segments pro-
trude
3
/
64
".
Check the steel plates. If they are not flat, the clutch will slip. Put all
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