Damaged kickstarter stop plate (94). Can only be due to violent backfire
causing excessive ignition advance, or too much throttle when starting.
Drill the rivet head to remove swaging and push out the pin.
Kickstarter spring disengages. This is due to the end of the spring taking
'a set' where is is located in the cover. Usually it is preferable to fit a
new spring.
Gear box noises. First check oil content. After considerable mileage
check layshaft bearing for wear, also layshaft fixed gear pinion (36).
Removing the kickstarter axle (45). Lever out the kickstarter return
spring from its anchorage in the cover, the opposite end of the spring will
come out easily, then pull out the axle.
To replace kickstarter assembly. Fit kickstarter axle, with pawl assembled
in cover, turn the axle so that the hole in it for the return spring is at
12 o'clock.
Fit return spring on the axle, insert the end of the spring, which is
turned down vertically into the hole drilled in axle. Using tool recom-
mended for spring removal, hooked in opposite end of spring, pull the
spring sufficiently to enable the turned in end to enter hole drilled in the
cover.
Replace inner and outer cover as detailed previously.
Dismantling the gear box. (Figures in parenthesis apply to Fig. 17.) If the
gear box is to be completely dismantled, first remove the clutch as
detailed for 'removing engine from frame', including the rear portion of
the front chain case. Have available a new set of gaskets.
Removing the outer cover (56). Remove drain plug (15), catch oil as it
drains.
Remove inspection cap (66) and disconnect clutch cable inner wire,
Remove bolt for indicator (62) leave pedal in position.
Remove kickstarter crank bolt (90) and take off the crank.
Remove five cheese-headed screws securing cover (68).
Remove cover by pulling on the gear change pedal.
Removing the inner cover (47). Remove ratchet plate and spindle (5).
Remove clutch operating arm and roller (82).
Remove lock ring (80), take away the body and ball.
Remove mainshaft nut (74).
Remove seven nuts (89) securing the cover.
Remove cover by tapping the rear portion until it is clear of the dowels.
Removing gear box internals. Remove low gear on mainshaft (39).
Remove striker fork (25) by unscrewing.
Remove striker forks (33 and 34).
Remove clutch push rod.
Remove mainshaft (11) with the gears on it.
Remove layshaft and gears; it may be necessary to rock the shaft side-
ways to extract from bearing.
Removing the cam plate (26). Remove the dome nut (20) and take out
the spring and plunger.
Remove two bolts (28 and 29) over the plunger housing.
Remove the cam plate and quadrant.
Removing the sleeve gear (23). Remove screw fixing lock plate (4).
63
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