First try the effect of releasing the nut fixing the cotter pin on the left
side of the arm. Tap the cotter pin upwards, then knock together the two
tubular members and drive back the cotter pin and retighten. This will
absorb end play, which is often associated with wear in the bushes.
To remove the bushes. Both bushes are a press fit in the frame. They can
be removed by using a tubular drift passed through one of the bushes.
The finished size of the bush in situ is ¾" +.0075" —.005". Pack the
spindle orifice with graphite grease before fitting swinging arm.
The accessory compartment. The ignition coil and electric horn are ex-
posed after removing the accessory cover on the left side of the machine,
by unscrewing the knurled knob then taking out the two ¼" diameter
bolts and nuts at the bottom of the compartment,
Tool box compartment. Fitted to the right side of the machine. Remove
the knurled knob, the tools are located in a second compartment, the lid
is secured, also by a knurled knob. To remove the compartment, take out
two
c" bolts and nuts which are visible when the lid is opened.
The central stand. The central stand pivots on the footrest rod. To re-
move the stand, take the footrest arms and with no load on the stand,
drive out the footrest rod. There is a distance piece together with a stop
plate each side of the engine support channel.
The stand spring. Usually trouble free. The spring is anchored between
the operating rod and a spacer. The spacer is secured by a recess in the
channel. Spring the channel apart, the spacer will fall out.
The stand stop. Is fitted between the right side pillion footrest arm and
the frame channel.
A rubber grummet, which is detachable, goes through the bracket to
prevent metallic contact.
Frame strip down (Heavyweight Model). Strip down as detailed for re-
moving the engine and gear box.
Take out both wheels, also take off the head lamp and loom by:
Disconnecting the battery wires and removing the twin seat.
Disconnecting horn, coil and rectifier cables (if alternator model),
Disconnecting control box cables (if fitted) and take it out of the tool
box,
Disconnecting stop light switch and rear lamp wires.
Release screw on head lamp rim and take it away with reflector
assembly. Disconnect main and pilot bulb wires; also speedo lamp wire.
Place the reflector in a safe place.
Disconnect speedo drive cable, pass the cable through the head lamp
and fork crown.
Remove dipper switch with cables,
Remove head lamp bolts, release clips on frame, take the head lamp
away with the loom.
Remove the front forks as described in 'Fork' section.
Remove frame cover, secured by two slotted screws.
Remove oil tank by taking out the top front fixing bolt.
Remove air cleaner (two bolts).
Remove tool box attached to rear frame loop by two ¼" bolts.
Remove both rear suspension units.
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