Clutch Dismantling
Before dismantling the clutch, the primary chain case cover must be removed as
described under Front Chain on page 22. The clutch springs must be compressed by
pressing the outer plate inwards until the circlip retaining the spring pressure plate
can be removed. Care must be taken to see that the springs are properly compressed
as damage may result if they are released suddenly and the job is best accomplished
with the aid of special clutch spring compressing tool 61-3191. When the spring
pressure plate is removed the three plates carrying friction pads can be withdrawn,
together with their mating plain plates. If the pads are burnt or otherwise damaged,
the plates should be replaced. Re-assembly is carried out in the reverse order.
Gearbox
The gearbox, although built in unit construction with the engine, is self-contained
as regards lubrication. Engine oil is used for lubricating the gears and primary drive,
and the correct level is determined by a dipstick incorporated in the gearbox filler
plug. (A, Fig. 6.)
Note. The oil used must be of grade S.A.E. 40 (page 20). Self-mixing engine oils
must not be used.
When topping up the gearbox pour the oil in until it just reaches the bottom of the
dipstick attached to the plug when the latter is placed in position, so that when it is
screwed down the oil level will reach the graduation.
To change the oil in the gearbox, remove drain plug E (Fig. 5) at the bottom of the
gearbox and drain out the old oil. Wash out the gearbox with flushing oil and refill
with new oil through filler hole A, to level of dipstick.
WHEELS
Hubs
These are fitted with ball journal bearings, and no adjustment is either provided or
required. The bearings are packed with grease during assembly and this should last
until the machine needs a complete overhaul.
Front Wheel Removal
Disconnect the brake cable at the lever on the brake cover plate and then remove
the nut securing the cover plate to the fork leg. Remove the caps at the bottom of the
fork legs, supporting the wheel as this is being done and withdraw the wheel. When
replacing make sure the spindle ends are level with the end faces of the caps.
Rear Wheel Removal
Disconnect the speedometer cable from the drive unit and unscrew the adjuster
from the brake rod. The rear chain should be disconnected at its spring link and
unwound from the rear wheel sprocket. It is advisable to leave the chain in position
on the gearbox sprocket. It will also be necessary to uncouple the brake plate arm
from the swinging fork. Finally, slacken the spindle nuts sufficiently to allow the
wheel to be withdrawn. During re-assembly make sure that the brake plate bolt is
securely tightened. Check also that the chain adjusters are firmly against the ends of
the lugs.
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