Remove gear indicator by unscrewing the
centre bolt from the positive spindle.
Remove the gear change lever by unscrew-
ing the pinch bolt and pulling
off
the lever.
Remove the seven cheese headed screws
holding the cover in position and withdraw
the cover carefully in order to avoid tearing
the paper washer fitted to this joint.
If
the joint
is difficult to break, there
is
a point at either
end which overhangs the inner cover to which
careful punching may be applied.
No
difficulty should be experienced when
refitting, the coverscrews should all be just
pinched down and finally tightened in opposite
pairs.
Some oil will have been lost due to the
cover removal and should be replenished
through the clutch worm inspection hole until
oil begins to drip from the level plug hole
normally plugged by the square headed
.level
plug situated to the rear of and on the
same
level
as
the
kick
starter crank.
45.
POSITIVE
FOOT
CHANGE,
DISMANTLING.
·
With the outer cover removed the positive
foot change mechanism becomes accessible.
To
dismantle, remove the
two
nuts securing
the U section outer plate and withdraw the
plate followed by the lever return spring, pawl
carrier and ratchet plate. Note that there is
a spacing shim fitted behind the latter.
It
-is
unlikely that the cam plate secured behind
the shoulders of the two studs which carry the
assembly will ever need removal, but the pro-
cedure is obvious.
46.
POSITIVE
FOOT
CHANGE,
ASSEMBLY.
·
Examine all parts for wear likely to result
in
lost movement, particularly the spindle
bushes in both covers, the ends of the pawls
and the pawl pin; obtain any replacements
necessary and re-assemble, checking first that
the two studs are quite secure and placing the
spacing shim on the short shaft of the ratchet
plate. Remember to insert the knuckle pin
visiole through the aperture in the inner cover
into the hole in the ratchet olate arm whilst
the ratchet plate is being fitted. Spread the
pawls
to enter the ratchet teeth whilst pushing
home the pawl carrier.
47•
INNER
COVER,
REMOVAL.
Screw the clutch cable adjuster
as
far down
as
possible, and with a large screwdriver and
movable spanner, rotate the clutch worm lever
in a
clockwise
direction till the cable nipple
.
20
.is clear of the lever. and withdraw the cable
from its slot in the lever. Unscrew the adjuster ·
and the cable is completely disconnected from
the gearbox.
Remove the eight nuts securing the cover
and withdraw
it
from the studs, being careful
not to tear the paper washer fitted to the joint.
The
cover will bring with
it
the kick starter,
. crank, clutch worm and fittings and the main-
shaft bearing.
48.
INNER
COVER,
FITTING.
Thoroughly clean the joint faces and apply a
little jointing compound to each face, place
the paper washer in position over the studs
and against the gearbox face.
Fit
the cover into.
position.
It
will probably be necessary to press
the
kick
starter pawl into its recess in the kick
starter crank before the cover can be pushed
right home.
Fit
the eight securing nuts and
washers and just pinch each one, finally
tightening the nuts
in
opposite pairs. Refit the
clutch cable and adjust as describedinpara.43.
49.
INNER
COVER,
DISMANTLING.
The
dismantling of the footchange mech-
anism having already been dealt with, only the
clutch operating mechanism and kick starter
remain ..
The
clutch worm may be completely
unscrewed from its
nut
and with the nut
removed from the cover, the main shaft
bearing may be drifted out.
The
hardened
roller in the end of the clutch worm which rubs
on the clutch thrust rod may also be drifted
out and a replacement fitted
if
necessary. Lever
off
the cupped pressing which covers the kick
starter return spring and remove the spring,
when the kick starter axle complete may be
withdrawn from its bush. This will enable
the pawl pin, pawl, plunger and spring to be
removed.
If
the nose of the pawl is badly wom
or chipped,
it
should be renewed.
It
is unlikely that the kick starter bush
will
ever require renewal,
but
it
may be drifted
out if necessary.
50.
INNER
COVER,
ASSEMBLING.
Examine the kick starter cam and stop pieces
riveted into the cover.
They
,should never
need renewing,
but
may have worked loose and
require re-riveting.
Press the kick starter axle bush and main-
shaft bush into the cover and screw home the
clutch worm nut.
Fit
kick starter pawl, plunger
and spring to kick starter axle. Remaining
parts may be fitted now or after the cover
is
fitted to the gearbox.
When fitting the kick starter return spring,
its free end which locates
in
one of the slots
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