10.
Removal of Engine
and
Clutch sprockets
Remove the alternator stator by undoing three nuts. The primary chafn is endless hence it
is necessary to remove both the engine and clutch sprockets simultaneously. Remove the
central hexagon nut securing the alternator rotor, which
can
then
be
drawn
off,
taking
care
not to lose the key. The engine sprocket is mounted on
splines and can be removed along with
the clutch sprocket using extractor
PED
2004
ST
1
1.
Removal of Final Drive Sprocket
.-.
Remove the clut h as described above. Remove the primary
chain
tensioner. Remove the
Y
primary chaincase mer by removing three nuts. Remove the folding of the tab washer which
is
provjded for locking the
final
drive sprocket nut. Hold the sprocket and remove the nut (right
-
hand thread). The sprocket can then be withdrawn.
12.
Re-assembly of the Clutch Plates
When re-assembling the clutch plates the following order must be observed.-The clutch pad
must
be
fitted into the main drive shaft, plain dished plate (dish projecting out wards].
Friction plate with inserts. plain flat plate. friction plate bonded.
;lain dished plate (dish
projecting inwards). friction plate bonded, clutch front plate
3
springs on the clutch centre
lugs.
CLUTCH ASSEMBLY
In
the case of 500cc one more plain
flat plate and one friction plate
will
also
have to be
fixed
aftkr the plate with
inserts
has been assembled.
The other three
springs are located by
means of bosses on the clutch cap.
Tighten the
spring pins
as
far as they
will
go.
If
the clutch lifts unevenly, it
is
probable that one of the springs has taken
a
set.
in
which case new spring should be
fitted.
The friction plate with inserts should
be renewed
if
badly worn or when the
inserts have become loose in their plate.
The bonded friction plates require renewal
when worn or charred.
(A
light change to
a blackish colour should not be mistaken
as
shamed). Excessive or premature wear
of the plates is due to either
running the vehicle at
hd
clutch application or depriving the
clutch plates of oil, with insufficient or no
ofl
in
the clutch chain case.
13.
Primary
Chain Adjustment
Access to the primary chain adjuster is gained by removing the primary chain cover which
is held
in
position by a single nut. Before removing the nut, place a bay under the engine to
collect
the
oil from the chaincase.
Beneath the bottom
run
of the chain is a curved slipper chain tensioner pad on which the
chain rests. This can be raised or lowered by turning the
adjusting screw below the
chain
tensioner pad after having first slackened the locknut.
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