TRANSMISSION
(GEARBOX)
D
Fig.
06.
Klckstart
quadrant
and
spring.
Arrow
Indicates
correct
spring
location.
To reassemble the
mechanism.
first refit
the
sleeve, spring, pinion and
ratchet
to
the
transmission
mainshaft,
and
reassemble the tab washer. Then
screw
on
the
retaining nut
to
the
torque
figure
given
In
"General Data".
Do
not
over-tighten
the
retaining
nut
as
this
may
result
in
failure
of
the
inner
steel
sleeve.
Fit
the
return
spring
to
the
kickstart
quadrant
as
shown
In
Fig.
06.
Assell'l:le
the
spindle Into
the
~Id
st'rt
bush, and locate
the
return
spring
onto
the
anchor peg
at
the
rear
of
the
cover. Fit
the
oil
seal
over
the
spindle, and assemble
the
klckstart
crank, locking It Into position
with
the
cotter
pin
from
the rear. Refit
the
outer
cover
as
shown
in
Section
02.
00
not
forget
to
refit
the
oil seal.
Refill
the
gearbox with
the
correct
grade of lubri-
cant (Section A2).
SECTION
04
DISMANTLING
AND
REASSEMBLING
THE
GEARSHIFT
MECHANISM
Remove the four
nets
and locking
washers
securing
the
gUide
plate.
Withdraw
the
plate, curved
return
springs, and plungers and springs.
Thor-
oughly tlean
the
pam
In
kerosene
(paraffin) and
inspect them fer
wear
etc., as
shown
In
Section
D6.
Use a smear
of
oil
to
assist
re-assembly.
When
refitting the retainer
plat~,
remember
that a
locking washer fits under each
of
the
four nuts.
Refit
the
springs and plungers,
taking
care
that
they
are
not
suddenly ejected from
their
seats during
assembly.
It
Is
unlikely
that
the gearshift
fork
will need
to
be
removed,
but
If,
for any reason, It does, It should
be
remembered
that
it
Is
keyed
In
the
quadrant.
It
will
therefore
be necessary
to
use a
drift
or
an
arbor press
to
part
these
Items, and a similar
procedure
will be required
to
reassemble
them.
SECTION
05
DISMANTLING
AND
REASSEMBLING
THE
GEARSHIFT
CROSS
SHAFT
Remove the Left side footrest, and also
the
p'rlmary
drive
outer
cover, after draining
the
011
from
the
primary drive assembly. Remove
the
nut
and
washer from the end
of
the
cross
over
shaft.
Note
the
position
in
which
the
cross shaft
quadrant
is
fitted, and remove
the
quadrant
from
the
shaft.
Take off
the
transmission
outer
cover
on
the
right
side of
the
machine,
as
described
In
Section
02.
The cross-over shaft
can
then
be
withdrawn
from
the
right side.
Note
that
the
spllned end
of
the
shaft
Is
to
the
right side of
the
machine.
Reassembly
Is
mainly a reversal
of
the
dismantling
procedure.
The
cross-shaft
quadrant
on
the
drive
side should be fitted
In
the
position from which
it was removed (See Fig.
07).
Next,
refit
the
transmission
outer
cover,
taking
care
to
position the cross shaft link lever ready for
fitting
onto
the
splines
of
the
cross shaft as
the
cover
Is
tapped home.
The
refitting
procedure
is
detailed
in
Section
02.
On
the
primary drive side,
check
that
the
gasket
is
In
good condition.
If
any
doubt
exists,
it
should be
replaced.
Use
a smear
of
grease
when
locating it
.on
the
Joint face.
07
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