TRANSMISSION
(GEARBOX)
D
the
kickstart
return
spring
for
fatigue
cracks
and
signs
of
wear,
particularly
·at
the
centre
where
It engages on
the
splines
of
the
spindle.
(2)
Examine
the
klckstart
spindle
bush
for
wear.
If the required measuring Instruments are not
available, use
the
spindle
as a gauge and feel
the
amount
of
play.
(3)
Examine
the
klckstart
ratchet
mechanism for
wear, paying particular
attention
to the rarcher
teeth,
ensuring
that
they
have
not
become
chipped
or
rounded.
Check
that
the
thin
steel
bush
is
a clearance
fit
in
the
kicks
tart
pinion, and
that
the
spring
Is
not
badly
worn.
(4)
Finally, check
that
the
klckstart
stop
peg
is
firmly
pressed
Into
the
Inner
cover, and
Is
not
distorted.
SECTION
D7
RENEWING
KICKSTART
AND
GEARSHIFT
SPINDLE
BUSHES
If
It
.Is
found necessary
to
renew
the
klckstart
spindle bush, this
s~ould
be
done
by
completely
stripping
the
outer
cover
of
Its
assembly
parts
and
heating It
to
100·C. (boiling
water
temperature),
then
driving
the
bush
out
using a
suitable
shouldered
drift. Press
In
the
new
bush
while
the
cover
Is
still
hot.
Adopt
a similar
procedure
for
rc:noval
of
the
outer
cover
gearshift spindle
bush.
The
Inner
cover
bush
does
not
usually we2r much,
even
after great
mileage has been
covered.
However,
If
It
Is
required
to
renew
the
bush,
the
Inner
cover
should
be'
removed (Section
DB),
and
the
camplate operating
quadrant
disconnected.
Using a suitable tap (e.g.
~
In.
dla. x 10
Whit.),
cut
a thread
In
the
bush
to
a
depth
of
~
In.; heat
the
cover
to
10Q·C.,
then reinsert
the
tap. or, prefer-
ably, a sulta&le bolt.
Grip
the
bolt
(or
tap) firmly
In
a vice, then drive the cover away, using a hide
mallet, until
the
bush
Is
free.
A press
or
SUitably
shouldered
drift
Is
required
to
drive
In
the
new bush, which
shoul~
be
done
whilst
the
tover
Is
still hot.
SECTION
D8
DISMANTLING
THE
TRANSMISSION
(GEARBOX)
Remove
the
outer
cover
as snQwn
In
Section
D2,
leaving
the
transmission
with
5th
(top)
gear
selected.
Remove
the
rear
right
engine
mounting
plate,
together
with
the
rear
brake
pedal (See Section
B1
page
B5).
Straighten
the
tags
on
the
lock
washer,
and
unscrew
the
klckstart
pinion
ratchet
retainer
nut
from
the
end
of
the
malnshaft. This
should
be
easily achieved
with Sth (top)
gear
selected
and
the
rear
brake
applied.
Remove
the
outer
primary
cover.
and
dismantle
the
drive,
shown
In
Section C,
not
forgetting,
finally,
to
remove
the
key from
the
transmission
mainshaft.
The
gearbox
inner
cover
Is
retained
by a
socket
screw,
tWO
cross head
screws,
and a
bolt
(See
Fig.
DB).
When
these
are
removed,
the
cover
can be
released by tapping It
outwards
with
a
hide
mallet.'
Withdraw
the
engaging dog from
the
layshaft (See
Fig.
09). Then remove
the
c1rcllp from
the
end
of
the layshaft with a pair
of
c1rcllp pliers. Pull
the
selector rod
oUt
and
then
remove
the layshaft first
gear with Its selector fork.
Withdraw
the
second
gear from
the
lays
haft and
then
remove
the
main-
shaft complete with first,
second,
and
third
gears
In
position. Remove
the
malnshaft fourth and
lay-
shaft
third
gears with
their
selector
forks, and
then
withdraw
the
layshaft
with
the
fifth and fourth gears
In
position. Detach
the
two
brass
thrust
washers
which locate over
the
needle
roller
bearings.
Before removal of
the
camplate,
the
malnshaft high
gear will have
to
be
detached
from
the
gearbox
sprocket, and withdrawn from
the
crankcase. This
can
be
done
by
removing
the
circular plate from
the
primary Inner coYer at
the
rear
of
the
clutch.
tapping back the
bent-over
portion
of
the
locking
plate, and unscreWing
the
large hexagonal
gearbox
sprocket
nut
(1.B75"
across
the
flats).
To
facilitate
removal
of
the
nut,
Workshop
Tool
number
60-6125
09
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