Specifications

Working conditions and tools
When a major overhaul is contemplated, it is important that
a clean, well-lit working space is available, equipped with a
workbench and vice, and with space for laying out or storing the
dismantled assemblies in an orderly manner where they are
unlikely to be disturbed. The use of a good workshop will give
the satisfaction of work done in comfort and without haste,
where there is little chance of the machine being dismantled
and reassembled in anything other than clean surroundings.
Unfortunately, these ideal working conditions are not always
practicable and under these latter circumstances when
improvisation is called for, extra care and time will be needed.
The other essential requirement is a comprehensive set of
good quality tools. Quality is of prime importance since cheap
tools will prove expensive in the long run if they slip or break
when in use, causing personal injury or expensive damage to
the component being worked on. A good quality tool will last a
long time, and more than justify the cost.
For practically all tools, a tool factor is the best source since
he will have a very comprehensive range compared with the
average garage or accessory shop. Having said that, accessory
shops often offer excellent quality tools at discount prices, so it
pays to shop around. There are plenty of tools around at
reasonable prices, but always aim to purchase items which meet
the relevant national safety standards. If in doubt, seek the
advice of the shop proprietor or manager before making a
purchase.
The basis of any tool kit is a set of open-ended spanners,
which can be used on almost any part of the machine to which
there is reasonable access. A set of ring spanners makes a useful
addition, since they can be used on nuts that are very tight or
where access is restricted. Where the cost has to be kept within
reasonable bounds, a compromise can be effected with a set of
combination spanners - open-ended at one end and having a
ring of the same size on the other end. Socket spanners may also
be considered a good investment, a basic
3
/8 in or
1
/2 in drive
kit comprising a ratchet handle and a small number of socket
heads, if money is limited. Additional sockets can be purchased,
as and when they are required. Provided they are slim in profile,
sockets will reach nuts or bolts that are deeply recessed. When
purchasing spanners of any kind, make sure the correct size
standard is purchased. Almost all machines manufactured
outside the UK and the USA have metric nuts and bolts, whilst
those produced in Britain have BSF or BSW sizes. The standard
used in USA is AF, which is also found on some of the later
British machines. Others tools that should be included in the kit
are a range of crosshead screwdrivers, a pair of pliers and a
hammer.
When considering the purchase of tools, it should be
remembered that by carrying out the work oneself, a large
proportion of the normal repair cost, made up by labour
charges, will be saved. The economy made on even a minor
overhaul will go a long way towards the improvement of a
toolkit.
In addition to the basic tool kit, certain additional tools can
prove invaluable when they are close to hand, to help speed up
a multitude of repetitive jobs. For example, an impact
screwdriver will ease the removal of screws that have been
tightened by a similar tool, during assembly, Without a risk of
damaging the screw heads. And, of course, it can be used again
to retighten the screws, to ensure an oil or airtight seal results.
Circlip pliers have their uses too, since gear pinions, shafts and
similar components are frequently retained by circlips that are
not too easily displaced by a screwdriver. There are two types of
circlip pliers, one for internal and one for external circlips. They
may also have straight or right-angled jaws.
One of the most useful of all tools is the torque wrench, a
form of spanner that can be adjusted to slip when a measured
amount of force is applied to any bolt or nut. Torque wrench
settings are given in almost every modern workshop or service
manual, where the extent to which a complex component, such
as a cylinder head, can be tightened without fear of distortion or
leakage. The tightening of bearing caps is yet another example.
Overtightening will stretch or even break bolts, necessitating
extra work to extract the broken portions.
As may be expected, the more sophisticated the machine,
the greater is the number of tools likely to be required if it is to
be kept in first class condition by the home mechanic.
Unfortunately there are certain jobs which cannot be
accomplished successfully without the correct equipment and
although there is invariably a specialist who will undertake the
work for a fee, the home mechanic will have to dig more deeply
in his pocket for the purchase of similar equipment if he does
not wish to employ the services of others. Here a word of
caution is necessary, since some of these jobs are best left to
the expert. Although an electrical multimeter of the AVO type
will prove helpful in tracing electrical faults, in inexperienced
hands it may irrevocably damage some of the electrical com-
ponents if a test current is passed through them in the wrong
direction. This can apply to the synchronisation of twin or mul-
tiple carburettors too, where a certain amount of expertise is
needed when setting them up with vacuum gauges. These are,
however, exceptions. Some instruments, such as a strobe lamp,
are virtually essential when checking the timing of a machine
powered by CDI ignition system. In short, do not purchase any
of these special items unless you have the experience to use
them correctly.
Although this manual shows how components can be
removed and replaced without the use of special service tools
(unless absolutely essential), it is worthwhile giving considera-
tion to the purchase of the more commonly used tools if the
machine is regarded as a long term purchase Whilst the alterna-
tive methods suggested will remove and replace parts without
risk of damage, the use of the special tools recommended and
sold by the manufacturer will invariably save time.