Specifications

36
Chapter 1 Engine, clutch and gearbox
2 Fit the neutral switch contact to the end of the selector
drum, and then lower it, contact downwards, into the crankcase
half, so that the contact aligns with the neutral switch. It will be
necessary to lift the selector fork assembly slightly, so that the
selector fork pins can be engaged in their tracks in the selector
drum. When the assembly has been installed correctly, lubricate
it with engine oil, and check gearbox operation by turning the
selector drum.
3 Lubricate the crankshaft big end and main bearings with
clean engine oil, then lower the assembly into position in the
crankcase. The main bearing bosses will not require heating in
order that the bearings may be fitted, as they are fitted with
steel inserts which mean that a simple, sliding, fit is possible.
4 The assembled kickstart mechanism should now be
installed in the right-hand crankcase half; slide the assembly
into position, ensuring that the return spring engages in its hole
in the casing. The upper half of the ratchet should be pulled
upwards, the assembly twisted clockwise, and then pushed
inwards to engage the stop. The assembly will now be retained
by the pressure of the return spring.
32.2a Slide 3rd gear pinion (20T) onto mainshaft, fit washer
and circlip, then ...
32.2b ... fit 4th gear pinion (23T), washer and circlip
32.2c Fit circlip, followed by ...
32.2d ... slotted washer and
32.2e ... 5th gear pinion (25T), dogs inwards