Service Sheet No. 1003 (contd.)
Make sure that the petrol tap s turned off and uncouple the banjo un on at the carburetter end of the
petrol p pe. Be careful not to lose the two f bre washers or the small gauze f lter wh ch s f tted ns de the banjo
un on.
The petrol tap rod s supported by a bracket wh ch s secured to the nears de rocker cover stud; remove the 4
¼ nch nut on ts stud l ft the bracket off the stud and sw ng t to one s de. Replace the nut loosely on the
stud to reta n the f bre and steel washers.
On the r ght-hand s de of the mach ne w ll be seen the gearchange lever, f tted to the quadrant sp ndle; take
off the nut secur ng the lever to the sp ndle end and pr se the lever off the squared end of the sp ndle.
Now depress the k ckstarter lever and d sconnect the cha n from the lever by remov ng the spr ng
l nk.
The k ckstarter sprocket and the cha n can be removed after the un t has been taken out of the frame,
but the sprocket can be removed at th s stage f necessary, t s f tted on to a taper shaft wh ch s keyed.
Remove the nut secur ng the sprocket, and w th an open-ended spanner beh nd the sprocket and aga nst
the adjacent Ph ll ps head screw, tap the end of the spanner sharply so as to jerk the sprocket from the
taper on the shaft.
D sconnect the speedometer dr ve from the rear hub by unscrew ng the un on nut (F g. 3). The
speedometer dr ve cable s the upper of the two cables wh ch run to the rear wheel, the lower one
be ng the brake cable. Also d sconnect the rear brake cable by tak ng out the spl t p n and clev s
p n wh ch secure the cable end to the brake lever on the rear hub.
Remove the two black and yellow w res wh ch run from the d str butor to the left-hand and r ght-
hand gn t on co ls by tak ng off the two nuts on top of the co ls. Note that the longer of the two
cables (black and yellow) goes to the r ght-hand co l.
W th a su table tool such as a screwdr ver or a hammer shaft, press n the clutch lever on the
eng ne, sl p the n pple out of the lever, pull the outer cas ng out of the lug and place the spr ng on
one s de. Push the cable down under the frame out of the way.
It w ll now be necessary to turn to the left hand s de of the mach ne, and here w ll be seen the curved support
arm on the rear dr ve un t. Th s support arm must be removed before the un t can be taken out of the frame,
s nce t passes round the left-hand vert cal column of the frame.
Unscrew the three nuts at the rear of the curved arm wh ch secure t to the rear dr ve and remove the hollow
bolt at the front end of the curved support arm, (th s s the bolt wh ch also carr es a grease n pple). Take off
the large d ameter steel washer wh ch s pegged.
Now d sconnect the lower end of the rear suspens on damper un t, and sw ng the damper un t up and out of the way.
Ra se the rear dr ve and gently pr se off the curved support arm. L ft ng the rear dr ve un t w ll allow
suff c ent clearance for the support arm to pass over the p ll on passenger's footboard.
The three bolts wh ch secure the rear end of the support arm should now be taken away s nce they are
l able to foul the frame as the un t s be ng removed.
Remove the rear mudguard by tak ng out the four 1/4 n. d ameter nuts and bolts, two at the front on
the cross member between the two vert cal tubes of the frame and two at the rear wh ch also carry the
s lencer and petrol tank support bracket.
Unscrew the two 3/8 n. nuts on the bolts attach ng the eng ne un t to the two vert cal frame tubes at
the rear of the frame. On the left-hand tube t w ll also be necessary to take out the two 1/ 4 n. bolts secur ng
the quarter port on of the cl p. Dr ve the bolts part ally through but st ll allow them to support the eng ne.
Now remove the front eng ne plates by tak ng off the nuts on the two crankcase studs and remove the two
5/16 n. bolts and nuts wh ch secure the "L" shaped eng ne plates to the chass s cross member. When the
bolts secur ng the plates to the cross member have been removed sl de the plates off to left and r ght from
the studs. The eng ne w ll now be supported only by the two 3/8 n. bolts through the rear brackets.
D sconnect the generator cables by break ng the connectors wh ch w ll be found underneath the
floorboards. Th s operat on w ll be eas er to carry out f each connector s broken nd v dually.
The un t s now ready to be taken out of the frame, and t s qu te easy to do so prov d ng the correct
procedure s adopted, wh ch s to dr ve out the two bolts hold ng the eng ne to the vert cal frame tubes, t lt
the un t forward so that the lugs on the eng ne clear the lugs on the frame and then t lt t s deways
towards the left-hand s de, at the same t me l ft ng t out. Th s w ll enable the rear dr ve to pass between
the two vert cal tubes.(Caut on to do ng yourself an njury through th s as t s awkward and heavy)
Complete d smantl ng of the eng ne, gearbox and f nal dr ve un t s descr bed on Serv ce Sheet No. 1004.
