Maintenance Manual and Instruction Book, 16H, Big 4, 18 and ES2

Fit steel band on to the sprocket. This should not be tight enough to distort the sprocket. Check all the clutch plates in the sprocket and on body for freeness. Fit sprocket to body. Revolve sprocket on race to check free movement. Fit plates to sprocket and body. Order of fitting is—plain steel, inserts, plain, etc. It will be noticed- on examination that the plates are slightly bevelled on the one edge. Fit the bevelled edge towards the sprocket. Revolve sprocket, ensuring that the plates are free. Fit circlip, retaining the plates, and fit clutch to Gearbox axle. Fit clutch thrust pin, clutch outer plate, spring cups, springs, and spring pins. Tighten right home. Fit oil bath outer portion. (Para. 42.) 48. REMOVAL AND DISMANTLING OF GEARBOX END COVER. Removal of end cover and gears may be readily carried out with the gearbox in position but for a complete overhaul it is best removed from the frame. Remove split cotter and pin from the jaw joint on the control rod. Remove the nuts holding the end-cover to the box, and remove end-cover complete. Remoye kick-starter axle return spring and cover from the bush, and the kick-starter pawl pin from axle, when the pawl, plunger, and spring are free. Remove clutch worm lever from worm, also the clutch worm nut. Pressed into the end-cover is the steel bush, that carries the kick-starter axle. /The head of the bush is recessed to take a compressed cork washer. The end of the axle is bored out and a phosphor bronze bush is pressed in, to carry one end of the layshaft. In the cover a ball journal bearing is pressed, to carry the end of the mainshaft (or axle). Between this bearing and the kick-starter wheel, a dished steel washer is fitted, with the concave side next to the bearing. The bem-mg can be pressed from the panel. /

Examine the back cover plate iace for wear by the clutch body centre. Examine clutch shock absorber rubbers. They may have become soft or cracked. 45. ASSEMBLY OF CLUTCH. Fit clutch body back cover plate to body, ensuring that the holes in the cover plate are in line with the holes in the body, and the spring studs an easy fit. Fit clutch body centre and fit clutch large shock absorber rubbers in the position to take the drive. Compress the rubbers in position and fit the small ones. Fit body front cover and tighten screws. Fit roller race on to the back cover plate, fit clutch back plate, and spring studs, fit stud nuts and tighten. Lock nuts with a centre punch. Test roller race for freeness on its track. 46. REMOVAL OF GEARBOX FROM FRAME. Remove kickstarter crank, gear indicator, and gear lever. Remove gearbox outer cover and release \clutch cable from clutch arm. Remove cable adjuster from inner cover. Remove oil bath outer portion, clutch and engine sprocket. (Para*. 41.) Remove rear portion of oil bath (para. 41), rear chain guard, held at the rear by a bolt and nut, and remove rear chain. Remove rear wheel. (Para. 56.) Remove toolbox held by three bolts, and rear mudguard, held by six bolts. ' Remove large hexagon nut on the tof> gear­ box bolt, also the two bolts holding the gearbox adjuster plate. Unscrew the adjuster bolt from the gear­ box bolt and withdraw the top gearbox bolt. Remove the gearbox bottom bolt and nut, and lift gearbox from frame. 47. FITTING OF GEARBOX TO THE FRAME. To refit the gearbox, reverse the order of the removal operations. When fitting the top bolt, the tapped hole in the bolt must be in such a position as to allow the adjuster bolt to enter.

THE GEARBOX.