Engine/Primary Transmission

C

SECTION C14
DISMANTLING PRIMARY TRANSMISSION AND CLUTCH
Whilst removing either the clutch or the engine sprocket, the transmission should be prevented from turning by placing the rear brake pedal and left hand foot rest assembly loosely in position and applying the rear brake fully. Procced with dismantling as follows:
1	Using a suitable sized socket wrench 1/2 in. Whit. on the alternator rotor nut, remove the rotor nut as shown in Fig. C12.
2	As the rotor nut is removed, collect the fan disc washer from behind.
3	Remove the alternator stator. This is secured by three nuts and plain washers. As the stator is removed, it may be left hanging on the stator lead whilst the two snap connector terminals are disconnected beneath the air box.
4	At this stage remove the alternator rotor which is keyed to the engine crankshaft. If the rotor should prove to be extremely tight on the engine crankshaft, slight pressure may be applied from behind equally, using two flat section tyre levers. Remove the rotor key, packing collar and shims from the engine shaft.
5	Remove the three stator spacers from the stator mounting studs on the chaincase.
6	Slacken the clutch push rod adjuster nut and remove the adjuster and nut altogether.
7	In order to dismantle the clutch, a compressor tool part number 060999 is needed for the diaphragm spring of the clutch. The tool is shown in use in Fig. C13. Note that the tool has been screwed into the adjuster hole in the spring centre. The centre bolt must be lightly tightened and must be at least 1/4 in. engaged into the diaphragm spring centre. Now place a spanner on the withdrawal nut as shown in Fig. C13. Turning clockwise will tighten the withdrawal nut until pressure has been released from the diaphragm spring and the spring is completely free to rotate.
8	When the spring is compressed and free to rotate and using a screwdriver blade as shown in Fig. C14, lift the first end of the diaphragm spring clear of the circlip groove in the housing and commence to peel the circlip away from the groove.

9	The compressor tool and diaphragm spring should now be lifted clear as a pair.
It is not necessary to remove the tool from the diaphragm spring. If it is desired to remove the tool from the diaphragm spring, support the centre bolt to prevent it turning and slacken off the withdrawal nut to relieve all spring pressure. If this is not done there is a grave risk of the spring being released suddenly from the tool with possible injury.
10	Fit clutch tool 061015 over hub and remove the clutch centre nut and spring washer, or prevent the clutch from turning by the use of the rear brake pedal fitted loosely into position and applied whilst the nut is slackened.
11	Prepare to remove the engine sprocket, primary chain and remainder of the clutch as a set. This necessitates the use of engine sprocket puller part number 060941 assembled to the sprocket and engine crankshaft as shown in Fig. C15. It is essential that the side bolts are screwed into the sprocket at least 1/2 in. prior to tightening of the centre bolt for extraction purposes for otherwise the thread may be stripped. Now tighten the centre bolt of the puller against the crankshaft and shock the side of the sprocket using a soft metal drift and hammer, whereupon the taper joint between the sprocket and shaft should be broken.

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