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20
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Adjust the clutch push rod with the handlebar
adjustment slackened off completely. Screw in the
adjuster until there is just perceptible lift on
the diaphragm spring and slacken back one full
turn, holding in this position whilst the lock nut
is tightened completely.
It is possible for the clutch operating lever in
the kickstart case to have dropped down between the
thrust ball and roller against which the lever
lifts and if this has occurred, it will be found
that the clutch is inoperative, and it will be
necessary to remove the inspection cover which is
secured by two screws to the gearbox outer cover,
slacken back fully the push rod adjuster and lift
the lever back into position before adjusting. ln
fig C44 and C45 we show the lever in its correct
position and the lever as it may be found if it has
dropped.
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Assemble the shims on the crankshaft over the
engine sprocket, followed by the spacing collar
with the recess outwards.
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21
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Fit the rotor key, the inner end of which passes
into the recess in the collar.
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22
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Ensure that the rotor is free of any magnetic
particles it may have attracted whilst dismantled
and fit the rotor to the shaft and key, name and
timing marks outboards.
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23
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Assemble the rotor nut and fan disc washer and
with top gear engaged and the rear brake applied
fully, tighten the rotor nut fully to 70 to 80
Ibs./ft. (9.678 to 11.060 Kg/m).
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24
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Fit the three stator spacers on to the stator
mounting studs followed by the stator on which the
lead must be outboard at the 5 o-clock position.
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25
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Assemble the plain washers and stator securing
nuts and tighten to a torque setting of 15 Ibs./ft.
(2.074 Kg/m). Check the gap between the stator and
rotor which must give a minimum air gap of 0.008
in. to 0.010 in. (0.2032 to 0.254 mm). Any
misalignment of the stator mounting studs would
account for reduced air gap at any one given point
and can only be corrected by very careful slight
re-alignment of the studs.
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26
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Check that the chaincase sealing band is snugly
in position in the recess in the outer face of the
inner chaincase with the join in the band at the
top then place the outer chaincase in position.
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27
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Secure the outer chaincase using the single
centre sleeve nut and washer.
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28
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In order that the point is not overlooked it is
recommended that lubricant is added to the
chaincase at this stage.
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29
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Refit the left hand foot-rest and brake pedal
assembly, securing with three nuts, two washers and
the stop lamp lead support bracket acting as the
third washer on the bottom stud.
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