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During re-assembly ensure that the spring
retaining washer is fitted over the main spindle of
the pawl carrier and that the spring has been
assembled over the ratchet plate as illustrated in
Fig. D8. Tighten the stop plate set scrows and
assemble the splined end of the pawl carrier past
the 'O' ring in the cover. Locate the spring peg
between the logs of the spring and push the pawl
carrier fully home, engaging between the legs of
the spring. Check the carrier action and that the
spring is correctly located. The set screws should
be tightened only when the action of the pawl
carrier has been checked for full freedom of
movement. Now fit the pawl spring with its double
cranked leg downwards, ensuring a minimum but
perceptible clearance, between the two legs of the
spring and the pawl.
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SECTION D12
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REFITTING THE GEARBOX OUTER COVER
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Having dealt with the outer cover as described
in Section D11, ensure that the joint facing is
perfectly clean and proceed with assembly as
detailed below:
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1
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Fit the inner cover to outer cover gasket,
retaining in place during assembly with a smear of
grease. Ensure that the gasket engages
satisfactorily over the cover dowels.
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2
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To ensure cover alignment during assembly retain
the ratchet spring in the central position with the
index finger of the right hand and guide the case
over the kickstart shaft with the thumb of the left
hand engaged through the filler cap hole.
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3
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Drive the outer cover fully home and assemble
the five screws of equal length to retain the outer
cover in position. If the cover is very difficult
to push into position, check whether the pawl has
rotated due to the pawl scissor spring not having
been held securely in position, during final
assembly. The cover should be removed, the ratchet
pawl reset and re-assembly undertaken.
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4
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Fit the gearshift pedal and kickstart crank,
then check the action of the gearbox, rotating the
rear wheel as the gear pedal is moved to the
various gear positions. If all is well, assemble
the gear position indicator pointer and replenish
the gearbox with oil.
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5
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Connect the clutch cable through the inspection
hole in the gearbox outer cover, engaging and
locating the nipple in the operating lever.
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6
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Finally assemble the gasket, inspection cover
and screws to the gearbox outer cover, and check
the security of the drain and level plugs.
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