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

THE TRANSMISSION.

41. REMOVAL OF OIL BATH.

Fig. 11.

h Remove the footrests, footrest rod, and brake pedal. Remove the large nfit holding the outer portion of the oil bath, and remove the outer portion. Remove clutch spring screws, springs and cups (three of each), clutch outer plate, clutch thrust pin, and clutch retaining nut. Engage low gear and obtain assistance to hold the rear wheel while the nut is being removed. Remove clutch body. A special tool may be obtained for this purpose if necessary. Remove engine sprocket (a claw-type extractor will remove this), and engine sprocket, clutch and chain can be removed together. Remove rear portion of oil bath, held to the crankcase by bolt, to the engine plate by a nut, to the rear chain guard by a bolt, and by a nut on the gear box pivot bolt. 42. FITTING OF OIL BATH. Assemble in the reverse order. Examine rubber washer fitted round the

flange of the inner portion. This must be in a good condition to retain the oil in the case. Fill oil bath with oil to the level of the plug near the bottom of the outer portion of the oil bath. 43. CLUTCH—TO DISMANTLE. Remove outer portion of the oil bath, and clutch. (Para 41.) A steel band is pressed round the clutch sprocket to prevent an excess of oil entering the clutch plates. The plates can be removed with the band in position, but it must be removed to examine the driving slots in the sprocket. Remove circlip holding clutch plates on to the body. Remove plates. There are six plain steel plates, and five steel plates with ferodo inserts. Remove clutch sprocket. Place an old gearbox main axle (if available) in a vice with the splined end above the jaws, and fit body to axle. Remove the three screws holding the front cover plate.