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Installing Gearbox
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and screws.
Test the action of the kickstarter pedal, making sure that there is
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sufficient tension in the spring to return the pedal smartly and that
it
is not becoming
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"coil bound" when the pedal is depressed fully.
Check that the gear selection
is
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correct.
Re-fill with oil until
it
begins to overflow from the level plug hole. Screw
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the level. plug into the hole and replace the filler cap.
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INSTALLING THE GEARBOX
(RIGID FRAME MODELS)
Positioning the Gearbox
in
the Frame. Re-fit the clamp plates and chain
adjuster to the gearbox with the chamfered nut on the right hand end of the upper
stud. Tighten up fully. Fit the gearbox into the frame and slide the pivot bolt and
clamp bolt into position. Fit the clamp bolt nut and tighten both bolts slightly.
Screw the frame adiuster bolt end nut into the frame and tighten.
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Rear Chain.
Replace the chain over the drive sprocket and
fit
the spring link.
Cables.
Fit the speedometer cable to the drive and tighten up the securing nut.
Screw the clutch cable adjuster into the lug on the inner cover and
fit
the cable
nipple into the clutch lever.
Footrest Rod. If the removal process was carried out as described, the rod and
right hand footrest and footrest nut should have remained as one assembly. Enter
the free end into the engine
plazes from the right hand side making sure that the
rod passes through the distance tube between the rear engine plates.
Primary Chaincase Inner Cover.
Fit the oil retaining plate under the spring
plates. Place the engine plate to chaincase distance piece in position on the footrest
rod and
fit
the chaincase to crankcase and over the gearbox mainshaft.
Make sure
that the footrest rod projects into the chaincase. Secure the front end with the
three screws (not fitted to TR5). Position the rear chainguard to the chaincase and
secure with the set screw.
Battery Carrier and Air Cleaner.
Replace the air cleaner and battery carrier
and secure to frame and chaincase.
Fit the battery and connect the leads.
Far assembly of the Clutch and Engine Sprocket, etc.. see page
90.
L.H.
Footrest.
Fit to spindle and securely tighten the nut.
Footrest Pedal,
Grease the pedal spindle and
fit
the pedal.
Replace the spring
washer, plain washer and secure with the nut.
Exhaust System.
Re-fit the exhaust pipe and silencer assemblies.
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