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Assembling Clutch
Clutch.
Fit the clutch locking plate into the housing and to the clutch centre,
then assemble the plain washer, locking washer and nut to the gearbox mainshaft.
Well tighten the nut and lock by bending down the locking washer tabs. Remove
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the locking plate.
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Engine Sprocket. To this part on the models
ST
and 6T, first,
fit
the key to the
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shaft and then the plaln washer, rotor, locking washer and finally the securing nut.
TR5, TI00
&
T110-Fit the key, distance piece; locking washer and securing nut.
Clutch Plates. If new corked plates are to be fitted, first soak them in oil (SAE 20).
First assemble a steel plate to the housing and then a corked plate and so on until
all the plates are in position.
Clutch Push Rod.
Fit into the gearbox mainshaft.
Outer Pressure Plate.
Assemble this complete with cups to the clutch. Hold
in position and enter the four springs and then secure with the four slotted nuts.
Each nut should be just started on the pin thread to aid assembly. When all the nuts
are in position, screw them down until the thread of the pin is level wiih the outer
face of the nut.
Clutch Cable Adjustment.
Screw in the adjuster inside the gearbox filler cap
until the lever leans out about
15".
Now adjust the cable at the lug on top of the
gearbox to give
+
in. free movement in the cable.
Trueing the Clutch. The clutch outer pressure plate must spin true, otherwise the
plates will not separate when the clutch
is
disengaged, thus causing faulty gear
changing and the engine to stall in traffic due to "creep". To check, disengage the
clutch by operating the handlebar clutch lever and depressing the kickstarter when
the pressure plate can be observed rotating. If the pressure plate "wobbles" mark
the place which projects the furthest and screw in, half a turn, the nearest slotted
nut. Repeat the test.
It
must be emphasized that extra care taken with this
operation will make for a smooth and effective clutch engagement.
Primary Chain Adjustment. Check, and if necessary carry out the adjustment
as
described on page
92.
Chaincase Outer Cover. Grease the paper gasket and fit to the outer cover.
Position the outer cover to the inner cover but on the models 5T
8
6T
thread the
alternator cables through the hole in the inner cover and then secure the cover
with the fixing screws. Pull the alternator leads through the inner chaincate to
prevent them fouling the primary chain. Connect the alternator leads and slide
the grommet down the cable and press the boss on the outside of the inner cover.
Footrest and Brake Pedal. Replace the left hand footrest and tighten the nuts on
both sides of the footrest rod.
Fit the brake pedal and secure.
Exhaust Pipe and Silencer. Replace.
Oil.
Remove the chaincase filler cap and pour
f-
pint of oil
(SAE
20)
into the crtlng
Replace the filler cap.
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