30
l
Use the valve spring compressor to press down the
valve spring retainer.
l
Install the collets, and slowly remove the spring
compressor. Ensure that the collets are seated
properly holding the retainer down.
l
Repeat same procedure for exhaust valve.
l
Assemble cam shaft.
l
Assemble both rocker arms & then respective pins.
l
Fix locking plate for camshaft and inlet rocker arm pin
with the help of screw pan cross.
Clutch Assembly :
l
Take wheel clutch and assemble plate friction and
plate clutch alternatively on it starting with a friction
plate.
l
Insert Hub clutch into the subassembly described
above by matching teeth of Hub clutch and mate
clutch.
l
Then place the above described subassembly into
Housing complete clutch.
Sequence of clutch plate assly.
Intermediate Shaft Assembly :
l
Assemble cluster gear on intermediate shaft in such
a way that small gear of the cluster gear faces
towards threaded end of the shaft.
l
Then assemble 4th driver gear wheel.
l
Assemble kick driven gear.
l
Then press bearing on the intermediate shaft.
Intermediate Shaft Assembly
Main shaft Assembly :
l
First assemble circlip on the main shaft (towards
threaded end of mainshaft).
l
Put shoulder washer on the circlip.
l
Hold mainshaft vertical and slide cross into the slots
of mainshaft. Position the cross in the slots where a
circular groove is provided and rotate cross by 90°.
Check that the projection provided at the centre of
cross is facing upwards.
l
Assemble gear selector inside main shaft. Match the
projection on the cross with the slot of gear selector.
Check that the grooves provided on Gear selector are
facing towards the holes provided on mainshaft for
fixing spring loaded balls.
l
Assemble washer on the gear selector.
l
Tighten the stem on the cross.
CAUTION : STEM HAS LEFT HAND THREADING.
l
Assemble 1
st
gear wheel (largest) on the mainshaft in
such a way that the larger collar should be facing
towards stem side or lesser collar should be facing
towards threaded end of mainshaft.
l
Assemble 2
nd
gear wheel (2
nd
largest) on the mainshaft
in such a way that the larger collar is facing towards
1st gear wheel.
l
Assemble 3
rd
gear wheel on to the mainshaft in such
a way that the larger collar is facing towards 2nd gear
wheel.
l
Assemble 4
th
gear wheel in such a way that the larger
collar is facing towards 3
rd
gear wheel.
l
Then assemble shoulder washer and fix circlip.
l
Put one steel ball into each of two holes provided
on the mainshaft after smearing slight amount of
grease on it.
l
Assemble spring on each ball.
l
Compress both the springs with the help of thin plates
or hacksaw blade and assemble the cup on the
springs.
The cup should be assembled in such a way that
lower diameter of cup should be facing towards gear
wheels.
Clutch Cover Assembly :
l
Press first oil seal then bearing & fix circlip for
mainshaft from the outer side of clutch cover.
l
Assemble adjuster with nut for Rear brake cable .
3
rd
friction plate
(P.No.28 10 1184)
Summary of Contents for Legend 00300728
Page 1: ...Service Station Manual Service Station Manual USA MODEL NO 00300728...
Page 26: ...22...
Page 63: ...60...
