SCOOTER SERVICE SHEET
250 c.c. O.H.V. TWIN CYLINDER SCOOTER
REMOVAL OF THE ENGINE, GEARBOX AND FINAL DRIVE NUT
When the engine and transmission are removed for overhaul they must be taken out as a complete unit
comprising the engine, gearbox and final drive.
Remove the side valances as described in Service Sheet No. 1001.
1003
Printed December 1959.
Drain off all the oil by removing the lowest Phillips head screw and the filler plug on the primary and the
rear drive housings, the two 1/4 in. bolts at the rear of the gearbox, and the drain plug in the base of the
sump.
(this can be the bit where your whole bike can end up covered in oil,so use plenty of paper/tissue on the
floor rubbers around the drainage area,the concrete or surface underneath the bike)
Raise the rear wheel clear of the ground. For this purpose a block or small wooden trestle as
Fig. 2
is
necessary and assistance will be required to lift the machine and place the block underneath the rear cross
channel on the frame.
(The Chu recommends a decent sized block so she wont fall off)
Remove the rear wheel by taking off the three hub nuts, which have a normal
right-hand thread. These nuts are countersunk both sides and can be fitted either way.
Now take off the air ducting around the cylinder head; it is secured by two small
nuts on 1/4 in. diameter studs which also secure the exhaust pipes.
After these nuts are removed take out the one 1/4in. diameter bolt which
secures the carburetter air pipe; this is on the top cross member between the two
vertical pillars of the frame, and is immediately below the petrol tank.
Disconnect the sparking plug leads.
Now prise off the lug securing the air duct on the left-hand stud and lift the air
ducting complete with the carburetter air pipe clear and place on one side.
Next remove the exhaust pipes by taking off the remaining 1/4 in. nuts from the
studs nearest the rear wheel, and slacken off the clips securing the exhaust pipes to
the silencer and the two bolts at the top of the silencer. This will enable the
silencer to be swung away from the pipes and the exhaust pipes can then be taken
off the studs securing them to the cylinder.
The right-hand side exhaust pipe also carries the spring, which tensions the
kickstarter chain. The spring will therefore have to be unhooked from the exhaust
pipe and the chain link before the right-hand pipe can be placed on one side.
Fig. 2.
Fig. 3
Disconnect the speedometer drive from the rear hub by
unscrewing the union nut (
Fig.3
). The speedometer drive
cable is the upper of the two cables which run to the rear
wheel, the lower one being the brake cable. Also disconnect
the rear brake cable by taking out the split pin and clevis
pin which secure the cable end to the brake lever on the rear
hub.
Remove the two black and yellow wires which run from
the distributor to the left-hand and right-hand ignition coils by
taking off the two nuts on top of the coils.
Note that the
longer of the two cables (black and yellow) goes to the right-
hand coil.
With a suitable tool such as a screwdriver or a hammer
shaft, press in the clutch lever on the engine, slip the nipple
out of the lever, pull the outer casing out of the lug and
place the spring on one side. Push the cable down under the
frame out of the way.
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