250 c.c. O.H.V. TWIN CYLINDER SCOOTER
COMPLETE DISMANTLING OF THE ENGINE, GEARBOX AND
FINAL DRIVE NUT
If the oil has not already been drained from the unit it should be done at this stage. To drain
the final drive take out the Phillips head screw immediately below the oil level plug and remove
the oil level plug as well. The primary drive is on the left-hand side of the unit and carries the
clutch lever and the contact breaker unit; to drain, remove the Phillips screw immediately below
the rear or final drive bearing and again remove the oil level and filler plug to allow the oil to
flow.
To drain the gearbox, remove the two hexagon bolts, one above the other, at the rear of the
gearbox just behind the gearchange assembly. The sump is drained by removing the plug on the
right-hand side bottom corner of the sump; this is the rectangular container under the engine. ,
Dismantling should only be undertaken by someone with mechanical experience, otherwise
serious harm could result to the unit. If in doubt place the job in the hands of the Dealer.
Before cleaning off any accumulation of oil or dust look for obvious signs of oil leakage. The
points where this occurs usually show as very clean spots whereas the rest of the unit, though
oily, will also be dirty with an accumulation of road dust.
Where the unit is heavily coated with dust and oil it is as well to wash it comparatively clean
before dismantling.
During the actual dismantling care should be taken to look for signs which show that a
particular part requires replacement. In the case of bearings they should be clean and polished, if
there are any score marks or signs showing that the metal has "picked up" the bearing or bush
should be replaced. Ball or roller bearings should spin quite freely without excessive play, and if
there are signs of lumpiness or grit in them, it is an indication that the balls or rollers or the races
are pitted and here again the parts should be replaced.
It is good policy to use only sound and unworn spanners and in certain cases, it is essential that
an appropriate service tool is handy. Detailed below are those service tools which are used for
dismantling the unit. Although one or two operations can be done without them, such as removal
of the valve springs and contact breaker, (these are covered by service tool number 61-5001 and
5005 respectively), the use of the tools will facilitate the work.
Service tools are as follows:
61-5001 Valve spring compressor.
61-5002 Extractor for generator and flywheel.
61-5005 Extractor for contact breaker cam and auto advance unit.
61-5007 Extractor for clutch.
61-5019 Extractor for speedometer drive. 61-
5022 Crankshaft holder.
61-5025 Universal extractor (for primary drive and timing pinion-)
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