Stripping Motorcycle For Transmission Repair

1. Remove battery ground wire. Remove footrest and chain housing cover. If motorcycle is equipped with compensating sprocket, use Compensating Sprocket Shaft Nut Wrench, Part No. 94557-55, to remove compensating sprocket shaft nut. If not equipped with compensating sprocket, use 1-3/8 inch socket or box wrench to remove nut. Loosen nut by striking wrench handle several sharp blows with hammer.

2. On 1965 models, remove chain adjuster mounting bolt and large brass starter shaft thrust washer.

3. Remove push rod adjusting screw lock nut (nut on center screw on clutch sprocket), slip washer (any metal washer about 1-3/4 in. in diameter with 3/8 in. hole) over push rod adjusting screw and replace lock nut. Remove three spring tension adjusting nuts and pull clutch outer disc and spring collar assembly off clutch drive hub pins. Move clutch sprocket and motor sprocket out with chain, and remove from shafts.

4. On 1964 and earlier models, remove cotter pin, nut, flat washer and spring from each of the two inner chain guard rear mounting bolts. Bend back the ears of screw lock away from the three cap screws around the engine sprocket shaft that secure the front end of inner chain guard to engine crank-case, and remove cap screws and lock. Remove oil drain pipe from inner chain guard.

5. On 1965 and later models, remove clutch hub using Clutch Hub Nut Wrench, Part No. 94645-41 and Clutch Hub Puller, Part No. 95960-41A. Remove mainshaft key. Loosen the five transmission base mounting bolts. Remove the three bolts attaching chain housing to engine crankcase and four bolts attaching housing to transmission. Remove the two chain housing stud nuts attaching starter housing to chain guard. Remove wires connected to starter solenoid terminals. Pull inner chain housing loose from mainshaft using Putte*., Part No. 95960-41A which has four screws to fit tapped holes in chain housing. Care must be taken to be sure housing moves out squarely as front end is snug fit on shoulder of crankcase. As housing is pulled out shake starter assembly shaft to free it from gear in starter motor housing. Remove chain oiler hose at oil pump. Remove chain housing oil return hose at rear of chain guard and vent hose at T-connection and move housing away. Remove battery carrier bracket and regulator ground strap from right side of transmission. Remove right Buddy Seat footrest bracket. Remove starter motor bracket and pull starter motor out left side. Remove kick starter crank.

6. On all models, remove clutch control rod from clutch release lever by loosening lock nut at pedal (foot control clutch) or at booster connection (hand control clutch) and turning rod out until length has been increased enough to slide flat portion out of slot in clutch release lever.

7. Disconnect shifter rod from transmission cover by removing nut and bolt or cotter pin and clevis pin.

8. Disconnect speedometer drive cable and housing from transmission. Disconnect neutral indicator switch wire clip.

9. Remove rear chain connecting link and chain. Remove bolt which secures transmission to support bracket on right side of frame.

10. Remove bolts and cap screws which secure transmission mounting plate to chassis.

11. Remove complete transmission with mounting plate.

Reassembly is made in reverse order excepting as follows:

On 1965 models, when installing chain housing, "Grade A" Loc-Tite must be used on main shaft to secure inner race of ball bearing in case to shaft.

The four nuts securing the transmission to mounting plate as well as the bolt which secures transmission to frame support bracket should be left loose to facilitate easy alignment of the chain housing with engine crankcase and transmission bolts.

Case bolts on engine and transmission should be tightened evenly so housing does not bind on transmission mainshaft or shoulder on engine crankcase. Final tightening should start at three bolts at engine crankcase, then four bolts at transmission, then four base mounting nuts and bolts securing transmission to chassis bracket.

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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