Cleaning And Inspection

Clean all parts thoroughly in gasoline or cleaning solvent and blow dry with compressed air. Inspect valve tappets for excessive clearance in guides. Valve tappets should be .0005 to .001 in. loose in tappet guides. Guides are .0005 to .001 in. press fit in crankcase. Excessive tappet-guide clearance is serviced by fitting new tappet, and/or new guide. It is recommended practice to replace complete tappet when only the roller is excessively loose or badly worn; however, it is possible to replace tappet roller kit (6) individual parts. If this is done, roller must turn freely (.0005 to .001 in. loose on needle bearings) and have about .008 in. sideplay after new roller pin is securely riveted to tappet.

1. Tappet guide screw

2. Tappet screw with nut

3. Tappet guide

4. Tappet and roller

5. Tappet guide "O" ring

6. Tappet roller kit

7. Rear cylinder exhaust cam gear

8. Rear cylinder intake cam gear

9. Front cylinder intake cam gear

10. Front cylinder exhaust cam gear

13. Idler gear

Figure following name of

14. Idler gear shaft fiber washer

15. Gearcase cover gasket

16. Flywheel shaft pinion gear

17. Oil pump drive gear

18. Cam gear needle roller bearing (4)

19. Rear exhaust cam gear shaft bushing

20. Cam gear and timer shaft bushing

21. Pinion gear shaft bushing

22. Front intake cam gear shaft bushing part indicates quantity necessary :

23. Front exhaust cam gear shaft bushing

24. Idler gear shaft bushing (2)

25. Oil separator bushing assembly

(1962 & earlier) 25A. Oil separator bushing (1963 & later)

26. Breather oil separator seal ring spring (1962 & earlier)

27. Crankcase oil strainer, retaining pin and gasket

28. Gearcase cover bushing pin (7)

29. Idler gear shaft r one complete assembly.

Figure 3D-11. Gearcase and Tappet - Exploded View

If end of valve tappet adjusting screw is worn hollow from action of push rod, it should be replaced to ensure accurate tappet-valve stem adjustment.

Inspect tappet guide rubber "O" ring (5, Fig. 3D-11)

for wear or damage.

ASSEMBLY (Fig. 3D-11)

Assembly is essentially the reverse order of disassembly. Apply a light coat of oil to the tappet and in particular, the tappet roller assembly. If tappet is not located correctly in guide, tappet roller will be crosswise to guide and cam, and serious damage may result when pressed into crankcase.

Pull tappet out to limit of travel and hold in place with a clip or other means to prevent tappet from dropping into crankcase when installing the assembly.

Insert "O" ring (5) on guide (3). Assemble adjusting screw and nut (2) in tappet (4) and then insert tappet into guide (3). Align screw holes in tappet guide with screw holes in crankcase and press assembly into position using a piece of tubing or a block of soft wood. Tappet guides are a soft malleable cast iron, therefore, be extremely careful not to damage the guide during the pressing operation. With screw (1) in place, recheck free movement of tappet in guide.

gearcasi and timing gears


Thoroughly clean area around gearcase cover and tappets. Blow all loose dirt from crankcase with compressed air. Loosen exhaust pipe port clamps (1) and muffler clamps and lower exhaust pipe free of gearcase cover. Remove footrest (2), gear shift foot lever (3) and breather pipe (4).

Remove 5F).

circuit breaker (5) or magneto (see Section

Figure 3D-12. Removing Tappet Guide Revised: 9-66

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