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1. Exhaust pipe port clamp (2)

2. Footrest

3. Gear shift foot lever

4. Breather pipe

5. Circuit breaker

6. Gearcase cover

8. Gearcase cover screw (11)

9. Clutch cable

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

Figure 3D-13. Removing Gearcase Cover

Remove push rods (7) as described in "Removing and Installing Push Rods," Section 3B.

Place a pan under gearcase to collect oil when cover is removed. Remove gearcase cover screws (8) and free cover from crankcase. Cover is located on dowel pins which fit rather snugly. The cover must be worked off these pins carefully to avoid damage to joint faces. Do not pry off with screwdriver inserted between joint faces. Use a hammer and a block of wood, and tap lightly at the end where the cover projects beyond the gearcase.

Remove valve tappets and valve tappet guides only to establish correct cam gear end play. See "Valve Tappets and Valve Tappet Guides." Pull clutch cable (9) forward (as positioned on .motorcycle), at the same time press cable inward and down to free from cover.

Refer to Fig. 3D-11 and proceed as follows. Remove cam gears (7, 8, 9 and 10) and cam gear plates (11). (Cam gears are numbered on cam lobe from one to four, from the rear exhaust valve cam forward.) When cam gears are removed, note whether or not cam gears have thin steel spacing washers (12) on either end of cam gear shafts. If any of the cam gears mentioned have spacing washers, be sure the same ones are used on each shaft when reassembling if the same cam gears and case cover are used again.

Free idler gear (13) with fiber washer (14) by lifting generator up and away from crankcase. Discard gasket (15). Pinion gear (16) is a press fit on pinion shaft splines. With Pinion Gear Puller, Part No. 96830-51, remove pinion gear from pinion shaft. Oil pump drive gear (spiral gear) (17) is located on splined shaft behind pinion gear. Remove spiral gear which is a slip fit on splines.

CLEANING AND INSPECTION (Fig. 3D-11)

With gasoline or cleaning solvent thoroughly scrub the gearcase compartment, gearcase cover and gears to remove any oil and carbon deposits. Blow out all gearcase cover oil passages and bushings with compressed air. Clean old gasket sealer from joint faces with carbon tetrachloride or other cleaning solvent. Carefully examine timing gears for excessive wear by inserting gears in case cover. Check for looseness in bushings and for amount of lash between gears. If teeth are pitted, scored, cracked, chipped or if faces of teeth are worn, replace gears. Check the gear shafts for damage and pitted surfaces and measure shafts with a micrometer for extent of wear. If any cams are found with rough or pitted surfaces, replace gear. The idler gear shaft (29) is a press fit in the gear and can be replaced, providing the gear is in good condition.

Check pinion gear (16) for press fit on pinion shaft. The slightest lash will usually result in noisy operation, often mistakenly attributed to the other timing gears.

Check cam gear needle roller bearings (18) and idler gear bushings (24) in right crankcase side and cam gear shaft and pinion gear shaft bushings (19, 20, 21, 22, 23 and 24) in gearcase cover for extent of wear. These bushings normally do not require replacement until an engine has run up extremely high mileage.

Specified clearance for cam gear shafts in cover bushings and for pinion gear shaft in cover bushing is .0005 to .001 in. Specified clearance for cam gear shafts in crankcase needle roller bearings is .0005 to .0025 in.

When bushings are worn to the extent of increasing-clearance to .001 in. or more over specified limits, they should be replaced, as the cam gears are likely to become very noisy with excessive clearance in the bushings. Examine the face of each bronze bushing-

Figure 3D-14. Removing Bushing from Gearcase Cover

flange for wear. If bushing flanges are badly worn replace bushings.

Examine cam gear plate (11) for excessive wear or damage. Replace, if necessary. Check the operation of the oil separator bushing assembly (25 and 26) used on 1962 and earlier models. Bushing is spring-loaded and should have free action and be fully extended in gearcase cover.

Fixed type bushing (25A) should have 1/16 in. running clearance with generator oil slinger washer.

Inspect the crankcase oil strainer (27) to make sure it is not plugged with any foreign material.

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