- triumphscooterstriumphscooters.co.uk/wsb5911712103/resources/1004+250+dismantle...250 c.c. o.h.v....

250 c.c. O.H.V. TWIN CYLINDER SCOOTER

COMPLETE DISMANTLING OF THE ENGINE. GEARBOX AND FINAL DRIVE NUT

If tht' oil ha", not aln'ariy \Wt'll drailH'cl from tile unit it ",honl<1 lw done at thi:-: :-:tage. Tu drain the final elrin' take Ollt the Phillip:; head :;cn'\\" imnwcliateiy hdo\\- the oil kn'i plug and rt'lllO\"P the oil kn'] plug a:-: \\-{'ll. The primar:-.: drin' i..- on the left-hanel :,>ic1e of tlw nnit and carries the clutch h,\'('f and the contact hn'akt'r unit; to drain, n-'lllO\'(, the Phillips sen'w illlllwdiatel.v belm\- the fear Of final driH' hearing and again H'IllO\-{, the oil le\Tl and filler pIng to allow till' oil to flO\\-.

To drain till' gear\)o:-.:, H'mo\"!:' tht' two hexagon bolts, Olll' ahoyt:' the other, at the rt-'ar of tilt, gearbox just hehind the gearcilangc a:-;:-;emhly'. The sllmp j::-; draineel hy remoying the ping Oll till' right-hand ~id(' hottom corner of till" ~l1rnp; thi~ i~ the rf'ctangular container under t11(' ('ligllH'.

J)i~lllantling ~hould onl~' be undertaken by ~Onlt'OIW with mechanical experience, otherwise_":'(Tion~ harm could r('snlt to tll(' unit. If in doubt place the joh in th(' haIHb of the Dealer.

Hdort, cleaning off al1~' accumulation of oil or dust look for ()lJ\'iol1~ ~igns of oil leakage. Tlw PUillb where thi~ occ\lr~ usnally ~how a~ yery clean spob- \\'hpreas tl)(' r('st of the unit, tilOllgh oil~', \\'ill also IH' dirty with an accumulation of road du~t.

\Ylwre the nnit i~ lH'a\'il~- coated with du~t and oil it i~ as \\'ell to wash it comparath'ciy' ,1('<111 lwfofc (li",nlantlillg.

])uring tlit' actual dismantling can' ",liould Iw taken to look for signs which show that a particular part requires repian'llH'nt. In the cast' of h('aring~ they should 1)(' clean and polislwd, if tilert' an' :lIly ~con' mark~ or ~iglls showing that thc metal ha~ "picked up" the hearing or hush . ..;llOuld Iw replaced, Hall or roller bearings ~hould ~pin quite fn.>(,l,V without C'xccssiyl' play, and if there are ~igns of hllnpilll'~s or grit in tiwITI it is an indication that the hall~ or roller:-:; or till' racl'~ are pitted and hen' again the part~ ~ho111d Iw replaced.

It i~ good P()lic~- to \l~(' onl~' ~onnd and un worn ~panners and in certain cases it i~ l':;~ential that an appropriate ."t'ITicl' tool is handy. Ddailcd helow arc those :;cITice tools \\'hich an' u~{'d for di",mantling the unit. Although one or two operatioll~ can he done withont them, sHch a~ r(--'mo\'al of the \'ah'(' spring", and contact breaker, (these arc co\'('r('(l h~- s{--,ITic(' tool 1I111nlwr (-}I ;)()()l and ,::;O();) n''';I)('ctin'I~'), tl1l' IN' of tlw too]:..; will facilitate the \york.

(i 1 SOO 1 (il ;)()()2

(,I-,::;()();)

(il ;i007

(il ·5()19 (i 1 ;i( )22

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\-a_hT "pring COlllIHT~sor.

E,'\tractnr for g('lwrator and fiy-\\'Iw{'l. J~xtraC1()r f()r C()lltaC! hr('akt'r cam anti ;tllto ,1(\\"<1I1C(' unit.

Extractor for clutch. Extractor for speedoll1t'tt'l' drin'.

Crank~haft holder. l-ni\'('rs;d t':dmctor (for priman' ,jri\'(' and timing pinions).

www.triumphtigress.com

250 c.c. O.H.V. TWIN CYLINDER SCOOTER

COMPLETE DISMANTLING OF THE ENGINE. GEARBOX ANDFINAL DRIVE NUT

If the oil ha:-: not aln'cHl}' be('n drailH'cl from the unit it :-:hould 1w done at thi:-: :-:tagc. Tn

drain the final elrin' take Ollt the Phillip:; head ",crew imnwcliately he\o\\' thi' oil len'l plug and

relllO\'(, the oil len'] plug a:-: w{'ll. The prinlar:v' drin' i ... on the jeft-hanet side of tlw nnit and

carries the clutch \C'H'[ and the contact hn'akef uIlit; to drain, rell1O\'f' the Phillips sen'w imlllcdiately' belm\' the fear Of final driH' hearing and again H'lllo\'(' the oil le\Tl and filler plug toallow til(' oil to flO'\',

To drain the gcarbo:-.:, H'mo\"!:' the two hexagon bolts, olle abovt:' the other, at the rear oftllt' gearbox just hehind the gearchangc a:-;:-;cmhl.\'. The sump is drainccl hy removing the pingon till' right-hand siell' hotton] corner of till" ~l1rnp; this i" the H'ctangular containpr under t11('('ligllH'.

Di"mantling :-;hould only' be undertaken by ~om(;,OIW with mechanical t'xlwricllce, otlwrwi:-;c...:,niolls harm could result to tIlt' unit. If in doubt place the job in the haIHb of the Dealer.

Befon' cleaning off any accumulation of oil or dust look for olJ\'iol1~ ~igns of oil leakage.TIlt' PUillb where thi" occllr..; usually ~how as yt:'ry clean "pob \vhpn'<-ls tl)(' r('~t of the unit,thollgh oily, will also IH' dirty with an accumulation of road dust.

\\"lwre the unit i" IH'<1\'il y' coated with dust and oil it is as \\'pH to wash it comparathTly'rll'an ]wfore (lisnlantling.

During the actual dismantling care should lw taken to look for signs which show that aparticular part require;; replan·ment. In the cast' of hearings they should he clean and polished,if there an' :lny scon' mark" or signs "howing that the metal has "picked IIp'' the bearing orhush .";]lOuld be replaced. Hall or roller b('arings should spin quite frt't'ly without cxcessiyc pia,"',and if then' are sign..; of hllnpille~s or grit ill them it is an indication that the hall~ or rollers orthl' races are pitted and ht'fl' again the parts :-;hollid \w replaced.

It i~ good policy to n~e onl~' :-;onnd and unworn spanners and in certain ca.ses it i:-; e;;sentialthat an appropriate ;;\'n'ice tool is handy. Ddailcd below arc those ;;elTice tools which an'used for dismantling the unit. Although one or two operation;; ca.n he done withont them, sHchas H'l1loyal of the \'ah·(, springs and contact breaker, (these are co\'er('(\ by' s{'ITie(' tool 1I1ilnlwr(-i) '=;()Ol and ,::;()(l;) n·"p(·ctin'I~'), tl1l' nse of tl1(' tools will facilitate the \york.

~t'ryicl' tools an' a~ fol1o\\':-,:61S001 \';-J..hT "pring comprl's:-,or.61 '=;()()2 E.'\tractor for g(,lwrator and fty'wlwt'l.(,!-,::;O()'=; J~xtractor for ClHltact hreaker cam anti allto a(\Y;:1I1Cl' unit.61 '=;00] Extractor for clutch.(i1 ·5019 Extractor for spcedometer drin·.(i1 '=;022 Crankshaft holdcr.(i1 ,'1()2S l'ni\'l'rs;L! (':-.:tmctor (for priman' ,lri\·(· and timing pinions).

Service Sheet No. 1004 (contd.)

Dismantling Drive Side of Unit \\"itl1 the :.pamwr provided in tIll' toolkit H'IlIO\T tll(' t\\'O :,parking plug~! take off the two

1 in. nut." holding the rocker box conT, l"eI11OYt' the :-.kd W(1:-;]1('1":-; and iibrc \\'as]wrs and ITI110\T

tIte cO\'er. Examine the Co\Tf gasket to dpcidc whl'tht'r or not it can still lw lIsed. If the gasket is damaged in a11:'1: way, as for ('xalllpk, jf parts of it han' adlwr('d to the c~'lind('r iwacl, Of if it is compn:'sspd too thin, it i,,,; advisahle to lISt' a lW\\' one.

Slackcll off the two union scrp\ys holding the oil feed pipe to tlw rockt'r box and crankcase, and [CmOH' thE' pipe) lcaying thr' unions scn·\\'pr! into hoth tIlt' crankca:-;(' and ('vlinder head.

R(,ll1o\,(~ till' SCH'1l Illlb and waslwrs which hold tll(' cylinder head to till' hlock. F011r of these arc at the rear in.-;ide the rOCk('1' box and tiJrc(' at the front adjan'nt to tile sparking plllgs. Till' .smaller ring spanner pro\"id('d in the toolkit is the most . ...;nitahk tool to u . ...;(' on tbc:-,e nuts.

Take off the cylinder head and in this cast', although tll(' gasket may appear to \)(' in good condition, since it is a comparativdy cheap and certainly an important item, it is arh'isahk to llse a new one wlH~n reassembling.

Thl'n~ Illay he no IH'ed to dismantle the rocker as:-.cmbly but in cast' this operation is described 8t a later stage_

Contact Breaker. Fig. 4.

A standard type of SCH'\\"cirinT can he used to take off the contact br(,aker co\'('f by removing the t\VO a/ Hj in. screws, following which the co\"cr can he placed to one side after the rubher grommet holding the leads has heen slid out of the "t-" shaped slot in the cO\"t'r. t'-nscrew the two long hexagon nuts (C) Fig. 4, wlJich are slightly to the left and right of th(' contact hreaker platt' and take off the phdt' complete with the leads after disconnecting tlw hlack and white lead from the left-hand ignition coil and the hlack and yellow lead from the right-hand coil.

The contact breaker cam and automatic a(1\"a11Ct' and retard unit is retailWcl hy the ce11tre holt which is now \"isihk. ~la("kl'll off the bolt and if tool number 61·-;)()();i is not available tap the holt side-\yay's to relt'as(' the unit from the tal-wred

shaft. If thl' tool is availahl(' take ont tilt' holt, in"';~'I"t the tool and \\"ithdraw the 11nit hy" screwing the tool in clockwis('.

Ta.h' of! the plain . ...;kd bush frolll tilt' hearing ,...;upport arlll :-:pindk and tll(' plain :-:kd thrust \\"asher behind the lm.sh, notillg that the washer is fitted with tlw chtullkr('d side to\\"anls the primarY (h'in' ('on'}".

The prilllary drin' con'}" ibl.'\f is held ill position hy" scn'n Pbillip~ head scn'\\'s and one 1 in. nut and a :::",i 16 in. nut and bolt at the fronL This holt also carries the starter l!Iotor support bracket Wh(,11 a starter i:-- httt·rl.

,


Con1act Breakcr.Fig. 4.


Dismantling Drive Side of Unit\Yith the spanner provided in tlll' toolkit H'IlIO\T til(' t\\"O sparking plugs, take off the two

1 in. nuts holding the rocker hox conT, remove tIl{' skd w(1,,]1('r:-; and Jibre washers and ITI110\T

the cover. Examine the covcr gasket to dpcidc whdhef or not it can still lw lIsed. If thegasket is damaged in any' way', as for exampil', jf parts of it han' adlwrcd to the c~'lind('r !lead,Of if it is compn:,sspcl too thin, it i...; advisahle to lISt' a Ill'\\' one.

Slacken off the two union scre\Ys holding the oil feed pipe to the rocker hox and crankcase,and remove thE" pipe) leaving thr' unions scn·\\,ed into hoth tIle crankcase and cvlindN head.

H.(,ll10\,(~ the SI'H'lJ 1mb and \\'<lslwrs which hold til(' cylinder IH'a<l to the hlock. F011r of1hese arc at the rear in:-;ide the rock('1' box and thrc{' at the front adjaCl'nt to the sparking plugs.The .smaller ring spanner provided in the toolkit is the most .__nitahlc 1001 to u.--e on t!lc:-,c nuts.Take off the cylinder head and in this case, although the gasket may appear to lw in good condition, since it is a comparatively' cheap and certainly' an important item, it is arh'isahk 10 usca new one when reassembling.

Thl'n~ may he no IH'ed to dismantle the rocker assembly but in case this operation isdescribed 8t a later stage.

A standard type of sCH'w(irinT canhe used to take off the contact breakercover by removing the tv,'o a/ Hj in. screws,following which the co\'er can be placedto one side after the ruhher grommet holding the leads has heen slid out of the 'It'''shaped slot in the cover. t'nscrew the1\\'0 long hexagon nuts (C) Fig. 4, wbicharc slightly' to the left and right of thecontact hreaker plate and take off theplatt' complete with the leads after discOlllwcting the hlack and white lead fromthe left-hand ignition coil and the blackand yellow lead from the right-hand coil.

The contact breaker cam and automatic <:uivanct' and retard unit is retainedhy' the centre holt which is now visihle.~lackt'n off the bolt and if tool number6I--;10();i is not available tap the holt sidc

\yays to release the unit from the talwrcdshaft. If the tool is availahle take Ollt tht' bolt, in--~'I't the tool and \\"ithdraw the unit b)-' screwingthe tool in clockwis\'.

Tah' oll the plain .--ted bush frolll tilt' hearing ,__ upport ar1l1 :-:pindk and the' plain siL'd thrustwasher behind the Im.sh, noting that the washe!" is fitted with tlw challlfered side tc)\\"anls theprimarv drin' cover,

The primary drin' con'}' ihl'lf is held ill position hy" scn'll Phillips head scn'\\'s and one1 in. nut and a ::',i 16 in. nut and bolt at the front. This holt also carries the starter 1lIotor supportbracket whell a starter i:-. fltt('rl.

,


\\'hen all the ~cn>w,,! nut:-; and bolt" an' rcmoyt'd, the prilllar~' drivc coypr can \)(' taken off, the .ioint being broken hy gently tapping till' ('(AN with a ra\\"hide mallet or a hammer ~ilaft hut great earl' must 1)(' takell or tll(' conT may he cracked or distorted.

'I'll(' clutch push rod \\"ill come a\ya ..... \\"ith thl' coY('r. Th(' conditio1l ot tl1(' pllo"pllOl" hr!)ll/J' pad on t1w ])11:-;h rod .... l!onld lw car('fllll~' ilut('d and if it "1]()\\",, :-..il~ll" of h;\ying \\"orn ()r Ill!' Ilwlal

haying "picked up", the push rod "hould \w l"CpLICl'd. :\lakl' SUIT that thl' "mall rubhn ,,(),. ring on the pu,.;h rod shaft i:-; ill good conditioll, and if IH'c('"sar~' rl'plact' it to pn'H'nt kakagl' uf oil through tlw push rod bon'. The fil~al drin_' support arm hearing is a PH'SS fit into the prilllar,\' driyc CO\Tr and if it is to lw }"('1l10\'cd tlH' cm"er ",ilonld 1)(' heated in boiling water, and

tilt' hearing drin'n out witil a suitahle punch through till' hole ill tlH' hOllsing. 'I'lli' replacement 111l1"t be fitted "'hile th{' coyer is still hot. (This method should lw employcd WilCIH'n'r a IH'aring is to Ill' }"('llloyecl from an aluminillll1 ca"t'.) Tilt' contact hreakl'r dri"t, is ."imply a sliding fit 1!l thc hroll/c hush ill tIll' ]"('ar primar,v dri\'t, C;l"'{,.

Ht'forc ITlll()ying till' clutch, llatit'll tht' Llb wa",hn on thl' larger prilllary driY('Jl gl'ar and slackl'lI

on till' centre lint. Tilis opnatioll \\"ill 1)(' facilitated if the unit is

jl\ac{'d in gear hy operating tIt(' gl'archange spindle and tht' hrake

applied with a suitahlt' kngth of tlllH' OYt'r till' hrake kn.'!".

:\0\\' llIlSClT\\' till' tlm't' clutch pn'..:sun' sprillg llllt:-.. To ;l\"oid tiltillg tht' platt' and locking till' !lilt:-. giv(' t'ach l1ut appro:\:imatt'l,\" Ollt' full tllrn at a tillH'. \\'h('n all tilt, llllb arc off take of[ the springs ,llld place till' pressure plate 011 onc :--i<l('. The\1 rl'placl' the "prillg and nut un 011(' of the stwl:-; to kl'ep thl' nllit iIltact during dismantling. Flatt('n th(' star "haped tah washer undn the clutch centre nut and

H,c'moving Clutch Cnit Fig. S.

re1110\'(' tlH' nllt, again locking the unit in th(' manller just dl'scrilwd. Cr(';L1 cart" lll\l",t \1(" t:tk('ll

to a\'oid damaging the clutch :-;pring stllcl~ for th{'y can \Try easil:,-; Ill' ill'l1t it titt' Spall1lt')

",lips. \\'hen the llut is off rt'lllO\T the "tar washer and, u."ing sl'ryicc tool lHlllllwr ()! SOlO,

dra\\" off the clutch Cdltn' alld clutch compld<' a:; in Fig. 5.

The clutch housing and gl'ar i . ..; a pu"h fit on'r the hearing and can Iw tak<'ll off \\"ithout an e:\:tractor. It should tlt' noted that lhcrc is a thrust washl'r bdwl'(,ll tltl' cnd of tilt' clutch

S!t'L'\T and tll{' "plirwd clutch ct'ntr(', and this washer ha" the ch'·l.lnfcn'd fact' outwards t()\\"anb tht' clutch.

The driYing and drivell pia tt's should be can'full~' ('x;tlllillt'd. If tll(' skt'l driyillt; platt',": an' badly scon't! tltc~' "houl(1 1)(' J"('pl:ln'd and if tIll' hOll(kd <lri\('11 platl's h;t\T till' S{'gllH'llts

wurn thin tl]('s\' abo should 1)(' n'piac('d. (TII\' ",('<]11('11('(' of a,,;sl'lllhl~· is lirst a driY{,ll piat{' with a hOIHlt,d lining against tilt' n'ar pr(,ssurc platt', than .\ plain sted driYing plak and ";0 Oil

aitcrnatdy.

www.triumphtigress.comService Sheet No. 1004 (eontd.)

l"nit1{('llloYing ClutchFig. 5.

:\0\\' UllSClT\\' thc tlm'(' clutchprt'..:sun' spring ]Jilts. To <l\"oidtiltillg the platt' and locking thl'!lilts gi\'\' each IlUt appro:\:imatelyolle full turn at a time. \\'hell alltlll' llUts arc off take of[ the springs,ultl place the pressurc plate 011 oncside. Then rl'place the spring andnut un OlW of tile studs to keep the\lllit intact during dismantling.Flatten tht' star shaped tah washerunrlt'r the clutch u'ntre nut and1"('1110\"e the nut, again locking the ullit ill the manner just (kscrilwd. Cre;Lt cart' 1I111St )1(' takl'l1to a\'oid damaging the clutch :spring studs for th{'y can \Try easily be Ill'l1t it tIll' ~pall1H'1

slips. \\'hen the nut i:s off relllO\T the ~tar washer and, u:sing SLTYicc tool llllnl1Wl" (i! ,:')O()7,dra\\" off the clutch centre and clutch complete as in Fig. 5.

\\'hen all the SCft'\VS, nuts and holts an' rcmoyed, the primary' driYc covpr can 1)(' taken off,the .ioint being broken hy gentl.\-' tapping tl1(' CCAN with a ra\\"hidc mallet or a hamnwr shaftbut great care must 1)(' taken or the conT may be cracked or distorted.

'I'll(' clutch push rod \\"ill coml' a\yay \\"ith the coY('r. The conditioll oj tll(· pll()spllO!" h!'()ll/T

pad 011 the push rod .-.honld lw carefully' noted and if it ,,11m\'s sil~l1S of h;lyillg \\"mll or till' 11H'lal

having "picked up", the push rod should \w ]"l'placl'd. :\lakl' SUIT that till' small ruhbn ';()"ring on the push rod shaft is ill good condition, and if llCccssary' n'place it to pn'H'nt leakagl>uf oil through tll(' push rod bon'. The fil~al drin_' support arm hearing is a press fit into theprimar,\' clriyl' CO\Tr and if it is to lw n'1l1o\'cd tIl(' CO\"N should 1)(' lwated in boiling water, andtilt' hearing driYl'n ont witll a snitahlc punch througli thl' hole in the hOllsing. The replacementmust be fitted while the co\"cr is still hut. (This method should be CrnplOyTcl whclwn'r a I)('aringis to Ill' relllo\"cd from an alUlllinillll1 cast'.) 'I'll(' contact breakLT drive is ,..;impl)' a sliding fit1ll thc hroJ1zc hllsh ill till' n'ar primal',\' dri\'l' C;lse.

Hd'ort, n'llloYillg the clutch,llatti'll tlw Llb washn on thc largerprilllary driY('n gl'ar and slackt'nolT the ccntre nut. This opl'ratioll\\"ill 1)(' facilitaicd if the unit isplaced in gear hy operating tIl('gl'archange spindk and the brakeapplied with a suitablt' kngth oft1l1)(' o\"er till' brake kn.T.

Till' clutch housing and gear i,,,; a push fit on'r the hearing and call Iw takl'll off \yithoutan e:\:tracto1". It should he noted that there is a thrust wa~hcr betwl'Cll till' end of tIlt' clutchslt.'l'\T and the splined clutch centre, and this washer has the chamfLTed [ac(' outwards t(}\yardsthe clutch.

The driYing and dri\'l'n plates should he cardull~' ('x:lminl'd. If tlw skl'l driYing platt',":an' hadly scored thc~' ~houl(1 Iw 1"l'p!:ln'd and if till' hOlHkd dri\('ll platt'S han' thl' sl'gml'lItsworn thin tlwst' also should ]w n'plact'd. (TIlt' St'![llellCl' of a~sl'!llhl~· is lirst a driYell plate witha hOJ1(lt'd lining against tilt' H'ar pressure platt', than ,\ plain stl'vl driyillg plak and so Oil

a!ternatdy.


Thl' plain ,-;tl't'l clntch hOll:'.ill~ \warilJg ,,It'l'\T can 1w slid off the main:;haft. ~ott, that it i:fitted \\"jtlt thl' larger dianwkr tom-lrcb till' pngine.

lla\-ing pn'\"jo\l,,!y flattt'llVd tIll' tab \\"a:;\lt-'r and :-:.\ackcllcd off the lIut on the large primary drin'll gear, thi" gear can llO\\" lw drawn off the gt'arhox main,.;haft using s(Tyicf' tool number (11· 5()25 fittpd with tht' ",hurt extractor kgs BI-17:~2 (Fig. (':;). The final reIno\'al of the gear should lw carrit:'d out \yith can', and jf possibk \\"jth the key in the gt'arhox lllainshaft at 12 o'clock PO-;itloll "inCl' if tht· k;('\" i:- loost' and drops down lwhind the oil :;ea1 it may cause ltamagt'.

Cnscn'\\ tht, "i:\ 1 ill. lluts holding tIll' priJ1lar~' drin' iIlllt'f c(Jn'!" to thl' crankca:-;c and

IT1ll0H' the \':aslwrs, The joint call 1)(' hroken hy tapping gently \\'ith a rawhide malld or something similar. The illller cm'pr abu carri('", the crankshaft main hearing housing and if this hearing is to he changt,d O\\'ing to llotic('ahk rtlnglllll'SS or up-an(l-down play it will be lwcessary to flatt('ll the tah \\'asl)(,1"s Oil thv fom rl'tainillg holts, fel110n' the holb and tak\-' off the hearing

plak, The hearing itself can then IX' H'llloYt'd from the inner drive conT hy' heating the cast' in boiling ,,'ater and then tapping gently out on to a wooden bench, The replacement :·;jlOuld lw titted "'hile tilt' coY('r is ",till hot and th(' rcplacement bearing is cold, There is abo all oil s('al ill tht' con'r, which is fitted from the inside, (i,e., the clutch side with the lip to\\'anb the hearing,)

Hchinrl. the primary clrin: inn('\' CO\'(T tJl(>re is a rubber "0" ring pn'sscd on to the boss on the outsick of the onicr chain conT. If this "0" ring has become soft or enlarged then a replacement "houlrl. he fitted on reassembly. l{(,lllo"ing Primary Ccar

Fig. (,. I twill nO\\" be possible to H'IllO\'(' tIll' outer chaill CO\"(T h~' taking ont thl' ninc Phillips IH'ad screws, hut careful note should lw ll1ar\(' of their respcctiyc positioll" and lengths, Ikfo[{' final ITmO\'al of the coYer takp out the chain adjuster s('r('\\' hy unscre"'ing thl' locknllt (lJl(lITmoying the screw completely.

,\gain break thl' joint hy tapping gently \\'itll Cl rawhick mallet and ITmOyt: the con'r. Thi.<; may come a\\'ay compkte \\'ith the ~lipper pad and it,; fulcrum pill, or tIlt' pad may remain in tIlt' n'ar portion of the ~\\'inging ann C;l~(', It should be noted that the pad mnst he quite frr~e on thl' lwaring pin.

In tIll' outer chain (O\"(T will 1)(' fOllllcl Cl hall bearing at the rear and an oil seal at the front. Tt", hall bearing ('all 1)(' H'l11m'Ccl hy' heating the case in boiling watPf and then tapping gently on to et hench, Thi:' oil seal is Iltted from the oubicil' of the case, with the lip pointing inwards. \\'I]('n replacing care ."holllcl be taken to ('llSUH' that it is fitted squarely in the hole and is not tilt('d to Ollc sid(', The \Yoodrnff key in the gearbux lllainshaft should now be l'l'mo\'ed ca rcf\llly to ;t\'oid .lamagc' t(l the k('y' or to lllt' ,..;haft.


l{ellloying Primary (;earFig. (,.

Service Sheet No, 1004 (contd.)

Thl' plain ,-.;t('(,\ clntch hOll:'.ing lwarilJg ,,It'l'\T can 1w slid off the main:;haft. ~ott, that it i:-;fitted with the larger dianwkr toward", till' engine.

1[a\-ing pn·\"jo\l"ly flattt'llVd tIll' tab \\'a,,]\(-'r and :-.lackcllcd off the lIut on the large primar~y

drin'll gear, tbi:-; gear can no\\" he drawn off the gparho:\ main,.;haft using scryice tool number(";1--- 5025 fittpd with the ",hort extractor kgs BI-17:~2 (Fig. (':;). The final removal of the gearshould he carrit:'d out with can', and jf possibk with the key in the gearhox Inainshaft at12 o'clock po"itlon sinCl' if tllt, k;t'\" is loose anel drops down lwhind the oil "cal it may causedamagt'.

Cnscn'\\ tllt, ,,1:\ 1 ill. lluts holding tl\l' pril1\ar~' drin' illlWf C(JV('J" to the crankca:ic andITlllOVe the \':ashcrs. Thl' joint call 1w hroken hy tapping gently \\'ith a rawhide mallt:'t or somcthing similar. The inncr c·o\'(,1' abu carries t1w crankshaft main bearing housing and if this hearingis to be changt'd O\\'ing to llotict'ahk rOllgllllcss or up-anel-down play it will be lwcessaryto flattt'n the tah waslwrs Oil the fom rl'tainillg holts, remon' the holb and take off the bearing

platt'. The bearing itself can thenhe H'llloyed frolll the inner driveconT hy' heating the casc' in boiling water and then tapping g('ntl~/

out 011 to a wooden bench. Thereplacement :';}lOuld 1)(' fitted whiletl!c coy('r is still hot and th(' re

placement bearing is cold. Thereis abo an oil :;eal in the coyer,which is fitted from the inside,(i.e., the clutch :;ide with the lipto\\'anb the hearing.)

Hehinrl. the primary drin..'inner coycr tJl(>re is a rubber "0"ring pressed on to the boss on theoutsick of the onter chain canT.If this "()" ring has become soft

or enlarged then a replacement"houlrl. he fitted on reassembly.

I t will now be possible toH'1ll0\'(' tIll' outer chaill coyer by taking ont thl' nine Phillips head screws, but careful note shouldlw ll1ar\l' of their respl'ctivc positions and lengths, Ikfof(' tinal ITmO\'al of the coYer take outthe chain adjustn SCI'('\\' hy UllSCl'C\\'ing the locknut (lJl(lITmoYing the screw completely.

Again break the joint hy tapping gently with a rawhidc' mallet and lTlllO\T the cover. Thi,<;may COlTll' away compkte \\'ith the slipper pad and it,; fulcrum pill, or the pad ma,Y remain intl\(' rear portion of the ~\\'inging ann ca~('. It should be noted that tlw pad mnst he quite frr~e

on the lwaring pill.

In the outn chain COHT will he fOllllel a hall bearing at the rcar and an oil seal at the front.Thi' hall bearing can lw H'm()\'Ccl h y' heating the case in boiling water and then tapping gentlyon to a hench, The oil ~eal is htted from the outside of the case, with the lip pointing inwards.\\'IH'n replacing carl' ."hollid be taken to l'nSUrt' that it i:; tit ted squarely in the hall' and is nottilted to 011c sidl'. The \Yoodrllff key' in the gearbox lllainshaft should now be removed careflilly to it\'oid .lamagc' t(l the ke'y' or to lllt' ,..;haft.


Flatten till' tab wa~lwr on the fear cu:-:h dri\"{, unit and 11l1SCIT\\" tIlt, HUl, locking the

a:-,,,cl1lhl~' by applying tile [('ar brake. The nut has a normal right-hand thread. The gl'arhox :-;prockt-'t nut has no tab washer and is also llll:.;crewl'd in a llormal anti-clnck\\"j,,(, din'ction.

lIen' again it will be nece"sar~' to lock the unit hy applying the rear hrake, or altl'rnatiYt'I~' h~' applying a sub:-:tantiai too1 \)(->tW(,(,l1 the fear lmh stU(l:-, and locking again:'t tht· bench.

::-.:row ITIllO\"(' the single cOlllltt'rsllnk screw which rdains the bra].;:t' dnllll 011 the stub axle

and "licit' the drum off. l"sing a rawhide malll't or copper hamn1l'r, gentl:.,: tap the stub (1'.:1('

through the cllsh elrin' to~yards tIlt:' \Y]w('! side. The (,l1sh dri\"(' can then lw taken ont of tll(' chain and tlw g('arhox "prockpt togl'tht'r with chain call 1)(' takell off tht' sp\ined g('arhox main

s\taft.

Behind the cush elrin-' and rear :-;procket a,"~(,ll1h!y are the ~pl'l'donlt'tt'r drin' and thnl.-;t

washer, the latter heing hetw(,(,Il the spt't'dollwtl'r c1rin' and the H'ar sprocket, and insi<k till'

inner chain ('o\'('r is a hearing rl'taill('d h.\" a lock ring lia\-ing a normal rig-hr-hand tlm'ad. T(j

H'1Il0n' tlli;; Iwaring it will \W Twcess:lry Jirst t(j t'xtract tilt' slwl'dornl'ter dri\-{' n:-.ing s('ryiu' too\

nnmber 61 5()19. \\"hl'1l thi;; is taken out it \,'ill 1w St't'l1 that t11('r(' is a !WP;;S1\lT pad kt into

the cas(' at tlw oppo",itc ('nd of tilt' '''p(·t'dntlH'tt'r

elrin· .

. -\fter th(' hearing lock ring ha,,,; Ill'en ITmoyed,

tile case should 1)(' ileated in hoiling watN and the Iwaring dropped Ollt in the manner pn'\-iol1s1y

c1cscrilwd, and the rpplaCeIlll'I1t, if necessary, fitted whih· the case is still hot. .:\' otl' that tilt' sp('cdometer

drive is fitted with till' flange outwards, (i.l'., towards thl' cush drivc and rear sprocket unit). Tl\{' plain

"tt'('l washer can Iw fittt'd ('itlwr "'ay ronnd.

If the cosh drin' is to 1)(' dismantll'd for fitting

IH.'\V nthhcrs tht' :-->pidt'f should 1)(' ptTs:-->vd ont of thl' '''prockl't u:;ing a \\""oo(kn plug or similar tool on tIlt'

c('ntre splincd portion and ."ll]>portillg the sprocket on one of the ciOllhk Hl\Y of t(>pth, as in Fig. 7. Do

not attt'rnpt to prist' thl' spidn out with Cl SCl"t.'\\-

dri\'t'f undf'r tht' flange as this ll1a~' canst' the flangt'

to break away.

The cush dri\'(' comprisl's twd\"(' rnhlwr"" which arc fitted l)('t\\'('el1 the spider and sprocket Yal](,:-..

On SOI11(, early models all tW('h-i' nthlwrs \\"('1"C soft;

later nHHicb emplo .... , six :-->oft and six hard rnhlwrs,

l'artiIl!-.( tllt' Cu:-->11 (lriy('

Fig. 7.

tlU' hard ones being fitted immediately to till' ldt of till' Yallt'", looking ill:-->id(' tilt' rear ;;procket,

as in Fig. H. '1'he:-->(' hard rnhh('rs an' usuall .... · paint('rl whitt,.

Take off the H'ar hrake shocs hy pr('s:-:ing th(' JOWl'!" sho(' dm\"11 and at tilt' saIlle tiIlle t\\-ist

ing it off the brake calli and fuicnun pin. The inner chain ("()\,'t'r can nO\,' 1)(' takell ofT the pi\-ot

stuh. Xotc th(' rnhher "0" ring 011 tl1(' stub.

The phosphor hronze hu:;h in the front ('Ild of tht' cover i", it pr(';;:; fit alld tilt· uS\lal lllt'tilot\ of t'xtradioIl should he t'l1lplo~'l'd if it i:-: \\-orn and thtTdOH' to 1)(' rt·plaCt·tl.

www.triumphtigress.comService Sheet No. 1004 (contd.)

Flatten the tab wa~lwr on the fear cu:;h dri\"{, unit and 11l1SCIT\\" tllt· Hut, locking theassembly by applying the [('a1' brake. The nut has a normal right-hand thread. The gl'arhoxsprockt't nut has no tab washer and is also un:-;crc\\,cd in a nOrTn'l1 anti-clockwist> din>ction.I len' again it \vill be necessar:v to lock the unit h.v applying the rcar hrake, or altl'rnativcly h~'

applying a substantial too] betw(,C'l1 the [car 1mb sturl:-; and locking again:,t tilt' hel1ch.

::-.:row ITIllOY(' the single countersunk screw which rl'tains t11e brak\' dnnll on tile stub axleand :;licit' the drum off. l"sing a rawhide mal1l't or copper hamnwr, gentl:.,: tap the :;tub (1'.:1('through the cush elrin' to~Yarcls tIlt:' wlwt'! siele. The cl1sh dri\"(' can thcn 1w taken ont of til('

chain and tlw gearhox sprockpt togt,tlwr with chain can \w takell off tht' splilled gt'arhox maill

shaft.

Behind the cush drive and rear :-;procket assembly" are the spl'cdomt'tt'l" drin' and thnt.-;twasher, the latter ht'ing hetween the spt't'dollwtn c1rin' and the n'ar sprocket, and inside tl1{'inner chain cover is a hearing retained by a lock ring lIa\"ing a normal righr-hand tlm'ad. T(JrCTllOn' this Iwaring it wi]] lw lwcessary lirst to t'xtract till' sptTdorneter dri\"{' nsing st'rviu' toolIlumlwr 61 5019. \VIH'1l this is taken ont it \\"ill 1)(' st't'n that tl1('l"e is a prt'ss111T pad kt illtothe case at tlw opposite end of til(' .sl)('('dorndt'r

drin'.

l'"rtilll-( tllt' Cn~11

Fig. 7.

The cu:;h dri\'c compri:.;c:; twelve rllhlwrs, whicharc fitted Iwtween the :;pider and sprocket valH's.On :.;onw early mode]:; all tweh"t' nthlwrs \\"(TC soft;later nIode\:.; employ' six :.;oft and six hard rnh\wfs,tht' hard ant's heing fitted immediately to tht' left of the yallt'S looking in"ide tilt' rcar :.;prockd,a:; in l<ig. H. These hard rnhht>rs an' Ilsllall.\' painter] whitt"

If the cush drin' is to lw dismantled for fittinglH'\V nthhcrs the spidN should he pre:;setl ont of the.sprockt,t u:;ing a \yoockl1 plug or similar tool 011 tllt'centre :.;plincd portion and .snpporting the :.;prockt'ton one of the dOllhk nl\Y of te(>th, as in Fig, 7, Donot attempt to prise the :;pickr ont with a scn'\\"tlriw'r undt-'r the flange as this ll1a~' canst' the flangt'to break awa.\·.

After thl' hearing lock ring ha,-,; bl'en ITlllon:cl,the case should Iw heated in hailing watN and thehearing dropped out in the manner pn'\"iousl}'clcscrilwd, and the replaceJlwnt, if necessary, fittedwhile the case is still hot. .:'\ ote that tIw specdometerdrive is fitted with t]1(' flange outwards, (i.t'., towanlsthe cush drive and rear sprocket unit). Tlw plain"tccl washer can Iw fittt'd ('itlwr \\'av ronnd.

Take off tht' rear hrake shoes h.\' pn':;"ing the lowl'l" shoe dO\nl and at till' sanlt' timt' t\\"i:-:.ting it off the brake calli and fulcnun pill. The inner elwin [m't'r can nO\\" lH' takell ofT the pin)t:;tnh. ::\otc the rnhher "0" ring on the stub,

The phosphor hronze hush in the front t'nd of the cover is a pre~s fit and tilt, u:';11al llwthodof extraction :;hould he t'l1lplo~'ed if it i" worn and thtTdon' to 1)(' rt'plaCt'tl,


\11 oil -':'t'aJ i~ /itkd ill Ill(' co\-('r fmm tlw hr,\1.;:(' ,11tH' "ilk, agaill with the lip of the oil ~('al

f:lCing i1l\\"anb to\\"anb Ill(' \)('arl11;";. Jj' a nV\:l('('lll('llt i~ III lH' iltt('d l\w old :,-('al can \)(' pri-.;('d ollt with a :-.('I'('\\'(II-j\"('1' \)1)1 ('an' -,,:\]()u\li :llw;l\'" hI til)..;\'ll \\'hl'll fitting a Ill'\\ oil '-,('al to ,'"'l'l' that

it ie; in..;('rkd .-.;q1iarl'l~· illt() thl' liD]!', :Illd gr(';lI (';\1"(' "jl(lltld 11(' 1;\1.;:(']) (I) ;t\'qid all\' damage to

11\1' t'I'alh\'r ('dgl' (If tll(' "('a1.

TIl(- hra]':;(' (';1111 -.:.pindk (';\11"1)1' ]"('1110\,(,11 l)~ Llkill,~ ()fi tltl' Jll1t hehind t\1(' hrake arm, and

drawill,t..:" 111(' calll OHt tuward-.:. tll(' 11\1\1 _"id(" It, !lO\\'l'\"('r, till' cam i" quitl> fret' in the housing and th('j"{' is 1H1 apparent (','\:n',,'I\'(' \\'I'ar Oil thl' calll fact' then' is no !leed to <1i"turh it. Th(' l'lli<'llllll pill i:-- :--t'('\\\"(,<\ 11\":1 11l1t nil tlH' iu:--idt, ()f the cm"er; h(']"(' again tlwH' i", no w'('1\ to (li"tnrh il 111111'''''': tIlt'\"(, i.., ()In'j(lll:-- <I:l1])a.*-:(', '1'111' tl\"I) IIlCltirJ11 d()w(,I" in the co\'n ",llnuld Iw lIndamagl:d

<ll1l\ ;\ ~IlI)(1 III ill 11](,lr holl'''',

Dismantling Timing Side of Unit I )i"lll:tlllli])g' of tIll' kft-hand or prilllar~' drin' si(lt' is 110\\" complptcd and attt'ntioll can be

~i\'('!l 10 till' right-haml side of tlw unit.

If tlll' f:11l c(lId ha<.; not :tircari v ht'l'll r('ltlo\'{'d, lITlSCH'\\" tlH' thrc'e "mall Phillips IH'ad S(TeWS

awl tht' OIl(' plain screw at tilt' top right-hand front \yhich also carried till' throttlt' cahle clip. t Tn"cn'w and J"('mO\"(' till' nut ",('cnring tIll' kick.<.;tar1 Cl' ,"'J )nlcket an( \ rp

mon' tlw sprocket COlll

plete with the chain and "pnng. Take ou t tIll' \Y()()drnff key, being can'fnl not to damage tll(' kt,\" or tlw -.:Int in th(·

:-:11 a ft.

Fig. H. nut s(,curing tlit' fiywht,t'l

and fan can now \w rcmOl'cd h~r scrcwing in a normal <l.nti-ciock\\"i-.:t' dir('ctioll, using all 11 Hi ill. \\,hitworth ring

spanner. The crallk"haft, hO\\"(','('r, 1l111"t 1)(' prn"('lllt'd frolll turning h~' holding th(' oppo"itl' :-;ir\t> ,\'itlt scn"iCt, tool llurnlwr 61 ;;()22.

\\'ith tht' flywh('el centre llut rt'mo\'cd, tht, n~"\\"lw('1 can \)(' ('xtractl'(l with "cn"ice tool nurn\wr 61-5002. Thi:-; will expost' tIll' ~tator unit sl'Cllrt'd to th(' crankca:;e hy three 5,/16 in. 11l1t" and washer:;, which .;;h011111 hi' 1l11"cn'wvd II:-;ing a tllbular :-;paJlIwr to a\"oid damage to the

www.triumphtigress.comService Sheet No. 1004 (cootd.)

\11 oil -:'t'aJ i~ /itkd ill tlw ('m'('r frnm tlw hr,ll.;:(' "ht)(' "ilk, agaill with tlw lip of the oil ~('al

f:lCing i1l\\"anb to\\'anb tIl(' 1warlng. Jj' <\ HVLJ('('Jl\('nt i" Itl lH' Ilttl'd II\(' old :',('(11 can 1)(' pri"edo\lt with a :-.;cn,\\'(IJ-j\"('r 1111tl'an' -..:!JOU)I! :l1W;l\'" lH tal('Jl \\'hl'll fitting a Ill'\\ oil ,,('al to ."-l't' that

it je; in-;('rkd '''qllart'!~· illlll thl' llllll" :11\11 1-:1'(';11 (':\1"(' ",llllltld III' 1;ll.;:(,]) tl) (l\'qid all\' damage to

11\1' fl'alht'r ('dgl' (If tll(' "-I'a1.

TIH' hrak(' (',nil -;pindk (';\11"1)(, H'Jll()\,(,d l)~ Llkill,~ nil tlte nl1t hehind tIl(' hrake arm, and

drawill,t..:" 111(' calll out tu\\'ard" tlw ll\lh ."idl'. 11, Il()\\'\'\"('r, tIll' cam i" quitl' [rc(' in the housing

and thl'n' i" ]HI apparent (',,\:('(',,-':'\\'(' \\'l'ar Oil 111(' cam fact' then' is Ilo nced to <1i"turh it. TheI'ulnnlll pill i:-:- :-:-('('1\\"('<\ 1~\-:1 11Ut nil tIll' in:--idt, of tht' cu\-er; hcn' again tlwH' i", no Tl('l'd to clj"tnrhit 1111\(''';.'' 11\(']"(' i..; t)ll\'itlll."; d;111l([.~I" TIll' tWI) IIlc.1tirJ!1 dO\wl" in the co\'n ,-;ltould Iw u!1clamagt'dand ;\ ~o(1I1 lit ill tl\('ir !ltlll''';.

Dismantling Timing Side of UnitI )i"lll:llltlillg' of tl](' kft-hand or primary' drin' ",i(lt' i", no\\' comp]ptcd and att('ntion can be

~i\'('ll 10 til(' right~hand side of til(' unit.

If 11](' f:lll ctnd ha" no1 :tlread v \Jt't'n feltlO\'{'<!, UllSCH'\\" tlH' thrt.'e "111all Phillips lH'ad S(TPWS

and the one plain "ere\\"at tilt' top right-handfront which also carriedtill' throttlt' cahle clip.t Tn"cn'\\' and 1"<.'1110\"(' tht'nut ",ccuring tlH' kick~

....;tarter >",procket and r('~

mo\'<.' tlw ",prockct e()m~

plete with the chain and"pnng. Take (lll t the\Yoodruff key, being ('an'~

ful \lot to damage tIll'kt,v Of tIll' -.:lot ill tht,

-.:11 a ft.

Hublwr .ASSC'lllhl,vFig, H.

C\l",b DnvC' The large e:--.:t('n",iOll

nut securing the fiy'w!H't'land fan can now Iw re

Tl1o\'ccl by ",crewing in a normal anti-c!ock\\-i-:e direction, n-:ing an 11 J(-) ill. \\'hit\Vorth ring

spanner. The crank"haft, hO\\"('\'t'r, I11ll-:1 Iw prn-\'ntt'd ffOlll turning h~' holding the oppo"itl'"itk \\'ith sen-iet, tool nllfnlwr (-il ;;022,

\\'ith the flywhccl <-'entre llut H'Tl1o\'cd, tht, n~'\\'lw('1 can \w ('xtractl'cl with "en-icc toolnumber 61-5002, Thi:-; will c:--.:po"'c the ~tator unit sl'Cllrt'd to thl' crankca:;e hy three 5/'16 in.11ut" and wa:;lwr:;. which .;;,hOll1d hi' 1111"Cn'\\"('<1 using a tuhular -:panner to a\"(lid damage to the


~tator unit. 'Yith the nuts and \vaslwfs removed the stator can be drawn of[ the tilrt,t' ...;tuels by' simply pulling it av.;ay and threading the leads through the rubber grommet in the hack of th(, cast', The three distance pieces on the studs should 1)(' takt'll awa~' to (l\'oid lH'ing lost in suh",cqllt'llt dismalltling. Carefully prise out the \YoodrufT b'.\· frolll tIlt' lllain;-,haft, ag;:lin

taking care to ayoirl damage to tlw key or tht' slot in tll(' shaft.

If the machine is fitted with a starter motor, tlw t\',·o 5/1H ill. bolts secnring t1)(' lIlotor to tilt' back of the timing gear conT should be removed and the starter takell <i\\,<'lY". In tilt' case of models without startC'[ a blanking plate is fittf>d in lieu of starter and this piatt' IWl'd not ]1(.

(Ii . ..;tllr\)ed,

Slightl.\' to the left of the starter sprocket is a projection il:l .. ying two flats; this is til(' cam plate plunger housing, Using a spanner which is a good fit on the two fiat:--:, IlllSC1TW tIlt' hOlbiJlg

III a ]]ormal anti-clockwise dirf'ction and r('mon' it complete with tl1(' pltLllgN and spring.

The g('arbox l'lld con.T can now he r('moved after the fin' Phillips head scre\\'s ha\'(' ht'('n

taken out; again tll{' joint will han' to he hroken by tapping g(,lltl~' with a rawhidl' lllalll'1.

Remoyal of the end con:'r will expose the outer portion of the cam plate and the s('I('('tor quadrant together with its scissor spring, the spring being retained in the inner cover by a largl' hcxagon-hea(h'd bolt.. l~nscrcw this large holt and dra\\-' it out noting that as it is drawn through tll{' spring it will remove thE' star washer which is litt('d Iwtwt'en the holt and the cast', Tlte sl'lt'ctor quadrant can then he taken out quite easily if a thin strip (lf steel such as a table knife is slipped Iwhveen the two plungers and the cam plate, (Sf'f' Fig .. 9), The other end of tlw quadrant spindlt' is simply a push fit into t hl' hack of the cast'.

T\H' two plungers should lw unclamag{'d on their chamfered ('nds and quite frt't' to nlo\'(' in the iloll",ing, and should not 1)(' distmht'd if tlw\' an' sati:--:brtor~·.

The next optTation is to remo\'(' the timillg and gearhox cO\'('r which is in 011(' pi{~c{',

Take out the five large countersunk scr('\\'s holding thl' timing con'r around the crankshaft alld the fIn' Phillips head screws on the gearbox Co\Tr portion, (Two of these are inside the

Rell1()\'ing Sdf'ctor Qnadrant

Fig. 9.

gearbox portion on the left-hand side of til(' selector quadrant .. ) Do not cli",tllrh the S(Tt'\\, on the timing cover portion; this retains the kickstarter stop plate. Sl'e' Fig. 10 ..

",lotter[

\\"ith all screw", rcmo\'ecl the cover can now he withdrawn, bringing with it t\](' gearhox mainshaft, carn plate, selector forks, layshaft and gear cluster. S{'l' Fig. 1 L


~tator unit. '''iill the nuts and \vashers removed the stator can be drawn of[ tht' thrt,t' ...;tudsby simply.' pulling it av,ray and threading the leads through the rubber gromnwt in the hack ofthe cast', The three distance pieces on the studs should be takt'll away to <l\'oid lH'ing lost illsuh:-;cfjuent dismantling. Cardully prise out the \YoodrufT kt',v from tlw lllainshaft, ag;;\intaking care to a\'oid damage to the key or the slot in til(' shaft.

If the machine is fitted with a starter motor, the hvo 5/lH in. bolts securing tilt' motor totilt' back of the timing gear cover should be removed and the starter taken away'. In tilt' caseof models without starter a blanking plate is fittt>d in lieu of starter and this plate IWI'd not 1w(li ...;tllrhf'd.

Slightly' to the left of the starter sprocket is a proj('ction h:lying two flats; tbis is tilt, camplate plunger housing. Using a spanner which is a good fit on the two flah, IlIlSC1"l'W tl](' h01biJlgIII a normal anti-clockwise dirf'ction and. remove it complete with tilt' plungN and spring.

The g('arbox ('IHI coyer can now he removed. after the fin' Phillips head screws lla\"c ht'('n

taken out; again tllt' joint will han' to he hroken by tapping g('ntl:v with a rawhid(' lllalll'1.

1\.e111oyal of the end cover will expose the outer portion of the cam plate and the s(,I('ctorquadrant together with its scissor spring, thespring being retained in the inner cover by alarge hcxagon-headpd bolt. l~nscrcw this largeholt and dra\\' it out noting that as it is drawnthrough the spring it will rcmovc the star washerwhich is litt('d lwtwt'en the holt and. the case.The s(,lector quadrant can then he taken outquite easily if a thin strip of steel such as a tableknife is slipped Iwhveen the two plungers andtill' cam plate. (See Fig. 9). The other end oftlw quadrant spindle is simply a push fit intot he hack of the case.

TIH' two plungers should he undamagedon their chamfered ends and quite free to moveill t1le hou",ing, '<lnd should not IH' di",tmlwt! iftill'\' an' satisbctor~',

The next optTation is to r('mo\"(' the timilJgand gearhox CO\Tr which is in one piece.

Ren1()ving Selector ~:'hladrallt

Fig. 9.

Take out the fivc large countersunk screwsholding the timing cover around the crankshaftand the nn' Phillips head screws on the gearboxCO\Tr portion. (Two of these are inside thegearbox portion on the left-hand side of the selector quadranL) Do notscn'\\' on the timing cover portion; this retains the kickstarter stop plate,

disturhSl'e Fig,

the slotted111.

\\"ith all screv,'s removecl the cover can no\"., he withdrawn, bringing with it til(' gearboxmainshaft, carn plate, selector forks, layshaft and gear cluster. Scc' Fig, It.

•


(~('arhnx and Timing- C nvef ~cr('w",. Fig. 10.

.\:-; till' a,,:-;cmhly is dn.1\YI1

ont it may' \)(' that till' tilm:.;t \\",l:-,]wr \Y!licil is tlttl'rl to Ilw lI}:lin",\laft \\'il1 drop into tIll' ca:-;\', 1 00],;: for thi:-; w(I:-;\wr ,tllc1 if it <1(")1':; drop replace it tt-n;poraril:v 01l t lw gearho-, maill

:;haft so that it:-- location is P'llwllllwrcd. I twill \w ncc('ssary (\uri1ll.": this opnatioll to hold t\](' CUll l,bt" cl'lltrall...,' to

;l"oid fouling ('it\l('r 1 he llPlwr

or 10\\,(']" portion", of the g,'arho'( e,l",\',

In sonw cases t\1(' :-.l'lector fork spinc11v lllay remain in thl' gcarbo:-.:. Tt i . ..; Silllplv a pl1:-;11 iit into th(' gearbox and tIll' (,()\Ocr •

. -\t this stage it ",h(lUld be noted that tlwrt, i" ,l possihilit..., of th(' top front {'ng-int' monnting st11d dropping out of tIlt' crankcas{' if it ie.; all {'a:-:.~· tit in tilt' ra,,(', and "inc(' it i~ (':-;:-:.entiai that rili" "tud is in position before the gearhox and timing C()\"(T and the primary driv{' illllN CO\"('1'S

an' titted the point should 1)(' horne in mind for rvas~t'lllhl~'. It i~ t\wr('forl', a wi,,(-' pr(cl1ltioll

to replace the two nut" 011 to thi~ stud ~o that it i:-. retained in position.

The only parh now left in tlw gl'<llhox arc till' pinion s\('('\"(' and the main hearing. Tltc' pinion sleevc call lw c1rin:'n through the hearing into t1H' gearho:'\ and this will r{'ll'a~(' th(' g('arh()~~ ~procket di:-;tance piece which tit:-; ()\Tr tlw pinion ~k('\"(' on th(· ollt"id(, of tIll' g('arhox,

'I'll(' pi\'ot :-;tnb for till' chainrasl' :-:.winging :lrlli unit b fixed to thl' gearhox hy' fOlll"

holh and two lucking platl'~ that an' lllnwd tip OH'r the holh. It i~ n~()st llnlikely' that the stuh v,·ill ba\'l' to be ft'-placed hut it bas to be ft'!l1o\"('d to allow replacement of till' gearhox lllainshaft bearing if examination pro\"(',.; this to \w 11i:'('(':;S;:\1")".

T{('ll1o\T tll(' stnh h~' turning hack the locking piatl's and taking out till' four holh, hut OhyjollSly- if tilt' mainshaft ht'aring has to he n'-1ll0\'ed it is Iwttl'r to do this when the compkte Hnit ha~ been ~tripI)(='(L 'I'll(' ll,.;nal 111ethod of re111o\'al and replacelllent is t'Illployed hut it lllUst 1)(' tappccl from thc' outside of the gearbox and replaced from till' insick. The "amp applies to thc' lay-

"llart ])hospilol' 1Jl"(lJlZI' lwaring.


(~earhnx and Timing- CnVCf ~cr('w:..;.

Fig. 10.

.\:-; tile a:..;:-;('mhl~' is dn.1\YI1

ont it ma.\' 1)(' that tile tbm:.;t\\";l:·;]wr \Yl1ich is tlttl'rl to IlwJI};lill,,11aft will drop into tll('('a,,(', look for tlli:-; wa"lwl" ,melif it dOl's drop replace it tt'n;poraril:v on the gt'arho-'\ maill:-;haft so that it", location isJ"I'llWITl1)(,l"c(]. I twill Iw neces

sary Iluri1ll.": this opna1ioll tohold tl](' CUll platt' cClltrall.\' to(l\'()id fouling ('itller 1he upper

O!" 10\\,(']" portion:..; of the g"arho:\:

C'l:-;('.

In SOJlW cases tIl(' :-;l'1ector

fork spindle may remain in tllt,

gcarbo:-:. Tt i...; simplY a pl1s11

fit into th(' gearhox and tlll'cover.

Fif!. 11.

1{('mO\T tl\(, stnh by turning

hack the locking platee.; and takingout till' four holb, hut ohYionsly' iftil(' mainshaft hl'aring has to he rcmO\'ed it i:". IwttlT to do thi:-; whenthe complete unit has been :".tripped.Tlw ll:".nal method of l"cmO\'al andr('placelllcnt is l'mp]oyed hut it lllU-;tbe tappl'(l frOlll the outside of thegearbox and replaced from tl1('in:-;ick. The "ame appliee.; to the' lay"llart l)ho:,;phol' ]Jl"(lnZI' lwaring.

.'\1 this stage it ""h(,uld be noted that t1w]"(' i" a possihilit.\ of the top front cngint' mounting:-;t11<1 dropping ont of the crankcase if it i" all ea:-:.~· tit in tilt' ra"e, and "inc(' it i" (,,",,,entia] thatrhi-; -;tlld i:-; in po:-;ition bdore the gearhox and timing CO\"(T and the primary drive inner co\'{'r-;an' Jitterl the point :-;hollid 1)(' horne in mind for rl'a-;:-'t'lnhl~·. It i~ t11('[('for(', a wi"e precwrion

to replace the two nut" on to thi:-. :-;tud "0 that it i" retained in po-;ition.

The onl.\' part:-. now left in the g(',uhox arc till' pinioll -;1ee\"(' and the main hearing. Tltc'pinioll slee\'(' can he c1riyen through the ht'aring into tlw gearho:'\ and thi" will releas(' the g('arho~~ "procket di"tcl.llc(' piece which iib O\Tr tJw pinion ,,!c(,\,(' on tll(· ou[-;idt, of tll(' gearhox.

T1H' piyot ;;tub for til(' chainca"c :-:.winging :mli unit r-; 11X('<1 to the gearhox by fOlll"

holt:-; and two locking platt''' that an' lnnwd up 0\"('1' the holt;;. It is l1~{)st 11ll1ikel~'

that the stuh \\·ill llayc to be n'-

placed hut it has to he n'moH'd toallow replacement of till' gearhoxlllain:-;haft bearing if examinationpro\'{'-; tlli:-; to lw IH:'c('ssar~·.

•

Service Sheet No. 1()()4 (contd.)

Dismantling the Gear Cluster Take ont the ~t'kctor fork :,pindh', which is a push tit into thl' cO\'('r, and rt'll1on.' thl' two

st'It'ctor forks. The maillshaft and layshaft call then he rcmo\,t'd from the bearings in tlH' outer CO\"('f, and thi." will only lean' the cam platl' and its pin)t pin in the outer COH'L TIll' calll

plate can be ITmm'pr! h~' taking nut the split pin and drawing out the pi,"ot pin from the ;.;idc. The kickstarter _"pindk and ratchd .,:.lick on to the cnd of till' layshaft. The ratchet pawl should lw ('xCllllirH'd to SC(' that it is ill good cOlldition and that the small piung('r and spring nnderI1l'ath till' }Kl'\"I ,lIT not sticking. If the pa\\"] is \\"om or damaged it should he replaced. The ratcill't kdh insir\l' ttH' low gear and kicbtartt'f pinion ~hollld abo iw (~xamin('d to make ~u!"(' that it i:; fit for fl1rtlHT 11~(,.

TIll' lll(lin~ilaft pill):;phor hrolll-l' 111l~h ill tilt' IHltcr COHT io; an int{'rkn'nn' llt alld jo; abo Jlq.~g\'d OIl the fan' to jllT\Tllt it n'\'()l\'ing. {{('placl' thi~ 11l1~h only if wear i~ appan'nt.

'I'll\' 20T ~liding dog pillilJ1l can he , .. did off till' lllaill~haft ,..;pJincs ica\'ing ill(' small HiT pinion, \yhich is a pr!':;,,,; jit on the :;haft, retaining in po:;itioll tile 25'1' pinion, The mainshaft 16'1' and 25'1' pinioll~ ;UT ~('I('ctiH'I\ a~~t'lllhkd during manufacturl' and if an.'": one of th(':;(' parh has to \)(' !"eplac\'d tll(' (' III pI 1'1 t (L''';('lllhl,\'

I1nd('r part 11I1llllll'r 76 J17-l lllll:--t he

()lltaiIH'(i,

:-:'illliLL1'I,\', tilt' 2,,'1' Ll\";!laft pillioll i..; rvtair\('rl Oil tilt' :--llafl \1\' th(' 17'1' pillillll,

al:;o a tight prl''';-; Ill, alld thi~ a~:--t'llll)I,\' i:-alwa\':-. .";l1ppli('r\ cOlllpktl'. TIll' part

lllllllber is 76 :{()I~,

RClTIOval of the Timing Gear To n'\11O\'(' thl' timing g-('ar it \\ ill 1)('

n('('('~~an' to hold the crank:-.h:dt u,..;ing ~lT\'ice tool (-)1 5022.

Flatten tIll' tah w(l",lwr on t11(' larf,:'('

timing or ('am~haft pinion and lln~cr('\\

til(' nut in Cl nonnal anti-clock\\'i~e directioll; till' call1~haft pillioll i.-; then 1':\

tr;l(~t('d fmlll tlte ~haft \bing :-'('ITiCt, to()l Fig. 12,

l\clll()\-ing ('aIllshaft t'ini()ll

Fig. 12.

(11-5()25 littl'd \,-itlt kg:-; Gl 17:;2 (:;hurt kg~), ~l'l'

The large crank~llart ])iniull Illlt i,,,; ;lgain lIn~cn'\n'(1 ill an anti-c1ock\yj:;e dircctiOll, There is 1I0 tab wa,-;lH'r and thl' tool rc<]uin'd i~ a llormal 11 16 ill. \\'hitworth :;palllwr. To \\'ithdraw till' pillion ~l)('cialloJlg holt~ 1111\,-;t 1)(' lI:-:>cd \,-itl! (':\:tractor llI1111lwr 61-5025. Th('se are nUlllbl'red (j 1 5()()(i.

It will Ill' noted that hoth pinion:; arc 1llarked to facilitate rea:;~{'mbly and that the crank:-.haft pinioll \lilt kl..-; a ITgi:;tn \\"hich goe~ against the Plll1011, There i~ abo a c.10\\"(·1 in the crank..;haft \\'hich l()cat('~ till' small n,-lllk:;haft pillion,

www.triumphtigress.comService Sheet No. 1()()4 (contd.)

Dismantling the Gear ClusterTake ont the ~t'kctor fork Spilld](', which i~ a push tit into the eo\'('f, and remon.' thl' two

st'lt>ctor forks. The mainshaft and layshaft can then he removed from the bearings in tlH' onterCO\"('f, and thi." will onl.\' lean' the cam platl' and its pin)t pin in the outer cover. The camplate can be ITmm"('r! h.\' taking nut the :-;plit pin and drawing out the pi\"ot pin from the ;.;idl'.The kick..;tartcr _"pindk and ratcJwt slide on to the end of th(' lay'shaft. The ratchet pawl shouldlw ex;unirH'd to set' that it is ill good condition and that the small plunger and spring underneathtill' pawl ,lIT not sticking. If the pa\\"j is \\"om or damaged it should he replaced. The ratclll'tkdh insidl' ttw low gear and kicbtartt'f pinioJl ~hol1ld abo be (~xamin('d to make ~urc that iti:; fit for fl1rtlwr 11~(,.

TIll' lllaiJl~haft pllo:;phor hrolIZ(' 111l~h

Iwgg\'d on the fan' to pn'\Tllt it n'\'o!\'ing.ill tht' outer coyer io; an interferl'nce ilt and jo; abo

{{('place thi~ l>l1~h only' if wear i~ appan'nt.

~l'l'

H.clllo\-ing ('aillshaft l'ini()ll

Fig. 12.

littl'd \\-itlJ kgs Gl 17:t~ (:;hort kg~).

RClTIOval of the Timing GearTo I"('mo\'(' the timing g-t'ar it will !H'

lll'Ct'~~an' to hold the crallk-;h;dt U,..;illg~lT\'ice tool (-)1 5022.

Flatten tlll' tah wa",lH'r on t11t, largt'timing or cam~haft pinio1l and lln~cr('\\

the 11Ut in a nonnal anti-clock\\'i~edirec-tioll; till' c<lm:--,haft pinion i...; then e:\-

tr;l(~t('d from the ~haft Ibing :-,('ITiCl' tlHd (11-5025

Fig, 12.

:-:'illlil:Lrl,\', the 2,,'1' Ll\..;llaft pinio]] i:;rvtairH'rl Oil tIlt' -;llafl !J\' the 17T pillillll,al:;o a tight pre-.:.:; lit, alld tlli~ a~,";t'llll)I,\' i-;alwa\'-; .-':'\lppli('r! cOlllpktl'. Tll(' partnumber is 76 :{()1~.

TIll' 20'1' ~liding dog pilli(lll can he ,..did of[ thl' lllain~haft ,-;pJines lea\'ing Ill(' ~11lall HiTpinion, \yhich i~ a pre:;,,,; jit Oil the :;haft, retaining in po:;itioll the 25'1' pinion. The main~haft

16'1' and 25'1' pinio1l~ ;lIT ~t'lt'ctiq'l\ a~~elll!Jkd during manufacture and if anyone of the:;(' parhhas to 1)(' rcplac('d tIll' l: lllpll'tt d-;-;('lllhl,\'

I1ndl'r part 11111nl)('r 76 J17-l Illll~t he\llltailH'(i.

The large crank~ll<lrt ]linion Illlt i,,,; ;Lgain un~cn'\n'd in an anti-clock\\"be Llirection. There isno tab wa,..;]wr and the tool lTquin'd i~ a normal 11 16 ill. \\'hitworth spalllwr. Tn withdrawthe pinion ~p('cialloJlg bolt~ 1l11l,~t bl' u:-:>cd with c:\tractor 1lI11111wr GI-5025. These are numbelTd(j I 5()()(j.

It will Ill' noted that hoth pinion:; arc marked to facilitate reassembly and that the crank-;haft pinion nut ha,,,; <l n'gi:;tn \\"hiclJ goe~ against the PIl11011. There i~ abo a dow('l in thecrank..;haft \\'hieh locatl'~ till' small cr,-Lllk:;!laft pinioll.

•


Removal of the camshaft pmlOll \vill expose the oil pump link which is driven by an eccentric 011 the camshaft and is retained in position by a phosphor bronze plate held by two larg(' countersunk screws. These scre\vs call be removed with a normal type screwdriver, after \\·hich thl' phosphor bronze plate can be taken off and the distance piece removed showing the eccentric and linkage assembly.

To remove tlll' link, flatten the tab washer underneath the screw head on the oil pump plunger, take out the bolt and then slick the link out of the fork cnd. It can then be takc]] off the carn:-5liaft together with the eccentric.

Tlll'rc is a \Yoodruff key in the cnd of the camshaft and if this is undamaged and a good tit it l1~'l'd not be disturbed for ITmOyal of the camshaft, which can be slid out of the crankcase from l'ithcr elHl.

This unit uses a timed camshaft breather \\'hich is simply a hole drilled straight through the camshaft, lining np with holes drilled through the centre camshaft bearing. The breather is therefore open at e\'tTy half H'Yolution of the camshaft.

To rt'mo\'c the camshaft turn the block upside dovm so that the cam followers drop away from the shaft and then slide the camshaft out. The unit can then be turned the right way up and the cam followcrs dropped down into the crankcase.

Turn thl' unit uF,;jd ... , down again and remoye the twelve Phillips head screws retaining the :-,UlllP co\'t~r. The coyvr can then be taken a\vay together with the haftle plate and the oil pump iilhT, which is fitted o\'cr thc oil pipe between the baffle plate and the sump COYer.

TIll' oil pipe i:; all interference fit into the crankcase and should not be disturbed if it is l111dalllag{~(l.

C;askets arc fitted between the crankcase and the baffle plate and between the baffle plate and the sump coycr. The engine breather cover, which is to the bottom rear of the cylinder block, can he remoycd together \vith the fibre gasket by taking out the small 3/16 in. Phillips head 5crew. The only attention required in this case will be to clean it of any dirt or accumulation of sludge.

Removal of the Oil Pump llnscrew the slotted plug which will be seen on the crankcase joint face; this has a normal

right-hand thread. \\'ith the plug removed the remaining parts of the pump can be taken out, u~ing a piece of thin wire bent to a hook at the end, First lift out the spring, if this ha,:; not come away with the screw plug, then drop out the first steel ball; next lift out the long plunger noting that the small hole with the countersunk face is uppermost. Then another spring and another steel ball with finally a thin washer, again having a countersunk face or ball seating which is uppermost, (i.e., next to the ball). \Vhen these parts are removed it only leaves the plunger which is connected to the link and the phosphor bronze plunger bush which should not be disturbed.


•


Removal of the camshaft PJnlOll \vill expose the oil pump link which is driven by aneccclltric on the camshaft and is retained in position by a phosphor bronze plate held by twolarge countersunk screws. These scre\vs call be removed with a normal type screwdriver, after\dlicb the phosphor bronze plate can be taken off and the distance piece removed shO\ving theeccentric and linkage assembly.

To remove the link, flatten the tab washer underneath the screw head on the oil pumpplunger, take oui the bolt and then slick the link out of the fork end. It can then be takc]] offthe carn:-5haft together \",ith the eccentric.

Tlll'rc is a \Yoodruff key in the end of the camshaft and if this is undamaged and a goodtit it l11'l'd not be disturbed for ITmoval of the camshaft, which can be slid out of the crankcasefrom l'ithcr eml.

This unit uses a timed camshaft breather \".,hich is simply a hole drilled straight throughthe camshaft, lining np with holes drilled through the centre camshaft bearing. The breatheris therefore open at every half revolution of the camshaft.

To remove the camshaft turn the block upside dO\lm so that the cam followers drop awayfrom the shaft and then slide the camshaft out. The unit can then be turned the right wayup and the cam followers dropped down into the crankcase.

Turn the unit upside down again and remove the twelve Phillips head SCIT\VS retaining the:-;UlllP cover. The cover can then be taken a\vay together \\'ith the taftle plate and the oil pumptilter, which is fitted ovcr thc oil pipe between the baffle plate and the sump cover.

The oil pipe i:; all interference fit into the crankcase and should not be disturbed if it islllldalnagcd.

C;askets arc fitted between the crankcase and the baffle plate and between the baffle plateand the sump cover. The engine breather cover, which is to the bottom rear of the cylinderblock, can he removed together \vith the fibre gasket by taking out the small 3/16 in. Phillipshead screw. The only attention required in this case will be to clean it of any dirt or accumulation of sludge.

Removal of the Oil PumpUnscrew the slotted plug which will be seen on the crankcase joint face; this has a normal

right-hand thread. \Vith the plug removed the remaining parts of the pump can be taken out,using a piece of thin wire bent to a hook at the end. First lift out the spring, if this ha<; notcome away with the screw plug, then drop out the first steel ball; next lift out the long plungernoting that the small hole with the countersunk face is uppermost. Then another spring andanother steel ball with finally a thin washer, again having a countersunk face or ball seatingwhich is uppermost, (i.e., next to the ball). \Vhen these parts are removed it only leaves theplunger which is connected to the link and the phosphor bronze plunger bush which should notbe disturbed.


Removal of the Connecting Rods and Pistons \Vith the crankcase and cylinder block upside down on the bench flatten the tab waslH-'rs

underneath the connecting rod cap bolt nuts and unscrew the nuts. Take off the tab washers and lift off the big cnd caps. These arc numbered and the caps must be mated with the corresponding numbers on the connecting rods. If the bolts are a tight fit in the caps they should be gently tapped through with the handle of a mallet.

Each connecting rod complete with piston should then be drawn upvt"ards through the cylinder bore and taken, out from the top of the cylinder. Each piston should he immediately marked on the inside face to show which bore it was taken from and which way it was fitted; a good plan is to mark the inside of the skirt \"ith the letter "L" for the left-hand cylinder, putting the mark on the back of the skirt to denote which way round the piston \vas fitted. :'\ note should be made of which way the number on the connecting rod \vas fitted, or altt-'rnatiydy, mark the \veb of the rod in a similar mannC'r to the piston to indicate which cylinder it came from and which \\'ay round it \Vas fitted. Do not in any circumstances mix the big ('nd nuts and bolts; the nuts should be placed immt-'diatcly on the bolts from \\'hich they \"'Tn~ taken to facilitate reassembly. If the wrong nut is fitted to a bolt it will affect its position and may make it difficult to seCllrc by the tab washers.

\Vith the removal of the connecting rods and pistons the crankshaft can be drawn out from the left-hand side of the cylinder block.

'nle big cnd h('arings sllould he bright and free from any score marks, If there is any sign of seizure then the bearing shells should be replaced; in the same manner the crankpins 011 the crankshaft should be clean and bright. Pistons should be carefully examined to see that the rings are free in their grooves and that they are

Crankshaft Sludge Trap Fig. 13.

not carboned up or broken. If there is any suspicion that the rings are worn they should be remon~d and gaps checked with the ring inside the cylinder bore. The gaps should be bct\, .. Tcn .OOG in. and .(HO in.

If the unit has covered a considerable mileage there may be a certain amount of slurlge huilt up in the crankshaft sludge trap, in which case it is ad\'isable for it to be cleaned out. Procedure is to take out the slotted plug on the drive side end of the crankshaft and the grub screw in the centre of the crankshaft and then to draw out the sludge trap. (See Fig. 13). The pas:-;age ways should be cleaned very thoroughly in petrol or by using a suitable degrcasing plant.

\\'hcn [('a.-;semhling the sludg(' trap insert the trap into the shaft, then the small centre grub scrcv .. ' and finally the large screw. Both the screws must then be centre-punched afteI final tightening. This is most important.


Removal of the Connecting Rods and Pistons\Vith the crankcase and cylinder block upside down on the bench flatten the tab washers

underneath the connecting rod cap bolt nuts and unscrew the nuts. Take off the tab washersand lift off the big end caps. These arc numbered and the caps must be mated with the corresponding numbers on the connecting rods. If the bolts are a tight fit in the caps they shouldbe gently tapped throngh with the handle of a mallet.

Each connecting rod complete with piston should then be drawn up\'t"ards through thecylinder bore and taken. out from the top of the cylinder. Each piston should he immediatelymarked on the inside face to show which bore it was taken from and which way it was fitted;a good plan is to mark the inside of the skirt \"ith the letter "L" for the left-hand cylinder,putting the mark on the back of the skirt to denote which way round the piston \vas fitted ..A note should be made of which way the number on the connecting rod \vas fitted, or alternatively', mark the \veb of the rod in a similar manner to the piston to indicate which cylinder itcame from and which way round it \Vas fitted. Do not in any circumstances mix the big endnuts and bolts; the nuts should be placed immediately on the bolts from \\'hich they \vcn~ takento facilitate reassembly. If the wrong nut is fitted to a bolt it will affect its position and maymake it difficult to secure bythe tab washers.

Crankshaft Sludge TrapFig. 13.

'1'1le big end hearings sllouldhe bright and free from anyscore marks. If there is anysign of seizure then the bearingshells should be replaced; inthe same manner the crankpinson the crankshaft should beclean and bright. Pistonsshould be carefully examinedto see that the rings are free intheir grooves and that they arenot carboned up or broken. If there is any suspicion that the rings are worn they should beremoved and gaps checked \vith the ring inside the cylinder bore. The gaps should be hct\\'ecn.OOG in. and .010 in.

\Vith the removal of theconnecting rods and pistons thecrankshaft can be drawn outfrom the left-hand side of thecylinder block.

If the unit has covered a considerable mileage there may be a certain amount of slurlgcbuilt up in the crankshaft sludge trap, in which case it is advisable for it to be cleaned out.Procedure is to take out the slotted plug on the drive side end of the crankshaft and the grubscrew in the centre of the crankshaft and then to draw out the sludge trap. (See Fig. 13).The passage ways should be cleaned very thoroughly in petrol or by using a suitable degreasingplant.

\Vhcn reassembling the sludge trap insert the trap into the shaft, then the small centregrub scrt~\V and finally the large screw. Both the screws must then be centre-punched afteIfinal tightening. This is most important.

•


The only' parts now left are the ftxed items :mch as studs and the crankshaft hush. This is a press fI.t into the timing side and again the hlock should he heated in hot water or a snitable degrcasing vat, if the old hush is worn or scored and therefore to lw replaced. ::\ote that the replacement is fittf'd from inside the crankcase and that there is a 1< eating pPg through the steel face of the bush into the case,

Any stud can be removed (althongh this is not normally necessary) by :->crcwing on two of the appropriate nuts, locking them, and then unscrewing the stud \\'ith a spanner on the lower of the two nuts. A TIew stud can be replaced in similar manner, this time using the spanlwr on the top of the two nuts. \Vhen the replacement stud has been scrf'\ved home, simply unlock the t\VO nuts and take off, but care must be taken not to overstrain a stud when fitting. Xote that in general a screw thread into the crankcase is B.S.F. whereas the thread for the nuts is usually C.E.!. In some cases, however, a \Vhitworth thread is used into an aluminium case, but it is always the coarser of the two threads on a stud which goes into the case. If there is any doubt as to which end of the stud to insert, check the threads \vith one of the nuts which fits that particular stud. Another guide is that it is usual1:v the longer \C'ngth of thread \vhich enters the case .


•


The only' parts now left are the ftxed items such as studs and the crankshaft hush. Thisis a press fit into the timing side and again the block should be heated in hot water or a snitabledegrcasing vat, if the old hush is worn or scored and therefore to be replaced. Kotc that thereplacement is fitted from inside the crankcase and that there is a 1< eating peg through thesteel face of the bush into the case.

Any stud call be removed (althongh this is not normally necessary) by scrc\ving on two of theappropriate nuts, locking them, and then unscrewing the stud \\'ith a spanner on the lower ofthe two nuts. A TICW stud call be replaced in similar manner, this time using the spanner onthe top of the two nuts. \Vhen the replacement stud has been scrf"\ved home, simply unlockthe t\VO nuts and take off, but care must be taken not to overstrain a stud when fitting. Xotethat in general a screw thread into the crankcase is B.S.F. whereas the thread for the nuts isusually C.E.!. In some cases, however, a \Vhitworth thread is used into an aluminium case,but it is always the coarser of the two threads on a stud which goes into the case. If then' isany doubt as to which end of the stud to insert, check the threads \vith one of the nuts whichfits that particular stud. Another guide is that it is usually the longer length of thread \vhichenters the case.

- triumphscooterstriumphscooters.co.uk/wsb5911712103/resources/1004+250+dismantle...250 c.c. o.h.v....

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