"URMAN CLUTCH /FTEN RECEIVING SCANT ATTENTION THE CLUTCH IS OFTEN WORN OUT BY STRIPDOWN THE TIME AN ENGINE %30)4% OR MAYBE BECAUSE OF THE FACT THAT MOST RIDERS TAKE THEIR BIKEgS CLUTCH FOR GRANTED THEY MANAGE TO PERFORM REMARKABLY REBUILD COMES AROUND WELL TRANSMITTING POWER IN AN ATMOSPHERE OF HOT OIL $!S A RESULT OF THIS APPARENT RELIABILITY THE CLUTCH ON MOST MACHINES WILL +EN DE 'ROOME ONLY BE LOOKED AT WHEN A COMPLETE ENGINETRANSMISSION REBUILD IS CALLED FOR )T IS THEN USUALLY DISCOVERED THAT ALTHOUGH THE CLUTCH WAS WORKING EXPLAINS WHAT TO WATCH PERFECTLY WELL IT IS COMPLETELY WORN OUT AND UNABLE TO STAND UP TO THE DEMANDS OF A NEWLY REBUILT ENGINE FOR ON THE CLUTCH FITTED 4HIS PHOTO STRIPDOWN IS OF A !-# SINGLE CLUTCH AND IS INTENDED TO TO !-# MACHINES INDICATE THE AREAS TO PAY PARTICULAR ATTENTION TO
-OST gON THE ROAD PROBLEMS WITH SHOULD BE LOOKING TO SEE IF THE INSERTS AS CLUTCHES TEND TO BE CAUSED BY THIS THE WORN DOWN BADLY BURNT OR SOAKED IN OIL PUSHROD ADJUSTER NOT BEING CORRECTLY SET )F WORN OR BURNT REPLACE THEM )F HOW UP /N MOST MACHINES THE ADJUSTMENT EVER THE LATTER IS THE CASE IT IS SOMETIMES SHOULD BE CARRIED OUT THUS POSSIBLE TO REMOVE ALL THE OIL IN A SUITABLE A 3CREW CABLE ADJUSTER AS FAR AS POSSIBLE SOLVENT !GAIN AS WITH SO MANY OTHER INTO THE GEARBOX FOR MAXIMUM CABLE THINGS IF IN DOUBT THE BEST CHECK IS TO SLACK COMPARE THEM WITH NEW ITEMS IF POSSIBLE B 7ITH THE LOCKNUT SHOWN IN THE PICTURE 4HE PLAIN STEEL PLATES OFTEN SUFFER LOOSENED SCREW IN THE CENTRE ADJUSTER UN FROM CORROSION PROBLEMS )F YOURS TIL IT JUST TOUCHES THE PUSHROD LOOK ANYTHING LIKE THE ONE IN THE C 5NSCREW THE ADJUSTER A QUARTER TO HALF PHOTOGRAPH NEW ONES ARE ESSENTIAL BUT A TURN AND RE TIGHTEN THE LOCKNUT CHECK THEY ARE AVAILABLE BEFORE THROWING D 2E ADJUST THE CABLE TO GIVE ABOUT THE OLD ONES AWAY /N BOTH PLAIN STEEL AND SLACK AT THE HANDLEBAR LEVER FRICTION PLATES CHECK ALSO THAT THEY ARE FLAT )F YOUR MACHINE HAS A "URMAN " AND FREE FROM BURRS AROUND THEIR INNER GEARBOX g"g WILL BE STAMPED ON THE AND OUTER gDOGSg OUTER CASING AND AFTER CARRYING OUT THE 4HE CLUTCH DRUM WILL OFTEN EXHIBIT ABOVE IT PRODUCES A gCLONKg WHEN PULLING WEAR MARKS SUCH AS THESE )N THIS PAR IN THE CLUTCH LEVER THIS IS A SURE SIGN THE TICULAR CASE REPLACEMENT NEEDED BUT IF CLUTCH OPERATING MECHANISM WITHIN THE WEAR IS NOT TOO EXTREME CAREFUL WORK WITH GEARBOX NEEDS ATTENTION THE FILE MAY WITHIN REASON SAVE THE DAY &IRST THING TO DO WHEN DISMANTLING )NCIDENTALLY IF THE PLATES ARE GOOD IN ALL A CLUTCH IS TO REMOVE ALL OF THE SPRING OTHER RESPECTS APART FROM BURRS AROUND RETAINING NUTS PREFERABLY WITH THE SPECIAL THE DOGS THESE CAN ALSO BE CLEANED UP TOOL SHOWN THOUGH A MODIFIED WITH A FILE AGAIN WITHIN REASON SCREWDRIVER WILL DO )F THE SPRINGS MAKE )T IS CONVENIENT TO REMOVE THE IT DIFFICULT TO UNDO THESE NUTS IT HELPS TO PUSHROD AT THIS STAGE AND INSPECT IT FOR LEVER THE SPRINGS BACK A LITTLE WITH A SMALL STRAIGHTNESS AND WEAR 4HE EASIEST WAY TO SCREWDRIVER AS SHOWN CHECK IT IS STRAIGHT IS SIMPLY BY ROLLING IT 4HIS SHOWS THE COMPLETE NUT SPRING ALONG A DEAD FLAT SURFACE )F IT IS BENT A NEW AND CUP ASSEMBLY )T IS WORTH CHECK ONE SHOULD BE FITTED ALTHOUGH IT IS POSSI ING THAT ALL THE CUPS ARE THE SAME AS EACH BLE WITH CARE TO STRAIGHTEN ONE !S FOR OTHER AND ARE IN FACT THE CORRECT ITEMS FOR WEAR A BALL BEARING IS OFTEN FITTED AT ONE YOUR BIKE )F THE SLOT IN ANY OF THESE NUTS OR BOTH ENDS AND THIS CAN WEAR A gDENTg IS BADLY CHEWED UP ITgS WORTH FITTING NEW IN EITHER END WHICH IF ONLY SLIGHT CAN BE ONES SAVING A LOT OF TROUBLE ON RE TIDIED UP WITH A GRINDER )N THE EVENT OF ASSEMBLY THE PUSHROD BEING BEYOND REPAIR AND A NEW ONE UNAVAILABLE ONE CAN BE MADE !S THE SPRINGS TEND TO WEAR WITH USE FROM A LENGTH OF SILVER STEEL OF THE RIGHT CHECK THE LENGTHS OF EACH SPRING DIAMETER BY CUTTING TO LENGTH HEATING www.ajs-matchless.infoAGAINST EACH OTHER AND ALSO IF POSSIBLE BOTH ENDS TO CHERRY RED AND PLUNGING IN AGAINST A NEW ONE )F THE DIFFERENCE IS AS GREAT AS THAT SHOWN REPLACE THE WHOLE SET COLD WATER )T IS A FALSE ECONOMY TO JUST REPLACE THE !FTER BENDING BACK THE TAB WASHER ONES THAT APPEAR SHORT IF FINED UNDO THE CENTRE CLUTCH RETAIN )T IS NOW POSSIBLE TO REMOVE ALL THE ING NUT AND REMOVE BOTH CAREFULLY 4HE CLUTCH PLATES ALBEIT THAT IS SOMETIMES TAB WASHER CAN OFTEN BE RE USED PROVIDING CALLS FOR A LITTLE HELP FROM EITHER A IT IS NOT BADLY DAMAGED BY BENDING UP A SCREWDRIVER OR A COUPLE OF SMALL MAGNETS DIFFERENT PART OF IT ON RE ASSEMBLY 7ITH ALL THE PLATES OUT CHECK EACH ONE )F YOU HAVE NOT ALREADY DONE SO CAREFULLY /N THE FRICTION PLATES YOU IT IS NOW WORTH PLACING A TRAY
#,!33)# -/4/2#9#,% -%#(!.)#3 SERVICE NOTES.
CLUB MEMBER? THE VMCC's OWN AGREED VALUE INSURANCE SCHEME On your CLASSIC or VINTAGE BIKE, if you are over 25 years old and a member of: * Ariel Owners Club * The Vintage Motor Cycle Club * AJS/Matchless Owners Club * Velocette Owners Club * Vincent Owners Club * BSA Owners Club * Morgan 3 Wheel Club * Scott Owners Club * Sunbeam Owners Club * BSA Gold Star Owners Club * Cyclometer Club * Norton Owners Club * British Two Stroke Club * Brough Superior Club * Le Velo Club + London Dounglas Owners Club * Panther Owners Club * Royal Enfield Owners Club * Triumph Owners Club * Rudge Enthusiasts * BMW Owners Club * Greeves Riders Association * Trident and Rocket 3 * Jap Vintage Club * Italian Motorcycle Owners Club * MV Augusta Owners Club * Cossack Owners Club * Harley Davidson Riders of GB * Ducati Owners Club * International Laverda Owners Club * Indian Owners Club * Classic Racing * Bantam Owners Club * I specialise in handling these Club Schemes ONLY, to give members the very best attention, complete range of policies includes:- * Comprehensive or T.P.F. & T. on Vintage/Classic over 15 years old * Agreed Value * No Mileage Limitations * Non-Road Policies for bikes in store or under restoration * Continental www.ajs-matchless.infotouring extensions * Modern Bike Policy also available * Get full value from your Club Membership now and phone or write today to: CAROL NASH 1st FLOOR, PAUL HOUSE, STOCKPORT ROAD, TIMPERLEY, ALTRINCHAM, CHESHIRE, WA15 7UQ TEL: 061 980 1305
CLASSIC & MOTORCYCLE MECHANICS SERVICE NOTES
A FIXED PLATE INTERNAL ACTUATING E CLUTCH SPRING PLATE F LOCK NUT FOR CLUTCH ROD THRUST B CLUTCH INTERNAL OPERATING LEVER. CUP C GEAR BOX MAINSHAFT G THRUST CUP (in clutch pressure plate) D CLUTCH SPROCKET FOR CLUTCH ROD. Clutch, gearbox main shaft and clutch operating mechanism.
off its splines. If the clutch retaining nut has at some tune been allowed to work loose, quite serious wear may have developed on the splines in the clutch centre. Only real cure here is a replace- ment which might be hard to find. Have a good look at the clutch spring studs for damage of any sort. On re-assembly, be very careful that the shoulders of these studs do not become trapped. This is easi- ly avoided if it re-assembled in the same way in which it was removed. This is where the tray comes into If you decide to replace the play. If the entire centre bearing rollers, be careful. On Burman and assembly has not already fallen out and some other clutches, they are not stan- its rollers run off all over the place, dard ¼"x¼" rollers. If you can't find the carefully remove the outer thrust washer correct size it should not be too difficult to reveal the rollers behind. The clutch to find someone to grind a little off the drum can now be removed at which point end of some standard rollers — this is the rollers will now fall into the tray really important as the clutch will lock up www.ajs-matchless.infosolid if not dealt with properly. beneath. Examine all the components of the Re-assembly is reasonably inner bearing, including the outer straightforward but do not forget race which is fined into the middle of the to bend over the tab washer after tighten- drum. Quite a lot of slack can be allowed ing the centre nut up fully. This nut beneath the clutch as with most of them, in this bearing assembly as it only does (check your manual) is usually tightened Burman in particular, bits and pieces start anything when the clutch is disengaged. up to something around 70ft.lbs. dropping out and getting lost. Take hold What you should fee looking for is severe • Ken de Groome specialises in AJS of the outer drum to keep it in place, pitting and/or signs of the case-hardening and Matchless singles and can be con- then, grasping the studs, ease the centre breaking up. tacted on 0945 870382.
CLASSIC & MOTORCYCLE MECHANICS