Spark plug Spark plug gap Squish Ideal 0.9mm (Between 0.85mm -1mm) Head nut torque 18 ftlbs  Engine oil (gearbox and clutch) type: Light Gear Oil Engine oil 800ml on an …

This procedure is to be carried out when doing any between race meeting inspection / ring change and strip down of the engine. Remove spark plug Diagonally undo head nuts …

(between meetings or at track) Place blue roll or clean rag around con rod at crank case mouth to stop any dropped items going in to the crankcase. See photo …

Required 2 Blocks 1” thick wood and metal bar Place bar through small end eye (no bearing) Place blocks of wood either side of head blot’s see photo below Turn …

to enable access to clutch and strip down Remove 3 bolts and remove end cover of the clutch operating system place drip tray underneath Remove clutch mechanism locking plate and …

MUST be a puller with crank over fitting sleeve. Clutch Puller If no fitting sleeve  or Puller used with a point that does into the center of shaft there is …

Undo all 14 crack case screw Tap right hand side away from left This may require heat on crank area Right hand case Left hand case with crank and gear …

Set up on 4” block as photo Put into 3rd gear to check dog penetration it should be flush with penetrated gear (1st) Remove Neutral Holder Ball and spring (from …

As with crank split Heat and remove from the left case Remove main bearing oil seals replace every rebuild Remove main bearing oil splash shield by removing circlips on out …

– Based on a Tony Holmshaw (TH) clutch Remove from crank and place on bench Undo bolts on face of clutch one turn on each bolt doing every other bolt. …

Fit Crank oil seals Lube seals with 2-stroke oil Special mandrel for oil seals to stop damage to the seals Tap in to place crank case evenly use blunt drift …

Large washer 1st with recesses facing crank case Then needle roller bearing Primary drive / clutch center Washer with recesses facing crank case Clutch on Fit puller on clutch with …

Re fit studs (if removed) Double Nut top of stud and tighten from top nut  repeat for all 4 studs Fit piston Lubricate well with 2 stroke oil Small end …