PART THE LAST
A problem with the clutch adjustment surfaced after reassembling the clutch. Fitting a new cable failed to produce a well-adjusted clutch. Closer inspection showed the threaded boss in the new pressure plate I had fitted previously was binding. This meant the adjuster felt as though it was up against the clutch pushrod, even though there was still a gap. The result was too much lever movement before the clutch plates released. Running a tap through the boss soon allowed proper adjustment and restored the full working range of the lever. You have to wonder why the fabricator didn’t do that?
Although I left the gearbox itself alone, I replaced the outer cover’s seals and bushes, pinion and kickstart quadrant. The original tended to jam, and grinding down the worn first tooth didn’t help. Perhaps foolishly, I thought a new quadrant and pinion would perform flawlessly. They didn’t. Out of ideas, I took the kickstart mechanism apart and refitted it several times. Somehow I arrived at an assembly that was just so, and it has worked reliably with only an occasional jam ever since.
The headlamp shell wiring had long been a source of trouble, especially when it came to the headlamp itself. The wiring needed tidying up anyway, so I
