TOPIC:

Hi,

Because the clutch has been slipping I'm replacing the plates. Got all the screws out and just about to get an oil filter wrench to take the oil filter off.

The footrest mount stops me pulling the cover straight off.

My theory is that without the oil filter in the way I will be able to rotate the cover
enough to manoevre it off.

I presume I don't have to take the engine out to change out the clutch!?

I din't have to take the engine out when I did mine, but I can't remember exactly how I got the cover off.

Ohh that was a blonde moment. Oh course you can just take off the whole footrest frame assembly.

So anyhow, clutch taken apart. Three broken friction plates, the three outer ones.
Close examinaton reveals a partially missing tang from the clutch basket and a slightly bent one (inwards)
Friction plates were difficult to get off on the last few millimetres so I carefully filed a couple of the basket "fingers" and a mil off the bent tang. This allowed the plates to actually slide and not to bind.

I 've put everything back together now, but I would appreciated some advice about aligning the kickstart return spring so it has tension as I put the cover back on.

cheers Neil

Is there anybody out there that could offer some advice on getting this
kickstart back together?
I'm in London, and need to get the bike going again very soon.

Thanks Neil

Nothing like answer your own questions! Found info on the German Gilera forum
with pictures showing the allen screw which provides a peg for one end of the spring sprag to attach to.

My spring is a bit worse for wear and the one of the coils is indented which means it doesn't want to slide along the shaft.

There was a kickstart shaft and spring on ebay so I bought it. Also asked Bob if he had one....waiting to see.

While its good develping an understanding of the Bi4 engine, working by headlight in a basement garage for the last day or so isn't much fun

zeroviz wrote:

Found info on the German Gilera forum

Oh you found it by yourself, so there is no need to send it
BTW it is also described in the workshop manual.

ciao joachim