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Stripping the motor 4.Motor and Transmission Reassembly

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Having stripped the motor and reassembled the crankshaft into the crankcase and right side transmission case I'm going to reassemble the transmission. I had noticed that the primary drive chain is slack and the sprockets on the rear of the clutch hub had hooked teeth. I got a replacement chain as a DID 25H 64Link. For reasons I dont understand this chain is a smaller design than the other 2 transmission chains and it appears prone to stretching and has no tensioner to compensate. I'm replacing the clutch hub and it's integral sprocket as well. It seems sensible to change the clutch sleeve bearing and spacer washer as well. I'll check the camshaft sprocket teeth as well when I get around to refitting that. New primary drive chain Camchain on crankshaft... note wrong position of chain guide... see on... it should fit inside the loop of the cam chain. Adding spacer washer New clutch sleeve bearing NOTE.... in this pic the cam chain is positioned wrongly... the oil flinger/...

Twistgrip, Carburettor and Throttle Cable

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When I first bought this bike. The throttle twist grip would hardly rotate. The cable was present and attached at the throttle end, although not attached to the carburettor. Investigation showed that the cable outer had become crushed and damaged, resulting a rusty amalgamation, and there was no way the cable could be rescued. New cables are very expensive. I therefore decided That eventually I will have to manufacture a replacement  Luckily throttle cable universal kits are around half the price of a new cable. It was not immediately obvious how to dismantle the twist grip.  The grip itself consists of a rubber sleeve that slips over an inner tube. The tube has a spiral groove on the inside that engages with a slider in the handlebar and to which the cable is attached. Twisting the sleeve therefore pulls the cable to and fro in a groove in the handlebars. The sleeve itself has to be loose in order to rotate. There is a small grub screw that passes through a slot i...