remove the original flywheel, stator plate, H.T. coil, rectifier or
regulator and wiring loom.
the new loom to the frame, also fit the new C.D.I. unit and regulator.
(We recommend fitting these two items under the rear of the frame
where the original coil was located, C.D.I. unit on the same side
as the coil, regulator on the opposite side), Using electronic mounting
the new stator plate to the engine with the three locating bolts central
in the slots. Place the new flywheel on to the crankshaft, but do
using a dial gauge to set the timing, the cylinder head, exhaust and
head cowling must be removed, (a timing disc can also be used for
the same job).
the cowling and cylinder head are removed you can now fit the dial
gauge to the top of the cylinder. Rotate the flywheel until you find
the T.D.C. (top dead centre - the highest point that the piston travels
up the cylinder).
When you have found the T.D.C. set the dial gauge at zero. On the
outer lip of the flywheel there is an arrow which faces the magneto
flange. With the dial gauge set at zero at T.D.C. make a notch on
the magneto flange opposite the arrow on the flywheel. This is now
your T.D.C. mark.
the T.D.C. mark, rotate the flywheel anti-clockwise so the dial gauge
rotates to 2.0mm/19 degrees (if using a timing disc) for GP electronics
or 2.5mm/21 degrees for LI/SX electronics (if using a timing disc).
at this point make a notch oppositie the arrow on the magneto flange.
through the window on the flywheel (five o'clock) you will notice
two lines inscribed on the outer edge of the flywheel. These two lines
have to match up exactly with the two lines on the stator plate pick-up
box when the flywheel is at 2.0mm B.T.D.C. (before top dead centre)
or 19 degrees B.T.D.C.
the two sets of lines on both stator plate and flywheel do not line
up, you will need to remove the flywheel, slacken the stator plate
bolts and rotate the stator plate in the direction needed to line
up both stator and flywheel. When the two sets of lines meet up exactly
your timing is set and should not need altering.
fitting the flywheel, make sure both taper surfaces are dry and clean,
and that the key is undamaged and a firm fit in both keyways. The
centre nut has a spring washer below it, and the flywheel must be
held with a flywheel holding tool whilst the nut is tightened (anti-clockwise)
with a torque wrench to 50 lbs/ft (6-6.5 kgs).
cylinder head and cowlings etc.
all bulbs from 6Volt to 12Volt.
the wiring diagram as supplied with the kit.