Part 1 - Changing the Clapper Plate Gasket
By Mike "IRONMAN" North (ubrew@webhart.net)You’ll need some basic workshop tools but in particular a scrim bar, 0-1 micrometer, discombobulator and ¾ combination wrench.
First, use the ¾ wrench to open the bottle of Guinness - this is fundamental to standard workshop procedures. Next, remove the six McDonalds head bolts holding the clapper plate cover to the clunker case. If you have trouble removing any of the bolts just take a hammer and chisel and slice off the bolt head - it probably doesn't need that many anyway. Take a long pull at your Guinness. Now, using the scrim bar gently pry the clapper plate cover off being careful not to scratch your nail varnish. With the cover removed you can see the clapper plate nestling against the clunker shaft. Here’s where you need your 0-1 micrometer - use it to clamp the clapper plate to the clunker shaft, don’t worry about over tightening, the marks will file off, probably.
Take another pull at your Guinness.
With the clapper plate clamped use a belt sander to remove the old gasket. Now using a piece of lint free anti static cloth wipe the worst of the oil off your ham sandwich. Its probably time to open another Guinness.
Fitting the new gasket is a breeze, just smother it with HP sauce and stick it to the clapper plate. Using your hammer and chisel, reset the clapper plate gap to 5 thou, plus or minus half an inch. Replace the clapper plate cover and ‘voila’ the job is done. Don’t worry if you have a slight oil leak - its an old mechanics trick that helps to lubricate your clutch and prevent the kart chassis from rusting. I guess we didn’t use the discombobulator, but we’ll find a use for that next time.
Next time I’ll tell you how to dispose of your used engine oil and hazardous materials in your neighbour’s garden, and also how to evade capture or prepare a credible legal defence.