Gilera Nordwest, Workshop Manual

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Tappet adjustment - Conventional, but limited space means you need a
special tool to hold the adjuster screw while you tighten the lock nut.
A Gilera tool is available, but you can make do by using a 6mm box
spanner for the lock nut, and a screwdriver long enough to work through
the middle of the box spanner for the adjuster. As you cannot use a
tommy bar through the box spanner, you will need a ring spanner that
will fit over the the top end of the box spanner. Set the engine at TDC by
the mark on the alternator and check the clearances. You will need to
curve the feeler gauge to get it under the cam.
Inlet - 0.05mm Exhaust 0.10mm cold Torque locknut 10-12 Nm
Gear selection problem - Refusing to change up at high revs,
particularly between second and third are probably due to a faulty or worn
gear selector pawl (part no. 321536). The teeth don’t fully engage on the
dogs of the selector drum and result in the pawl slipping off the selector
mid-way through the gear change. On high mileage bikes it is possible
that the teeth and/or dogs become worn or that the spring which lightly
presses the pawl against the dogs (part no. 328993) becomes a bit soft.
It appears that a batch of Nordwests which were on sale from June 93
were fitted with incorrectly manufactured pawls. The pressing wasn’t
deep enough so that the teeth of the pawl didn’t engage on the dogs of
the selector drum, and the edges of the teeth weren’t square to it’s plane.
Pawl (part no. 321536) Spring (part no. 321176) Gasket (part no.
947243)
The pawl can be replaced once the left hand engine cover has been
removed. To do this you will need an alternator puller. As you will need
one of these to change the cam-belt anyway, it could be well worth while
checking the pawl when you come to change the cam-belt even if you
have not yet experienced the symptoms. Unless the pawl is seriously
worn or faulty, you shouldn’t have a problem unless you are in the habit
of going well into the red through the gears.
Changing Cam belt - Gilera recommend changing the cam belt every
12,000 km. It would probably be safe for a bit longer but it should not be
ignored. You will need a puller for the alternator, but the puller is not
common with other bikes. A pattern puller is available from the Italian
firm of Bazzetti via Venhill (the cable people) part no. Nordwest/RC 5343
38*1.5mm.
Support the bike with a paddock stand, axle stands or whatever you
have. Tank off, spark plug out, cam belt cover off, rocker box covers off,
sprocket cover and gearlever off. Now remove the four screws from the
alternator cover. You will probably not be able to pull it off because it is
a tight fit, so tap it gently around the edge with a hide or nylon hammer
and with a bit of wiggling it should come off. DO NOT LEVER IT WITH A
SCREWDRIVER as you can easily damage the machined faces.
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