Engine Disassembly - Royal Enfield Classic 500 2009 Service Manual

Engine Dismantling, Inspection & Assembly
COMPONENTS THAT CAN BE
REMOVED WITHOUT REMOVING
THE ENGINE FROM FRAME.
✰ Cylinder head assembly
✰ Cylinder block
✰ Magneto assembly
✰ Primary drive
✰
Clutch assembly
✰
Timing gears
✰
Oil pump Assembly
✰
Gearbox foot control mechanism
✰
Kick Main Spring replacement
✰
Self Starter
replacement.
ENGINE NEED TO BE REMOVED
FROM THE FRAME FOR THE
FOLLOWING JOBS:
✰ Crank case repair/change
✰ Crank case centre gasket change
i.e liquid sealant gasket.
✰
Crank shaft main bearings LH &
RH replacement.
✰
Gears, Mainshaft or Layshaft, Sleeve
Gear repair / replacement
✰ Mainshaft or Layshaft Bearings
replacement.
✰ Self starter Idler Gear jack Shaft
replacement.
✰
Kick Starter Gear, Pawl, Spring or
Plunger replacement.
✰
Roller Hydraulic
(RHVL) replacement.
Sprag Bearing
Valve Lifter
05-2

ENGINE DISASSEMBLY

✰
Cylinder Head Sub Assembly
✰
Cylinder Barrel Sub Assembly
✰
Cover RH Sub Assembly
✰
Components dismantling on Crankcase
RH
✰
Cover LH Sub Assembly
✰
Components dismantling on Crankcase
LH
✰ Opening / splitting of Crank case RH
& LH
✰
Gear Train removal
✰
Lay shaft and Main shaft sub Assembly