Detail Of Foot Gear Change; Adjustment Of Clutch Control; Dismantling And Reassembly Of Clutch - Royal Enfield G Workshop Maintenance Manual

ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL
4. The layshaft high gear and kickstarter pinion
should be assembled on the layshaft and the
kickstarter shaft and ratchet assembled into it
before fitting the end cover. Do not forget the
washer between the layshaft high gear and
kickstarter pinion and the kickstarter shaft.
5. See that the kickstarter shaft is in the working
position (cotter flat to left when facing end
cover) otherwise the cover will not go home.
6. The joint between the gearbox case and the
end cover should be made with gold size,
shellac or a similar jointing compound.
7. Note the oil retaining "scrolls" either side of
the ball bearing in the cover.
Make sure that all parts are clean on assembly.
For use in normal climates it is preferable to pack the
recesses in the gearbox housing with soft grease and
then top up to the level of the filler plug with gear oil.
The oil will be found to run into the box more easily if
the engine is started up and allowed to tick over, so as
to rotate the gears and shafts. On no account must
heavy yellow grease be used in these boxes.
CLUTCH.

32. Dismantling and Reassembly of Clutch.

The construction of the clutch is shown in Fig.
30. To dismantle the clutch plates unscrew the three
spring pins and lift away the springs, pressure plate,
cover over cush rubbers, friction plates and steel
plates. To remove the clutch sprocket from the
centre, spring off the large circlip which secures it.
To remove the clutch centre, unscrew the attachment
nut and withdraw the centre from the mainshaft
using the extractor shown in Fig. 11.
When reassembling the clutch note that two of
the steel plates are dished and the third one is flat.
The correct order of assembly is clearly shown in Fig.
30. Do not forget to replace the cush rubber retaining
cover before fitting the pressure plate. Make sure that
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DETAIL OF FOOT GEAR CHANGE

Fig. 35
the three distance tubes inside the springs pass
through the holes in the pressure plate. Tighten the
spring pins as far as they will go. If the clutch lifts
unevenly the probable reason is that one of the springs
has taken a set, in which case a new set of springs
should be fitted.

33. Adjustment of Clutch Control.

1/16 in. free movement. To adjust, disconnect the
control wire from the lever M, on the gearbox (see
Fig. 36).
Hinge the lever back and adjust by means of the
screw A, holding the sleeve B to prevent it turning.
Turn the screw A to the left to give more clearance to
the control wire ; to the right to take up clearance.
It is essential that the clutch control has about