Re-Assembling The Gear Box; Adjustment Of The Neutral Finder; Lubrication Of The Gear Box - Royal Enfield 350 BULLET 1989 Workshop Maintenance Manual

5. Re-assembling the Gear box

The procedure is the reverse of that given above for dismantling but the following points should be
noted.
If the main shaft top gear pinion and dog have been removed, make sure that the dog is replaced the
right way round or third and top gears can be engaged simultaneously.
Make sure that the trunnions on the operator fork engage with the slots in the inside operator.
See that the main shaft is pushed right home. (It may be tight because of the felt washer inside the
final drive shaft nut).
The layshaft top gear and kickstarter pinion should be assembled on the layshaft and the kickstarter
shaft and ratchet assembled on to it before fitting the end cover. Do not forget the washer on the
layshaft between the kickstarter pinion and kickstarter shaft.
The joint between the gear box and the inner cover should be made with shellac or any similar
jointing compound.
Make sure that all parts are clean before commencing assembly. The gear box should be packed
with soft grease (veedol '00' grease or equivalent) filled up to the correct level.
On no account must heavy yellow grease be used.

6. Adjustment of the Neutral Finder

The neutral finder is adjusted by means of an eccentric stopper secured to the front of the gear box
cover by a bolt which limits the travel of the operating pedal. Slacken the bolt and turn the eccentric
stopper until the correct movement of the pedal is obtained.

7. Lubrication of the Gear box

Current machines have the gear box filler plug at the top of the box and a level plug at the rear.
Remove both plugs and fill, with the machine on level ground until the oil commences to flow from the
level plug.
Check the level every 800 to 1,600 Km. when the gearbox is warm.
For initial filling up of gear box VEEDOL `00' grease is recommended. During routine
maintenance, topping up may be done with SAE 50 oil.
The capacity is 700 grams (Approx.) of `00' grease mixed with SAE 50 grade oil to a thick
consistency.
Page 36
WORKSHOP MANUAL BULLET
NEUTRAL FINDER