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Page 24
Royal Enfield "Interceptor" Workshop Manual
the bearing in the box and
-H--H
in. diameter
for the bearing in the cover.
When refitting the bearings stepped drifts
of 2¼-1-H in. diameter and Ht-Hin. diameter
must be used for the bearings in the box and cover
respectively.
Note the oil seal in the recess behind the larger
mainshaft bearing.
68.
Change-Gear Mechanism
If the two nuts securing the change-gear
ratchet mechanism are slackened the adjuster plate
can be set in the correct position. In this position
·
the movement of the gear lever necessary to engage
the .ratchet teeth will be approximately the same
in each direction.
If the plate is incorrectly adjusted, it may be
found that, after moving from top to third or from
bottom to second gear, the outer ratchets do not
engage the teeth on the inner ratchets correctly.
If, when fitting new parts, it is found that the
gears do not engage properly, ascertain whether a
little more movement is required or whether there
is too much movement so that the gear slips right
through second or third gear into neutral. If
more movement is required, this can be obtained
by filing the adjuster plate very slightly
.
at the
points of contact with the pegs on the ratchet ring.
If too much movement is already present, a
new adjuster plate giving less movement must be
fitted .
.
69.
Reassembling the Gearbox
The procedure is the reverse of that given in
Subsection 66, but the following points should be
noted:-
If the mainshaft 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 mainshaft is pushed right home.
It may tighten in the felt washer inside the final
drive shaft nut.
The layshaft top gear and kickstarter pinion
should be assembled on the layshaft and the kick-
starter 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
the kickstarter shaft.
The joint between the gearbox and the inner
cover should be made with gold size, shellac or a
similar jointing compound.
Make sure that all parts are clean before
commencing assembly.
In normal climates the
recesses in the gearbox should be packed with
soft grease and the box should be filled up to the
correct level with engine oil. (See Subsection 73.)
On no account must heavy yellow grease be used.
70. Dismantling and Reassembling the Clutch
The method of removing the clutch is described
in Subsection 46.
When reassembling the clutch, the following
sequence must be adhered to, after first securing
the clutch sprocket with the large circlip.
·
Fit the cush rubbers, retaining plate and three
distance tubes, and follow with the pressure plate
assembly as follows:-
Plain dished plate (dish projecting outwards.)
Friction plate (with inserts on early models).
Plain flat plate.
Friction plate (with inserts on early models).
Plain flat plate.
Friction plate (with bonded facings).
Plain dished plate (dish projecting inwards).
Friction plate (with bonded facings).
Front plate.
Pressure plate and springs.
When
.
reassembling the pressure and front
plates, see that the three distance pieces are
fitted over the pins securing the pressure plate to
the clutch centre drum.
These.
must pass through
the holes in the front plate into the three recesses
in the clutch centre retaining plate.
Note that
three strong (13g) and three weak (14g) springs
are used. These must be fitted alternately and, in
the case of later models with adjusting screws on
three arms of the pressure plate, the 14g springs
must be fitted behind the adjusting screws.
The
three pressure plate pins must be locked up tight.
If the clutch lifts unevenly adjust one or, if
necessary, two of the adjusting screws in the
pressure plate (later models).
These screws can
also
be used to increase the spring pressure when
wear has taken place on the friction surfaces but
care must be taken not to screw them in too far.
This could reduce the lift of the clutch by causing
some of the springs to become coil bound, thus
causing clutch drag.
·
71.
Adjustment of Clutch Control
It is essential that there is about
~
in. free
movement in the clutch cable, to ensure that all the
spring pressure is exerted on the plates.
There are three points of adjustment for the
clutch control. The first is in the clutch operating
lever in the gearbox and is accessible after remov-
ing the lower inspection cover in the front cover
of the gearbox (see Fig. 16). The clutch cable
should be slacked right off or, preferably, discon-
nected when making this adjustment.
Slacken
the locknut and adjust the centre screw in or out
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