Royal Enfield 500 TWIN 1949 Workshop Maintenance Manual page 43

ROYAL ENFIELD WORKSHOP MANUAL
the cam lobe; turn the engine until this is so. The
key on the projecting part of the contact breaker
base must engage with the keyway in the
armature shaft. Refit the hexagon headed screw
and tighten with care. It must not be slack,
neither must undue force be used.
The main bearings of the Magdynos are
packed with grease during manufacture and need
no attention until a general overhaul is
undertaken.
2 (b). Adjustments
Check every 3,000 miles.
(i) Setting contact breaker gap. The contact
breaker gap must be set to 0.012 in.-0.015 in.
when the contacts are fully separated. To adjust
the gap, turn the engine until the contacts are
fully opened. Slacken the locking nut of the
adjustable contact and turn the contact by its
hexagon head until a feeler gauge of appropriate
thickness is a sliding fit in the gap. Tighten the
lock nut and re-check the gap.
(ii) Adjusting the Timing Control Cable. Any
slackness in the cable can be taken up by sliding
the waterproofing rubber shroud up the cable
and turning the hexagon headed cable adjuster.
After adjusting, return the shroud to its original
position over the adjuster and central barrel.
2 (c). Cleaning
To be carried out every 6,000 miles. Check
the contact breaker contacts and, if necessary,
clean them as described in Subsection 2 (a).
Wipe the outside of the magneto to remove dirt
or grease. Check the cable adjuster and control
barrel for signs of water ingress.
Remove the high tension pick-ups and polish
with soft dry cloth. The carbon brushes must
move freely in their holders. If necessary, clean
with a petrol-moistened cloth. Should either
brush be worn to within 1/8 in. of the shoulder it
must be renewed.
Whilst the pick-up mouldings are removed,
clean the slip ring track and flanges by holding a
soft dry cloth
suitably-shaped piece of wood while the engine
is slowly turned.
The high tension cables must be kept clean
and dry.
2 (d). Renewing High Tension Cables
If, on inspection, either high tension cable
shows signs of deterioration, it must be replaced,
using neoprene covered rubber cable. To fit a
new high tension cable, bare the end for about
3/8 in., thread the knurled moulded nut over the
cable, and thread the bared cable through the
washer removed from the old cable (see Fig. 3).
Section G1b Page 2
against them with
Bend back the strands radially and screw the
nut into the pick-up moulding.
2 (e). Renewing Timing Control Cable
The Bowden timing control cable should be
renewed if it becomes frayed, otherwise
moisture may enter the contact breaker housing.
To do this, slip back the rubber shroud and,
by means of the hexagon at the base, unscrew
the control barrel. If the cable and the plunger to
which it is attached are now pulled upwards, the
a
cable nipple can be disengaged from the plunger
slot. Soften the solder and remove the nipple.
Thread the new length of cable through the
rubber shroud, cable adjuster, control barrel,
sealing washer and restoring spring. Solder the
nipple to the end of the cable. Engage the nipple
with the slot in the plunger and screw the control
barrel into the body, ensuring that the sealing
washer is correctly fitted between the barrel and
the body.
Take up any slackness in the cable by means
of the adjuster before refitting the rubber shroud
in position.