Royal Enfield 250 CLIPPER, Workshop Maintenance Manual

Page: 35 / 96

ROYAL ENFIELD WORKSHOP MANUAL
PAGE 35
fork R. The latter is located by a spring plunger S
engaging with a notched plate which is part of the
operator arm R.
The kickstart lever is connected to the pinion
F on the layshaft by a ratchet mechanism which
automatically disengages when the lever is
released.
Five-speed Gearbox
The positions of the clutch sprocket, main
shaft, mainshaft sleeve, final drive sprocket,
layshaft, operator fork and kickstart mechanism
are similar to the four-speed gearbox, but the
number and arrangement of the pinions differ as
can be seen in Fig. 4. The operation of the
gearbox is shown diagrammatically in Fig. 3.
3. Adjustment of the Clutch
Slide back the plastic cover where the clutch
cable enters the top of the crankcase. This will
expose the clutch cable adjuster (see Fig. 1).
Slacken the locknut and screw in the adjusting
sleeve so that there is slack in the clutch cable.
Slacken the locknut on the clutch pushrod
adjusting screw which is protruding through the
generator-, or off-side, cover in line with the
gearbox main shaft and immediately in front of
the kickstart spindle.
Turn the slotted adjusting screw until it begins
to tighten up, then slacken it back one complete
turn. This will ensure that the clutch operating
lever inside the cover is in its best working
position.
Screw out the clutch cable adjusting sleeve on
the top of the crankcase until there is not less than
1
/
16
in. free movement of the clutch cable when
the clutch lever on the handlebar is operated.
Tighten the locknut and replace the plastic
sleeve.
Owing to the initial bedding down of the clutch
friction material, it may happen that the clearance
in the clutch control is taken up during the first few
hundred miles with a new machine and will require
adjustment soon after delivery.
4. Adjustment of the Gear-Change Mechanism
To obtain access to the gear-change
mechanism, the generator cover must be removed
as described in Section C, Subsection 2.
(a) To adjust the Selector Pawls. Slacken the
¼ in. pin D (see Fig. 5) and move the backplate so
that it is in the central position in the slot, i.e., so
that the pawls lie flat on the ratchet teeth.
(b) To adjust the Selector Rod. Slacken the
locknuts on the turnbuckle on the selector rod.
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