Royal Enfield 350 BULLET 1949, Workshop Maintenance Manual

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ROYAL ENFIELD WORKSHOP MANUAL
SECTION D2
Service Operations with Engine
Removed
“ 350 and 500 Bullet” Engines
1. Removal of the Engine from the Frame
Disconnect the battery leads and remove the
battery.
Turn off the petrol and disconnect the petrol
pipe.
Take the slides out of the carburettor.
Remove the air cleaner.
Remove the exhaust pipe.
Disconnect the electric horn leads.
Disconnect the control cable from the
magdyno.
Disconnect the engine steady.
Remove the rear chain.
Remove the footrest bar.
Support the engine on a suitable box or wood
block.
Remove the centre stand and the stand stop.
Remove the front engine plates.
Remove the bolt securing the rear engine plate
to the frame.
Lift out the engine.
2. Removal of the Gear Box
Remove the primary chain case, engine
sprocket and clutch (see Section C.2, Subsection
24).
Remove four 3/8 in. nuts and the gearbox can
then be withdrawn from the engine.
3. Dismantling the Crankcase
350 + 500 c.c. Engine . Drain the oil tank by
removing the drain plug.
Having removed the engine from the frame as
described in Subsection 1, dismantle the cylinder
head, barrel, piston, timing gear, magdyno, etc., as
described in Section C.2.
Remove the nuts on the driving side of the
engine from four fixed studs at the rear of the
crankcase.
Remove six studs passing through the
crankcase.
The two halves of the crankcase can then be
separated.
The timing side outer roller race and the
bronze bush will remain in the timing side half of
the crankcase.
The driving side ball race and the driving side
outer roller race will remain in the driving side
half of the crankcase.
The driving side inner roller race and the
inner distance piece will remain on the engine
shaft.
The flywheel assembly may be difficult to
remove from the driving side of the crankcase
owing to the shaft being a tight fit in the inner
race of the ball bearings. This is particularly
likely in the earlier engines with two ball
bearings. In this case push the shaft out of the
bearings using crankshaft extractor E.5121.
4. Main Bearings
To remove the Outer roller race(s) (or inner
ball race on earlier 350 Bullet engines) from the
crankcase halves, heat to 100°C or more and
drop the half case sharply on a flat block of
wood or bench, when the race(s) will drop out,
together with the distance piece in the case of
the driving side and the thrust washer in the case
of the timing side.
Remove the circlip from the driving side
crankcase and re-heat to remove the second ball
race.
To replace the bearings, heat the crankcase
and press in the races in the following order
Driving Side. Use Special Tool No. 4817.
Small steel washer.
Cork oil-retaining washer
Large steel washer.
Ball bearing complete.
Circlip.
Outer distance piece*
Outer roller race*
* On 500 and later 350
engines. (On early 350
engines a distance piece and
inner ball race)
Timing Side. Use Special Tool No. 4816.
Steel thrust washer. Outer
roller race.
Care must be taken to see that the lead on the
outside of the outer roller race enters the case
first to make sure that it is square with the
housing.
5. Replacement of the Cam and Idler Spindles
To remove the cam spindles heat the
crankcase and tap the spindles out from inside.
Section D2 Page 1
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