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ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL
TRANSMISSION
GEAR BOX.
27. Removal of Gearbox from Frame.
The method of removal of the gearbox from the
frame is described in Para. 13.
All operations on the gearbox can, however, be
performed with the box in the frame except the
removal of the inside operator fork and the bearings in
which secure the cover over the gear operating
mechanism and lift this cover away. Disconnect the
clutch control (if in machine) hinge the lever back,
and lift out the clutch adjusting screw and sleeve.
The end cover can then be removed from the
gearbox after undoing the five hexagon headed bolts
A (see Fig. 29), the screws B and F, the operator
locating plunger spring box C, and the mainshaft
gearbox shell. To remove the mainshaft, however, it is
necessary to take off the outer half of the primary
chain case, dismantle the clutch and withdraw the
clutch centre. To remove the final drive sleeve and
layshaft it is necessary to remove both halves of the
primary chain case and the countershaft sprocket.
Having done this, it may be thought preferable to
remove the gearbox from the frame.
28. Removal of Gears and Shafts.
To dismantle the box, first remove the kickstarter
crank, the nut securing the gear indicator pointer and
the gear operating lever. Then remove the four screws
bearing nut D. (This nut has a left-hand thread). There
is no need to disturb the foot change ratchet
mechanism when removing this cover as access to the
bolt A1 can be obtained by removal of the return
spring E. The kickstarter mechanism will come away
with the cover, leaving the mainshaft, layshaft and
final drive sleeve located in the gearbox.
If it is required to remove the mainshaft, this can
now be drawn straight out after removal of the clutch
(see Paras. 13 and 32) which, however, should be
done before taking off the gearbox end cover. The
mainshaft high gear pinion and dog will come away
with the shaft (see Fig. 30).
REMOVAL OF GEARBOX END COVER
Fig. 29
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