ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL
Page 21
To remove the layshaft and final drive sleeve, the
countershaft sprocket must first be removed. This, of
course, necessitates removal of the inner half of the
chain case if the box is still in the frame. The
countershaft sprocket nut should be undone before
removal of the gearbox end cover. Having removed
the clutch, countershaft sprocket, end cover and
mainshaft, the final drive sleeve and layshaft can be
drawn out of the box.
29. Removal of Ball Races.
The mainshaft ball bearings can be removed from
the box and the cover by means of the drifts shown in
Figs. 31 and 32, while the drifts shown in Figs. 33 and
34 are suitable for refitting these bearings. Note the
felt washer in the recess behind the larger mainshaft
bearing and the dished pen steel washer between the
bearing and the felt washer. The second dished pen
steel washer (having the smaller central hole) fits on
the other side of the mainshaft bearing and is nipped
between the inner face of the bearing and the shoulder
on the final drive sleeve. Note that both pen steel
washers have their raised centre portions facing
towards the clutch and countershaft sprocket.
30. Foot Change Ratchet Mechanism.
Fig. 35 shows this mechanism dismantled. Note
the slots in the adjuster plate which allow this to pivot
after loosening the pins which secure it. If the plate is
incorrectly adjusted, it may be found that, after
moving from top to third or bottom to second gear,
the outer ratchets do not engage the teeth on the inner
ratchets correctly. When the adjuster plate is correctly
adjusted, the movement of the gear lever necessary to
engage the ratchet teeth will be approximately the
same in either direction.
If the gears do not engage properly, ascertain
whether they require a little more movement or
whether too much movement is given so that a hard
kick goes right through second or third gear into
neutral. If more movement is required, this can be
obtained by filing the stop plate very slightly at the
points indicated. If too much movement is already
present a new stop plate must be fitted to give less
movement.
31. Reassembling the Gearbox.
No difficulty should be experienced with this but
the following points should be noted :
1. If the mainshaft high gear pinion and dog have
been removed, make sure that the dog is
replaced the right way round (see Fig. 30). If
this dog is reversed, third and top gear can be
engaged
simultaneously-with
disastrous
results.
2. When reassembling make sure that the
trunnions on the operator fork engage with the
slots in the inside operator.
3. See that the mainshaft is pushed right home.
(It may tighten in the felt washer inside the
countershaft nut.)
DRIFT FOR REFITTING
GEARBOX COVER BALL RACE
Fig. 34
DRIFT FOR REFITTING GEARBOX BALL RACE
Fig. 33
DRIFT FOR REMOVING GEARBOX BALL RACE
Fig. 31
DRIFT FOR REMOVING
GEARBOX COVER BALL RACE
Fig. 32
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