Royal Enfield CO, Workshop Maintenance Manual, Page: 3 / 52

ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL
Page 3
CONTENTS
Para Page
LIST OF ILLUSTRATIONS .......... .......... 4
PERIODICAL ATTENTIONS .......... .......... 4
DATA .......... .......... .......... .......... .......... .......... 5, 6
LIST OF TOOLS ............. .......... .......... .......... 6
ENGINE ................. .......... .......... .......... .......... 1-26 7
Decarbonising ............ .......... .......... .......... 1-9 7
Removal of Cylinder Head .......... ......... 1 7
Removal of Cylinder and Piston .......... ......... 2 7
Removal of Valves .......... .......... ......... 3 7
Removal of Carbon .......... .......... ......... 4 7
Piston and Rings .......... .......... ......... 5 8
Big-end Bearing ............. .......... .......... ......... 6 8
Small-end Bearing .......... .......... .......... ......... 7 8
Valves, Springs and Guides .......... ......... 8 8
Reassembly of Engine .......... .......... ......... 9 9
Timing Gear ............. .......... .......... .......... 10-12 9
Valve Timing .................. .......... .......... ..... 10 9
Magneto Timing ............ .......... .......... ..... 11 9
Tappet Adjustment .......... .......... ..... 12 10
Complete Overhaul ............. .......... .......... ..... 13-22 10
Removal of Engine from Frame .......... 13 10
Dismantling the Crankcase .................. .......... 14 11
Removal of Tappets and Guides .......... 15 12
Dismantling Flywheels ............. .......... .......... 16 12
Connecting Rod ............. .......... .......... .......... 17 12
Removal of and Replacing Mainshafts ........... 18 13
Reassembly of Flywheels .................... .......... 19 13
Removal of Crankcase Main Bearings ............. 20 15
Replacing Crankcase Main Bearings ........... 21 15
Reassembly of Crankcase ................................ 22 15
Lubrication System ............ ........... ............... 23-26 17
Principle of Operation .......... ........... .................... 23 17
Reasons for Excessive Consumption .......... 24 17
Replacing Pump Discs .............. .................... 25 18
Draining System ............. .......... .................... 26 18
TRANSMISSION ............. .......... .......... ............... 27-37 19
Gearbox ......... ........... .......... .......... ............... 27-31 19
Removal of Gearbox from Frame ........... 27 19
Removal of Gears and Shafts ........................... 28 19
Removal of Ball Races .............. ..................... 29 21
Foot Change Ratchet Mechanism ........... 30 21
Reassembly of Gearbox ............ ..................... 31 21
Clutch ............ ........... .......... .......... .............. 32, 33 22
Dismantling and Reassembly of Clutch 32 22
Adjustment of Clutch Control ..................... 33 22
Chains ............ .......... .......... .......... ................ 34-37 23
Lubrication ..... .......... .......... .......... ..................... 34 23
Tensioning ...... .......... .......... .......... ..................... 35 23
Limits of Wear .............. .......... ..................... 36 23
Removal, Repair and Replacement .......... 37 23
WHEELS .............. .......... .......... .......... ................ 38-44 23
Removal and Replacement ..................... 38 23
Tyres ................... .......... .......... ..................... 39 23
Rims ................... .......... .......... ..................... 40 24
Spokes ................ .......... .......... ..................... 41 24
Brakes ................. .......... .......... ..................... 42 24
Wheel Bearings .......... ..................... 43 24
Cush Drive Rubbers .......... ..................... 44 25
FRAME AND FORK ...... .......... .......... ................ 45-50 25
Alignment of Wheels 45 25
Adjustment of Fork Links 46 25
Worn Swivel Pins or Bushes 47 25
Adjustment of Steering Head 48 26
Dismantling and Reassembling Steering
Head 49 27
Steering Damper 50 27
Para. Page
CARBURETTOR 51-53 27
Adjusting Slow Running 51 27
Dismantling Carburettor 52 27
Causes of High Petrol Consumption 53 27
LIGHTING AND IGNITION SYSTEM 54-103 29
Magneto 54-67 29
Lubrication of Contact Breaker Mechanism 54 29
Cleaning Contact Breaker 55 59
Adjustment of Contact Breaker 56 29
H.T. Cable 57 29
H.T. Pick Up 58 29
Suppressor and Immobilizer 59 29
Magneto Drive 60 29
Timing Ignition 61 30
Removal and Replacement of Magdyno 62 30
Slipping Clutch 63 30
Dismantling Magneto 64 30
Test and Repair of Magneto 65 31
Reassembly of Magneto 66 31
Reassembling and Testing Slipping Clutch 67 32
Sparking Plug 68, 69 32
Dismantling, Cleaning and Setting 68 32
Testing 69 32
Charging Circuit 70 32
Dynamo 71-81 34
Removal 71 34
Dismantling 72 34
Cleaning Commutator and Brushes 73 34
Making Connections to Dynamo or
Regulator Terminals 74 34
Treatment of Badly Worn Commutator 75 35
Sticking Brushes 76 35
Worn Brushes 77 35
Test and Replacement of Field Coil 78 35
Test of Armature 79 36
Special Attention if Water has entered
Dynamo 80 36
Reassembly of Dynamo 81 36
Regulator and Cut-Out 82-87 36
Description 82 36
Adjustment 83 36
Cleaning Contacts 84 36
Mechanical Setting 85 36
Adjustment of Cut-Out 86 37
Regulators for use with NIFE Batteries 87 37
Ammeter 88, 89 37
Removal and Replacement 88 37
Ammeter Faults 89 37
Battery 90-94 37
Topping Up 90 37
Checking Conditions 91 37
Cleaning 92 37
Earthing Connections 93 37
Charging 94 38
Headlamp 95-98 38
Removing Lamp Front and Reflector 95 38
Setting and Focussing 96 38
Cleaning 97 38
Bulbs 98 38
Tail Lamp 99 38
Cables 100 38
Lighting Switch 101 39
Electric Horn 102, 103 39
General 102 39
Method of Adjusting 103 39
LUBRICATION CHART 40
INDEX 50, 51
SUPPLEMENT FOR BURMAN GEAR BOX 41-49.
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