Royal Enfield Bullet 1995 Owner's manual

Page

Nos.

PREFACE, ROLJTINE MAINTENANCE

TECHNICAL SPECIFICATIONS

DESCRIPTlON OF ENGINE PARTS

DECARBONISING

SERVICE OPERATION

SERVICE OPERATION - ENGINE - REMOVED FROM FRAME

GM

FRAME

FRONT FORK [HYDRAULIC)

WHEELS

ADJUSTMENT OF BRAKES

PRECAUTIONS

BOX

REAR

SUSPENSION

-

GENERAL

350cc & 500cc

ENGINE ON FWE

INSTRUCTIONS

l

-

6-9

-

10- 13

TYRES

IGNITION

WIRING

ELECIIUCAL CONNECTION DETAILS

CARBURETTOR

SERVICE LIMITS

TROUBLE

TORQUE VALUE CHART

SPECIAL TOOLS

METRlC CONVERSION

-

REMOVAL

AND

LIGHTING SYSTEM

DLAGWS

SHOOTING

AND

REPLACEMENT

TABLE

101-106

107

PREFACE

-

We take pleasure senice. Most of the servicing can well done by the average owner. diagrammatic Sketches and photo illustrattons have been introduced for better understanding. However for an owner who feels any stripping and re-building for a major overhaul, we strongly reco work be done by an authorised 'ENFIELD that

the

use of proper service maintenance tools and genuine Enfield best results. Whilst every care

no liability can be accepted by Royal Enfield or the publisher for

or injury caused due to errors or omissions in the

PRECAUTIONS

reassembhg Motor-cycle parts.

-

with new ones, for 'safe riding'.

-

diameter and from inside to outside diagonally, with specffied tightening torque.

-

in

releasing this Maintenance Manual as a guide t

N

uncertain of his ability to, undertake

DEALER/DISTRIBUTOR

is

taken to ensure that the information

AND

Observe the following points without fail, when dismantling and

Be sure to replace packings, gaskets, circlips.

Tighten bolts & nuts starting from the larger diameter ones to the smaller

Use always genuine spares and recommended grade of oils only.

GENERAt

INSTRUCTIONS

.

in

this

informations

manu

10s

given.

'0'

rings and cotter pins

-

When using a torque wrench for checking, always loosen the bolt or nut by half turn and then tighten to the specified torque. wrench for loosening

a

bolt or nut.

Never use torque

L

B~.G

the Enfield parts ex-stock.

It

side

SPARE

When ordering spare parts for your Motorcycle it

Always quote the Engine Number and Frame Number and description of part required.

is

advisable to indicate the colour scheme especially while ordering parts for frame.

panels,tank, mudguards, etc.,

PARTS

is

advisable to deal direct with

official dealer/distributor, who should be able to supply most of the

n

\

/

ROUTINE

MAINTENANCE

Introduction

Periodic routine maintenance is a continuous process that commences immediately after

be

the machine is used. It must

if

basis

condition and to ensure long, trouble free service.

the machine is not used frequently.

Maintenance should be regarded

carried out at specified mileage recordings, or an a calendar

-

as

an

insurance

policy,

to keep the machine

in

peak

The various maintenance tasks are described under their respective mileage and The intervals between the various maintenance tasks serves only as a guide. gets older or used under particularly adverse conditions, it would be advisable to reduce the

period between each check.

ease

For In

order to cut the routine maintenance tasks, a good selection of general workshop tools

ab~olutel~essential.

is

Included phillips head screw drivers and

No special tools are required for the normal roufine maintenance tasks. The tools contained

in

the tool Mt supplied with every new machine

not available, the tools found

of reference each service operation is described

in

the kit must

be

a

range of

pair

in

the average household

if

circlip

m

will

prove adequate for each task, or

in

detail under the relevant heading.

will

usually suffice.

As

period.

the machine

if

they are

A daily check of the Motorcycle is essential both from mechanical and safety aspects. good idea to develop this checking procedure in a specific sequence so that It become as instinctive as sequence

will

give advanced warning of impending mechanical failures and

actually riding the machine. Done properly,

this

wtll

simple checking

conditions

may jeopardize the safety of the rider.

-

Clean the motorcycle with a clean cloth.

-

Check engine oil leve1,using the dipstick provided in the oil

upto

'H'

mark.

-

Check proper operations of all controls

If

necessary top up ofl to the required level.

viz.

clutch, accelerator, brakes,

tank

cap. Maintain oil level

aI1

lights

horns.

-

Check tyre pressure, with a pressure gauge. Cneck tyre pressure when the tyres are

a

cold. It is worth purchasing

give consistent readings than

;;

<G?i'air-.r.-*,6z7-.---..

as>

G.

-

-. .

-;$$,~g~@;gss~~:~gon@:3@Psr*~Rear

o

,

-.-

.--

-

Check tyres for foreign materials and remove them to prevent possible punctures.

-

Check for adequate fuel

-

Check for proper charging of the battery after startlng the machine.

x*2~;<p:p:>.;:.;:2?<:2:*-.-+<q2=s3@~*.:

G~~+z.2~a.42.G..-c

-P----

~~~~~~~e2~z2~2~~-~~~v:L+g.~~~~~E5~+zs2~:~~~~:~~

small pocket pressure gauge which

garage

;~~+X*?:~T+;.E%*~~~*-

in

the petrol

forecourt gauges which tend to be less dependable.

,,,;

-pT3-.

?!..

-:<-n-.&$.&zg

,136::

PSI:

tank,

for the journey planned.

can

be relied upon, to

It

is

ultimately

which

and

a

-

Check ofl levels - engine & clutch

-

Check contact breaker gap and adjust

-

Check and adjust tappet clearance

-

Check clutch, throttle and kont brake cables and adjust

-

Lubricate rear chain

-

Adjust kont &rearbrakes

-

Check wheel rims, for excessive runout, breakage of spokes and tyres tor cracks or cuts.

-

Check condition of battery and electrolyte level, and top up with distilled water upto the

if

necessary

if

necessary

if

excessive play noticed

d.

*.

,*

level provided.

-

Clean,' and adjust plug gap or replace spark plug.

-

Check and service contact breaker

-

Check and adjust Ignition

-

Check and adjust valve tappet clearance.

timhg.

points.

-

Clean airfilter.

-

Clean, tune up carburettor.

-

Clean fuel tap gauze.

-

Clean fuel

-

Check and adjust clutch.

-

Adjust front & rear brakes.

-

Check front fork oil level.

-

Check etc.

Carry

following:

-

out

Change ofl-engine & clutch. Clean or replace ofl fflter

tank

and fuel lines.

all

elecmcal connections and functions of head

alI

the operatiom mentioned for

,

Light.

hf

monthly suvfce

trafficator, horn, speedameter.

and

check

the

-

Change front fork ofl

-

Check front & rear brake linings and replace

-

Check for play

-

Check operation of steering lock and lubricate

-

Check operation of side stand and condition of

in

steering head

bearings

lf

necessary

and adjust

if

necessary

sprlx.

TECHNICAL SPECIFICATIONS

Engine

-

BULLET

-

350

CC

Single

Cubic Capacity Stroke Bore-Nominal Actual Compression Ratio compression Pressure Engine outpl l t Torque

Piston

Ring Plaln (2) Scraper

Ring

Maximum rir-g gap permissible Gudgeon Crank Connecthg rod small end diameter

Cylinder 4 Stroke

and

dearan

end gap

pln

diameter

piston

ce

rfngs:

in

grooves

in

bore

diameter

crankshaft:

Driving side Ball bearLng Roller

bearing

Timing

CamW

Valve

Exhaust opens Exhaust closes Inlet opens Inlet closes Rocker bearing inside diameter Rocker spindle diameter Inlet Exhaust valve stem diameter

Vdve

Valve guide external diameter Tappet.guide internal diameter Tappet guide external diameter

side Roller

lift

tizuing

valve

stem diameter

guide

bearing

with

-012"

clearance

internd diameter

~rication Clutch

Engine sprocket Clutch Sprocket

Primary

drive

chain

with

Overhead

: : : : :

: : :

: :

:

: : : :

:

: : :

:

: : :

:

: :

:

: :

:

: :

:

Valve

346cc 9Omrn. :70rnm

69.875 mm/2.751

7.25 : 1 110 + 5 PSI (recommended)

18

BHP

/

5625 RPM

2.74kgm/2875RPM

Dimensions for new .001/.003" .002/.004" .015/.020

0.030" .7498/.7500'!

1.24875/ 1.249"

.7505/.7507"

25 X 62 X 17 25x62~ 17 25x52~ 15mm(NU205orN205R) .3125

in.

.3125in.

75" BTL)C 35"ATDC 30" BTDC 60" ATDC .625/.626" (J3irnensions for new Components] .6235/.624" .3425/.3430 .3405/.3410 .3437/.3447' .6270/.6275 .3752/.3760n

.7505/.7510n Dry sump, Wet multiplate,OiI immersed 25 teeth

56

teeth

3/8" pitch Duplex chain.

OU:

mm

tank

in.

components]

(63051

(NU

305 orN 305)

integral

with

crank

case

Gear

Box:

Overall Mainshaft ball bearings

Final

Rear

Brake

Carburettor

Main jet Pilot jet

Contact Breaker [Coil igdtion):

Points gap

Timhg before

Spark plug Spark plug gap

Condenser (Capacitor)

Suspension:

Front Stroke Rear

Wheel

we

Wheel Bearings

Font &Rear)

Brakes

Front Rear

Fuel

Full Tank Capacity Reserve Capacity

Oil

Fork Clutch

Gear

gear

ratios

drive sprocket

drive chain

dnun

sprocket

T.D.C.

Rim

Type

Size

:

.

tank

Capacity h Grade:

Tank

box

5.32,

7.26, 9.80, & 14.80

Small

-

6303

Large

-

6206

16 teeth

5/8" pitch chain

38

teeth Mikd-W-24 90 25

0.14/0.16" (0.35 to 0.4

:

1/32" (0.8 14

mm.

:

0.46 to 0.50 mm

:

0.18 to 0.25

Telescopic,

155

mm

Pivoted fork with shock absorbers

WM

2- 19

3.25

3.50 17 X 40 X 12

Mechanical, internally expanding shoe type

mm

178 153

mm

:

14.5litres

:

1.25 litres

:

2.25 litres,

:

200

ml.

:

420

ml.

:

700 grams of veedol'00'

mm)

diameter B7HS

M.F.D.

hydraulic

X

19 Front)

X

19

(Rear)

mm

X

38

mm

X

25

mm

SAE

20 W 50

on

each

leg.

approximately SAE2O W

mm)

(NGKI

damping

(6203) or 6203

Twln

Leading shoes

Single Leading

Hydraulic

grease

or

equivalent

ZZ

Shoe

oil

or

40

(for topping

SAE-

10 W 30

up

use SAE-20 W 501

Dimensions:

Weight Pay load Ground clearance Overall length Overall width Saddle Height

Wheel base

Electxicals:

System

Dry)

(Max)

:

172Kg.

:

14cm.

:

212cm(2120mm)

:

75

:

85

:

137 cm (1370 mm)

(140mm)

cm

(750

cm. (850

mm)

TECHNICAL SPECIFICATIONS

-

BULLET

-

500

CC

8ingle

Cubic

Cylinder

Capaclty

4

8tr~ke

Stroke

Bare-Nornlnal

Actual

CornpresstDn Compression Pressure Engine output

Torque

Piston

IUng

clearance in

matn(2)

and

Ratlo

piston

rlngs

pxwes

:

*raper

Rtng

end gap

Maximum

Gudgeon pin diameter

Crank

Connecflng rod

Crankshaft

DrMng

Roller

pln

bearing

Tlming

Camm

Valve

lift

Valve

thing

Exhaust opens Exhaust Inlet opens

Inlet

clmes

Rocker

Inlet

valve

Exhaust

Vahre gulde internal diameter

Valve

guide Bppet guide internal diameter Tappet guide external diameter

I~bricatim

Ln

bore

rlng

gap permissfble

dlarneter

small

:

side Ball

side

Wer

dth

bearLng

bearJng

.O1T

closes

bearing

spindle diameter

valve

inside

stem

diameter

stem diameter

external

diameter

end diameter

clearance

diameh

Clutch

Englne sprocket Clutch himarydrtvechaln

with

werhead Valve

:

499

:

90mm

:

84mm

:

83.96/83.97

:

6.5:l

:

1 10

:

22 BHP/5400 RPM

:

3.5Kgm/3000RPM

:

(Dimensions for new components)

:

.001/.003-

:

.002/.004"

:

.015/.020n

:

0.038

-.

.

.7498/.7500"

:

1.24875/1.249"

:

.7505/.7507

:

25

:

25 X 62 X 17

:

25~52~15mm(NU205orN205RI

:

-3125in

:

.3125in.

:

75"

:

35"ATM)

:

3O0BTDC

:

6O0ATDc

:

.625/.626"

:

.6235/.6240n

:

.3425/.3430m

:

.3405/.341OR

:

.3437/.3447'

:

.6270/.6275

:

.3752/.3760"

:

.7505/.7510"

:

Dry

:

Wet multlplate,

:

25 teeth

:

56

:

3/8" pitch Duplex

CC

f 5 PSI

X

82

BTM)

sump.

teeth

mm

(Recommended]

X

17

mm

[Dimensions

-

Oil

tank

Oil

(63051

(NU

305

integral

lmmeraed

chatn.

or

N

3051

for new Components]

with

crank

case

Gear

b~x

:

Overall

Overall gear ratios

Ffnal

Rear

Carburet tor Malnjet FUot jet

Contact

Points gap

Tfming

Spark plug spark plug gap

Condenser (Capacitor)

Snspdon

Front Stroke

gear ratios

drive chain

drive

chain

Breaker

before T.D.C

:

Rear

Wheel

me size

Wheel Bearings

Front

Bfm

&

Rear)

Type

:

Brake

Front

Rear

Fuel

tank

:

Full

Tank Capacity

Reserve capacity

Oil

Capacity & grade

Oil

tar&

Fork Clutch

Gear

Box

Mmensione

Weight Pay load

Ground clearance

Overall

Saddle Height

Wheel base

Electrlcals

System

:

(Dry)

(Maxl

length

width

:

(Coil

ignition)

:

5.01, 6.83.9.22 & 13.93

:

Small - 6303

:

Large - 6206

:

17

teeth

:

5/BWpitchchaln

:

Mikcarb-W-28

:

110

:

25

:

0.14/0.16" (0.35 to 0.4

:

1 /32" (0.8 mm)

:

NGK BR

:

0.46 to 0.50

:

0.18 to 0.25

:

Telescopic.

:

155

:

Pivoted fork with shack absorbers

:

WM2- 19

:

3.25 X 19 Front)

:

3.50~ 19(Rear)

:

17x40x12mm~6203)or6203ZZ

:

Mechanical.

:

178

:

153

:

14.5 litres

:

1.25 litres

:

2.25

:

200

:

420

:

700 grams of veedollOO' grease (for topping up use

:

168

:

172

:

14

:

212

:

75cm (750mm)

:

85

:

137- (1370mm)

:

12VDC

8

ES

or equivalent

mm M.F.D

Hydraulic

mm

internally

mm

X

38

mm

X

25

mm

litres.

SAE-20W50

ml.

on each leg. Hydraulfc

m].

approximately SAE-20W40

~g.

cm

'

(140

mm)

(2120mml

(850

mm)

-

mm)

damping

expanding

Twin

leading shoes

Single lea- shoe

shoe type

Oil

or SAE 10W30

SAE

20W50)

ENGINE

PARTS

1.

CrankcaseD/S

2. Crankcase T/S

3.

Joint washer

4.

011

filler

car,

wllar

6. Idler pun mlndle

7.

Timing

8.

Tappet guide

9.

Cylinder

10.

ctrc1l.R

12.

Ball

14.

Distance

15. Distance

16. Roller

1

7.

Stud, Crank Case Neck

shalt

base

(SeeuQrl

healing

tube tube

bearing

mUer

stud

(outer) (Inner)

bearing

18. Washer. Crank Case Neck Stud

P

19. Nut, Crank Case Neck Stud

20.

Stud

Crank Case Bottom

Jolnt

21. Washer. Cmnk Case Bottom Joint

22. Nut. Crank Case Bottom Joint

Head

and Cylinder

and

CylMer

24. Washer.

Stud

25.

Washer. Stud

26.

27.

Nut. Head

SW

Nut.

Head

and

CyUnder

Cylinder

Stud

28.

Crank Case Distributor

--

29. Washer.

30.

P

Nut, below dLsMbutDr

-

Stud

below

Distributor

31. Stud-Front engine plates

32. Washer, Front Englne

33.

Nut,

Ront

34.

Read

35.

Washer. Rear Ensine Plate

36.

Nut RearEnginePIate Stud, Crank Case Rear Joint

37.

38.

washer. Crank Case

Engine

engine

plates

plate

Plate

Rsar

Joint

39. Nut, Crank Case Rear Joint

40.

Stud.

Crank

Case

Rear Jolnt

41.

Washer, Crank

Case

Rscu

Jolnt Nut. Crank Case Rear Joint

42.

44.

Oil

Seal

Retainer

45.

Nut,

OU

Seal Retainer

-

46.

Distributor flanae pin

47.

Distributorjlange pin wash&

-

50. Washer. Tappet Cover Stud

-

--

c?

51. Tappet Cover

52. Washer (Fibre), Tappet

Couer

Stud

53. Washer

(Steel), Tappet

Cowr Stud

pipe

cover nut

unlon

54. Tappet

55.

Oil

56. Washer, 5

7.

Washer Oil fllter Cause

58.

Oil

59.

Breather pipe

OU

Pipe

Union

feed & return filters

~

60. Breather pipe cllp

61. Piston

62. Gudgeon Ipln

65. Piston

ring

(compression)

lower taper

66. Piston

ring

(compmpression)

top. chrome

67. Connectfng

68.

Connectfng Crank pln

69.

70. Thrust

rod

rodmtirtg

washer

bush

71. Cmnk pln nut

72.

Crank pin oU hole grub

mew

73. Crankpin nut keeper screw Thrust wzsher

74.

75. Thing shaJt

76. Driving shaft

77.

F& wheel T/S

79. Lock

rim

80. TIS shaft nut

82. Engine sprocket

distance

tube

83, Engfne sprocket 25T

84. Alternator

distance tube

P

85.

Push

rod

inlet

86.

Push

rod

exhaust

88.

Push

rod

end

bottom

89. Push

90.

91. Tappet

92.

93.

94. Cyllnder

95. Stud.

96. Rocker oil pipe wrnplete

97. Rocker Oil Union Bush 129. Washer, Decompressor 160. OU cleaner spring

98. OU

99. Washer

101. Cylinder head

102. Valve

103. Stud Rocker 1

04.

l

05.

1

G6.

107. Rocker, Met

108. Rocker, exhaust 139. Timing wwrjotnt washer 72.

nxi cup lock nut

Pushdcup

Culinder barrel ioint washer CqIMer barrel

headjoint washer

CylMer Base

Washer

union

Union

auLde

bush

Oil

~

Plpe

~

'

banjo

Box

Stud Rocker Washer, Rocker

Nut, Rocker Bearing

Bearinq

Bearing

l l 7. Nut (long) Rocker

118. Valve 149. 11 9. Valve spring

120. Valve spring. outer

121. Valw spring. Inner

122. Valw sprtng

123. Valw split wllar

124. Valve

125. Spark plug

126. Spark plug cap 1 2 7. H.T.

128. Decompressor

stern

Lead

WY

130. Washer. Decompressor

MY

131. Washer (Plain), Decompressor My

132. Decompressor My

133. Spring.

134. Spring

135.

Cable

136. Cable block 13 7.

Decompressor

assembly Timing

138.

Decompressor

Cap.

block

wwr

Box

ab,

cap

Decompressor

spllt pin

bottom

top

mlue

&le

148. Timing pinion 20T

Key

150.

ou

p-p

mrm

151.

Ollpumpdlscspring

/

52. Sprtng

153. Casket

154. OU pump aver

155. OU pump

156. Nut, 15 7. Washer,

158. Stud;

159.

011

161. Felt washer

162. Tht =her 011

163.

164. Washer, OU Cleaner

165.011 cleaner

166. Washer.

Nut

167. Nut.

168. OU

169.

,011

170.

011

1 71. Plunger Ifeedj

end

pad

011

hrmp

cover

screw

Oil Clsaner Stud

011

Cleaner Stud

0[1

Cleaner

cleaner eiement

cleaner

spring

cap

011

Ckaner

Oil Cleaner

pumr,

dlsc

lfeedl

pump

dlsc

(return)

pump

spindle

-

--

(rekm

Cowr

cap

Cap

CQD

109. Rocker beating inlet l 10. Rocker be&g

1

1 1. Rocker

112. Rocker bearing cap, exhaust

113. Gasket

1 14. Rocker

115. Rocker

1 16. Nut

bearing,

bow,

bor

(short)

aap,

Met

exfmst

Rocker

exhaust

Box

Met

140. Distributor pinion ~lstributor plni6&

141.

142. Idler

143. Idler

144.

145.

146.

1 4 7.

DW~

pWn bush

IdlerpWn thrust washer

cam

Cam.

Cam

4OT

wet

exhaust

bush

nut

40T

173.

ou

f&plug

174. Washer 1

75. Cork

1

76.

1 77. Spring

oil

Timing mwr

Coveiscrew.

retainer

washer.

screw

Tlmlng

ENGINE

Decarbonising:

After a few thousands of Kms. of run the carbon. build up in the engine

will

cause general

falling off in power, accompanied by increased fuel consumption and starting trouble.

Decarbonising

carried out without removing the engine will vary from machine to machine depending upon the frequent short journeys

will

normally be necessq approximately every

fiom the frame. The mileage between decarbonising

will

need more attention than one which is used for fast long distance

8,000

Kms. and this

can

type of usage. A machine used for

touring.

1.

Removal of the petrol tank

Close the petrol tap. Disconnect the fuel hose from petrol tap end. Remove the two studs which holds the petrol

2.

Removal of

the

Cylinder head

tank

to the frame and

pull

the

tank

upwards.

Remove the engine steady eye bolt. Disconnect the high tension lead from the spark plug. Remove rocker oil pipe.

Remove the exhaust pipe and silencer.

air

Remove the

filter by undoing the bolts on the sides of the

Push the carburettor back clear of the studs after removing the

air

filte; body.

fudng nuts.

Remove the rocker box covers.

(LH

Remove the decompressor cable from the lever end of the handle bar

in

Crank the engine until both valves are closed. (Keep

Compression stroke).

side)

be

CYLINDER

Remove the rocker

arms and bearings

HEAD

completely after removing the

nuts on each.

Lift

out the push rods

both inlet

&

Remove the six

cylinder head nuts

washers.

Lift

the cylinder head off the barrel, tapping it genly beneath the exhaust and inlet ports with a wooden mallet.

tap

Do Not

the fins.

four

3

exhaust.

/

1

6".

&

3.

Removal of Cylinder and Piston

Slacken the two clamp nuts on top of the

crank-case

neck

REhfOVAL

-

Of

PISTON

Remove the

1/4"

nut above the tappet chest and

circlip retaining the gudgeon pin on the timing side of piston taking care not to drop the me.

Extract the gudgeon pin using special

(with adaptor if

may

be

replad the same

necessary),

so

that the pin and the piston

way

round, i.e., split skirt toathe

front.

During

getting

4.

Removal of Valves

this

operation

put a piece of

clean

in. Finally cover the crankm with

VALVE SPRING COMPRESSOR

lift

the barrel

circlip into the crank

Tool

PED

20

15

m.g

in

the top of the

a

clean

cloth

to

prevent

To

remove the valves from the cylinder head,

first lift

off the end caps from the valve stems. If this has stuck, it driver. Using compressing tool ampress the valve springs and remove the split collars from the valve tip. Slacken back the ampressing tools

crankcase

ingress

can

and

to

prevent foreign matter

of dust and dirt

be

removed by a screw

PED

20

release the springs.

18

ST

Withdraw the valve

and

place its springs, top

spring collar, bottom collar, the end cap and

split conical collars together in order that they may

be

reassembled with the valve from which they were removed.

If the valve will not slide easily through the valve guide. remove any of the valve stem

with

sIight burrs on the end

a

carborundum stone or by using a fie Jeweller's file to remove any sharp edge or burr. If the burrs are not removed and

Ihe

valve

is

forced out. the valve guide may

be

damaged.

5. Decarbonising the Cylinder head - Combustion Chamber

6.

Hston and Rings

If the piston rings are in good condition they can be put back, taking care to fit them in their

original grooves and the same way up. If the

gaps, are more than specified

senice

limits

fitlgs show bmwn or black patches or if their

(Page 79), when in position

in

the barrel, new rings

should be fitted. The correct gap for new rings is given in the technical specifications (pages

6

13

8

)

for

350

which

and 500cc. The gap should be measured

will

be found at the top or bottom of the bore.

in

the least wdrn part of the cylinder

Only For 350cc:

The original size of the cylinder bore is 2.751" (69,875rnm). If the wear at any point

bore exceeds

.008" the cylinder should be rebored to .020" and

should be rebored to

.040" &er a further .008"Wear). Piston sizes available are .020 and .040"

an

oversize piston fitted. (It

oversize.

The original side clearance between the piston rings

and grooves

is

.003". If the grooves show a wear of

.005"

CRANKSHAFT

the piston should be replaced.

7.

Big end bearing inspection

Examine the condition of

ttle

big end while the piston

is

removed. About .010" - .026" end float is permissible and it

will

be possible to rock the connecting rod slightly. The

with

big end has a floating bush approximately

.003" However,

an original clearance of

if

a

DEFINITE up and down play can be felt, engine should be stripped further to have the big end renewed.

BIG

END

in

the

BEARING

8.

Valves, Valve

6-

Guides and springs

STEM

spur

sPNNC

INNER SPRING

OUTER

F

@B-

L!

spRING~~

VALVE

a

CAP

COLLAR

SPRING

GUIDE

Wear

on the vahe stems

and ifa de£inite step has formed, the valves should renewed. Before replacing the valves, ground on to their

with a reasonable amount of

be

cut with a cutter (included angle

refaced

good

will

pocket has by than the

new valve but the exhaust valve has more clearance Met valve.

special tools are required which

The

less than made down to diameter for a

length Support of

in

a

universal grinder. Do not attempt

seats by an excessive amount of

cause pocketing and restrict the flow of

already

cuttlng with a v&e seat cutter larger

vahre head.

Test the valve guides for

in

them. Both valves shuld

To remove the valve guides

ht is a piece of tube with

7/8".

fYom

9/

1/3"

1/2".

the

seats,

been

The second is a mandrel about

16"

diameter bar

can

be

seen on examination

if

good

faces are not formed

grinding.

formed this must

wear

by

fYom the head. two

can

an

internal

with

~SSOR~Y

CABLE

ADJ

USTINC

they

must be

the

seats

90')

and the valve

to

grinding.

gases.

be

removed

in

diameter

trying

the fit of

be

quite

(.002")

be

easily

the end turned

SCREW

made.

bore of not

4"

be

must

form

This

If

free.

than

long

a

cylinder head on the

valve guide. Using the mandrel. force the guide out of the

head with a hand press or by using a hammer.

To

fit

a new guide, support the head at the correct angle

and use a hand press and the same mandrel.

is

press

hammer and a mandrel,

oiighml& respectively.

limits,

9.

freely.

the carbon it

will

done without completely dismantling it. Having disconnected the control cable from unscrew the decompressor from the cylinder head. Compress the spring and remove the spring cap. Unscrew the adjusting pull the cable sideways out of the block. Push the spring.

not available, the guide

Check the length of

2.020

If

they should

Decompressor

If

the decompressor holds compression and

there is no need

fYom the head of the vdve.

be

necessary

screw

tube

which

to

the

and

2.095

these have reached the specified sewice

be

renewed.

to

interfere with it except

to

regrind it on its

and locknut f?om the cable block and

fits

over the collar of the

If

a hand

can

be

replaced using

prevent damage to the guide.

valve springs which are

for the inner and outer springs

operates

to

remove

If

the valve

seat

the

is

leaking.

This

can

be

handle bar.

a

upwards and pull the cable nipple out of the body, It will now be possible to remove the cable and nipple through the spring,

leaving the decompressor body and spring detached from the

control cable.

The spring and the cap should now be replaced. The valve may be ground in by applying a

thin

coating of grinding paste on the seat of the valve and twisting it to and fro by means of the

cable block at its upper valve through a complete wash the whole assembly thoroughly in

Make sure that all traces of grinding paste have been removed.

end and occasionally lifting the valve ffom

revolution before lifting, as this

will

g;oove the seat. Mer grinding,

petrol, opening and shutting the valve while doing so.

If

the paste should get into the

its

seat. Do not rotate the

cylinder serious damage would be caused.

If the valve shows a tendency to stick-up in the body but otherwise is satisfactory,

in

be cured by washing

petrol, though in this case it will not be necessary to disconnect the

this

can

control cable.

If

the decompressor valve is badly burnt or bent it must be replaced.

10.

Re-assembly

after

Decarbonising

Before building up the engine, see that all parts are scrupulously clean and place them on

a clean tray, work bench or

fit

a

new gasket between the cylinder barrel and the crankcase.

Smear clean oil over the piston and space the ring gaps. The second ring

over a clean sheet of paper. While re-assembling it is advisable to

is

a taper ring and

is marked TOP on the upper surface.

WARNING:

oil into the cylinder and consequent smoking.

of

Place the piston over the connecting rod front and-insert the gudgeon bore and gently push barrel over the piston while keeping the rings compressed in and seat it gently on the barrel gasket. Refit the

When fitting the head

This mark should be on top when fitted. Reversing the ring will result

small end ensuring the split skirt is facing the

pin. Secure the gudgeon pin with the circlips. Oil the cylinder

1/4"

nut above the timing chest.

again,

apply jointing compound sparingly on both sides of the gasket,

in

pumping

their grooves

Replace the six nuts and tighten them progressively and diagonally from one side to the other

to prevent distortion.

WARNING:

Excess compound may block oilways.

Place the push rods with the adjustable parts downwards. The shorter pushrod is the Inlet. Ensure valve stem caps are fixed on the valve stems. Position the rockers and bearings. making sure that the oil feed holes are at the bottom and that the caps and bases are tightened down. Adjust the push rods after ensuring piston is

in

TDC'

on compression stroke.

The silencer could be cleaned of carbon using a hot caustic soda solution,

NOTE:

engine has been

The cylinder head and base nuts should be checked agaln for tightness,

run

long enough to get it thoroughly

warm.

Tighten the clamp nuts on crankcase

finally. For torque tightening or cy. head nuts please refer torque chart on

in

if

necessary.

PageNo.

line when

after

the

100

-

CYLINDER HEAD 350CC

CYLINDER HEAD

SW

CC

SERVICE OPERATION

-

WITH

1.

Removal

First place a tray under the engine to hold the oil which

removed.

Remove the exhaust pipe and silencer. Remove ten screws from the

care not to lose the

NOTE:

cranked.

Draw

While refitting the

holes. using a

Ensure that

it should be renewed to ensure oil flow to the big end bearing.

NOTE:

Ensure proper

engine is

it

again properly. Wipe the oil that has oozed out

ENGINE

of

the

&ct,,'F

When

This

will

preven? damage

off the

running

timing

little grease (not compound)

xw

the

cork p ug

The Alter chamber should be !Wed with clean oil before the

functioning of oil pump by checking oil flow at rocker

at

ON

Tixning

S

cover,

timing

cy+

slow speed. Slacken the oil pipe banjo union to see the oil-flow and clamp

FRAME

cover

washers, one for each screw.

the

timing

07

the pumpworm or the pump spindle.

in

position

ersd

it lightly

in

h$$&

cover ensure that theJoint wasH%r

is

cover it

if

necessary

to

hold

the hole

is

Important that the engine

dlafrf",

it

in

with

position.

the pump worm.

will

a

is

escape when the cover

timing

H

/~.44w~r4

en mallet

woo8

correctly located over the ofl

If

the plug is damaged

timing

ripe

cover,

<

is

cover is refitted. union whenit&e

is

taking

gently

-

OIL

FILTER

ELEMENT

IN nMlNG

COVER

2.

CIeaning/Replacement

Element

The oiI filter is located immediately below the oil pumps. The felt element should the first Krns. Fit a new element every

-

Oil

Feed

be

taken out and washed

800

Kms. and subsequently, every

and

of

Oil

Filter

Return Filters

in

the

timing

in

petrol after

8,000

Kms.

cover

4.000

I

VALVE

TIMING

MARKS

The filter element can be removed unscrewing the nut holding the end cap in position. When re-assembling the filter take care that no grit or other foreign matter is it. After replacing the Alter element it to

nm

the engine at idling for about five minutes to ensure that oil reaches the big end. cover has been removed,

with clean

The feed and

drain

can be cleaned by rinsing reassembly ensure the filters are not twisted.

3.

Overhauling

-Remove the timing cover.

-Remove the end covers from both pumps.

-Remove the pump discs and plungers.

-Remove the pump spindle which

--Check the fit of the plungers able to be moved

plugs

oil

before replacing the cover.

return filters are fked on

in

oil sump and crank case. These

of

in

fill

the filter chamber

in

a solvent and during

Oil

feed and

in

and out by hand.

stlcldng

is

essential

If

the

return

can

be pulled out only from the front or return pump end.

the pump discs which should

by

to

tfming

the

Pumps

FELT

METAL

WASHER

be

-4

I

WASHER

SPRING

&ding fit and should be

011

FEED

d

RETURN PUMPS

ASSK

W""

PLUNGER

FEED

When matching a plunger in the pump

the plunger

If

the pump disc is not seating properly in the

should be ensured that the pump disc matches properly and

timing

Lap the discs special tools PED fme, grey surface is obtained on the pump disc face.

cover.

in

the pump dfsc. Using metal polish until it is just

in

the timing cover with fine metal lapping paste or liquid metal polish using

2034

ST

for feed pump disc and PED

disc,

if

it is found to be too

timing

cover or

2035

ST

tight

a

fit, carefully lap

free.

if

a

new pump disc is fitted, it

has

a perfect seating in the

for return pump disc,

until

a

NOTE:

purpose of this is to hold the disc. off before the pump is finally assembled. Care should

Wash traces of grinding paste. Check the pump disc springs for fatigue by assembling cover and placing the pump covers cover taken place on the teeth.

Reassemble the oil pumps, replacing the cover gaskets. Before fitting each cover pump chamber with clean oil. Having assembled the pumps, lay the the oil ports using an oil direction and it the timing cover on the engine.

NOTE:

unscrewing the feed plug in the timing cover between the oil pumps and the oil return checked

flow.

4.

Removal

Unscrew the pump worm using the hexagon head behind the worm, with special tool PED

2006.

CAUTION:

be loosened and when turned anticlockwise the

Replacement pump discs have a lip left at the opposite side of the lapped face. The

central

all

components and passages. thoroughly with petrol, after lapping,

in

if

the springs are correct. The pump spindle should be renewed

can.

Turn

can

then

be

checked

With the engine running, the oil feed to the big end

by

slackening

of

Withdraw the timing pinion using special tool PED

The worm nut has a left hand thread. When turned clock wise the worm nut can

the rocker pipe banjo bolt on the cylinder head and obsen?ng the oil

Pump

Worm

whether the pumps are operating correctly. Before replacing

£ill

the filter chamber

and

in

the housing

position. The latter should

during

be

taken not

lapping-in. it should

to

damage the lapped face.

be

held 1_/8"off

if

timing cover flat and

the pump spindle with a screwdriver

with

clean oil and fit the filter element.

can

be checked

Timing

Pinion

20 13.

worn nut gets tightened.

to

remove

in

the

excessive wear

in

a

by

clockwise

partially

be

filed

timing

has

£ill

can

all

the

be

NOTE:

and is undamaged. This forms shaft, timing side. If necessary this should be replaced and care should fitted correctly.

CAUTION:

the timing shaft end bearing leading to premature failure of the big end floating bush, engine bearings and other parts.

When refitting the timing cover ensure that the cork is in position

a

seal between the oil feed plug and the oil passage

be

If this cork is not fitted or damaged. thkoil feed to the

will

tend to escape past this point causing starvation of lubrication

big

end

in

the worn nut

in

the

taken

bearing

to

through

to

crank

have it

the big

5.

Removal

Loosen the distributor pinion nut and pull out the distributor pinion off the distributor

shaft after removing the idler pinions.

of

Contact

breaker

housing.

Loosen and remove the three screws which and seperate from crankcase. Remove the contact breaker cover. Remove the base plate after removing the two hex bolts securing

Pull

out the contact breaker shaft from the housing. The two sintered bushes provided in the housing would have to be replaced only shaft.

Reassembly is just the reverse process of dismantling but take care to replace the washer

between the contact breaker housing and the crank case.

6.

Valve

The cams are integral with the cam pinions. They

have internal sintered iron bushes running on fixed

spindles in the timing chest.

The cams and the timing pinion are provided with timing marks to set proper valve timing. The procedure is detailed below.

Bring the piston to TDC Match the

exhaust

with

the timing pinion so that the two punch marks coincide on both. Match the cam so that the single punch mark coincide on both. Push the cams home towards the crankcase.

Timing

cam

(provided with two sets of punch marks)

inlet cam to the exhaust

it.

\

secure the spigotted contact breaker housing

if

excessive radial play

is

noticed on the distributor

DE7AlL OF FELT OIL

CLEANER

S-

7.

Tappet Adjustment

It is very essential to ensure that the valves are closed

cam. The tappet clearance should

-

Cold

be

adjusted properly to achieve this and to cater to certain

rnruusn~er~~~~s

-&,

h

amount of thermal expansion of the working components. We recommend tappets to be set at cold. Provision for adjustment

is

sits

I

the tappet cover.

piston to

\

so that both the valves are at the closed position.

This

marks, ammeter needle in its centre position, when ignltion

given at the bottom end of the push rod which

overfie tappet. Access to

Proceed as follows for adjustments. Bring the

MARK

ON

INLET

B:

MARK

ON

C:

MARK

ON TIMING PINION

fully

during the closing period of the

TDC

at the end of compression stroke,

may be ensured by seeing the valve timing

if

the timing cover is open or through

is

switched on.

CAM

EXHAUST

'NIL'

this

CAM

clearance for the

is

by removing

Check the push rods. They must rotate thumb free without any up and down play.

if

In case the push rods do not rotate freely or

up and down play is noticed, the push rods

need to be adjusted.

Loosen the lock nut

adjuster,

till

the conect push rod freeness is achieved. Retighten the lock nut after adjustments

in

the adjuster,

by

holding the top nut. Thread

in

or out, the bottam

are complete.

CAUTION:

If

the cylinder head has been disturbed for

any

attention, ensure proper fitment

of valve stem caps and rocker bearings before proceeding to tappet adjustment.

NOTE:

Owing

to the

initial

bedding down of the wearing surfaces, the tappets on new

engines may require adjustment after the first few hundred kilometres of run.

8.

The Clutch

The 350cc clutch has five driven plates and four

-

350cc

and

500

cc

driving

plates, including the fiiction disc

on the sprocket.

500cc clutch is similar to that of 350cc. except that there

The

are

six driven plates and five

driving plates.

Also the lugs on the clutch sprocket and the splines on clutch centre are longer.

9.

Removal

Remove the

in the

clutch front plate, clutch pad and the clutch retaining spring.

chain case. Remove the centre nut

To remove the clutch unscrew the clutch spring

of

the Clutch

L.H.

front foot rest Place a

in

tray

beneath the primary chain case to collect the oil

in

the chain case outer

and

remove the cover.

pins. Lift away the spring cap, sprlngs,

main shaft. The assembly of driving and driven clutch plates

The

clutch sprocket

can

then be withdrawn along

chain and engine sprockets (see point 10).

The clutch

centrg can be removed only after the engine sprocket, primary chain and the

clutch sprocket has been removed.

with

the

To remove the clutch centre hold the clutch with a brake bar (Special Tool No.

and

remove the centre retaining nut and washer with a box spanner. The clutch centre can

be

then

withdrawn from the shaft using extractor (Special Tool

No.

PED

REMOVAL OF

2005).

CLUTCH

PED

ASSEMBLY

2025)

1.

Clutch centre and back plate oqsernbly

2.

Cllrtch&

3.

Clutch sprocket drum

3.

Clulch sprocket friction disc

3.

Cl~lfch s~rocket frfctton dlsc rfuet

66

7.

Clutch svrocket ball coae rfoets

8.

Clutch sorocket balL5 13/16" dial

9.

Clutch retatnlna spring

10.

Clcrtch tntermedlote wlo

U.

Clutch plate /insert t&

(NISI

re

IN/S1

(N/SL

ldtshedl

12.

CIutch intermediate plaWfZaU

13.

Cltltch bded plate ossprnbly

-

17,

Clrrtch s~rina screw

38.

Clutch

J

9.

Clutch

20.

Washer matn shaft

21.

Nut matn short

p&

rod

fs~m

INlrlocl

CLUTCH ASSEMBLY

-

SW

CC

ket

P

-

82

v

-

SW

rocket

rite-

56

-

T

&

drw

rivet

baILs

dd[al

fN/SL

.-.

-

10.

Removal of Engine

Remove the alternator stator by undoing three nuts. The primary chafn is endless hence it is necessary to remove both the engine and clutch sprockets simultaneously. Remove the central hexagon nut securing the alternator rotor, which not to lose the key. The engine sprocket is mounted on the clutch sprocket using extractor

1

1.

Removal of Final Drive Sprocket

Remove the clut h as described above. Remove the primary

primary chaincase mer by removing three nuts. Remove the folding of the tab washer which

provjded for locking the

is hand thread). The sprocket can then be withdrawn.

12.

Re-assembly of the Clutch Plates

When re-assembling the clutch plates the following order must be observed.-The clutch pad

must

be

fitted into the main drive shaft, plain dished plate (dish projecting out wards].

Y

and

Clutch sprockets

can

then

be

drawn

splines and can be removed along with

PED

2004

ST

chain

final

drive sprocket nut. Hold the sprocket and remove the nut (right

tensioner. Remove the

off,

taking

care

Friction plate with inserts. plain flat plate. friction plate bonded.

projecting inwards). friction plate bonded, clutch front plate lugs.

of the plates is due to either clutch plates of oil, with insufficient or no

running the vehicle at

CLUTCH ASSEMBLY

ofl

in

the clutch chain case.

In

the case of 500cc one more plain

flat plate and one friction plate have to be has been assembled.

The other three means of bosses on the clutch cap. Tighten the go.

If

the clutch lifts unevenly, it

probable that one of the springs has taken

set.

in

a fitted.

The friction plate with inserts should

be renewed inserts have become loose in their plate. The bonded friction plates require renewal when worn or charred. a blackish colour should not be mistaken

as

shamed). Excessive or premature wear

hd

clutch application or depriving the

;lain dished plate (dish

3

springs on the clutch centre

will

also

fixed

aftkr the plate with

springs are located by

spring pins

which case new spring should be

if

badly worn or when the

as

far as they

(A

light change to

inserts

will

is

13.

Primary

Access to the primary chain adjuster is gained by removing the primary chain cover which is held collect

chain rests. This can be raised or lowered by turning the tensioner pad after having first slackened the locknut.

in

the

Beneath the bottom

Chain Adjustment

position by a single nut. Before removing the nut, place a bay under the engine to

oil from the chaincase.

run

of the chain is a curved slipper chain tensioner pad on which the

adjusting screw below the

chain

PRIMARY

CHAIN

ADJUSWENT

The chain should be adjusted.

so that there is

1

/4" up and down movement at the centre of the top run of the chain. Remember to tension at

check the chain

3

or 4 places and then

adjust accordingly. Ensure that

the chain tensioner pad moves freely and the lock nut of the adjuster is retightened after carrying out the adjustment. The chain is to be renewed if its length has increased by

than the length of a new chain.

After replacing the chain

cover. remember to replenish the

Qty..

[SAE

-

430 to 450

14.

Adjustment of the Clutch control

chaincase with oil to the case[approx

leve1,plug in outer chain

-

It is essential that there should be about 3 to 4mm free movement in the clutch cable. to

all

ensure that

the spring pressure is exerted on the plates.

3/4"

20) up

There are two

~oints of adiustment on the clutch cable. The first is the midway adjuster at

A

CillTCH

ADJUSWEhT

ON

GEAR

BOX

the middle of the cable just above the chain case. The adjustment is made by screwing the adjuster screw in or out of the adjuster body. Tighten the the screwed collar after adjustment has

been made.

The other point is at the handle bar

end. Loosen the lock nut and the adjuster to increase play and vice versa to reduce play. Tighten lock nut after carrying out adjustment. if the adjusters have reached their

maximum position then the adjustment

can

be carried out cover. Before proceeding on the adjustment, turn in both cable adjusters to their fully closed position [fully in position).

To make the adjustment, remove the inspection cover, slacken the

in,

central screw

to get the desired free play on the clutch lever at the handle bar end. Tighten

the locknut after adjustment has been made.

locknut on

thread

in

Homver

in

the gear box outer

locknut and turn the

-

Owing to initial bedding down of the clutch plate inserts. the clutch control may require

adjustment after the first few hundred

be examined soon after delivery and adjustment made

Krns with a new machine. This point should therefore

if

necessary. Initially, excessive play

the cable can be taken up through midway adjuster and the adjuster at the handle bar end.

fn

NOTE:

6000 from its position,

The clutch adjuster ball

and

clutch rod may require cleaning and greasing around

rniles/10000Krns of run. To do this, loosen and carefully remove the clutch adjuster

taking

care not to drop it into the gear box outer cover.

Start the engine and tilt the motorcycle towards the gear box side. so that the clutch rod

can be removed. Wash thoroughly. the clutch rod and adjuster and look for chipped or

worn

clutch rod ends and free rotation of the clutch adjuster ball.

Smear multipurpose grease on the clutch rod and reassemble into the grease on the clutch adjuster ball and carefully reassemble to ensure free play is

15.

Ntting the Alternator

maintained on handle bar end and tighten lock nut.

in

its location. Adjust the adjuster

The dternator consists of two parts. the stator and the rotor. The stator

mainshaft. Smear

is

mounted on to

the primary chaincase inner by three studs and nuts.

is

The rotor, which contains the permanent magnet,

and

is

located by a key and secured by a special nut and spring washer. The designed

mounted on the end of the drive shaft

radiai

air

gap between the rotor and the poles of the stator is 0.25mm ( 0.010") and care must be taken when refitting to see that it

is

not less than O.15mm

(O.OOG"]

he

stam

at

any

point.

SINGLE PHASE ALTERNATOR

-a

f~xed ring

wrth

c4ib

sry

carrying

via the

powec

rectlfler

to

the

Fit the rotor first, making sure that it

Attention must be given to the proper seating of the key. Finally secure the rotor with the

appropriate washer and nut.

Having fitted the rotor, the stator may then be fitted on to the chaincase inner with the coil

connections facing outwards. Replace the shake proof washers and the nuts on the studs and

six

tighten gently. Insert

25.4mm [l") wide. Check whether the s&ips are free in position.

not free, gently tap stator [at the opposite end) to centralise the same such that become free. Tighten the stator nuts and ensure the strips move freely. Gently crank engine. recheck the strips are free. Repeat this process at 3 or 4 places and then withdraw the strips.

strips [preferably non magnetic material) O.15rnrn

is

located concentricaUy on the end of the drive shaft.

(0.006")

If

one or more of the strips are

thick and

all

the strips

16.

the engine because it acts as a non-return valve between the crank case and outside atmosphere. causing a partial vacuum in the crankcase and rocker boxes which prevents the passage of oil into the cylinder. If the breather is not

instead of partial vacuum, giving rise to smoking or oiling of the plug.

17.

the engine from the frame.

Function

The efficient operation of the breather is of paramount importance to the performance of

Gear

The gears, ratchet mechanism etc, of the gear box can also be serviced without dismantling

Please refer page

Box

of

Breather

acting efficiently it may cause pressure in the crankcase

33

for dismantling the gear box.

SERVICE OPERATIONS

ENGINE

l.

Removal of

k

Disconnect alternator leads, off petrol tap and disconnect the fuel pipe. cable.

the engine steady bolt,

engine on a suitable box or wood block,

L.Remove the kont engine plates and the small bolt fixing the stand spring bracket and fixes rear mudguared, the engine.

2.

Remove the primary chaincase outer, clutch assembly, stator and rotor, engine sprocket and clutch sprocket. Remove the clutch centre and chain case inner.

Remove four

3.

Drain

case bottom. Having removed the engine

gear, etc.,

E.

Removal of the Gearbox

Dismantling the Crankcase

the oil

REMOVED

the

Remove the

M.

Remove the stud securing the rear engine plate to the frame,

3/8"

nuts and the gearbox

tank

by removing the feed and return flter assembly plugs located

as

described

Engine

air

filter assy.,

H.

Remove the rear chain,

kom the frame dismantle the cylinder head, barrel, piston, timing

in

the chapter "Decarbonising".

FROM

from

the Frame

B.

F.

FIPAlME

Disconnect the spark plug cap. Suppressor cap

D.

Remove carburettor

Remove the exhaust pipe and Silencer,

I.

Remove the footrest

K.

Remove the centre stand and the stand stop.

can

then be withdrawn from the engine.

assy.

along with throttle

G.

Disconnect

&.H.),

J.

Support the

N.

in

the crank-

C.

Turn

Slide out

Remove the nuts on the driving side of the engine crankcase.

Remove six studs passing through the crankcase by undoing nuts. The two halves of the crankcase can then be separated.

The driving side outer race of bearings

The

driving side bearing inner race and the inner distance piece

shaft. (Crank shaft]

The flywheel assembly may be removed from the driving side of the crankcase.

4.

Removal

1.

Clean the crank case thoroughly as any trace of oil

discolour the bearing race while heating the crank case.

2.

Heat the crankcase in

circumferential gets heated up fairly, tap the crankcase on a wooden block [with gently so that it

3.

Remove the circlip from the driving side crankcase and reheat to remove the ball bearing.

and

Reassembly of

area

of the bearing boss and not directly on the bearing race. When the crankcase

will

drop down due to the expansion of the bearing boss.

main

an

oven or apply the naked flame of a blow lamp on the

remain

bearings

kom four fixed studs at the rear of the

in

the driving side half of the crankcase.

will

remain on the engine

92

in

the crankcase

bearing

race facing downwards)

will

burn and