Royal Enfield Classic 350 Service Manual Page 104
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- Table of contents
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✰ Remove Duplex chain along with
Sprag clutch and Clutch assembly.
✰ Remove Engine sprocket and sprag
clutch gear assembly.
✰ Fix Special tool No. ST - 25594-4
Clutch Spring Compressing Tool and
tighten the 2 long bolts fully so as
to hold the springs down loosen &
remove the other 4 bolts.
✰ Remove sprag clutch bearing.
NOTE :
Flange wide faces of the sprag
clutch bearing must face outwards.
DISMANTLING OF CLUTCH
ASSEMBLY
✰ Remove 2 hex bolts at opposite
locations
✰ Remove the special tool holding both
evenly to release the spring tension.
NOTE :
Loosen bolts in opposite direction simul-
taneously 5 threads each.
FLANGE FACE
Engine Dismantling, Inspection & Assembly
- Service Manual 1
- INTRODUCTION 2
- Foreword 3
- Contents 4
- Management System 7
- TOTAL VOLUME : 9
- COMPRESSION RATIO : 9
- HORSE POWER (HP OR PS) : 9
- TORQUE : 10
- CONVERSION : 10
- IGNITION TIMING : 11
- IDLING SPEED : 11
- FINAL DRIVE RATIO : 11
- Technical Specifications 12
- ENGINE NUMBER - DETAILS 15
- UNDER TANK AND SEAT TOP VIEW 21
- UNDER TANK LH VIEW 21
- UNDER TANK RH VIEW 21
- General Vehicle Information 22
- SERVICE DATA 25
- THREE 03 25
- WEAR LIMITS 26
- O.D. I.D 35
- Periodical Maintenance 36
- Auto Chain Tensioner 44
- SLOT POSITION 46
- Engine Lubrication System 55
- Lubrication System 56
- WHAT IS HYDRAULIC TAPPET : 58
- BENEFIT OF HYDRAULIC TAPPET : 58
- CUT SECTION 58
- VIEW OF RHVL 58
- WORKING PRINCIPLE : 59
- PRECAUTIONARY MEASURES : 59
- Auto Decompressor 60
- WORKING PRINCIPLE 61
- Auto Chain Tensioner Assembly 62
- Engine Breather System 63
- Crankcase RH - Coverside View 65
- Crankcase LH - Inside View 67
- CRANK CASE LH 68
- Crankcase RH - Inside View 69
- CRANK CASE RH - INSIDE VIEW 70
- Engine Cover RH 71
- Crankcase LH - Coverside View 73
- Engine Cover LH 75
- Gear Train Assembly 77
- Gear Shifting / Kick Starter 79
- CRANK SHAFT ASSY 81
- PISTON ASSY 81
- Damper Pad Position Details 83
- ENGINE DISMANTLING 84
- INSPECTION & ASSEMBLY 84
- DISMANTLING PROCEDURE 86
- REMOVAL OF THROTTLE CABLE 87
- REMOVAL OF THROTTLE BODY 87
- CLUTCH CABLE REMOVAL 87
- BATTERY REMOVAL 88
- REMOVAL OF SILENCER AND 88
- EXHAUST PIPE 88
- REMOVAL OF E-START MOTOR 89
- REMOVAL OF DRIVE CHAIN 90
- REMOVAL OF SIDE STAND 90
- REMOVAL OF REAR BRAKE SWITCH 90
- CYLINDER HEAD ASSEMBLY 91
- ENGINE OIL DRAIN 91
- Magnetic Drain Bolt 91
- REMOVAL OF VALVES 92
- CYLINDER BARREL SUB ASSY 93
- REMOVAL OF COVER RH SUB 94
- ASSEMBLY : 94
- ING FROM CRANKCASE RH 97
- DISMANTLING PROCEDURE OF 98
- DISMANTLING COVER LH 102
- SUB ASSEMBLY : 102
- COMPONENTS FOR DISMANTL 103
- ING FROM CRANKCASE LH 103
- FLANGE FACE 104
- DISMANTLING OF CLUTCH 104
- ASSEMBLY 104
- LAYSHAFT SUB ASSEMBLY 112
- DISMANTLING OF LAYSHAFT SUB 112
- MAIN SHAFT SUB ASSEMBLY 113
- DISMANTLING OF MAINSHAFT SUB 113
- REMOVAL OF KICK STARTER SUB 115
- VITAL PARTS 116
- II. GEARS / SPROCKETS 116
- UNIDIRECTIONAL FITTINGS LIST 117
- TORQUE SPECIFICATION - ENGINE 118
- ASSEMBLY OF ENGINE BEARINGS 120
- CRANKCASE LH 120
- ENGINE ASSEMBLY 120
- CRANKCASE RH 121
- EX. RHVL 122
- INLET RHVL 122
- ASSEMBLING OF KICK STARTER 123
- SUB ASSEMBLY 123
- DRAIN BOLT 123
- TRIP PLATE 124
- ASSEMBLING OF GEAR ROCKER 125
- SHAFT SUB ASSEMBLY 125
- ASSEMBLING OF LAYSHAFT SUB 126
- ASSEMBLING OF MAINSHAFT SUB 127
- 3RD GEAR POSITION 129
- NOTE :NOTE : 131
- CUT PORTION 132
- SPRAG CLUTCH ASSEMBLY 134
- ASSEMBLY OF CLUTCH 135
- ASSEMBLING PROCEDURE OF 140
- AUTO DECOMPRESSOR 140
- ASSEMBLY PROCEDURE OF CAM 141
- VALVE TIMING 141
- OUTSIDE OIL SEAL 142
- INSIDE OIL SEAL 142
- PISTON SUB ASSEMBLY 145
- CLEANING 145
- INSPECTION 145
- EX IN 146
- VALVE SEAT INSPECTION : 150
- VALVE LEAKAGE TEST 151
- ENGINE MANGEMENT 154
- THE BENEFITS OF EMS ARE : 155
- Function of Components in EMS 156
- LEVEL 1 VISUAL 164
- LEVEL 2 TEST PIN 164
- LEVEL 3 DOL 165
- Trouble Shooting (EMS) 167
- CV CARBURETOR 169
- SEVEN 07 169
- CV Carburetor - Exploded View 170
- Functions of Carburetor 171
- TORQUE SPECIFICATION 173
- MIXTURE SCREW 174
- INSTALLATION OF CARBURETOR 175
- CARBURETOR TUNING 176
- PROCEDURE 176
- Carburetor Maintenance 177
- CHASSIS 179
- WHEELS & BRAKES 179
- EIGHT 08 179
- Front Wheel Removal 182
- Chassis, Wheels & Brakes 183
- SUSPENSION & STEERING 199
- 3 FORK STROKE LENGTH : 130 MM 200
- Suspension & Steering 201
- REMOVAL AND ASSEMBLY OF 205
- REAR SHOCK ABSORBER 205
- RECHARGING OF SHOCK 205
- ABSORBERS 205
- SWING ARM 205
- ELECTRICALS 209
- ELECTRICAL SYMBOLS 210
- Electricals 211
- MEASURING INSTRUMENT 215
- STARTER COIL 215
- PULSAR COIL 215
- IGNITION COIL 215
- Resistance 4 to 5 ohms 216
- E- STARTER MOTOR 217
- IC FLASHER 217
- ELECTRICAL PARTS 218
- DO’S AND DON’TS 218
- TROUBLE SHOOTING 222
- ELEVEN 11 222
- Trouble Shooting 223
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