Royal Enfield 250 CLIPPER, Workshop Maintenance Manual

Page 1: ...TINENTAL GT Including AIRFLOW model where applicable SPARES for ROYAL ENFIELD AMAL HITCHCOCK S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE 01564 783 192 FAX 01564 783 313 E MAIL in fo hitchcocksmotorcycles com WEB hitchcocksmotorcycles com w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 2: ...ROYAL ENFIELD WORKSHOP MANUAL PAGE 2 250 CLIPPER CRUSADER w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 3: ...NGINE IN FRAME SECTION D6a SERVICE OPERATIONS ENGINE REMOVED SECTION E11 GEARBOX AND CLUTCH SECTION F4 CARBURETTER SECTION G2f LIGHTING IGNITION SYSTEM SECTION G4a BATTERY MODEL PUZ7E SECTION G4c BATTERY MODEL MLZ9E SECTION G5d HEAD AND TAIL LAMPS SECTION H6 FRAME SECTION J7 FRONT FORK SECTION J8 FRONT FORK SUPER 5 SECTION K4 FRONT WHEEL 6 BRAKE SECTION K5 FRONT WHEEL 7 BRAKE SECTION L6 REAR WHEEL...

Page 4: ...ROYAL ENFIELD WORKSHOP MANUAL PAGE 4 CONTINENTAL CRUSADER SPORTS w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 5: ... with alloy top collars 1 11 16 Renew piston rings when gap exceeds 1 16 Renew when reduced by 1 8 Clearance in grooves Compression ring 0 005 0 003 Valve timing with 0 015 clearance Scraper ring 0 004 0 002 250 Clipper and Crusader Piston boss internal diameter 0 7501 0 7499 Exhaust opens 80 degrees before B D C Gudgeon pin diameter 0 7501 0 7499 Exhaust closes 30 degrees after T D C Con rod smal...

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Page 7: ...length Radial thickness 0 1215 0 1135 Inner with alloy top collars 1 1 2 Gap when in unworn cylinder 0 011 0 015 Outer with alloy top collars 1 11 16 Renew piston rings when gap exceeds 1 16 Renew when reduced by 1 8 Clearance in grooves Compression ring 0 005 0 003 Valve timing with 0 015 clearance Scraper ring 0 004 0 002 Piston boss internal diameter 0 7501 0 7499 Exhaust opens 57 degrees befor...

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Page 9: ...ted Compression ratios Earlier Models 250 Clipper 7 5 to 1 Crusader 250 8 to 1 Crusader Sports 8 5 to 1 Later Models 250 Clipper Crusader 250 Crusader Sports and 250 Trials 8 75 to 1 Super 5 9 75 to 1 1963 Models 250 Clipper Crusader Sports Super 5 Continental GT and 250 Trials 9 to 1 350 Bullet 7 5 to 1 5 Connecting Rod The connecting rod is produced from a stamping of Hiduminium RR 56 light allo...

Page 10: ...r and Crusader 250 are produced with silencing ramps to ensure silent running The camshaft employed on the Crusader Sports Super 5 Continental GT 350 Bullet and 250 Trials differs from that fitted to the 250 Clipper and Crusader 250 models in having a greater rate of lift and different opening and closing points There are no silencing ramps on these models 10 Valves The inlet valves are machined f...

Page 11: ...dels On all models adjustment is made by means of adjusting screws at the top of the push rods after removing the cylinder head cover 12 Timing Drive The camshaft is located in the camshaft housing which is cast in with the driving side crankcase and runs in oil retaining compo bushes It is chain driven at half engine speed from the timing sprocket on the crankshaft and the tightness of the chain ...

Page 12: ... sucks the oil from the crankcase through a third pipe in the chaincase and delivers it through a fourth pipe to a drilled passage in the top of the crankcase near the filter From there most of the oil passes through a second valve back to the oil tank but the back pressure caused by this valve forces some of the oil in the drilled passage through an external pipe connected to a union on the top o...

Page 13: ...ort Q in the disc C registers with the suction port W in the housing so that oil is drawn into the cylinder from the crankcase sump Position 2 The plunger A is being pushed into the cylinder hole in the disc C The port P in the disc now registers with the delivery port Z in the housing so that oil is forced out of the cylinder to the filter and thence to the big end Position 2 The plunger A is bei...

Page 14: ...a sprocket mounted on splines on the crankshaft to the clutch sprocket which is incorporated in the clutch itself and is mounted on the gearbox mainshaft The correct tension of the chain is maintained by an adjustable slipper with a chilled cast iron bearing surface accessible when the chaincase cover is removed An inspection cover is provided in the chaincase so that the chain tension can be chec...

Page 15: ... and after disconnecting SECTION C18 Service Operations with Engine in of Frame the petrol feed pipe the rear of the tank can be pulled upwards to release the clip and then lifted clear of the frame 5 Removal of the Dual Seat and Rear Mudguard The rear mudguard mudguard carrier and dual seat are removable in one unit after merely slackening off the two nuts on the rear suspension top fixing bracke...

Page 16: ...ther pinions the marks will only come opposite every 23 revolutions but this does not alter the timing once it is set For those who wish to check the valve timing the opening and closing points are given below 250 Clipper and Crusader 250 Exhaust opens 80 before B D C Exhaust closes 30 after T D C Inlet opens 50 before T D C Inlet closes 60 after B D C Crusader Sports Super 5 250 Trials 250 Contin...

Page 17: ... plate and setting the contact opening by means of a gauge If the contacts are worn or pitted refer to Section G The timing is adjusted by slackening the two screws holding the contact breaker plate to the crankcase and rotating the plate relative to the crankcase To set the ignition timing put the gearbox in top gear and turn the engine by means of the back wheel until the piston is 1 64 in befor...

Page 18: ...hat the faces are quite clean Then apply a thin coating of compound to each side of the gasket It is advisable to fit a new gasket each time the head is removed Place the head on the cylinder barrel and replace the five washers and nuts not forgetting the single Allen screw in the earlier alloy head and the two Allen screws in the later one Tighten down diagonally from one side to the other to pre...

Page 19: ... Removal of the Cylinder Barrel Remove the cylinder head see Subsection 13 Lift the barrel off the piston taking care that any pieces of broken ring do not drop into the crankcase Before replacing the cylinder barrel clean off the joint faces and fit a new paper washer 18 Removal of the Piston Remove the cylinder head and cylinder barrel see Subsections 13 and 17 With the tang of a file remove the...

Page 20: ...s is not employed The inlet valve face and seat can be cut at 45 in case of expediency but this may have a deleterious effect on the performance of the engine 21 Re assembly after Decarbonising Before building up the engine see that all parts are scrupulously clean and place them conveniently to hand on a clean sheet of brown paper It is advisable to fit a new gasket to the cylinder head and a new...

Page 21: ...ns as to the grade of oil to be used are given in detail in the Instruction Book 24 Removal of the Timing Chain and Sprockets Take off the primary chaincase as described in Subsection 1 and remove the timing chain tensioner slipper Remove the crankshaft sprocket nut and washer Withdraw the camshaft sprocket from the tapered camshaft using Special Tool No E 4870 The timing sprocket on the end of th...

Page 22: ... jointing compound sparingly The cam housing cover can be removed without dismantling the oil pump but the pump must be dismantled before replacing the cam housing cover in order to fit the pump plungers over the peg on the pump spindle correctly 27 Removal of the Contact Breaker Access to the contact breaker for adjustment can be obtained by removing the small circular cover at the front of the g...

Page 23: ... may occur All Models Rocker Feed Relief Valve The rocker relief valve can be seen if the oil filler cap on the top of the crankcase at the offside of the engine is removed It consists of a 3 16 in steel ball spring and plug screwed into the crankcase casting The correct pressure is obtained with the plug screwed right home If the valve is dismantled the ball can be removed by means of a small mag...

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Page 25: ...se Press the crankshaft assembly out of the near side half case by means of a hand press or by using Special Tool No E 6960 3 Main Bearings The main bearings consist of a roller bearing on the off generator side and a ball bearing on the near driving side The 350 Bullet has in addition a plain bearing situated between the ball bearing and the driving sprocket Should the bearing require attention o...

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Page 29: ...the crankshaft oil seal and the contact breaker spindle oil seal pressing them in flush with the casing Be sure that the seals are fitted the right way round i e with the open side towards the flywheel Lay the nearside half crankcase flat on two blocks or on a block with a hole in it and press the crankshaft into it with a hand press having first put the distance piece on to the shaft chamfer side...

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Page 31: ... pressure springs 350 c c Model This clutch employs six driven plates which comprise the clutch centre back plate four plain plates and the clutch cover plate There are five driving plates including the clutch sprocket each with friction material bonded to their surfaces Three pressure springs are used 2 Descripion of the Gearbox The gearbox itself is cast as part of the crankcase but forms a sepa...

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Page 35: ... main shaft and immediately in front of the kickstart spindle Turn the slotted adjusting screw until it begins to tighten up then slacken it back one complete turn This will ensure that the clutch operating lever inside the cover is in its best working position Screw out the clutch cable adjusting sleeve on the top of the crankcase until there is not less than 1 16 in free movement of the clutch c...

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Page 38: ...ight way round and in the right order as follows see Fig 6 Replace the clutch centre on the taper not forgetting the key Tighten the centre nut and bend up the tab of the tab washer Then replace the clutch sprocket and circlip making sure that the latter is right home in the groove The above applies to all three types of clutch From here proceed as follows for plate assembly Early 250 Models Plain...

Page 39: ...e mechanism Slide off the selector mechanism using two screwdrivers Remove two Allen screws H Fig 5 and take off the main shaft end cap together with the clutch operating lever This is not necessary if the clutch is removed Remove the main shaft nut LEFT HAND THREAD and the oil thrower Note that the recess in the oil thrower faces outwards This is not necessary if the clutch is removed Remove two ...

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Page 41: ...of this screw and a stop which holds the throttle open a very small amount The throttle slide is cut away at the back and the shape of this cut away controls the mixture at throttle openings slightly wider than that required for slow running There is a compensating system to prevent undue enriching of the mixture with increasing engine speed this system consisting of a primary choke surrounding th...

Page 42: ...ire changing of any parts of the carburetter Assuming that the carburetter has the standard setting to suit the particular type of engine any small adjustments occasioned by atmospheric conditions changes in quality of fuel etc can usually be covered by adjustment of the pilot air screw and raising or lowering the taper needle one notch If however the machine is used at very high altitudes or with...

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Page 44: ...irt is present or of course the float is punctured If it is necessary to remove the jet block note that this is withdrawn from the upper end of the mixing chamber after unscrewing the jet holder Be careful not to damage the jet block when re moving or refitting it Note that the large diameter of the jet block pulls down on to a thin washer A single strand of an inner control cable is useful for cl...

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Page 47: ...minations The rotor has a hexagonal steel core each face of which carries a permanent magnet keyed to a laminated pole tip The pole tips are riveted circumferentially to brass side plates the assembly being cast in aluminium and machined to give a smooth external finish The stator and rotor can be separated without the need to fit magnetic keepers to the rotor poles As the rotor turns rapid and re...

Page 48: ...od of the contact breaker so that no unwanted sparks can occur on the compression stroke of the engine Note that if the battery is removed the emergency start will not function unless the lead normally connected to the battery negative terminal is earthed The emergency start system functions better with a discharged battery than with a fully charged one Proper functioning of the emergency starting...

Page 49: ...nal screw and withdraw the rocker arm complete with contact and spring Before replacing the arm lightly smear the pivot with grease When refitting the contact breaker arm spring make sure that it is below the fibre washer i e between the fibre washer and the wiring tag from the condenser 2 c Contact Breaker Setting The contact breaker setting should be checked after the first 500 miles running and...

Page 50: ...ROYAL ENFIELD WORKSHOP MANUAL PAGE 50 WIRING DIAGRAM 1957 1961 MODELS WITH SCREW ON TERMINALS FOR SWITCHES G2F w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 51: ...MANUAL PAGE 51 WIRING DIAGRAM 1962 ON MODELS WITH PLUG ON SWITCH SOCKETS B BLACK P PURPLE Y YELLOW U BLUE G GREEN D DARK N BROWN S SLATE L LIGHT R RED W WHITE M MEDIUM G2F w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 53: ...the temperature For convenience in comparing specific gravities they are always corrected to 60 F which is adopted as a reference temperature The method of correction is as follows For every 5 F below 60 F deduct 002 from the observed reading to obtain the true specific gravity at 60 F For every 5 F above 60 F add 002 to the observed reading to obtain the true specific gravity at 60 F The temperat...

Page 54: ... recharging a low state of charge is to be expected Measure the specific gravity of the acid of each cell in turn with a hydrometer see Fig 3 The following table shows the state of charge at different values of specific gravities If the battery is discharged it must be recharged either on the motor cycle by a period of daytime running or from an external D C supply at the normal recharge rate of 1...

Page 55: ...re isolated from the venting chamber Internally the battery consists of three cell packs with separators formed from a dry inert micro porous material The use of this material means that a weaker filling acid can be used compared with the acid diluting wet wood separators formerly employed Guards are fitted across the cell packs to protect the top edges of the separators from damage by battery fil...

Page 56: ...stand for one hour Check the level and syphon off surplus acid from any cell where it has risen higher than the acid level line Thereafter keep the acid just level with the coloured line by topping up with distilled water A discharge can be taken from the battery one hour after it has been filled but if time permits it is advisable to first give the battery a four hour freshening charge at the nor...

Page 57: ...bulb contacts The outer surface of the lens is smooth to facilitate cleaning The inner surface is formed of a series of lenses which determine the spread and pattern of the light beams In the event of damage to either the lens or reflector a replacement light unit must be fitted 3 Replacing the Light Unit and Bulb Slacken the securing screw at the top of the headlamp rim Remove the front rim and L...

Page 58: ...Lucas No 384 6 volt 6 18 watt for larger capacity machines The 3 or 6 watt filament provides the normal tail light while the 18 watt filament is illuminated on movement of the brake pedal Care must be taken that the leads to the stop tail lamp are correctly connected as the use of the 18 watt filament on the normal tail light will not only discharge the battery but could cause trouble from excessi...

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Page 60: ... engage the front clip first and drop the assembly into position When tightening the nuts make sure that the heads of the bolts are right home in the recesses on the inside of the carrier attachment brackets 4 Removal of Rear Suspension Unit First remove the rear mudguard unit as des cribed above Undo the rear suspension top pivot pin nut and drive out the pivot pin Then hinging the suspension uni...

Page 61: ...housands of miles There are no grease nipples for the swinging arm pivot bearings when rubber bushes are fitted Recommended greases are Castrolease LM Mobilgrease MP Esso Multipurpose grease H Energrease L2 Shell Retinax A or Marfak Multipurpose 2 10 Removal of Petrol Tank The petrol tank is attached to the frame by a rubber mounted stud at the front and is clipped at the rear to a rubber sleeve s...

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Page 63: ...e fork is filled with a light oil S A E 20 to the level of a screw for lubrication Later Models Fork design and operation is basically as above and Fig 1 though the main tube is heavier and the spring is of smaller diameter The cap stud is integral with the guide tube and the spring stop plate is set further up the spring tube A Casquette is not employed on the Continental and GT model A different...

Page 64: ...rs will cause the steering to swing to full lock in either direction while at the same time there should be only the slightest trace of play in the bearings Do not forget to tighten the ball head clip screw and fork crown clamp bolts Before tightening the latter make sure that the cover tubes are located centrally round the main tubes so that the bottom tube does not rub inside the cover tube A pa...

Page 65: ... high strength aluminium alloy with an integral lug which carries the wheel spindle At the lower end of the main tube is a steel bush which is a close fit in the bore of the bottom tube The upper end of the bottom tube carries a bronze bush which is a close fit over the outside diameter of the main tube The bush is secured to the bottom tube by means of a threaded housing which contains an oil sea...

Page 66: ... stud and spring can now be withdrawn from the lower end of the main tube The steel main tube bush can now be tapped off the lower end of the tube if necessary using the bottom tube bush for this purpose Before doing this however it is advisable to mark the position of the bush with a pencil line so as to ensure reassembling it in the same position on the main tube The reason for this is that thes...

Page 67: ...pension unit to the link and swing the link downwards After removing the pins adjacent to the steering crown the suspension units may be withdrawn Should it be necessary to remove the link flatten the tab washer and remove the nut which also secures the lower mudguard bracket onto the inside of the foot The fulcrum pin may then be withdrawn When reassembling do not omit the thrust washers on eithe...

Page 68: ...moving the two bolts which screw into the steering crown and the large central nut from the steering head The leads to the lighting switch and ammeter should be disconnected from the battery rectifier tail lamp alternator and earth points at their lower ends or at the plug and socket connectors when these are provided If it is required to remove the lighting switch and ammeter these are push fits ...

Page 69: ...ecure the two centre rivets first so as to ensure that the linings lie flat against the shoe Standard linings are Ferodo AM2 which are drilled to receive cheese headed rivets A number of early Crusader 250 models were fitted with brake linings bonded to the shoes These should be returned for servicing when necessary 4 Removal of Brake Operating Cam To remove the operating cam unscrew the nut which...

Page 70: ...st excluder and the nuts on the spindle Tightening the nuts should not have any effect on the ease with which the spindle can be turned If tightening the nuts makes the spindle hard to turn this may be taken as proof that the bearings are bottoming in the recesses in the hub barrel before they are solid against the shoulders on the spindle In this case the bearing should be removed and a thin pack...

Page 71: ...the well in the rim When replacing the tyre fit the part by the valve last also with the edge of the cover at the other side of the wheel pushed down into the well A 2 75 21 in tyre is fitted to the 21 in wheel of the 250 Trials If the correct method of fitting and removal of the tyre is adopted it will be found that the covers can be manipulated quite easily with the small levers supplied in the ...

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Page 73: ... be withdrawn from the brake drum 3 Replacing Brake Linings Brake linings are supplied either in pairs ready drilled complete with rivets or ready fitted to service replacement brake shoes When riveting linings to shoes secure the two centre rivets first so as to ensure that the lining lies flat against the shoe Standard linings are Ferodo AM2 which are drilled to receive cheese headed rivets A nu...

Page 74: ...e that there is clearance between the inner faces of the outer bearing races and the bottom of the recesses fit the distance washers cover plate dust excluder and the nuts on the spindle Tightening the nuts should not have any effect on the ease with which the spindle can be turned If tightening the nuts makes the spindle hard to turn this may be taken as proof that the bearings are bottoming in t...

Page 75: ...t close to the valve see that the edge of the cover at the other side of the wheel is pushed down into the well in the rim When replacing the tyre fit the part by the valve last also with the edge of the cover at the other side of the wheel pushed down into the well If the correct method of fitting and removal of the tyre is adopted it will be found that the covers can be manipulated quite easily ...

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Page 77: ...on the left hand side of the machine adjacent to the rear mudguard lean the machine to the left until the wheel can be rolled out between the mudguard and the righthand fork end When replacing the main portion of the wheel reverse the foregoing procedure taking care when replacing the speedometer drive gearbox that the driving dogs inside the gearbox engage with the slots in the end of the hub bar...

Page 78: ...n both adjuster cams Once the position of the cams which gives correct alignment has been found this alignment will however be maintained if both cams are moved the same number of notches direction of travel of the chain Replace the chain adjuster cams in their original positions or if necessary turn each of them the same number of notches to tension the chain and maintain correct wheel alignment ...

Page 79: ...hen necessary 5 Removal of Brake Operating Cam To remove the operating cam unscrew the nut which secures the operating lever to the splines on the cam A sharp tap on the end of the cam spindle will now free the lever after which the cam can be withdrawn from its housing Do not try and remove the brake shoe pivot pin it is cast into the brake cover plate and cannot be removed 6 Cush Drive The sproc...

Page 80: ... the nuts from locking the operation of the cush drive Do not forget to bend up the tabs of the three locking washers When re assembling the cush drive coat the inside of the bore of the sprocket brake drum liberally with grease where it fits over the hub barrel 7 Removal of Ball Bearings To remove the ball bearings take the complete wheel out of the machine and separate the main portion of the wh...

Page 81: ...ster cams the loose section of the spindle and the spindle nut The wheel is then ready for re assembly into the machine 13 Wheel Rim The wheel rim is WM2 17 in plunged and pierced with forty holes for spoke nipples The spoke holes are symmetrical i e the rim can be assembled to the hub either way round The rim diameter after building is 17 06 in the tolerances on the circumference of the rim shoul...

Page 82: ... described above Note that the brake cam is drilled for a grease passage but the end of this is stopped up with a countersunk screw instead of being fitted with a grease nipple This is done to prevent excessive greasing by over enthusiastic owners If the cam is smeared with grease on assembly it should require no further attention but in case of necessity it is possible to remove the screw fit a g...

Page 83: ...he rear brake rod adjusting nut completely and depress the brake pedal so as to disengage the rod from the trunnion in the brake operating lever Unscrew the brake cover plate anchor nut and remove this together with the washer behind it Disconnect the speedometer driving cable loosen the spindle nut and the centre bolt and mark the chain adjuster cams to ensure replacing in the same position Slide...

Page 84: ...and bearings having already removed the brake cover plate assembly and speedometer drive gearbox lift out the felt washers and distance pieces then hit one end of the spindle with a copper hammer or mallet thus driving it out of the hub bringing one bearing with it and leaving the other in position in the hub Drive the bearing off the spindle and insert the latter once more in the hub at the end f...

Page 85: ... liberally painted with soapsuds to facilitate entry of the vanes When reassembling the cush drive coat the inside of the bore of the sprocket brake drum liberally with grease where it fits over the hub barrel and also put grease on the inner face of the lockring The three Simmonds nuts should be tightened down solid as there is a shoulder on the stud which prevents tightening of the nuts from loc...

Page 86: ... the maximum permissible run out both sideways and radially being plus or minus 1 32 in Fig 5 shows the lacing when using Dunlop rims The key to correct lacing is the inside spokes to the large flange on the cush drive shell which must slope in the direction shown in Fig 5 With the Dunlop rim this spoke goes to the middle hole of one of the groups of three see Subsection 14 and the rim must be bui...

Page 87: ...cking them with grease after dismantling the hub as described above Note that the brake cam is drilled for a grease passage but the end of this is stopped up with a countersunk screw instead of being fitted with a grease nipple This is done to prevent excessive greasing by over enthusiastic owners If the cam is smeared with grease on assembly it should require no further attention but in case of n...

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Page 89: ...Inlet Valve Seat Cutter Crusader 250 250 Clipper T1891 Inlet Valve Seat Cutter Crusader Sports Super 5 Continental GT 250 Trials 20 T2053 Inlet Valve Seat Arbor 24 E4870 Camshaft Sprocket Extractor 25 E6978 Pump Disc Lapping Tool SECTION D 2 E6960 Crankshaft Extractor 5 E6977 Crankshaft Assembly Tool SECTION E 5 E5414 Clutch Centre Extractor w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 92: ...arriers made from steel pressings prevent any dirt from the back wheel soiling the bags Each pannier carrier is attached at three points The forward end is clipped to the mudguard carrier tube with two clips Part No 42196 and two screws 42202 The screw heads are on the outside with a large washer 5965 under each head and a collar 23941 between the carrier and each end of the outer clip Use nuts 27...

Page 93: ...eter drive and after removing two nuts the spring washers and the bridge piece from the bottom of the speedometer it may be removed To remove the ammeter it is only necessary to take off the rubber band from the body of the ammeter after disconnecting the leads and press down the small metal tabs which will be found turned outwards The ammeter will then pull out from the top of the fairing 5 Remov...

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Page 95: ...ue and white main bulb wires from the dipper switch and one green and brown pilot lamp wire through the hole in the lamp body shell Fit the body shell rubber washer between the fairing and the lamp body shell rim and line up the holes in the shell rim the washer and the fairing aperture rim Secure with the four screws and locking plates keeping the threaded plate at the bottom Connect the blue and...

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