Royal Enfield 350 BULLET 1949, Workshop Maintenance Manual

Page 1: ...ROYAL ENFIELD WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield 350 BULLET 1949 55 500 BULLET 1953 55 MAN 8 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: ...AL MONOBLOC CARBURETTER SECTION G1c LUCAS MAGDYNO SECTION G2b LUCAS DYNAMO MODEL E3LM SECTION G3a CONTROL BOX SECTION G4a BATTERY MODEL PUZ7E SECTION G5a HEAD AND TAIL LAMPS SECTION H1 FRAME SECTION J1 FRONT FORK WITH CASQUETTE SECTION J3 FRONT FORK WITH FACIA PANEL 500 BULLET 1953 SECTION J4 FRONT FORK WITH FACIA PANEL 350 BULLET 1950 53 SECTION K1 FRONT WHEEL DUAL BRAKE SECTION K2 FRONT WHEEL SI...

Page 3: ...ROYAL ENFIELD WORKSHOP MANUAL 350 BULLET 1951 350 BULLET 1955 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 4: ...2500 2490 in Length 328 327 in Graded rollers are available in steps of 0001 from 2490 to 2500 in Rocker Bearing Inside Diameter 626 625 in Rocker Spindle Diameter 6240 6235 in Inlet Valve Stem Diameter 3430 3425 in Exhaust Valve Stem Diameter 3410 3405 in Valve Guide Internal Diameter 3447 3437 in Valve Guide External Diameter 6275 6270 in Guide Hole in Cylinder Head 622 623 in Tappet Stem Diamet...

Page 5: ...ROYAL ENFIELD WORKSHOP MANUAL 500 BULLET 1953 500 BULLET 1955 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 6: ...in long Diameter 2500 2490 in Length 328 327 in Rocker Bearing Inside Diameter 626 625 in Rocker Spindle Diameter 6240 6235 in Inlet Valve Stem Diameter 3430 3425 in Exhaust Valve Stem Diameter 3410 3405 in Valve Guide Internal Diameter 3447 3437 in Valve Guide External Diameter 6275 6270 in Guide Hole in Cylinder Head 626 625 in Tappet Stem Diameter 375 374 in Tappet Guide Internal Diameter 3760 ...

Page 7: ...ROYAL ENFIELD WORKSHOP MANUAL 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 8: ...uminium RR56 light alloy The little end bearing is of alloy direct on to the gudgeon pin In case of wear after long service the little end can be bored out and fitted with a bush but this is rarely necessary The big end has a hardened chrome steel bush pressed in and a floating bush made from mild steel and whitemetalled 6 Crankcase The combined crankcase and oil tank are die cast from light alloy...

Page 9: ...to the oil tank 13 Ignition and Lighting System The lighting and ignition are supplied from a Lucas Magdyno which consists of a magneto running at 1 2 engine speed and a dynamo running at 1 1 2 engine speed 14 Carburetter See Sections F1 and F2 350 c c Engine Amal Type 276CX lA Amal Type 376 29 Monobloc 500 c c Engine Amal Type 289T lA 15 Air Filter The air supply to the carburettor is cleaned by ...

Page 10: ...ed and become clogged the oil pressure will lift the spring and cap off its Seating thereby automatically by passing the filter so that the big end will not be deprived of lubrication even though the oil may be dirty 17 Breather The efficient operation of the breather is of paramount importance to the performance of the engine because it acts as a non return valve between the crankcase and the out...

Page 11: ...he housing is uncovered by the disc and oil is drawn into the housing below the disc from the oil tank RETURN PUMP RETURN PUMP POSITION 1 POSITION 2 The ports in the housing are connected as follows X delivery to rocker gear Y suction from crankcase Position 1 The plunger A is being drawn out of the cylinder hole in the disc C The port T in the disc registers with the suction port Y in the housing...

Page 12: ...Yinthe housingandoilisdrawnintothehousingbelow thediscfromthetank RETURNPUMP RETURNPUMP POSITION1 POSITION2 Theportsarcconnectedasfollows X inthehousingisthedeliverytotherockergear Y inthehousingisthesuctionfromthecrankcase SandV aredrilledthroughthedisc TandU aredrilledfromtheundersideofthediscintothecylinderhole Position1 TheplungerA isbeingdrawnout ofthecylinderholeinthediscCbytheactionof thepe...

Page 13: ...ROYAL ENFIELD WORKSHOP MANUAL 350 500 BULLET SCRAMBLES 1954 350 BULLET TRIALS 1951 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 14: ... cams are integral with the cam pinions and the position for correct timing is marked on the pinions by small dots Rotate the engine to top dead centre and put the exhaust or right hand cam pinion in position so that the pair of dots on it are opposite the pair of dots on the timing pinion on the crankshaft Put the inlet or left hand cam pinion in position so that the single dot on it is opposite ...

Page 15: ...g on the contact breaker until the paper can just be pulled out Give the pinion a sharp tap to secure it on the shaft and then lock it by tightening the nut 5 Removal of the Petrol Tank Turn off the petrol tap Disconnect the petrol pipe Remove the two bolts which secure the tank to the frame at the front and rear and it can then be lifted clear 6 Removal of the Cylinder Head Remove the petrol tank...

Page 16: ...al of the Valve Guides To remove the valve guides from the head two special tools are required which can easily be made The first is a piece of tube with an internal bore of not less than 7 8 in The second is a mandrel about 4 in long made from 9 16 in diameter bar with the end turned down to 11 32 in diameter for 1 2 in Support the cylinder head on the tube which fits over the collar of the valve...

Page 17: ...ng with a little grinding in compound place a light short coil spring over the valve stem and beneath the head insert the valve into its appropriate guide press it on to the seat using a tool with a suction cup and with a backwards and forwards rotary motion grind it on to its seat Alternatively use a tool which grips the valve stem and pulls the valve on to its seat Frequently lift the valve and ...

Page 18: ...he timing cover if the springs are correct In the case of the 500 c c engine see that the steel end pads are in position on the outer ends of the springs The pump spindle should be renewed if excessive wear has taken place on the teeth Re assemble the oil pumps replacing the paper cover gaskets if necessary Before fitting each cover fill the pump chamber with clean oil Having assembled the pumps l...

Page 19: ...that the discs are seating properly When re assembling the breather apply jointing compound very sparingly to the back of the steel plate taking great care to keep it away from the discs or their seatings 350cc Engine Unscrew the body of the breather and examine the disc If it is faulty a new breather unit should be fitted as the disc cannot readily be taken out of the body 23 Removal of the Clutc...

Page 20: ...shaft is dismantled for any reason it is always advisable to fit a new spring to the relief valve in case the original one has become weak If the valve is set to give too high a pressure the pump disc will be forced off its seating 26 Removal of the Magdyno Remove the magdyno pinion See Subsection 18 Unscrew the nut on the fixing strap bolt and swing the strap clear The magdyno can then be withdra...

Page 21: ...ROYAL ENFIELD WORKSHOP MANUAL 500 BULLET RACER 1954 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 22: ...r roller race will remain in the driving side half of the crankcase The driving side inner roller race and the inner distance piece will remain on the engine shaft The flywheel assembly may be difficult to remove from the driving side of the crankcase owing to the shaft being a tight fit in the inner race of the ball bearings This is particularly likely in the earlier engines with two ball bearing...

Page 23: ...w grub screw must be fitted Mount the crankshaft between centres and true up to 0005 in on either side of the shafts If the readings for the two shafts are high on opposite sides the error can be corrected by gently tapping either or both of the flywheels If the readings are high on the same side of the two shafts it is probably due to dirt or foreign matter in the joints and the crankshaft should...

Page 24: ...n Subsection 4 Fit the inner distance piece and the rollers and cage in the driving side crankcase Lay the thrust washer on the bearing Assemble the flywheel into the bearing if necessary using the sprocket nut with suitable packing piece to draw the driving shaft through the inner race s of the ball bearing s Make sure that the crankcase face is clean and apply jointing compound to it Put the thr...

Page 25: ...ROYAL ENFIELD WORKSHOP MANUAL 350 BULLET 1949 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 26: ... inspection cover and disconnect the clutch cable Remove four screws and the gearbox outer cover can then be detached Remove the gear change mechanism by taking off the two nuts securing it Remove the main shaft bearing cover which is attached by two screws Remove four cheese headed screws and hexagon bolt Remove the spring box locating plunger nut and washer Remove the main shaft nut Left Hand Th...

Page 27: ...ROYAL ENFIELD WORKSHOP MANUAL Section E1 Page 2 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 28: ...e following points should be noted If the main shaft top gear pinion and dog have been removed make sure that the dog is replaced the right way round or third and top gears can be engaged simultaneously Make sure that the trunnions on the operator fork engage with the slots in the inside operator See that the main shaft is pushed right home It may tighten in the felt washer inside the final drive ...

Page 29: ...ping bolt in the horizontal lever and turning the lever on its spindle which is the end of the operating worm in the gearbox cover When correctly adjusted the lever should be approximately square with the cable when the clutch is fully lifted The position of the lever endwise on the worm spindle is important and it should be positioned so that it does not foul the kickstart lever 8 Adjustment of t...

Page 30: ...mber and where also the air supply to the pilot jet system is separate The type numbers of these carburetters are 74 75 76 and 89 These tuning instructions apply to both the above designs TWO DESIGNS AMAL NEEDLE TYPE CARBURETTER MODEL YEAR CARB NUMBER CHOKE DIAMETER MAIN JET NEEDLE JET N EED LE P OSIT ION THROTTLE VALVE PILOT 350 BULLET 1948 55 276CX 1A 1 140 106 3 4 0 037 350 BULLET 1956 58 376 2...

Page 31: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 2 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 32: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 3 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 33: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 4 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 34: ...means 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 surround...

Page 35: ...t require 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 o...

Page 36: ...ROYAL ENFIELD WORKSHOP MANUAL Section F2 Page 3 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 37: ...less dirt 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 ...

Page 38: ...d in the contact breaker casting see Fig 2 To reach the wick remove the backing spring and spring arm by withdrawing the single securing screw The wick is carried in a hollow hexagon headed screw which can now be withdrawn Take care not to lose the insulating washer or tube Moisten the wick with a few drops of thin machine oil and refit the hollow screw At this stage bend back the brass locking ta...

Page 39: ...loth Should the brush be worn to within 1 8 in of the shoulder it must be renewed Whilst the pick up moulding is removed clean the slip ring track and flanges by holding a soft dry cloth against them with a suitably shaped piece of wood while the engine is slowly turned The high tension cable must be kept clean and dry 2 d Renewing High Tension Cable If on inspection the high tension cable shows s...

Page 40: ...able and if necessary renew it as described above in Subsection 2 d iii Very occasionally the fault may be due to a cracked or punctured pick up moulding This type of fault is not easily detected by inspection and a check should be made by substitution iv If the Magdyno has recently been replaced or removed it may be incorrectly timed see Section C2 Subsection 4 v Check the contact breaker for cle...

Page 41: ...ROYAL ENFIELD WORKSHOP MANUAL Section G1c Page 4 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 42: ...th H M P grease which will last until the machine is taken down for a general overhaul when the bearings should be repacked 2 b Inspection of Commutator and Brush Gear About once every six months remove the cover band for inspection of commutator and brushes see Subsection 4 a vi 3 Test Data Cutting in speed Dynamo Cold 1 050 1 200 r p m at 7 volts Output test 8 5 amps at 1 850 2 000 r p m at 7 vo...

Page 43: ...s 16 20 oz and new springs must be fitted if the tension is low If the commutator is blackened or dirty clean it by holding a petrol moistened cloth against it while the engine is turned slowly by means of the kick start with sparking plug s removed Re test the dynamo as in v above If there is still no reading on the voltmeter there is an internal fault and the complete unit should be replaced if ...

Page 44: ...th a very sharp tool Do not remove more metal than is necessary Polish the commutator with very fine glass paper Undercut the insulation between the segment to a depth of 1 32 in with a hacksaw blade ground down until it is only lightly thicker than the insulation see Fig 3 4 d Field Coil Measure the resistance of the held winding by means of an ohm meter It this is not available connect a 6 volt ...

Page 45: ...e operation described in Subsection 4 b bearing in mind the following points i The field coil lead fitted with the short length of yellow tubing must be connected together with the eyelet of the earthed brush to the commutator end bracket by means of the screw provided ii The second field coil lead must be connected to terminal F on the moulded cap see Fig 6 iii The unearthed brush flexible lead m...

Page 46: ...ing point on the machine If a voltmeter reading is given the circuit from the battery to terminal A is in order If there is no voltmeter reading examine the wiring between the battery and the control box for defective cables or loose connections Re connect the cable to terminal A Check that the dynamo terminal D is connected to control box terminal D and that the cable is in good condition Similar...

Page 47: ... washer N B A dynamo run at high speed on open circuit will build up a high voltage Therefore when adjusting the regulator do not run the engine up to more than half throttle or a false setting will be made d Checking the electrical setting of the cutout If the regulator is correctly set but the battery is still not being charged the cut out may be out of adjustment Replace the control box in the ...

Page 48: ...ture 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 temperature must be...

Page 49: ...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 5 amp Secti...

Page 50: ...reflector and lenses are permanently protected thus the unit keeps its high efficiency over a long period A prefocus bulb is used the filaments of which are accurately positioned with respect to the reflector thus no focusing device is necessary The bulb has a large cap and a flange which has been accurately positioned with relation to the bulb filaments during manufacture A slot in the flange eng...

Page 51: ...88 Access to the parking bulb in the case of lamps with separate shells is obtained by removing the light unit as described in Subsection 2 In the case of lamps in which the parking bulb shows through a hole in the main reflector the bulb holder assembly should be removed This will come away bringing with it the parking bulb which will then be readily accessible In the case of lamps having the und...

Page 52: ...352 6volt 3 18 watt or Lucas No 384 6volt 6 18 watt The 3 watt or 6 watt filament provides the normal tail light while the 18 watt filament is illuminated on movement of the brake pedal 6 watt bulbs are now required by law in Great Britain on machines of more than 250 c c capacity Care must be taken that the leads to the stop tail lamp are correctly connected as the use of the 18 watt filament on ...

Page 53: ...ROYAL ENFIELD WORKSHOP MANUAL 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 54: ...ROYAL ENFIELD WORKSHOP MANUAL SECTION H1 FRAME EXPLODED VIEW OF LATE 1954 1955 350 BULLET AND 500 BULLET FRAME Section H1 Page 1 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 55: ... knocking them out with a hammer and drift and new races can be fitted either under a press or by means of a hammer and a wooden drift 3 Removal of Rear Suspension Unit The rear suspension units are readily removed by undoing the top pivot pin nut driving out the pivot pin then hinging the suspension unit back on the lower pivot pin removing the lower nut and pushing the suspension unit off the pi...

Page 56: ...g to prevent it closing in then grip the oil seal in a vice pass a bar through the eye in the top casting and pull and twist to withdraw the hollow metal plug from the end of the main tube Take care not to damage the new seal when fitting it After reassembling remove the oil filler and level plugs and fill with one of the following oil until it runs out through the level plug orifice Castrolite Va...

Page 57: ...l the bottom bearing tube with oil of one of the grades given below Remove the oil filler screw from the top casting replace the spring and carefully insert the plunger head into the bottom bearing tube pushing it down slowly so as to spill as little oil as possible and allow time for oil to enter the damper chamber and pass up the inside of the top bearing tube Tighten down the top bearing and oi...

Page 58: ... six inches above the ground but if the alignment is checked also towards the top of the wheels it will be possible to ascertain whether or not the frame is twisted so as to cause one wheel to be leaning while the other is vertical To do this it is always necessary to remove the mudguards and unless a straight edge cut away in its centre portion is available it will be necessary also to remove the...

Page 59: ...ROYAL ENFIELD WORKSHOP MANUAL 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 60: ... between the spring stud and the bore of the valve port forming a hydraulic damping system A compression spring is fitted inside the main tube between the upper end of the spring stud and the upper end of the main tube The lower end of the main tube and upper end of the bottom tube are protected by a cover secured to the fork crown A special fork is available for sidecar machines This has bottom t...

Page 61: ... the bump stroke the larger diameter taper on the oil control collar 38075 enters the main counterbore of the valve port thus forming a hydraulic cushion to prevent metal to metal contact 3 Dismantling the Fork to Replace Spring Oil Seal or Bearing Bushes Place the machine on the centre stand disconnect the front brake control and remove the front wheel and mudguard complete with stays Unscrew the...

Page 62: ... stud project beneath the end of the bottom tube Now fit the nut and washer and pull the stud into position by tightening the nut If necessary fit the nut first without the washer until sufficient thread is projecting to enable the washer to be fitted 6 Steering Head Races The steering head bearing consists of two deep groove thrust races each containing nineteen 1 4 in diameter balls The bearing ...

Page 63: ... which forms the hydraulic damping medium All that is necessary is to keep sufficient oil in the fork to ensure that the top end of the bottom spring stud is never uncovered even in the full rebound position The level of oil in the fork can be gauged by removing the top plug screw and inserting a long rod about 3 8 in diameter If slightly tilted this will ledge against the nut at the upper end of ...

Page 64: ...the spring stud and the bore of the valve port forming a hydraulic damping system A compression spring is fitted inside the main tube between the upper end of the spring stud and the upper end of the main tube The main tube and upper end of the bottom tube are protected by a one piece cover secured to the fork crown and carrying a pressed steel lamp bracket welded to it A special version of the fo...

Page 65: ...tling the Fork to Replace Spring Oil Seal or Bearing Bushes Place the machine on the centre stand disconnect the front brake control and remove the front wheel and mudguard complete with stays Unscrew the bottom spring stud nut 38080 which will allow oil to run out of the fork down to the level of the cross hole in the spring stud Now knock the spring stud upwards into the fork with a soft mallet ...

Page 66: ... main tube is bottoming in the recess in the fork head in which it fits In this case the nuts on the fork crown clamp stud must be loosened and the sleeves separated see paragraph 7 thus permitting the main tubes to slide through the fork crown Do not forget to tighten the fork head pinch bolts and the nuts on the fork crown clamp studs after adjusting the steering head Before tightening the latte...

Page 67: ... the three fork head clip bolts make sure that the bolt heads and the sleeves are correctly positioned with the cut away portion engaging the main tube or steering stem Failure to do this may result in a cracked fork head When refitting the oil seal or fitting a new one great care must be exercised not to damage the synthetic rubber lip which forms the actual seal If the seal has been removed from...

Page 68: ...bearings A special version of the fork is available for sidecar use This has a modified fork head and fork crown setting the main tubes 1 1 2 in further forward thus giving less trail and providing lighter steering when used with a sidecar These sidecar forks also are fitted with a On early models the fork end was made of aluminium alloy screwed on to the bottom tube steering damper and have stron...

Page 69: ...ROYAL ENFIELD WORKSHOP MANUAL Section J4 Page 2 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 70: ...omparatively thin portion in front of the speedometer After removal of the fork head the lamp bracket tubes can be lifted straight off and the springs can be withdrawn from the upper end of the main tubes after unscrewing the oil level plug and the nut which secures the spring stud to the fork end and knocking the spring stud upwards 6 Removal of Main Tubes To remove the main tubes first dismantle...

Page 71: ...ROYAL ENFIELD WORKSHOP MANUAL 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 72: ...re that the machine stands securely on the rear wheel and centre stand if necessary place a weight on the saddle or a strut beneath the fork to ensure this 2 Removal of Brake Cover Plate Assemblies Lock the brake on by pressure on the operating lever 38905 R H or 38906 L H and unscrew the cover plate nuts 31347 The right and left hand cover plate assemblies can then be withdrawn from the respectiv...

Page 73: ... i d by 1 9 16 in o d by 7 16 in wide The Skefko Part No is RLS5 Equivalent bearings of other makes are Hoffmann LS7 Ransome and Manes LJ5 8 in Fischer LS7 7 Fitting Limits for Bearings The fit of the bearings in the hub barrel is important The bearings are locked on the spindle between shoulders and the distance pieces 30538 which in turn are held up by the cover plate nuts 31347 In order to prev...

Page 74: ...s while at the same time they can be and should be left free enough to be capable of being moved by hand in the direction of the slots The pins 252 are secured by locknuts 7916 which are centre punched as an additional precaution The leading shoes i e those towards the rear of the machine have a servo action which render them more effective than the trailing shoes This servo action causes the lini...

Page 75: ...lls of the tyre After inflation make sure that the tyre is fitting evenly all the way round the rim A line moulded on the wall of the tyre indicates whether or not the tyre is correctly fitted If the tyre has a white mark indicating a balance point this should be fitted near the valve 16 Tyre Pressure The recommended pressure for the front tyre is 181b per square inch for wheel loads up to 240 lb ...

Page 76: ...ake drum 3 Removal of Brake Shoes and Springs This is best done by unscrewing the pivot pin locknuts and the operating lever nuts after which the assembly of brake shoes return springs pivot pin and operating cam can be removed from the cover plate by light blows with a hammer and drift on the ends of the pivot pin and the operating cam The return springs can then be unhooked from the spring posts...

Page 77: ...and thus overload the balls The following are the manufacturing tolerances which control the fit of the bearings The figures for the bearings themselves are for SKF bearings but other manufacturers tolerances are similar Bearing o d 1 5622 1 5617 in Housing bore 1 5620 1 5616in Bearing bore 6252 6247 in Shaft diameter 6252 6248 in 8 Refitting Ball Bearings Note that the two ends of the spindle are...

Page 78: ...ng shoe By leaving the housing free to float the cam can follow up the leading shoe thus maintaining equal pressure between the cam and the two shoes and so making full use of the more efficient leading shoe Owing to the servo action the wear on the leading shoe with a floating cam housing is greater than that of the trailing shoe and in time the limit of float of the cam housing will be reached a...

Page 79: ...he large flange cross from the left to the right of the centre line With the Palmer rim the spokes from the large flange on the brake drum side go to the more steeply angled holes in the rim which must be on the left of the centre line when the brake drum is on the left i e none of the spokes crosses from left to right of the centre line 15 Tyres Standard tyres on the 250 Clipper and Model S are D...

Page 80: ...est way to grease the bearings is by packing 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 requir...

Page 81: ...ROYAL ENFIELD WORKSHOP MANUAL 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 82: ...ehind it may now be removed to prevent risk of them falling out when manipulating the tyre If however these are too tight a fit in the hub to come out easily they may be left in place The main body of the wheel can now be pulled across to the right hand side of the machine thus disengaging it from the fixed section of the hub barrel and the cush drive shell and enabling the wheel to be lifted out ...

Page 83: ...ment will however be maintained if both cams are moved the same number of notches 3 Removal and Replacement of Complete Wheel for Access to Brake Place the machine on the centre stand and remove the dual seat if fitted and detachable portion of the rear mudguard as if for removal of the main portion of the wheel only Disconnect the rear driving chain at the spring link and remove the chain from th...

Page 84: ...wn from its housing 7 Cush Drive The sprocket brake drum 39301 is free to rotate on the hub barrel Three radial vanes are formed on the back of the brake drum and three similar vanes are formed on the cush drive shell 39302 Six rubber blocks are fitted between the vanes on the brake drum and those on the cush drive shell thus permitting only a small amount of angular movement of the sprocket brake...

Page 85: ...the manufacturing tolerances which control the fit of the bearings The figures for the bearings themselves are for SKF bearings but other manufacturers tolerances are similar Bearing o d 1 8122 1 8117 in Housing bore 1 8115 1 8110in Bearing bore 6252 6247 in Shaft diameter Loose side 624 622 in Shaft diameter Fixed side 6252 6248 in 11 Refitting Ball Bearings In order to prevent the possibility of...

Page 86: ...e free from oil or grease damp etc Replace the felt washers distance collars the brake cover plate assembly speedometer drive gearbox distance collars 39315 and 39323 chain adjuster cams the loose section of the spindle and the spindle nut 36651 The wheel is then ready for reassembly into the machine 15 Wheel Rim The wheel rim is type WM2 19 in plunged and pierced with forty holes for spoke nipple...

Page 87: ...lt seals on to the brake linings this greasing point is of little value and the best way to grease the bearings is by packing 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 e...

Page 88: ...lace machine on the centre stand if necessary putting packing pieces beneath the legs of the stand to lift the wheel clear of the ground Remove the dual seat if fitted and the detachable portion of the rear mudguard Disconnect the rear driving chain at the spring link and remove the chain from the rear wheel sprocket leaving it in position on the gearbox countershaft sprocket Unscrew the rear brak...

Page 89: ...ets 5 Removal of Hub Spindle and Bearings To remove the hub spindle 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...

Page 90: ...agraph 3 dealing with the 6 in brake The method is precisely the same for the 7 in brake except that owing to the different type of return springs used it is in this case possible to remove the shoes from the pivot pin and operating cam before the latter are removed from the cover plate 10 Cush Drive The sprocket brake drum is free to rotate on the hub barrel Three radial vanes are formed on the b...

Page 91: ... approximately equal 13 Final Reassembly of Hub before replacing Wheel Before replacing the felt washers which form the grease seals pack both bearings with grease Recommended greases are Castrolease Heavy Mobilgrease No 4 Esso Grease Energrease C3 or Shell Retinax A These are all medium heavy lime soap or aluminium soap greases The use of H M P greases which have a soda soap base is not recommend...

Page 92: ...s are Dunlop 3 50 19 in Universal tread except on the 350 Bullet where a 3 25 19 in Universal tyre is used When removing the tyre always start close to the valve and 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 in...

Page 93: ... 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 grease nipple in its place and grease the ca...

Page 94: ...ntre Extractor 2 SECTION D2 3 E5121 Crankshaft Extractor 4 4 E4816 Roller Race Assembly Timing Side 3 4 E4817 Bearing Assembly Driving Side 3 5 E6462 Locating Plate for Assembly of Cam Spindles 4 6 E2775 Crankshaft Pot or Jig 350 Bullet 4 6 E2774 Crankshaft Pot or Jig 500 Bullet 4 SECTION H1 5 E5431 Frame Expander 5 SECTION I 3 E4912 Gland Nut Grips 5 3 E5418 Lockring Spanner 5 SECTION J3 3 E4912 ...

Page 95: ...ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 2 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 96: ...ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 3 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 97: ...ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 4 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 98: ...ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 5 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 99: ...ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 6 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 100: ...ROYAL ENFIELD WORKSHOP MANUAL NOTES 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 101: ...ROYAL ENFIELD WORKSHOP MANUAL NOTES 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 102: ...FIELD AMAL HITCHCOCK S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE 01564 783 192 E MAIL info 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 ...