Royal Enfield CONSTELLATION 1958, Workshop Maintenance Manual

Page 1: ...WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield CONSTELLATION 1958 on SUPER METEOR 1956 on MAN11 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: ...GEARBOX AND CLUTCH S METEOR 1961 CONSTELLATION SECTION E7 GEARBOX AND CLUTCH 1958 60 CONSTELLATION SECTION F3 T T CARBURETTER SECTION F4 MONOBLOC CARBURETTER SECTION G1d SR2 MAGNETO SECTION G1f K2F MAGNETO SECTION G2j GENERATOR RECTIFIER CHARGING SET SECTION G2j DISTRIBUTOR CHARGING SECTION G4a BATTERY SECTION G5d HEAD AND TAIL LAMPS SECTION H5 FRAME SECTION J1 FRONT FORK SECTION K6 FRONT WHEEL DU...

Page 3: ...SECTIONAL VIEW OF TYPICAL TWIN CYLINDER ENGINE EARLY TYPE 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: ...r 3743 3740 in Tappet Guide Internal Diameter 3755 3745 in Tappet Guide External Diameter 1 0125 1 0130 in Tappet Guide Hole in Crankcase Dia 1 011 1 010 in Tappet Clearance with cold engine Inlet Nil Exhaust Nil Valve Spring Free Length Inner 2 1 32 early 1 1 2 in late Outer 2 3 32 early 1 11 16 in late Renew when reduced by 3 16 in early or 1 16 in late Valve Timing with 012 in clearance Exhaust...

Page 5: ...1959 CONSTELLATION 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: ...er 3743 3740 in Tappet Guide Internal Diameter 3755 3745 in Tappet Guide External Diameter 1 0125 1 0130 in Tappet Guide Hole in Crankcase Dia 1 011 1 010 in Tappet Clearance with cold engine Inlet Nil Exhaust Nil For continuous high speed running set Exhaust tappet to 005 in clearance Valve Spring Free Length Inner 1 1 2 in Outer 1 11 16 in Renew when reduced by 1 16 in Valve Timing with 012 in c...

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Page 8: ...e 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 bearings are of alloy direct to the crankshaft The detachable bearing caps are bolted to the connecting rods by means of high tensile socket screws secured by cotter pins 6 Crankcase The combined crankcase and oil tank is die cast from light alloy in two ...

Page 9: ...n 15 Air Filter The air filter is a Vokes Micro Vee felt and gauze dry filter 5 in diameter and housed in a compartment of the toolbox 16 Lubrication System Lubrication is by the Royal Enfield Dry Sump system which is entirely automatic and positive in action The oil tank is integral with the crankcase ensuring the full rate of circulation immediately the engine is started and rapid heating of the...

Page 10: ...the engine as it acts as a non return valve between the crankcase and the outside atmosphere causing a partial vacuum in the crankcase and rocker boxes which prevents the passage of oil into the cylinders and consequent smoking and oiling of the plugs The breather is located on the driving side of the crankcase and consists of a small housing attached to the crankcase by three screws and having a ...

Page 11: ...drawn into the housing below the disc from the oil tank The ports in the housing are connected as follows W delivery to oil tank Y suction from crankcase X delivery to oil tank Z suction from timing chest Position 2 The plunger A is being pushed into the cylinder hole in the disc C The port T in the disc now registers with the delivery port X in the housing so that oil is forced out of the cylinde...

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Page 14: ...udgeon 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 bearings consist of white metalled steel liners which are renewable The detachable bearing caps are bolted to the connecting rods by means of high tensile socket screws secured by cotter pins 6 Crankcase The combined crankcase and oil tank are die cast from ...

Page 15: ...curing the front camshaft sprocket provides a drive to a tachometer if this is required This drive can be fixed to an aperture provided in the timing cover which is otherwise covered by a small plate 13 Ignition and Lighting System See Section G The ignition is supplied from a Lucas K2F magneto and the lighting and other electrical circuits from a 6 volt battery which is charged through a rectifie...

Page 16: ... passes The exhaust cam tunnel however has no holes but is kept full of oil to ensure adequate lubrication of the exhaust cams and prevent wear The oil level is maintained to a height in the groove in the tappet guide where a hole is drilled into the timing chest through which surplus oil from the exhaust rockers passes Both pumps are double acting one side of the feed pump supplying the big ends ...

Page 17: ... Third Gear 6 04 Top Gear 4 44 19 Clutch The clutch has five pressure plates and four friction plates including the sprocket which is lined on both sides with friction material The other friction plates have all Klingerite inserts on early models Later models employ a different friction material on the friction plate which is first in order of assembly to the following two plates These have a fric...

Page 18: ...rawn into the housing below the disc from the oil tank The ports in the housing are connected as follows W delivery to oil tank Y suction from crankcase X delivery to oil tank Z suction from timing chest Position 2 The plunger A is being pushed into the cylinder hole in the disc C The port T in the disc now registers with the delivery port X in the housing so that oil is forced out of the cylinder...

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Page 20: ...s 23 and 24 Remember that all three timing sprocket fixing bolts have Left Hand Threads While tightening the camshaft bolts the sprockets should be held The correct valve timing at 012 in clearance is as follows Exhaust opens 75 before bottom dead centre Exhaust closes 35 after top dead centre Inlet opens 30 before top dead centre Inlet closes 60 after bottom dead centre 3 Tappet Adjustment The ta...

Page 21: ...Section C4 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 22: ...ked through the inspection cover in the primary chain case and should it require adjustment access to the adjuster is gained by removing the chain case cover which is held in position by a single nut Before removing the nut place a tray under the engine to catch the oil from the chaincase Beneath the bottom run of the chain is a curved slipper on which the chain rests and which may be raised or lo...

Page 23: ... clipped at the rear to a rubber sleeve surrounding the top tube To remove the tank unscrew one front attachment nut tap out the stud and after disconnecting the petrol feed pipe the rear of the tank can be pulled upwards to release the clip and then lifted clear of the frame 10 Removal of Cylinder Head First remove the petrol tank and petrol pipe Subsection 9 The dual seat may also be removed if ...

Page 24: ...f 9 16 in internal diameter to prevent damage to the bore of the guide If a valve guide is removed for any reason an oversize one should be fitted in order to maintain the interference It is necessary to re cut the valve seat and grind in the valve after a guide has been replaced See Subsection 18 A worn exhaust valve guide may give rise to slight smoking from the exhaust pipe due to oil passing d...

Page 25: ...m aluminium alloy Scrape away all carbon from the valve heads and beneath the head being very careful not to cause any damage to the valve faces If the piston rings are removed the grooves should be cleaned out and new rings fitted For cleaning the grooves a piece of discarded ring thrust into a wooden handle and filed to a chisel point is a useful tool If the piston ring gaps exceed 1 16 in when ...

Page 26: ...ods down their tunnels on to the tappet heads shallow cups upwards Fit the copper cylinder head gaskets and see that the dowels are in position Replace the cylinder heads as described in Subsection 10 After the engine has been assembled run it for a brief period at a speed which will ensure that the ignition has been advanced by the automatic advance device If it is run too slowly blueing of the e...

Page 27: ...gneto sprocket Subsection 4 Lift the magneto chain off the cam sprocket Loosen the chain tensioner locknut and stud Lift the adjusting plate clear of the chain tensioner spindle Remove the chain tensioner spindle and sprocket Lift the chain off the sprockets 23 Removal of Pump Worm and Timing Sprocket Remove the timing chains Subsection 22 Unscrew the oil pump worm by means of the hexagon head beh...

Page 28: ... would make the engine very stiff to turn over and would damage the washer and allow leakage from the crankcase 32 Oil Pipe Unions The oil feed to the rocker gear is through pipes from unions at the back of the crankcase below the cylinder base to unions on the cylinder heads The unions are fitted with steel wire thread inserts to prevent the threads in the aluminium from stripping The method of f...

Page 29: ...ernative and more satisfactory method of assembling the alternator requires the use of Special Tool No T2055 This is a gauge 015 in greater in radius than the rotor and fits over the adaptor on the end of the crankshaft in the rotor s place The stator is then put in position on the stud in the chaincase and the nuts tightened up Remove the gauge and fit the rotor then check the air gap 35 Removal ...

Page 30: ... of the Timing Cover First place a tray under the engine to catch the oil which will escape when the cover is removed Remove the timing side exhaust pipe Remove the oil filler neck by taking out the three screws fixing it to the crankcase Remove the timing cover fixing screws Draw off the timing cover tapping it lightly if necessary In refitting the cover insert the two long screws through the cov...

Page 31: ...nt at the tightest spot Re tighten the locknut on the adjusting screw replace the chain cover and replenish with oil 6 Timing Chain Adjustment Before adjusting the tension of the timing chain turn the engine until the chain is in its tightest position checking the chain between all sprockets Adjust the tension so that there is 1 4 in movement of the chain The tension of the timing chain is altered...

Page 32: ...rackets later models Disconnect the oil pipes and plug leads Remove the exhaust pipes and carburettor s and induction manifold Remove the rocker box covers Turn the engine until both valves are closed Remove the five cylinder head nuts from each head and lift off In replacing the heads see that the dowels are in position in the cylinder barrels and that the push rods are the right way up shallow c...

Page 33: ... dead centre It is advisable to put a clean cloth over the mouth of the crankcase to prevent anything such as a piece of broken piston ring from falling in When replacing the cylinders clean off the joint faces and fit new paper joints two to each cylinder 16 Removal of Pistons Remove the cylinder heads and cylinders With a tang of a file remove the two outer circlips retaining the gudgeon pins Re...

Page 34: ...in circlip into the crankcase A clean cloth should be put over the mouths of the crankcase to prevent this 17 Decarbonising Having removed the cylinder heads as described in Subsection 10 scrape away all carbon bearing in mind that you are dealing with aluminium which is easily damaged Scrape gently and avoid scoring the combustion chamber or the valve seats which are of austenitic iron shrunk int...

Page 35: ...escribed in Subsection 10 After the engine has been assembled run it for a brief period at a speed which will ensure that the ignition has been advanced by the automatic advance device If it is run too slowly blueing of the exhaust pipes may take place After the engine has been run for some time and has become thoroughly hot go over all the cylinder head and other nuts to ensure that they are tigh...

Page 36: ...he magneto and chain Subsection 25 Loosen the chain tensioner locknut and stud Lift the adjusting plate clear of the chain tensioner spindle Remove the chain tensioner spindle and sprocket Lift the chain off the sprockets 23 Removal of Pump Worm and Timing Sprocket Remove the timing chains Subsection 22 Unscrew the oil pump worm by means of the hexagon head behind it This is a Left Hand Thread Wit...

Page 37: ...ep the compound away from the discs and seatings Where fitted the breather which operates through the end of the crankshaft may be inspected by removing the slotted plug from the head of the rotor retaining bolt See Fig 8 29 Removal of the Clutch Remove the engine sprocket and clutch sprocket together as described in Subsection 26 To remove the clutch hub hold the clutch with Special Tool No E 487...

Page 38: ... by a nut and tab washer on earlier models The radial air gap between the rotor and the poles of the stator should be 020 in in all positions and care must be taken when refitting to see that it is not less than 010 in at any point Fit the rotor first making sure that it is located concentrically on the end of the crankshaft Attention must be given to the seating of the key because a badly fitting...

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Page 40: ...x can now be withdrawn from the back of the crankcase after unscrewing the four nuts which secure it 3 Dismantling the Crankcase Drain the oil tank by removing the drain plug Having removed the engine from the frame as described in Subsection 1 dismantle the heads barrels pistons timing gear magneto etc as described in Section C Remove the gearbox as described in Subsection 2 Remove the two hexago...

Page 41: ...nnecting rod for a cotter pin head and this side must face outwards when the connecting rod is assembled on the crankshaft to avoid fouling between the cotter and the crankshaft web If it is necessary to replace the big ends a service crankshaft can be supplied with connecting rods fitted 6 Re assembly of the Crankcase Fit the outer roller race in the timing side crankcase the ball bearing in the ...

Page 42: ...il passage through the big ends is sealed by two screwed aluminium plugs locked by centre punching If the crankshaft is taken out of the engine for any reason the plugs should be removed and the oil passage cleared of sludge 8 Pump Worm Threads If the threads in the crankshaft into which the pump worm screws become damaged a steel wire insert can be fitted The crankshaft should preferably be retur...

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Page 44: ...l 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 T...

Page 45: ...Section E4 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 46: ...ints 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 shaft nut The ...

Page 47: ...te inserts the clutch control may require adjustment after the first few hundred miles with a new machine This point should therefore be examined soon after delivery and adjustment made if necessary 8 Adjustment of the Neutral Finder The neutral finder is adjusted by means of an eccentric stop secured to the front of the gearbox cover by a bolt which limits the travel of the operating pedal Slacke...

Page 48: ...ver on the handlebar Between the operating lever and the torque arm are four 1 4 in diameter steel balls in recesses so that when the levers are rotated relatively to each other the balls are forced out of the recesses forcing the levers apart and thus compressing the clutch springs 2 Description of the Gearbox The operation of the gearbox is shown diagrammatically in Fig 3 The clutch sprocket A i...

Page 49: ...ed pen steel washer between the bearing and the felt washer Later gearboxes use a neoprene seal with a flat washer The second dished pen steel washer if fitted has a smaller central hole and is on the other side of the mainshaft bearing and is nipped between the inner face of the bearing and the shoulder on the final drive sleeve However this is ommited from later gearboxes See that both of the di...

Page 50: ...e from the mainshaft and layshaft then passes through pinions M and K to the splines on the mainshaft sleeve and the pinion J is free on the sleeve Fig 3D Third Gear The sliding pinions have moved further over so that the dogs Q on the layshaft engage with the pinion N which drives the pinion L and thus the mainshaft sleeve the pinion M being free on the layshaft Fig 3E Top Gear The sliding pinion...

Page 51: ...arter pinion and the kickstarter shaft The joint between the gearbox and the inner cover should be made with gold size shellac or a similar jointing compound Make sure that all parts are clean before commencing assembly In normal climates the recesses in the gearbox should be packed with soft grease and the box should be filled up to the correct level with engine oil See Subsection 11 On no accoun...

Page 52: ...Section E7 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 53: ...it anti clockwise will take up the clearance Lock up the locknut and check that there is still clearance in the operating mechanism This can conveniently be done by means of a screwdriver in the slot in the end of the pressure plate withdrawing pin Surplus slack in the control cable can now be taken up by means of a mid cable adjuster which should be adjusted so that there is about 1 16 in free mo...

Page 54: ...the jet holder If you look up into the bottom of the mixing chamber when the jet holder has been removed the jet choke tube will be seen This is slotted to facilitate its removal which should not be necessary however neither should it be necessary to remove the choke adaptor but if it is removed take note of the washer beneath it Take note also of the two washers one above and the other below the ...

Page 55: ...Section F3 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 56: ... you to make your own device Compensation and Air Control The main jet does not spray directly into the choke bore of the mixing chamber It first passes through the needle jet and is there partially atomised by a blast of primary air which can be seen at the base of the main choke The richness of the mixture as it passes through the primary choke can be handlebar regulated by the air control at th...

Page 57: ...xture will be obtainable from tick over to full throttle mixture and anti clockwise to enrich it Adjust this very gradually until a satisfactory tick over is obtained but take care that the achievement of too slow a tick over that is slower than is actually necessary does not lead to a spot which may cause stalling when the throttle is very slightly open iii Throttle Cut away Having set the pilot ...

Page 58: ...ich 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 the upper end of the needle j...

Page 59: ...f 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 a very restricted air clea...

Page 60: ...Section F4 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 61: ...esent 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 clearing th...

Page 62: ...1 1 16 180 106 4 3 1 2 25 Continental GT 1965 on 389 217 1 1 8 270 106 3 3 1 2 25 350 Bullet 1955 late 1958 350 Clipper 1958 1962 Works Replica 1958 1961 376 29 1 180 106 3 3 1 2 25 350 Bullet 1959 1962 376 215 1 1 16 190 106 3 4 30 350 Bullet 1963 on 376 297 1 1 16 180 106 3 3 1 2 25 500 Bullet 1956 1958 389 9 1 1 8 200 106 2 3 1 2 30 500 Bullet 1959 1961 389 34 1 3 16 220 250 if no air filter 10...

Page 63: ...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 64: ... magneto rotor to occur relative to the drive The mechanism consists of two members flexibly coupled by pivoted spring loaded governor weights and toggles At low engine speeds and during starting the weights are closed and a delayed spark is produced As the engine speed increases the governor weights swing out and advance the rotor and thus the cam and the spark relative to the drive 2 Routine Mai...

Page 65: ...le but cut it off flush to the required length Remove the moulded cover slacken the cable retaining screw and pull out the old cable Push the new cable fully home and secure by tightening the screw The pointed end of this will pierce the insulation make contact with the cable core and lock the cable in place After fitting a high tension cable a continuity test should be made between the cover elec...

Page 66: ...connect the remote cut out switch and crank the engine If the engine now starts renew the connecting cable or switch Incorrect timing Check the magneto to engine timing See Section C4 ENGINE MISFIRES Defective fuel supply Inspect the carburetter petrol supply etc Sparking plugs need cleaning and Remove plugs from engine Clean off soot or adjusting carbon and check plug points for correct gap width...

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Page 68: ... the contact breaker arm spring The contact breaker arm may then be lifted from its pivot Wipe away any dirt or grease from the contact with a petrol moistened cloth If necessary use a very fine carborundum stone to polish the contact re cleaning afterwards with a petrol moistened cloth Smear the pivot pin with a little Mobilgrease No 2 before refitting the contact breaker arm Remove the cam ring ...

Page 69: ... be renewed if it becomes frayed otherwise moisture may enter the contact breaker housing To do this slip back the rubber shroud and by means of the hexagon at the base unscrew the control barrel If the cable and the plunger to which it is attached are now pulled upwards the cable nipple can be disengaged from the plunger slot Soften the solder and remove the nipple Thread the new length of cable ...

Page 70: ...rrent The rectifier requires no maintenance apart from an occasional check to see that the connections are clean and tight The nuts that clamp the rectifier plates together must never under any circumstances be slackened as the clamping pressure has been carefully adjusted during manufacture to obtain the correct performance characteristics A separate nut is used for securing the unit to the machi...

Page 71: ... parallel 2 Maintenance a Check wiring occasionally to see that all connections are clean and tight b Check tightness of rectifier securing nut LIGHTING SWITCH AT HEAD INTERNAL CONNECTIONS OF ALTERNATOR CIRCUIT DIAGRAMS FOR POSITIONS OF LIGHTING SWITCH Fig 3 WIRING DIAGRAM Fig 4 Section G2h 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 72: ...coils insulated from the laminations 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 t...

Page 73: ... is correctly fitted c fitting the stator so that the leads enter it at the top at the back of the stator and d timing the contact breaker correctly i e so that the points are just about open when the pistons are 1 32 in before T D C After starting on the EMG position the switch should be returned to the IGN position EMERGENCY STARTING CIRCUIT Fig 4 5 Direct Operation Short journeys without the ba...

Page 74: ...must be free from grease or oil If they are burnt or blackened clean with fine carborundum stone or very fine emery cloth afterwards wiping away any trace of dirt or metal dust with a clean petrol moistened cloth Cleaning of the contacts is made easier if the lever carrying the moving contact is removed Contact Breaker Setting The contact breaker setting should be checked after the first 500 miles...

Page 75: ...nd them back radially Screw the terminal into the pick up moulding To connect the cable to ignition coil model MA6 pass the cable through the rubber grommet push the metal clip into the end of the cable which should be cut off square insert the cable and clip into the socket in the end of the coil and slide the grommet into place to exclude water 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...

Page 76: ...ience 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 that indicated...

Page 77: ...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 Section G4a Page 2 w...

Page 78: ...termine the spread and pattern of the light beams In the event of damage to either the lens or the 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 Light Unit assembly Withdraw the adaptor from the Light Unit by twisting it in an anti clockwise direction and pulling it off Remove...

Page 79: ...att 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 excessive heat affecting the plas...

Page 80: ...Section H5 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 81: ...t pin See Section C paragraph 8 The procedure for all models is then as follows Remove the top pivot pin nut drive out the pivot pin then hinge the suspension unit back on the lower pivot pin After removing the lower nut the unit may be pushed off the pivot pin welded to the fork end 4 Servicing Rear Suspension Units The proprietary units fitted are sealed and servicing of the internal mechanism c...

Page 82: ...DUAL SEAT MUDGUARD ASSEMBLY 1961 ONWARDS Fig 3 Section H5 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 83: ...for the steering head as experience has shown that the provision of nipples at this point causes trouble through chafing and cutting of control and lighting cables If the steering head bearings are well packed they will last for several years or many thousands of miles Recommended greases are Castrolease Heavy Mobilgrease No 4 Esso Grease Energrease C I or Shell Retinax A 9 Dismantling the Rear Mu...

Page 84: ...etween 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 tub...

Page 85: ...troke 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 bottom spr...

Page 86: ...the 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 beari...

Page 87: ...oil 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 ...

Page 88: ...e 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 respective brake drums 3 Removal of Brake Shoes and Springs This is best done by unscrewing the pivot pin locknuts 28715 and the operating lever nuts 10314 after which the assembly o...

Page 89: ... necessary for the bearings to be a tight fit in the barrel but this fit must not be so tight as to close down the outer race of the bearing 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 b...

Page 90: ...e 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 after which the brake will continue to function as a fixed cam brake with some loss of efficiency This can be restored by removing the shoes and fitting them in the opposite positions Floating cam brakes are self centering and there is n...

Page 91: ... recommended pressure for the front tyre is 18lb per square inch for wheel loads up to 240lb 17 Lubrication No grease nipple is provided on later hubs due to the tendency to over grease resulting in grease finding its way past the felt seal on to the brake linings The correct method of lubrication is to pack the bearings with grease after dismantling the hub as described above Note that the brake ...

Page 92: ... the chain or brake The wheel incorporates the well known Enfield cush drive and also a 7in internal expanding brake 2 Removal and Replacement of Main Portion of Wheel for Tyre Repairs etc Place the machine on the centre stand if necessary putting packing pieces beneath the legs of the stand to lift the wheel clear of the ground Unscrew the loose section of the spindle and withdraw this together w...

Page 93: ...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 Make sure also that the speedometer drive gearbox is correctly positioned so that there is no sudden bend in the driving cable When replacing the connecting link in the driving chain make sure that the closed end of the spring link points in the direc...

Page 94: ...e drum cush drive shell assembly as described above To remove the bearing from the sprocket brake drum first remove the brake cover plate complete with brake shoe assembly then remove the distance collar and unscrew the bearing retaining ring with peg spanner Now screw the loose section of the spindle into the fixed section and drive out the bearing by hitting the hexagon headed end of the loose s...

Page 95: ...am housing correctly tightened wear on both linings should be approximately equal 13 Final Reassembly of Hub Before Replacing Wheel Before replacing the felt washers which form the grease seals pack all 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 o...

Page 96: ... 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 18 Tyre Pressures The recommended pressures for the rear tyre are 20 lb per sq in for a solo rider and 32 lb per sq in when a pillion passenger is carried 19 Lubrication Grease the bearings by packing them with grease after dismantling...

Page 97: ...Section M6 Page 1 SECTION M6 Special Tools 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: ...Section M6 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 99: ...Section M6 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 100: ...Section M6 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 101: ...Section M6 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 102: ...ng 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 Removal of the Front Wheel and F...

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Page 105: ...in 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 red and the bl...

Page 106: ...OTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE 01564 783 192 FAX 01564 783 313 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 ...