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ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 

 

WORKSHOP 

MAINTENANCE MANUAL

 

FOR THE 

ROYAL ENFIELD 

350 cc OHV G, 1945 - 1954 

G deluxe and 350 Clipper 

 1955 - 57 

and 500 cc OHV J and J2 

1945 – 1954 

MOTOR CYCLES

HITCHCOCK’S MOTORCYCLES 

ROSEMARY COURT 

OLDWICH LANE WEST 

CHADWICK END 

SOLIHULL 

B93 0EY      ENGLAND

 

Telephone 01564 783 192 

Fax 01564 783 313 

e-mail: 

[email protected]

 

Web: hitchcocksmotorcycles.com 

www.hitchcocksmotorcycles.com

Summary of Contents for 350 Clipper

Page 1: ...deluxe and 350 Clipper 1955 57 and 500 cc OHV J and J2 1945 1954 MOTOR CYCLES HITCHCOCK S MOTORCYCLES 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 ...

Page 2: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL 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 3: ...HAFT 11 15 ENGINE CRANKCASE 15 ENGINE LUBRICATION SYSTEM 16 18 GEARBOX 19 22 CLUTCH 22 23 CHAINS 23 CARBURETTER 25 28 MAGDYNO 29 32 DYNAMO type E3LM 33 36 CONTROL BOX model RB107 37 38 BATTERY model PUZ7E 39 40 HEAD AND TAIL LAMPS 41 43 FRONT FORK EARLY 45 47 FRONT FORK CASQUETTE 1955 1957 49 52 FRONT WHEEL 53 57 REAR WHEEL 58 63 SPRING FRAME 1955 1957 64 68 SPECIAL TOOLS 69 72 w w w h i t c h c o...

Page 4: ...ve spring when free length is reduced by 1 8 in Cam Bush inside diameter reamered after fitting 6255 in 6250 in Idler Pinion Bush inside diameter reamered after fitting 502 in 501 in Cam Spindle 6245 in 6235 in Idler Pinion Spindle 49925 in 49825 in TRANSMISSION Sprockets Engine 21 T 1 2 in P X 305 in W Clutch 42 T 1 2 in P X 305 in W Countershaft 18 T 5 8 in P X 380 in W Rear Wheel 46 T 5 8 in P ...

Page 5: ...haust closes 35 after t d c Inlet opens 30 before t d c Inlet closes 60 after b d c Valve Spring Free Length outer and inner 1 3 4 in Renew valve spring when free length is reduced by 1 8 in Cam Bush inside diameter reamered after fitting 6255 in 6250 in Idler Pinion Bush inside diameter reamered after fitting 502 in 501 in Cam Spindle 6245 in 6235 in Idler Pinion Spindle 49925 in 49825 in TRANSMI...

Page 6: ...ith 018 feeler 1 4272 Tyre Lever cranked type 2 4272A Tyre Levers spoon type 1 3482 Screwdriver 6 wire 1 14835 Extractor Nut Dynamo Pinion 1 16014 Grease Gun 1 16007 Tool Roll with strap less tools 4 25861 Hallite Washers for Push Rod Tubes No per Part Description Set No 1 29044 Double ended Spanner Engineers Patt 1 4 x 5 16 Whit 1 2976 3 8 x 7 16 Whit 1 24092 380 x 343 hex also 380 sq 2 24096 3 1...

Page 7: ...isconnect the exhaust lifter cable from the handlebar lever place the piston at the bottom of its stroke and lift the barrel off To remove the piston push out the gudgeon pin after removal of the wire retaining clips with a suitable tool such as the tang end of a small file and lift the piston off the rod Mark the piston so as to ensure reassembling the same way round 3 Removal of Valves To remove...

Page 8: ... if worn using a draw bolt as shown in Fig 4 both for withdrawing the old bush and fitting the new one After fitting the bush must be reamered the size to suit a new gudgeon pin being 7507 7505 in 8 Valves Springs and Guides Wear on the valve stems can be seen on examination and if a definite step has formed the valves should be renewed Test the valve guides for wear by trying the fit of a new val...

Page 9: ... for tightness after the engine has been run long enough to get it thoroughly warm TIMING GEAR 10 Valve Timing Access to the timing gear is obtained by removal of the timing cover after unscrewing the nine nuts securing it About half a pint of oil will run out of the timing case The cam wheels and magdyno drive idler pinions can now be pulled off their spindles having first turned the engine so th...

Page 10: ... of the valve stems and the rockers With a little experience however the correct tappet clearance can be obtained by feel the inlet push rod being just free while the exhaust has perceptible up and down clearance To make the adjustment see Fig 9 hold the push rod bottom end top hexagon and the locknut middle hexagon Unlock by turning the locknut to the left and make the adjustment by screwing the ...

Page 11: ...remove the stud securing the front of the crankcase to the bottom of the down tube of the frame and lift the engine out in a backwards direction Fig 12 shows the machine with the engine ready to lift out after removal of the front attachment stud 14 Dismantling the Crankcase To dismantle the engine remove the cylinder head cylinder and timing gear as described in Paras 1 2 and 10 Now unscrew the o...

Page 12: ...t a slightly bent and flattened drift must be used against the lower end of the guide itself After removal of the guides the inlet tappet can be lifted out but to remove the exhaust tappet it is necessary to knock out the cam spindle The only satisfactory way of doing this is by dividing the crankcase and knocking out the spindle from inside 16 Dismantling Flywheels If the big end bearing requires...

Page 13: ... in Figs 17 and 18 18 Removal of and Replacing Mainshafts The driving and timing side shafts are held in to their respective flywheels by means of tapers and keys and are easily removed after unscrewing the nuts which secure them Note the oil release valve in the end of the timing side shaft see Para 23 The hollow grub screw securing this must be screwed up tight and the end of the shaft centre pu...

Page 14: ...er under a press or between the jaws of a vice using a short piece of tube between the faces of each flywheel and the vice jaws see Fig 19 When assembling the flywheels line them up as closely as possible by means of a straight edge placed against the rim of the wheels at 90 either side of the crankpin To tighten the crankpin nuts use either the assembly jig shown in Fig 14 or grip one of the main...

Page 15: ...ce so that it falls out on tapping the case 21 Replacing Crankcase Main Bearings In order to ensure that the timing and driving side main bearing races are in line a mandrel such as is shown in Fig 21 should be used The races are MANDREL FOR FITTING CRANKCASE MAIN BEARINGS Fig 21 inserted about half way into their housings and the case assembled with the mandrel in position in the bearings see Fig...

Page 16: ...gh T and X to big end bearing and at same time oil flows into housing through Port Z Fig 23 Position 1 Plunger A is being drawn out of cylindrical hole in disc C Ports U and V in disc register respectively with suction passage Y and delivery passage Z in housing Oil flows through Y and U to fill pump cylinder and at same time oil in housing is forced through V and Z to delivery passage Fig 24 Posi...

Page 17: ...ssive pressure developing when the oil is cold This valve is designed to lift at 30 40 lbs per sq in pressure At the same time the secondary side of the feed pumps draws oil from the tank A through the gauze filter C and delivers it to the back of the cylinder The oil from both the cylinder and the big end is splashed round the engine by the flywheels and lubricates the piston main bearings and sm...

Page 18: ...tinued right to the top otherwise the driving pin on the end of the cross shaft will foul the disc Examine the lower face of the return pump disc for signs of it having been lifted off its seating by endways movement of the driving shaft and if necessary file a little extra clearance at the corner of the disc where the shaft may foul it When fitting a new feed pump disc make sure that it never sim...

Page 19: ...he final drive sleeve and layshaft it is necessary to remove both halves of the primary chain case and the countershaft sprocket Having done this it may be thought preferable to remove the gearbox from the frame 28 Removal of Gears and Shafts To dismantle the box first remove the kickstarter crank the nut securing the gear indicator pointer and the gear operating lever Then remove the four screws ...

Page 20: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 20 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 21: ... plate is incorrectly adjusted it may be found that after moving from top to third or bottom to second gear the outer ratchets do not engage the teeth on the inner ratchets correctly When the adjuster plate is correctly adjusted the movement of the gear lever necessary to engage the ratchet teeth will be approximately the same in either direction If the gears do not engage properly ascertain wheth...

Page 22: ...e clutch is shown in Fig 30 To dismantle the clutch plates unscrew the three spring pins and lift away the springs pressure plate cover over cush rubbers friction plates and steel plates To remove the clutch sprocket from the centre spring off the large circlip which secures it To remove the clutch centre unscrew the attachment nut and withdraw the centre from the mainshaft using the extractor sho...

Page 23: ...inks For the primary chain this means an increase in length of 3 4 in and for the final drive chain of 1 1 8 in When measuring chains for wear the load applied should be 28 lbs for the in pitch primary chain and 42 44 lbs for the 5 8 in pitch final drive chain 37 Removal Repair and Replacement Both chains are fitted with spring links to facilitate removal The springs can be removed with the finger...

Page 24: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 24 1954 MODEL J2 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 25: ...9 The type numbers are found on the engine connection Fig 2 CARBURETTER WITH PILOT JET SYSTEM Your carburetter may be vertical inclined or horizontal but diagrammatically this view applies to all models the variation being in the attachment to the engine and of the float chamber Fig 2 above is the sectioned view of the standard Amal carburetter as shown on sheet 1 figure 1 This is the standard des...

Page 26: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 26 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 27: ...Page 27 ROYAL ENFIELD 350cc and 500cc O H V 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 28: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 28 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 29: ...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 30: ...with a petrol moistened cloth 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 h...

Page 31: ... examine the H T cable 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 conta...

Page 32: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 32 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: ...rings are packed with 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 ...

Page 34: ...e see Fig 2 The correct tension is 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 com...

Page 35: ...d and take a light cut with 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 av...

Page 36: ...o is a reversal of the 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 ...

Page 37: ...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 38: ...seats correctly on the sealing 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 R...

Page 39: ...e varies with 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 ...

Page 40: ...rtunities for 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 recha...

Page 41: ...tor 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 engages w...

Page 42: ...tt M B C Lucas Part No 988 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...

Page 43: ... 564 is either Lucas No 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 ...

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Page 45: ... 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 steering damper and have stronger springs On early models the fork end was made of aluminium alloy screwed on to the bottom tub...

Page 46: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 46 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 47: ...ng the underside of the comparatively 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 m...

Page 48: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 48 1954 MODEL G 1947 MODEL J 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 49: ...of the main tube As the fork operates oil is forced 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 ...

Page 50: ...amping At the extreme end of 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 com...

Page 51: ... or three threads on 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 dia...

Page 52: ...s is effected by the 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 ...

Page 53: ...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 in the brake shoes...

Page 54: ...ter 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 bore 1 5620 1 5616in Bearing bore 6252 6247 in Shaft diameter 6252 6248 in 8 Refitting Ball Bearings Note that the two...

Page 55: ...he less efficient trailing 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 h...

Page 56: ...e the inside spokes to the 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 C...

Page 57: ...st 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 require...

Page 58: ...e centre bolt and withdraw this completely Spring the fork ends slightly apart so as to release the slip collar 38917 spacing collar 31993 or 32455 for Models S or G and J2 respectively from the spigot which locates it and slide the collar out of the fork end Disconnect the speedometer driving flex from the speedometer gearbox remove the inner tube from the tyre and withdraw it through the gap lef...

Page 59: ...urn springs can then be unhooked from the spring posts in the brake shoes thus allowing the whole assembly to fall apart In the case of Model J2 the springs can be unhooked without removing the operating cam or the pivot pin which is riveted to the cover plate 5 Replacing Brake Linings Brake linings are supplied either in pairs ready drilled complete with rivets Part No 37786BX 6 in shoes or 37787...

Page 60: ...c or make up this distance with tubular distance pieces Fit and tighten the spindle nuts 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 c...

Page 61: ... with the locknuts If the shoes are not correctly centered the brake will be either ineffective or too fierce depending on whether the trailing or leading shoe first makes contact with the drum With the brake assembly correctly centered and the screws securing the cam housing correctly tightened wear on both linings should be approximately equal 13 Final Reassembly of Hub before Replacing Wheel Be...

Page 62: ... 250 Clipper and Model S are Dunlop 3 00 19 in Lightweight Reinforced On the Model G the standard tyre is Dunlop 3 25 19 in Universal tread and on the Model J2 Dunlop 3 50 19 in Universal tread 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 v...

Page 63: ...ng 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 cam by this means of the tyre indicates whether or not the tyre is correctly fitted If the tyre has a whi...

Page 64: ...ROYAL ENFIELD 350cc and 500cc O H V WORKSHOP MANUAL Page 64 SPRING FRAME Model G deluxe and 350 Clipper 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 65: ...e easily removed by 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 suspens...

Page 66: ...ugh the hollow plug 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 ori...

Page 67: ... of the plunger head fill 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 dow...

Page 68: ... wheels at a point about 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 nece...

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