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

Page 1

WORKSHOP

MAINTENANCE MANUAL

FOR THE

ROYAL ENFIELD

350 c.c. O.H.V.

MOTOR CYCLES

MODELS CO,WD/CO

and WD/CO/B

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 CO

Page 1: ...c O H V MOTOR CYCLES MODELS CO WD CO and WD CO B 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 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: ...8 26 Dismantling and Reassembling Steering Head 49 27 Steering Damper 50 27 Para Page CARBURETTOR 51 53 27 Adjusting Slow Running 51 27 Dismantling Carburettor 52 27 Causes of High Petrol Consumption 53 27 LIGHTING AND IGNITION SYSTEM 54 103 29 Magneto 54 67 29 Lubrication of Contact Breaker Mechanism 54 29 Cleaning Contact Breaker 55 59 Adjustment of Contact Breaker 56 29 H T Cable 57 29 H T Pick...

Page 4: ...moving Magneto Armature Bearings 31 48 Mandrel for Replacing Magneto Armature Bearings 31 49 Contact Breaker Body and Tappet 31 50 Contact Breaker End Plate 31 51 Magneto Slipping Clutch 32 52 Wiring Diagram 33 53 Connections to Voltage Regulator 34 54 Exploded View of Dynamo 35 55 Undercutting Mica 35 56 Testing Brush Springs for Tension 35 57 Commutator and Brush Gear 35 58 Voltage Regulator Adj...

Page 5: ... 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 TRANSMISSION Sprockets Engine 19 T 1 2 in P X ...

Page 6: ...er Pin Spanner 255 hex with 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...

Page 7: ... 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 the valves f...

Page 8: ... end bush can be renewed 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 try...

Page 9: ...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 that bo...

Page 10: ...he 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 push ...

Page 11: ...ards direction Fig 12 shows the machine with the engine ready to lift out after removal of the front attachment stud Note In the case of machines having frame numbers 19827 24826 and 5038 30037 upwards the frames of which are fitted with tank tubes it is necessary to remove the front as well as the rear engine plates The engine can then be removed out to one side 14 Dismantling the Crankcase To di...

Page 12: ...lightly 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 rene...

Page 13: ...igs 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 punched...

Page 14: ...der 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 mainshaft...

Page 15: ... 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 22 A...

Page 16: ...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 Position ...

Page 17: ... 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 small e...

Page 18: ...d 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 simultan...

Page 19: ...nal 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 beari...

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Page 21: ...e 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 whether th...

Page 22: ...tch 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 shown in...

Page 23: ...ch the inner tube can be passed links 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 sprin...

Page 24: ... found to restore the efficiency of the brake once the linings have cooled down Alternatively grease can be burnt out of the linings with the aid of a blow lamp Washing the linings with petrol usually results in washing the grease into them and is not recommended If new linings are necessary make sure that those fitted are the correct size and type The lining material for both brakes is Ferodo B Z...

Page 25: ... bent it is possible that the lower portion of the wheels will be in alignment while the upper portion is not Any serious twist can be seen by looking along the machine to make sure that both wheels lie in the same plane In case of doubt this can be checked by using the string near the top of the wheels after removal of the mudguards battery toolboxes and engine cylinder If the wheels are in align...

Page 26: ...tal plates are correctly fitted over the boss on the bottom front fork lug 48 Adjustment of Steering Head To check for play in the steering head the weight must be taken off the front wheel by placing a suitable box beneath the engine crankcase Play can then be felt by trying to move the lower end of the forks backwards and forwards To distinguish between play in the steering head and in the fork ...

Page 27: ...in bolt securing the bottom plate to the steering stem Both these pins pass through slotted lugs on the plates and the plates can be tapped up or down as required in order to bring them parallel with the lower face of the steering stem Lock up the two in bolts tightly with the bottom and middle plates and the steering damper in such a position that the damper is perfectly free Binding of the dampe...

Page 28: ...d may make the mixture too weak at large throttle openings thus causing overheating The standard setting for this carburettor is as follows Main jet No 130 Throttle Valve 6 4 Needle clip in middle groove A MIXING CHAMBER H JET BLOCK BARREL O NEEDLE JET U NEEDLE VALVE B THROTTLE VALVE J PILOT HOLE P MAIN JET V SPRING CLIP C THROTTLE NEEDLE K PILOT FEED HOLE Q HOLDING BOLT W FLOATCHAMBERTOP D AIR VA...

Page 29: ...e setting is correct the gauge should be a sliding fit If there is an appreciable variation from the gauge slacken the lock nut and turn the contact screw by its hexagon head until the gap is set to the gauge Finally tighten the lock nut 57 H T Cable This should be 7 m m in diameter Other sizes such as 5 m m and 9 m m will not fit in the immobilizer and suppressor The cable must be replaced if the...

Page 30: ...abric gear which is held against the gear centre under the pressure of a star shaped spring to the pinion on the dynamo shaft The effect of a violent overload is to cause the fabric gear to slip relative to the gear centre and so prevents shock from being transmitted to the fabric gear 64 Dismantling the Magneto First remove earth brush and high tension pick up Then proceed as follows 1 Drive End ...

Page 31: ... the armature windings or the condenser and a replacement should be fitted TOOL FOR REMOVING ARMATURE BEARING Fig 47 It is important that the two ball bearings which support the armature are in good condition If they are packed on assembly with a grease such as a suitable high melting point grease they will stand an almost unlimited amount of normal wear but if they start to fail due to a bent sha...

Page 32: ...high melting point grease Fit driving end cover in position with paper gasket correctly located Replace H T pick up checking carbon brush to see that it is free to move in its holder and examine cork gasket for cracks Refit earth brush SPARKING PLUG Type Lodge H 14 Sintox or Champion L l0S 14 m m thread standard in reach 68 Dismantling Cleaning and Setting If the plug is oiled or carboned up it sh...

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Page 34: ...ted No reading at terminal B indicates either a broken wire between terminal B and battery or bad battery connections DYNAMO Lucas Type E 3 H M 71 Removal To remove the dynamo from the magneto portion of the Magdyno unscrew from the driving end plate the securing nut and slacken the two screws in the clamping band The dynamo can then be drawn away from its mounting 72 Dismantling Bend back the tab...

Page 35: ...and moving the brush in its holder If the brush tends to stick remove it and clean with petrol Check spring tension as shown in Fig 56 Correct tension is 10 15 ozs UNDERCUTTING MICA Fig 55 77 Worn Brushes Brushes which have worn to such an extent that they do not bear properly on the commutator must be replaced Remove machine from engine and withdraw dynamo cover band Remove screw securing eyelet ...

Page 36: ...battery or its state of charge Normally during daytime running when the battery is in good condition the dynamo gives only a trickle charge so that ammeter readings will seldom exceed 1 or 2 amperes If under normal running conditions it is found that the battery is continually in a low state of charge or is being overcharged then the regulator should be adjusted Always check that the D lead yellow...

Page 37: ... between the plates This will necessitate its return to a Repair Depot for rectification 92 Cleaning Wipe the top of the battery to remove all dirt or water Note Do not leave the battery in a discharged condition for any length of time If a motorcycle is to be out of use the battery must first be fully charged and afterwards given a refreshing charge about every two weeks 93 Earthing Connections S...

Page 38: ... clamping clip at the back of the reflector Slide the bulb holder backwards or forwards until the best lighting is obtained and finally tighten the clamping screw TAIL LAMP CAP REMOVED Fig 60 CABLES 100 Positive Lead to Battery Before making any alterations to the wiring or removing the switch from the headlamp disconnect the positive lead at the battery to avoid the danger of short circuits The l...

Page 39: ...This can be ascertained by removing the horn from its mounting holding it firmly in the hand and operating the push If the note is still unsatisfactory the horn may require adjustment 103 Method of Adjusting The adjustment of a horn does not alter the characteristics of the note but takes up wear of vibrating parts which if not corrected results in loss of power or roughness of tone If the horn is...

Page 40: ...HUBS 9 SPEEDOMETER DRIVE 10 10 MAGDYNO LUBRICATOR Lubricant Castrol Grand Prix or XXL Golden Shell or Triple Shell Mobiloil D or B B Essolube Racer or 50 Motorine B de Luxe or C Engine Oil or Grease Castrolease Medium Mobilgrease No 2 Shell Retinax C D Esso Grease Belmoline D Castrolease Heavy Mobilgrease No 4 Shell Retinax R B Grease Esso Grease Belmoline C Light Machine Oil The oils shown in bra...

Page 41: ...ee to rotate on the layshaft there is no drive through the gearbox To obtain first gear the layshaft clutch is moved to the right so that the external teeth on it engage with the internal teeth in the layshaft first gear thus clutching the gear to the layshaft Rotation of the mainshaft now causes rotation of the layshaft through the mainshaft sliding gear layshaft first gear and layshaft clutch In...

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Page 43: ...the paper washer which makes the joint between it and the gearbox shell The mainshaft third gear 15 can now be lifted away but before attempting to remove the rest of the gears it is essential to unscrew the screwdriver slotted plug see Fig 69 No 7 underneath the front of the gearbox at the kickstarter end After removal of this and the spring see Fig 69 No 5 above it the entire assembly of camshaf...

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Page 45: ...rder Note that the layshaft small gear 18 teeth is wider than the layshaft third gear 21 teeth and that the splines at one end of the layshaft are correspondingly longer The layshaft second gear 27 teeth is fitted next to the small gear and the first gear 32 teeth next to the third gear pinion b Assemble the layshaft and gears camshaft with operating forks and mainshaft sliding gear in a cluster b...

Page 46: ...control bush bolt spring box and springs control quadrant ratchet sleeve pawl pawl operating peg and pawl spindle into the kickstart case cover Make sure that the pawl is put back the same way round as it was originally fitted as it may not engage correctly if reversed d Before replacing the kickstart case cover make sure that the end of the kickstart spring is anchored on to its pin and wind up t...

Page 47: ...nd is fitted at the end of the camshaft furthest from the operating gear Note also that the operating forks are assembled with their forked ends next to each other When replacing the operating pegs make sure that they are the correct way round as they are chamfered to clear the inside of the gearbox casing 111 Foot Change Mechanism This mechanism though apparently complicated is actually quite sim...

Page 48: ... is ready to pick up the next tooth when the control lever is operated again The sector spindle 3 moves with the control sector quadrant 18 and carries on its outer end the gear indicator the position of which thus indicates which gear is engaged Note that this gear indicator is in line with the small fixed indicator when the gears are in neutral 112 Kickstarter Mechanism This is shown in Fig 71 O...

Page 49: ... a steel rod and then to wrap the chain round the driving sprocket which will be prevented from turning by holding the rod If the gear control is placed in the top gear position holding the driving sprocket will also prevent the mainshaft from turning 114 Lubrication After assembly pack the gearbox half full with Castrolease Medium Mobilgrease No 2 Shell Retinax C D Esso Grease or Belmoline D DATA...

Page 50: ...19 13 Cush Drive Rubbers Clutch 32 22 Rear Wheel 44 25 Cut Out Adjusting 86 37 Cylinder Base Nuts 2 9 7 9 Washer 9 14 9 11 Dimensions 5 8 Head Removal 1 7 Nuts 9 9 Washer 9 9 Removal 2 7 D Para Page DATA 5 6 Burman Gearbox 49 Decarbonising 1 9 7 Draining Oil from Engine 26 18 Dynamo 71 81 34 Armature Test 79 36 Attention if Water has Entered 80 36 Brushes 72 73 76 77 34 35 Commutator Cleaning 73 3...

Page 51: ... Consumption Reasons for Excessive 53 27 Tank Removal 1 7 Piston Dimensions 5 8 Limits of Wear 5 8 Removal 2 7 Rings 5 8 Push Rod Enclosure Tube Joint Washers 9 9 R Para Page Regulator See Voltage Regulator 82 87 36 Rims Wheel 40 24 S Security Bolts 39 23 Slow Running Adjusting 51 27 Sparking Plug 68 69 32 Spokes 41 24 Steering Damper 50 27 Steering Head Adjustment 48 26 Dismantling and Reassembli...

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