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Page 1: ...HOP MAINTENANCE MANUAL FOR THE 736 c c INTERCEPTOR MOTOR CYCLE TRADE lt AR C 1 M ADI LIKE A GIIN 1 THE ENFIELD CY CLE CO MP ANY LIMITED HEAD OFFICE AND WORKS REDDITCH WORCESTERSHIRE ENGLAND Telephone Redditch 4222 9 lines S T D RE9 4222 Telegrams Cycles Redditch ...
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 1965 INTERCEPTOR U K MODEL 1965 T T INTERCEPTOR U S A MODEL Frontispiece ...
Page 3: ... MONOBLOC CARBURETTER 74 General Description 75 Tuning the Carburetter s Exploded View of Monobloc 27 31 27 28 Carburetter 29 76 Tuning Sequence with Two Carburetters 77 Dismantling Carburetter 30 30 78 Causes of High Petrol Con sumption LUCAS TWIN CYLINDER MAGNETO 79 General 80 Lubrication 81 Adjustments 82 Cleaning 83 High Tension Cables 31 31 33 31 31 32 32 32 84 Renewing Timing Control Cable M...
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 cs c ii I o I CY 0 ll __ I I a V J I iil tO I L D O w z C z w 0 0 I D LaJ 0 a LaJ I z La 0 i5 a w C 0 _J a w ...
Page 5: ...Guide Hole in Cylinder Head Dia Tappet Stem Diameter 625 626 in 3743 3740 in 3755 3745 in 1 0125 1 0130 in l 011 1 010 in Tappet Guide Internal Diameter Tappet Guide External Diameter Tappet Guide Hole in Crankcase Dia Tappet Clearance with cold engine Inlet Exhaust Inlet Exhaust Nil Normal Nil running Nil Continuous 005 high _speed runrung Assumes 0005 in stretch of eye of rod and cap due to inte...
Page 6: ...ng Compression ratios are as follows Standard Pistons No compression plate 8 to 1 Standard Pistons I compression plate 8 to I Standard Pistons 2 compression plates 7 to 1 Low Compression Pistons no plate 7 to 1 Low Compression Pistons 1 plate 6 9 to I Low Compression Pistons 2 plates 6 6 to 1 5 Connecting Rods The connecting rods are produced from stamp ings of Hiduminium RR56 light alloy The litt...
Page 7: ...e secured by Bullock Type split collets locking in high strength aluminium collars The springs are specially designed to give a variable rate on compression 12 Timing Drive The camshafts are located in the crankcase running in bronze bushes They are diiven by an endless chain from the timing sprocket on the crankshaft and the tightness of the chain can be adjusted by means of the chain tensioner i...
Page 8: ...hen returned direct to the oil tank through a drilled passage Oil from the front exhaust cam tunnel overflows into the timing chest where it lubricates the timing chains and then drains to the sump beneath the baffle plate at the bottom of the crankcase Both pumps are double acting the primary side of the feed pump supplying the big ends and the secondary side the rockers and valve gear Both sides...
Page 9: ...that oil is forced out of the cylinder to the big ends At the same time the suction port Z in the housing is uncovered and oil is drawn into the housing below the disc from the oil tank y I z s CT RETURN PUMP POSITION2 W 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 crankcase Position 1 The plunger A is being...
Page 10: ... slacken the feed plug between the oil pumps The return oil pump can be checked by removing the oil filler cap so that the oil return pipe can be seen It may take several minutes for all the oil passages to fill and the oil to commence circuhting The feed to the rockers can be observed by removing the rocker box covers when oil will be seen flowing down the surface of the push rods 21 Valve Timing...
Page 11: ...s of the crankcase See Subsections 55 56 and 57 35 35 35 Cams have quietening ramps Least mech 35 82 anical noise Good torque and speed Better torque than 1 37 60 Sarne maximum speed Noisier Torque as 1 up to 80 m p h Better than 22 75 1 or 2 above 90 m p h Noisierthan l When automatic control is fitted no special extractor is required Merely unscrew the centre sleeve nut which secures the auto ad...
Page 12: ...in is altered by moving the quadrant after slackening the nut A which secures it see Fig 4 This rotates the eccentric spindle on which the chain tensioner jockey sprocket is mounted Tightening ofthe chain is effected by moving the quadrant to the left It is imperative that the quadrant is fitted the i ight way round and that the eccentric spindle is fitted correctly in the quadrant fork If the cha...
Page 13: ...at the dowels are in position in the cylinder barrels and that the push rods are the right way up shallow cups upwards See that the taper section Cross sealing ring and its seatings are perfectly clean and that the rubber seals for the push rod tunnels are in good condition and correctly fitted With the head upside down on the bench drop the packing shim into the recess first then the seal with th...
Page 14: ... in the slot and it is screwed i1 1to the_Plug hole in the cylinder head from the outside until the last coil is 1 to 1 threads below the top face A reverse twist of the tool will then break off the tag If the cylinder head has been removed the fitting of the insert will be facilitated if the tool is put through the hole from the inside and the insert screwed back from the outside If the cylinder ...
Page 15: ...right ring is visible on both valve and seating The faces and seats of the exhaust valves are cut at 45 degrees but the profiles of the inlet valves are of a special streamlined design which eliminates pockets and sharp edges and allows a smooth flow of gas without eddies If the inlet valves or their seats are pitted and require re cutting care must be taken to reproduce the correct profile as sho...
Page 16: ...e timing cover as described in Subsection 20 Remove the end plates from both pumps Remove the pump discs and plungers Remove the pump spindle which can be pulled out from the front or return pump end after removal of the lQcating screw Check the fit of the plungers in the pump discs which should have a minimum of clearance but should be able to be moved in and out by hand If when fitting a new dis...
Page 17: ...taking care not to lose the key Unscrew the engine sprocket nut using Special Tool No E 4877 The engine sprocket is mounted on splines and can then be removed with the clutch sprocket To remove the clutch sprocket unscrew the three pressure plate pins and remove the pressure plate assembly the centre retaining plate and the assembly of driving and driven clutch plates The clµtch sprocket can then ...
Page 18: ...ocket through it 52 Oil Pipe Unions The oil feed to the rocker gear is through pipes from unions at the back of the crankcase below 1 the cylinder base to unions on the cylinder heads The tapped holes into which the unions screw into the aluminium are fitted with steel wire inserts to prevent the threads in the aluminium from stripping The method of fitting the thread inserts is the same as that u...
Page 19: ...upport the engine on a suitable box or wood block Raise the centre stand and remove the spring Loosen the bottom gearbox nuts and swing the lower engine plates down Remove the front engine plates horn and stand Lift the engine out of the frame 56 Removal of the Gearbox Remove the engine sprocket and clutch Sub sections 46 and 49 Remove the rear half of the primary chaincase by removing three socke...
Page 20: ...use of a special steel and the fact that the threads are rolled after heat treatment Wiring the heads is not recommended If it is necessary to replace the big ends a service crankshaft can be supplied with connecting rods fitted 60 Reassembly of Crankcase If the main bearings have been removed fit the replacement ball bearing in the driving side crankcase and the outer roller race in the timing si...
Page 21: ...nd new threads tapped with a special tool Note hat the thread is left hand The method of fitting the wire insert is the same as described in Subsection 34 for the sparking plugs Gearbox and Clutch 63 Description of the Clutch The clutch is built into the clutch sprocket and is mounted on the gearbox mainshaft which pro jects through into the primary chaincase There are six driven plates which are ...
Page 22: ... dogs P and Q on the layshaft G The double pinion KL and the pinions M and N all slide together and are moved by the operator fork Rand are located by a spring plunger S which engages with a notched plate which is part of the operator arm R The kickstart lever is connected to the pm1on F on the layshaft by a ratchet mecha sm which automatically disengages when the lever 1s released 65 Removal of t...
Page 23: ...inions have moved so that tbe dogs on J are disengaged but the dogs P on tbe layshaft engage with tbe pinion M The drive from the mainshaft and laysbaft tben passes through pinions M and K to the splines on the mainsbafl sleeve and the pin ion J is free on the sleeve Fig 14D Tbird Gear The sliding pinions bave moved further over so that the dogs Q on the laysbaft engage with the pinion N wbich dri...
Page 24: ...l 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 73 On no account must heavy yellow grease be used 70 Dismantling and Reassembling the Clutch The method of removing the clutch is described in Subsection 46 When reassembling the clutch the ...
Page 25: ...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: ...then unscrew it two turns Now adjust the sleeve at the gearbox end of the casing until there is h in to n in slack in the control If the control is adjusted in this manner the finger adjustment at the handlebar end can be used to take up any slack which may appear temporarily as the result of the friction material swelling due to heat if the clutch has to be slipped a great deal in traffic This ad...
Page 27: ... by the position of this needle in the slide and by the size of the jet in which it works There is however a restricting or main jet at the bottom of the needle jet and the size of this controls the mixture strength at the largest throttle openings At very small throttle openings petrol and air are fed to the engine through a separate pilot system which has an outlet at the engine si e of the thro...
Page 28: ...ling speed for a given position of the throttle stop If the idling speed is then undesirably fast it can be slowed down by unscrewing the throttle stop a fraction of a turn It will be noted that of the four points at which adjustments are normally made i e pilot air screw throttle cut away needle position and main jet size the first and third do not require changing of any parts of the carburetter...
Page 29: ...rkshop Manual Page 29 ri VIEW OF PILOT JET AND AIR ADJUSTER ASS EMBLY EXPLODED VIEW OF MONOBLOC CARBURETIER f thoH re e FlJwett ers re Uoli he R 11 eae has ne iea r ch11mher llat is ethaP ioa itiloAAcaJ Fig 19 AIR VALVE ASSEMBLY JET BLOCK MIXING CHAMBER BODY MAIN JET HOLDER MAIN JET ...
Page 30: ...the new throttle position Repeat till the engine is running as fast as possible on the smallest possible throttle opening 7 Replace the right hand plug cap and lead and remove the left hand ones 8 Repeat 4 5 and 6 on the right hand carburetter 9 Replace the left hand plug cap and lead The engine should now be running steadily at a fast idle 10 Slow the engine down by unscrewing each throttle stop ...
Page 31: ... body The unit is designed for 3 point flange fixing Small breathing boles are provided in the body ofthe magneto These holes should not be allowed to become blocked On earlier models provision is made for altering the ignition timing by the manual control method in which the cam ring is moved relatively to the armature The lever controlling this movement is mounted conveniently on the handlebars ...
Page 32: ...g 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 cables must be kept clean and dry 83 High Tension Cables If on inspection the high tension cable shows signs of deterioration it must be replaced using 7 mm rubber P V C or neoprene covered ignition cable To fit a new high tension cable bare the end f...
Page 33: ...ars are given in a book let issued by the makers a copy of which we shall be pleased to forward upon request 87 Automatic Advance Mechanism This forms the coupling between the magneto driving sprocket and the magneto spindle It consists of two weights which are pivotally mounted and fly outwards due to centrifugal force when the engine speed increases thus advancing the angular position of the spi...
Page 34: ...ions 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 per formance characteristics A separate nut is used for securing the unit to the machine and this nut should be checked occasionally to see that it is tight RECTIFIER Fig 22 c Operati...
Page 35: ...reen and dark green on some early models leads at the snap connectors in the leads from the alternator This brings four instead of two coils into action both for daylight running and when running on the pilot lights the remaining two coils being short circuited or open circuited according to whether the short circuiting lead from switch to rectifier is connected or not The following are the approx...
Page 36: ...ET Another advantage of the 12 volt system is that it enables the Zener diode system of regulation to be used The Zener diode has the remarkable property of changing from a non conductor to a conductor at a critical voltage which can be arranged to be 14 volts i e when the 12 volt battery is discharged the Zener diode which is in a circuit in parallel with the battery does not take current but as ...
Page 37: ...ta MLZ9E MK Z9E 2 Nominal Voltage No of Plates per Cell Volume of Acid per Cell Amp Hr Capacity 10 hr rate 20 hr rate Recharge Current S G of acid for filling dry charged battery a Climates normally below 80 F 26 6 C b Climates normally above 80 F 26 6 C 6 9 90 c c 12 13 1 2 amps 1 260 1 210 6 9 80 c c 7 8 0 7 amps 1 260 1 210 Note The above acid densities are corrected to 60 F 15 5 C To prepare l...
Page 38: ...t rim and lens can then be inclined backwards or forwards as required before retightening the screw Horizontal aim on hese machines and on those with SS700P lamps 1s fixed and depends on the accuracy of machining of the fork head etc Correct vertical aim is most important and this should be adjusted with the machine carrying its normal load A beam set too high not only fails to light the road but ...
Page 39: ...by means of a small fixing RIM RUBBER SURROUND PARKING LIGHT EARLY U K MODELS Fig 27 screw After removal of the lamp rim the parking lamp Jens can be pulled out of the rubber body after which the bulb will be accessible Replace STOP TAIL LAMP L 564 Fig 28 ment bulbs should be 6 v 3 watt Lucas No 988 or 12 v 6 watt Lucas No 989 97 Tail Light The Lucas lamp Type564 Fig 28 isacombined stop and tail l...
Page 40: ... shorter one giving 54 in wheelbase on the earlier models for the English market and a longer one giving 57 in wheelbase for the American market and later models for the English market Two types of pivot bearings have been used at the forward end of the swinging arm a Bronze bushes working on a steel tube secured to the main frame by a long bolt passing through the pivot lugs Hardened steel thrust...
Page 41: ...can easily be renewed and the spring can be removed by pushing down on the top spring cover so as to release the split collar above it After removal of the split collar the top cover and spring can be lifted off When reassembling the spring should be greased to prevent rust and squeaking if it should come into contact with either of the covers when fitted Early machines were fitted with Armstrong ...
Page 42: ...diameter with one end stepped down to H in diameter to locate it in the inner sleeve of the bush Note This procedure will normally crap one or both the rubber bushes which should not be removed unnecessarily When fitting replacement bushes do not forget the distance piece between them 103 Centre Stand To remove the centre stand unscrew the nut from one end of the stand spindle knock out the latter...
Page 43: ...ze bush which is secured by means of a threaded steel housing containing an oil seal The spring which is loaded in compression only is fitted inside the upper end of the main tube with its upper end against the underside of the upper spring guide which is brazed into the upper end of the tube The lower end of the spring rests on top of the lower spring guide which is secured to a hollow spring stu...
Page 44: ...untered the s in or in hole should be opened up to in With the larger sized hole it is possible that most of the oil will bypass the valve port on the bump stroke thus tending to cause cavitation in chamber B In this case the drop in pressure in B will cause the upper disc valve beneath the lower spring guide to open thus admitting oil into chamber B from above and keeping it full On the rebound s...
Page 45: ...6 It 22 12 41952 45 50 67 5 It 21t 12 46615 30 89 7 21 8 Note that there is no spring suitable for heavy sidecar work that will fit in the 8 g main tubes For this class of work 12 gauge tubes W42695 with springs W41952 or 14 gauge tubes with springs W41569 should be used These tubes being of chrome molybdenum steel have ample strength for all ordinary road work with the heaviest sidecar 110 Reasse...
Page 46: ...oving the entire switch from the casquette or fascia panel U S A models have a plug and socket connector in the cable harness leading to the lamp see Figs 24a and 24b In the case of early U K models with no plug and socket connector all leads should be disconnected at their lower ends rather than at the switch Disconnect the lighting leads and driving flexes from the speedometer and revolution cou...
Page 47: ...s are Front 7 in x 1 in 43263 lined shoe U S A 43264A BX lining and rivets Front 6 in x 1 in 41342A lined shoe U K 41284A BX lining and rivets When riveting linings to shoes secure the two centre rivets first then work towards each end in tum This will ensure that the lining lies flat against the shoe Standard linings are Ferodo AM2 which are drilled to receive cheese headed rivets 117 Removal of ...
Page 48: ...rel To prevent any possibility of sideways movement of the hub barrel on the bear ings it is tl lerefore 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 follow ing are the manufacturing tolerances which control the fit of the bearings The figures for the bearings themselves a...
Page 49: ...f the machine At the same time the Wear on the leading shoe linings will be greater than on the trailing shoes and in time the limit of float of the cam housings will be reached after which the brake will continue to act as a fixed cam brake with some loss of efficiency This can be restored by removing the shoes and refitting them in the opposite positions 123 Final Assembly of Hub before Replacin...
Page 50: ...En field cush drive and also a 7 in internal expanding brake 131 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 with the chain adjuster cam preferably marking it to en...
Page 51: ...d up when the same notch position is used on both adjuster cams Once the position of the cams which gives correct alignment has been found this alignment will however be maintained if both cams are moved the same number of notches See also Subsection 104 positions or if necessary turn each of them the same number of notches to tension the chain and maintain correct wheel alignment The chain should...
Page 52: ... now free the lever after which the cam can be withdrawn from its housing Do not try to remove the brake shoe pivot pin as this is cast into the cover plate 135 Cush Drive The sprocket brake drum 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 Six rubber blocks are fitted between the vanes on...
Page 53: ...th a 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 section of the spindle To remove the bearings from the loose half of the hub barrel first lift away the distance collar speedometer drive gearbox the spacing collar and the felt washer Remove the bearing retaining circlip from the driving sproc...
Page 54: ...m housing should be left free to float but the shoes should be centred by leaving the screws just short of dead tight The brake cover plate assembly with the shoes should then be fitted over the spindle into the brake drum and the brake applied as hard as possible by means of the operating lever This will centre the shoes in the drum The screws should then be tightened dead tight and secured with ...
Page 55: ...quite easily with the small levers supplied in the tool kit The use of long levers and or excessive force is liable to damage the walls 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 fitt...
Page 56: ...h c o c k s m o t o r c y c l e s c o m Page 56 Royal Enfield Interceptor Workshop Manual Special T 2055 19 ASSEMBLY GAUGE IN USE TO CENTRALISE ROTOR Tools T 2053 INLET VALVE SEAT ARBOR T 2054 INLET VALVE SEAT CUTTER ...
Page 57: ...h c o c k s m o t o r c y c l e s c o m Royal Enfield Intercep_to_r Workshop Manual_ E 4869 TIMING SPROCKET EXTRACTOR E 4877 ENGINE SPROCKET NUT SPANNER E 4871 CLUTCH HOLDING TOOL E 5121 CRANKSHAFT EXTRACTOR Page 57 ...
Page 58: ...t c h c o c k s m o t o r c y c l e s c o m Page 58 oyaJ Enf elcj Interceptor Workshop Manual E 5414 CLUTCH HUB EXTRACTOR E 5477 T GUDGEON PIN EXTRACTOR E 5425 PUMP DISC LAPPING TOOL E 5790 TAPPET GUIDE EXTRACTOR ...
Page 59: ...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 Royal Sn field Interceptor Jforkshop Manual Page 59 fr I E 5418 E 4912 VALVE PORT C SPANNER OUTER TUBE HAND GRIPS ...
Page 60: ... 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 Royal Enfield _Interceptor _ Workshop Manual E 5431 FRAME EXPANDER E 5417 GLAND NUT HAND GRIPS E 4823 GEARBOX COVER BALL BEARlNG ASSEMBLY TOOL ...
