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ROYAL ENFIELD WORKSHOP MANUAL

SECTION E1

Gearbox and Clutch

" Meteor 700" " 500 Twin " " 500 Bullet" " 350 Bullet

1. Removal of Gearbox

This is described in section Cl or D1. The gearbox

can, however, be completly dismantled with the
engine in the frame except for removal of the inside
operator and the bearings in the gearbox shell.

2. To Dismantle the Gearbox

First remove the kickstart crank, the gear

changelever and the neutral finder and pointer.

Remove the top small 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 Thread).

The gearbox inner cover can then be removed

The mainshaft can be drawn straight out if the

clutch has been removed, which, however, should
be done before taking off the gearbox cover.

Section E1 Page 1

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Содержание 500 TWIN 1949

Страница 1: ...ROYAL ENFIELD WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield 500 TWIN 1949 57 700 METEOR 1953 55 MAN 9 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 ...

Страница 2: ...ON G1a LUCAS COIL IGNITION SECTION G1b LUCAS MAGDYNO SECTION G2a LUCAS DYNAMO MODEL C35SD SECTION G2b LUCAS DYNAMO MODEL E3LM SECTION G3a CONTROL BOX SECTION G4a BATTERY MODEL PUZ7E SECTION G5a HEAD AND TAIL LAMPS SECTION H1 FRAME SECTION J1 FRONT FORK WITH CASQUETTE SECTION J3 FRONT FORK WITH FACIA PANEL 700 METEOR 1953 SECTION J4 FRONT FORK WITH FACIA PANEL 500 TWIN 1950 53 SECTION K1 FRONT WHEE...

Страница 3: ...ROYAL ENFIELD WORKSHOP MANUAL 500 TWIN 1951 500 TWIN 1956 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 ...

Страница 4: ...ve Guide Hole in Cylinder Head Dia 625 626 in Tappet Stem Diameter 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 in Outer 2 3 32 in Renew when reduced by 3 16 in Valve Timing with 012 in clearance ...

Страница 5: ...ROYAL ENFIELD WORKSHOP MANUAL 700 METEOR 1953 700 METEOR 1954 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 6: ... Hole in Cylinder Head Dia 625 626 in Tappet Stem Diameter 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 in Outer 2 3 32 in Renew when reduced by 3 16 in Valve Timing with 012 in clearance Exhaust ...

Страница 7: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 8: ...l and is slotted 5 Connecting Rods The connecting rods are produced from stampings of Hiduminium RR56 light alloy The little end bearings are of alloy direct on to the gudgeon pin In case of wear after long service the little end can be bored out and fitted with a bush but this is rarely necessary The big end bearings consist of white metalled steel liners which are renewable The detachable bearin...

Страница 9: ...ming chest The tension of this chain is adjusted by moving the magneto fixing bolts in their slotted holes 13 Ignition and Lighting System Lighting and ignition are supplied from a Lucas magdyno which consists of a magneto running at 1 2 engine speed and a dynamo running at 1 1 3 engine speed The rate at which the dynamo charges the battery is controlled by an automatic regulator which limits the ...

Страница 10: ...manner one side of the return pump pumps the big end oil back to the tank from the crankcase and the other side the valve gear oil back to the tank from the timing chest Separate adjustable spring loaded relief valves control the pressure to the big ends and to the valve gear The oil supply to the big ends is through internally drilled passages and that to the valve gear through external pipes On ...

Страница 11: ...n 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 On early models Y X delivery to oil tank Z suction from timing chest and Z were reversed 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 tha...

Страница 12: ... The tappet clearance is adjusted by means of a screw in the outer end of each rocker Access to the adjusting screws is obtained by removing the covers of the rocker boxes The clearance between the end of the screw and the valve stem cap should be nil or as little as possible with the engine COLD To adjust the clearance loosen the locknut beneath the rocker arm turn the screw with a small spanner ...

Страница 13: ...rew This point can be determined by inserting a thin piece of tissue paper between the contact breaker points and turning the distributor housing until the paper can just be drawn out An alternative method is to remove the cap from the plug lead and tuck the lead between the fins of the cylinder Switch on the ignition and rotate the distributor until a spark is seen at the instant the points open ...

Страница 14: ...he correct tension is obtained and then lock the quadrant If the chain becomes too tight during adjustment slacken it right back and make the adjustment again After the adjustment has been completed and the quadrant has been locked in position turn the engine slowly and check the tension at frequent intervals to ensure that excessive tightening does not take place in any one position Meteor 700 Be...

Страница 15: ...t the head nuts and washers and partially tighten down When both heads have reached this stage fit the induction pipe and tighten the nuts The cylinder head nuts can now be finally tightened down progressively and diagonally from one side to the other to prevent distortion After the engine has been run long enough to get thoroughly hot the tightness of the nuts should be re checked 11 Removal of V...

Страница 16: ...el If a hand press is not available and the guide is replaced by a hammer use a piece of tube of 9 16 in internal diameter to prevent damage to the bore of the guide It is necessary to re cut the valve seat and grind in the valve after a guide has been replaced 14 Renewal of Sparking Plug Inserts A steel thread insert is fitted into each sparking plug bore to prevent damage to the threads in the a...

Страница 17: ...sured in the least worn part of the cylinder which will be found to be the extreme top or bottom of the bore While the cylinders and pistons are not in position on the engine cover the crankcase with a clean cloth to prevent the ingress of dust and dirt of all kinds Do not of course attempt to scrape the carbon from the pistons when the mouths of the crankcase are open 18 Grinding in Valves Wipe t...

Страница 18: ...correctly When the timing cover has been refitted on the engine the oil feed to the big ends can be checked by partially unscrewing the feed plug in the timing cover between the oil pumps and the oil return to the tank can be checked by removing the oil filler cap The feed to the rockers can be observed by removing the rocker box covers when oil will be seen flowing down the push rods The pump dri...

Страница 19: ... in the crankcase instead of a partial vacuum giving rise to smoking or over oiling See that the discs and backplate are clean and undamaged and that the discs are seating properly When re assembling the breather apply jointing compound sparingly to the back of the steel plate taking great care to keep it away from the discs or their seatings On earlier models fibre discs were used in the breather...

Страница 20: ...d at approximately l0 lbs per square inch The plug is prevented from moving by peening over the aluminium into the screwdriver slot with a small centre punch Big End Feed Relief Valve This is located in the inside of the bottom of the timing cover and consists of a 1 4 in diameter steel ball and a spring and plug It should be set to relieve the pressure at approximately 60 lbs per square inch The ...

Страница 21: ...ROYAL ENFIELD WORKSHOP MANUAL 500 TWIN 1950 500 TWIN 1957 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 ...

Страница 22: ...an then be withdrawn without disturbing the rear gearbox plates 2 Removal of the Gear Box Remove the engine sprocket Section C 1 Subsection 26 and clutch Section C 1 Subsection 29 Remove the rear half of the primary chain case by removing three socket screws and the chain tensioner pivot The gearbox can now be withdrawn from the back of the crankcase after unscrewing the four nuts which secure it ...

Страница 23: ... the condition of the bearings make sure that the caps are refitted the same way round on the same rods and that the rods themselves are refitted the same way round on the same crank pins In refitting the connecting rods the socket screws should be tightened progressively with a torque wrench set at 200 220 inch lbs If the cotter pins do not come in line remove the socket screws and use a differen...

Страница 24: ...ong peg which in turn is held by a grub screw in the timing side crank web If it is necessary to re fit the nut assemble the timing sprocket with the pump worm and nut in the crankshaft while out of the crankcase and tighten it up By means of a long drill through the hole in the crankshaft web countersink the nut to about 1 8 in Insert the locking rod and grub screw Remove the pump worm and sprock...

Страница 25: ...ROYAL ENFIELD WORKSHOP MANUAL 500 TWIN 1954 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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

Страница 27: ...ROYAL ENFIELD WORKSHOP MANUAL Section E1 Page 2 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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

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

Страница 30: ...eet 3 The type numbers are 274 275 276 and 289 An alternative design is made where the primary air to the main jet comes in through four visible ports around the base of the mixing chamber and where also the air supply to the pilot jet system is separate The type numbers of these carburetters are 74 75 76 and 89 These tuning instructions apply to both the above designs TWO DESIGNS AMAL NEEDLE TYPE...

Страница 31: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 2 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 32: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 3 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 33: ...ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 4 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 34: ... adjusted by means of this screw and a stop which holds the throttle open a very small amount The throttle slide is cut away at the back and the shape of this cut away controls the mixture at throttle openings slightly wider than that required for slow running There is a compensating system to prevent undue enriching of the mixture with increasing engine speed this system consisting of a primary c...

Страница 35: ...t require changing of any parts of the carburetter Assuming that the carburetter has the standard setting to suit the particular type of engine any small adjustments occasioned by atmospheric conditions changes in quality of fuel etc can usually be covered by adjustment of the pilot air screw and raising or lowering the taper needle one notch If however the machine is used at very high altitudes o...

Страница 36: ...ROYAL ENFIELD WORKSHOP MANUAL 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 ...

Страница 37: ...less dirt is present or of course the float is punctured If it is necessary to remove the jet block note that this is withdrawn from the upper end of the mixing chamber after unscrewing the jet holder Be careful not to damage the jet block when re moving or refitting it Note that the large diameter of the jet block pulls down on to a thin washer A single strand of an inner control cable is useful ...

Страница 38: ... Bare the cable for a length of about in thread the wire through the brass washer provided and bend back the strands see Fig 1 Finally screw the nut into its terminal 1 b Distributor Fig 2 illustrates the distributor model DKX It has a moulded contact breaker base and the shaft is carried in two porous bronze bushes A high tension distributor rotor is fitted on an extension of the cam spindle the ...

Страница 39: ...ke sure that the trouble is not due to defects in the engine carburetter petrol supply sparking plug s etc If necessary adjust the sparking plug gaps to 018 020 in This must be done by bending the earth points only not the central electrode Ensure also that the battery is not discharged i Examine the high tension cables If the rubber shows signs of deterioration or cracking the cable should be ren...

Страница 40: ...oil of a grade equivalent to Mobiloil Arctic or other good thin mineral oil for a minimum time of 24 hours 3 d Contact Breaker When trimming a pair of contacts it is not essential to grind down a slightly pitted contact but only to remove excess metal from the piled contact Should the pitting and piling be found excessive a replacement contact set comprising both fixed and moving contacts should b...

Страница 41: ...ROYAL ENFIELD WORKSHOP MANUAL Section G1a 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 ...

Страница 42: ...nd gear centre A 2 Routine Maintenance 2 a Lubrication To be carried out every 3 000 miles Wipe the outside of the Magdyno to remove dirt or grease then take off the contact breaker cover see Fig 2 Unscrew the hexagon headed screw in the centre of the contact breaker and withdraw the contact breaker from its housing Push aside the contact breaker arm retaining spring and prise the arm off its pivo...

Страница 43: ...ary clean with a petrol moistened cloth Should either brush be worn to within 1 8 in of the shoulder it must be renewed Whilst the pick up mouldings are 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 cables must be kept clean and dry 2 d Renewing High Tension Cables If on...

Страница 44: ...ally 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 an ignition cut out switch is fitted disconnect the cable at the magneto and retest If the Magdyno now functions normally the fault is in either the cable or the cutout switch Correct by replacement v If the Magdyno has recent...

Страница 45: ...ROYAL ENFIELD WORKSHOP MANUAL Section G1b 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 ...

Страница 46: ...mutator ends of the armature supported in ball bearings The arrangement of the commutator end bearing has been modified on later dynamos In earlier dynamos a thrust spring was fitted between the commutator and the inner journal of the bearing In later dynamos see Fig 1 the bearing is secured to the armature shaft by a screw and the thrust spring now loading the outer journal of the bearing is fitt...

Страница 47: ...e voltage It is sufficient to run the dynamo up to a speed of 1 000 r p m If there is no reading check the brush gear as described in vi below If there is a low reading of approximately 1 2 volt the field winding may be at fault see Subsection 4 d If there is a reading of approximately 1 1 2 to 2 volts the armature winding may be at fault see Subsection 4 e vi Remove the cover band and examine the...

Страница 48: ...h secure the insulated terminal plate carrying the terminals and brushgear On earlier models removal of the insulating plate will reveal the bearing retaining plate and thrust spring housing 4 c Commutator Examine the commutator If it is in good condition it will be smooth and free from pits or burnt spots Clean with a petrol moistened cloth If this is ineffective carefully polish with a strip of ...

Страница 49: ...ubstitution No attempt should be made to machine the armature core or to true a distorted armature shaft 4 f Bearings Ball bearings are fitted to both the commutator and drive end brackets When the bearings become worn to such an extent that they allow side movement of the armature shaft they must be replaced see Figs 6 and 7 The bearings should not be disturbed except for the purpose of replaceme...

Страница 50: ...ke care to refit the cover band in its original position and make sure that the securing screw when of flush fitting pattern does not short on the brushgear v Take care not to damage the oil seal If damage is caused a new seal must be fitted 5 Dynamo Polarity If a dynamo has been incorrectly connected on the motor cycle and its polarity has become reversed it must be re polarised To do this fit th...

Страница 51: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 52: ...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 ...

Страница 53: ... 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 complete...

Страница 54: ...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 availabl...

Страница 55: ...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 brush...

Страница 56: ...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...

Страница 57: ...aling washer N B A dynamo run at high speed on open circuit will build up a high voltage Therefore when adjusting the regulator do not run the engine up to more than half throttle or a false setting will be made d Checking the electrical setting of the cutout If the regulator is correctly set but the battery is still not being charged the cut out may be out of adjustment Replace the control box in...

Страница 58: ...ture For convenience in comparing specific gravities they are always corrected to 60 F which is adopted as a reference temperature The method of correction is as follows For every 5 F below 60 F deduct 002 from the observed reading to obtain the true specific gravity at 60 F For every 5 F above 60 F add 002 to the observed reading to obtain the true specific gravity at 60 F The temperature must be...

Страница 59: ...a low state of charge is to be expected Measure the specific gravity of the acid of each cell in turn with a hydrometer see Fig 3 The following table shows the state of charge at different values of specific gravities If the battery is discharged it must be recharged either on the motor cycle by a period of daytime running or from an external D C supply at the normal recharge rate of 1 5 amp Secti...

Страница 60: ...reflector and lenses are permanently protected thus the unit keeps its high efficiency over a long period A prefocus bulb is used the filaments of which are accurately positioned with respect to the reflector thus no focusing device is necessary The bulb has a large cap and a flange which has been accurately positioned with relation to the bulb filaments during manufacture A slot in the flange eng...

Страница 61: ...88 Access to the parking bulb in the case of lamps with separate shells is obtained by removing the light unit as described in Subsection 2 In the case of lamps in which the parking bulb shows through a hole in the main reflector the bulb holder assembly should be removed This will come away bringing with it the parking bulb which will then be readily accessible In the case of lamps having the und...

Страница 62: ...352 6volt 3 18 watt or Lucas No 384 6volt 6 18 watt The 3 watt or 6 watt filament provides the normal tail light while the 18 watt filament is illuminated on movement of the brake pedal 6 watt bulbs are now required by law in Great Britain on machines of more than 250 c c capacity Care must be taken that the leads to the stop tail lamp are correctly connected as the use of the 18 watt filament on ...

Страница 63: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 64: ...ROYAL ENFIELD WORKSHOP MANUAL SECTION H1 FRAME EXPLODED VIEW OF LATE 1954 1956 500 TWIN AND 1954 1955 700 METEOR FRAME Section H1 Page 1 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 65: ... knocking them out with a hammer and drift and new races can be fitted either under a press or by means of a hammer and a wooden drift 3 Removal of Rear Suspension Unit The rear suspension units are readily removed by undoing the top pivot pin nut driving out the pivot pin then hinging the suspension unit back on the lower pivot pin removing the lower nut and pushing the suspension unit off the pi...

Страница 66: ...g to prevent it closing in then grip the oil seal in a vice pass a bar through the eye in the top casting and pull and twist to withdraw the hollow metal plug from the end of the main tube Take care not to damage the new seal when fitting it After reassembling remove the oil filler and level plugs and fill with one of the following oil until it runs out through the level plug orifice Castrolite Va...

Страница 67: ...l the bottom bearing tube with oil of one of the grades given below Remove the oil filler screw from the top casting replace the spring and carefully insert the plunger head into the bottom bearing tube pushing it down slowly so as to spill as little oil as possible and allow time for oil to enter the damper chamber and pass up the inside of the top bearing tube Tighten down the top bearing and oi...

Страница 68: ... six inches above the ground but if the alignment is checked also towards the top of the wheels it will be possible to ascertain whether or not the frame is twisted so as to cause one wheel to be leaning while the other is vertical To do this it is always necessary to remove the mudguards and unless a straight edge cut away in its centre portion is available it will be necessary also to remove the...

Страница 69: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 70: ... between the spring stud and the bore of the valve port forming a hydraulic damping system A compression spring is fitted inside the main tube between the upper end of the spring stud and the upper end of the main tube The lower end of the main tube and upper end of the bottom tube are protected by a cover secured to the fork crown A special fork is available for sidecar machines This has bottom t...

Страница 71: ... the bump stroke the larger diameter taper on the oil control collar 38075 enters the main counterbore of the valve port thus forming a hydraulic cushion to prevent metal to metal contact 3 Dismantling the Fork to Replace Spring Oil Seal or Bearing Bushes Place the machine on the centre stand disconnect the front brake control and remove the front wheel and mudguard complete with stays Unscrew the...

Страница 72: ... stud project beneath the end of the bottom tube Now fit the nut and washer and pull the stud into position by tightening the nut If necessary fit the nut first without the washer until sufficient thread is projecting to enable the washer to be fitted 6 Steering Head Races The steering head bearing consists of two deep groove thrust races each containing nineteen 1 4 in diameter balls The bearing ...

Страница 73: ... which forms the hydraulic damping medium All that is necessary is to keep sufficient oil in the fork to ensure that the top end of the bottom spring stud is never uncovered even in the full rebound position The level of oil in the fork can be gauged by removing the top plug screw and inserting a long rod about 3 8 in diameter If slightly tilted this will ledge against the nut at the upper end of ...

Страница 74: ...the spring stud and the bore of the valve port forming a hydraulic damping system A compression spring is fitted inside the main tube between the upper end of the spring stud and the upper end of the main tube The main tube and upper end of the bottom tube are protected by a one piece cover secured to the fork crown and carrying a pressed steel lamp bracket welded to it A special version of the fo...

Страница 75: ...tling the Fork to Replace Spring Oil Seal or Bearing Bushes Place the machine on the centre stand disconnect the front brake control and remove the front wheel and mudguard complete with stays Unscrew the bottom spring stud nut 38080 which will allow oil to run out of the fork down to the level of the cross hole in the spring stud Now knock the spring stud upwards into the fork with a soft mallet ...

Страница 76: ... main tube is bottoming in the recess in the fork head in which it fits In this case the nuts on the fork crown clamp stud must be loosened and the sleeves separated see paragraph 7 thus permitting the main tubes to slide through the fork crown Do not forget to tighten the fork head pinch bolts and the nuts on the fork crown clamp studs after adjusting the steering head Before tightening the latte...

Страница 77: ... the three fork head clip bolts make sure that the bolt heads and the sleeves are correctly positioned with the cut away portion engaging the main tube or steering stem Failure to do this may result in a cracked fork head When refitting the oil seal or fitting a new one great care must be exercised not to damage the synthetic rubber lip which forms the actual seal If the seal has been removed from...

Страница 78: ... 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...

Страница 79: ...ROYAL ENFIELD WORKSHOP MANUAL Section J4 Page 2 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 80: ...omparatively thin portion in front of the speedometer After removal of the fork head the lamp bracket tubes can be lifted straight off and the springs can be withdrawn from the upper end of the main tubes after unscrewing the oil level plug and the nut which secures the spring stud to the fork end and knocking the spring stud upwards 6 Removal of Main Tubes To remove the main tubes first dismantle...

Страница 81: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 82: ... that the machine stands securely on the rear wheel and centre stand if necessary place a weight on the saddle or a strut beneath the fork to ensure this 2 Removal of Brake Cover Plate Assemblies Lock the brake on by pressure on the operating lever 38905 R H or 38906 L H and unscrew the cover plate nuts 31347 The right and left hand cover plate assemblies can then be withdrawn from the respective ...

Страница 83: ... i d by 1 9 16 in o d by 7 16 in wide The Skefko Part No is RLS5 Equivalent bearings of other makes are Hoffmann LS7 Ransome and Manes LJ5 8 in Fischer LS7 7 Fitting Limits for Bearings The fit of the bearings in the hub barrel is important The bearings are locked on the spindle between shoulders and the distance pieces 30538 which in turn are held up by the cover plate nuts 31347 In order to prev...

Страница 84: ...s while at the same time they can be and should be left free enough to be capable of being moved by hand in the direction of the slots The pins 252 are secured by locknuts 7916 which are centre punched as an additional precaution The leading shoes i e those towards the rear of the machine have a servo action which render them more effective than the trailing shoes This servo action causes the lini...

Страница 85: ...lls of the tyre After inflation make sure that the tyre is fitting evenly all the way round the rim A line moulded on the wall of the tyre indicates whether or not the tyre is correctly fitted If the tyre has a white mark indicating a balance point this should be fitted near the valve 16 Tyre Pressure The recommended pressure for the front tyre is 181b per square inch for wheel loads up to 240 lb ...

Страница 86: ...ake drum 3 Removal of Brake Shoes and Springs This is best done by unscrewing the pivot pin locknuts and the operating lever nuts after which the assembly of brake shoes return springs pivot pin and operating cam can be removed from the cover plate by light blows with a hammer and drift on the ends of the pivot pin and the operating cam The return springs can then be unhooked from the spring posts...

Страница 87: ...and thus overload the balls The following are the manufacturing tolerances which control the fit of the bearings The figures for the bearings themselves are for SKF bearings but other manufacturers tolerances are similar Bearing o d 1 5622 1 5617 in Housing bore 1 5620 1 5616in Bearing bore 6252 6247 in Shaft diameter 6252 6248 in 8 Refitting Ball Bearings Note that the two ends of the spindle are...

Страница 88: ...ng shoe By leaving the housing free to float the cam can follow up the leading shoe thus maintaining equal pressure between the cam and the two shoes and so making full use of the more efficient leading shoe Owing to the servo action the wear on the leading shoe with a floating cam housing is greater than that of the trailing shoe and in time the limit of float of the cam housing will be reached a...

Страница 89: ...he large flange cross from the left to the right of the centre line With the Palmer rim the spokes from the large flange on the brake drum side go to the more steeply angled holes in the rim which must be on the left of the centre line when the brake drum is on the left i e none of the spokes crosses from left to right of the centre line 15 Tyres Standard tyres on the 250 Clipper and Model S are D...

Страница 90: ...est way to grease the bearings is by packing them with grease after dismantling the hub as described above Note that the brake cam is drilled for a grease passage but the end of this is stopped up with a countersunk screw instead of being fitted with a grease nipple This is done to prevent excessive greasing by over enthusiastic owners If the cam is smeared with grease on assembly it should requir...

Страница 91: ...ROYAL ENFIELD WORKSHOP MANUAL w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 92: ...ehind it may now be removed to prevent risk of them falling out when manipulating the tyre If however these are too tight a fit in the hub to come out easily they may be left in place The main body of the wheel can now be pulled across to the right hand side of the machine thus disengaging it from the fixed section of the hub barrel and the cush drive shell and enabling the wheel to be lifted out ...

Страница 93: ...ment will however be maintained if both cams are moved the same number of notches 3 Removal and Replacement of Complete Wheel for Access to Brake Place the machine on the centre stand and remove the dual seat if fitted and detachable portion of the rear mudguard as if for removal of the main portion of the wheel only Disconnect the rear driving chain at the spring link and remove the chain from th...

Страница 94: ...wn from its housing 7 Cush Drive The sprocket brake drum 39301 is free to rotate on the hub barrel Three radial vanes are formed on the back of the brake drum and three similar vanes are formed on the cush drive shell 39302 Six rubber blocks are fitted between the vanes on the brake drum and those on the cush drive shell thus permitting only a small amount of angular movement of the sprocket brake...

Страница 95: ...the manufacturing tolerances which control the fit of the bearings The figures for the bearings themselves are for SKF bearings but other manufacturers tolerances are similar Bearing o d 1 8122 1 8117 in Housing bore 1 8115 1 8110in Bearing bore 6252 6247 in Shaft diameter Loose side 624 622 in Shaft diameter Fixed side 6252 6248 in 11 Refitting Ball Bearings In order to prevent the possibility of...

Страница 96: ...e free from oil or grease damp etc Replace the felt washers distance collars the brake cover plate assembly speedometer drive gearbox distance collars 39315 and 39323 chain adjuster cams the loose section of the spindle and the spindle nut 36651 The wheel is then ready for reassembly into the machine 15 Wheel Rim The wheel rim is type WM2 19 in plunged and pierced with forty holes for spoke nipple...

Страница 97: ...lt seals on to the brake linings this greasing point is of little value and the best way to grease the bearings is by packing them with grease after dismantling the hub as described above Note that the brake cam is drilled for a grease passage but the end of this is stopped up with a countersunk screw instead of being fitted with a grease nipple This is done to prevent excessive greasing by over e...

Страница 98: ...lace machine on the centre stand if necessary putting packing pieces beneath the legs of the stand to lift the wheel clear of the ground Remove the dual seat if fitted and the detachable portion of the rear mudguard Disconnect the rear driving chain at the spring link and remove the chain from the rear wheel sprocket leaving it in position on the gearbox countershaft sprocket Unscrew the rear brak...

Страница 99: ...ets 5 Removal of Hub Spindle and Bearings To remove the hub spindle and bearings having already removed the brake cover plate assembly and speedometer drive gearbox lift out the felt washers and distance pieces then hit one end of the spindle with a copper hammer or mallet thus driving it out of the hub bringing one bearing with it and leaving the other in position in the hub Drive the bearing off...

Страница 100: ...agraph 3 dealing with the 6 in brake The method is precisely the same for the 7 in brake except that owing to the different type of return springs used it is in this case possible to remove the shoes from the pivot pin and operating cam before the latter are removed from the cover plate 10 Cush Drive The sprocket brake drum is free to rotate on the hub barrel Three radial vanes are formed on the b...

Страница 101: ... approximately equal 13 Final Reassembly of Hub before replacing Wheel Before replacing the felt washers which form the grease seals pack both bearings with grease Recommended greases are Castrolease Heavy Mobilgrease No 4 Esso Grease Energrease C3 or Shell Retinax A These are all medium heavy lime soap or aluminium soap greases The use of H M P greases which have a soda soap base is not recommend...

Страница 102: ...s are Dunlop 3 50 19 in Universal tread except on the 350 Bullet where a 3 25 19 in Universal tyre is used When removing the tyre always start close to the valve and see that the edge of the cover at the other side of the wheel is pushed down into the well in the rim When replacing the tyre fit the part by the valve last also with the edge of the cover at the other side of the wheel pushed down in...

Страница 103: ... drilled for a grease passage but the end of this is stopped up with a countersunk screw instead of being fitted with a grease nipple This is done to prevent excessive greasing by over enthusiastic owners If the cam is smeared with grease on assembly it should require no further attention but in case of necessity it is possible to remove the screw fit a grease nipple in its place and grease the ca...

Страница 104: ...ROYAL ENFIELD WORKSHOP MANUAL Section M1 Page 1 Section M1 Special Tools For 500 Twin and 700 Meteor 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 ...

Страница 105: ...ROYAL ENFIELD WORKSHOP MANUAL Section M1 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 ...

Страница 106: ...ROYAL ENFIELD WORKSHOP MANUAL Section M1 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 ...

Страница 107: ...ROYAL ENFIELD WORKSHOP MANUAL Section M1 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 ...

Страница 108: ...ROYAL ENFIELD WORKSHOP MANUAL NOTES w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 109: ...ROYAL ENFIELD WORKSHOP MANUAL NOTES w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Страница 110: ...FIELD AMAL HITCHCOCK S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE 01564 783 192 E MAIL info hitchcocksmotorcycles com WEB hitchcocksmotorcycles com w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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