Summary of Contents for Royal Enfield 350 BULLET 1949
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ROYAL ENFIELD WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield 350 BULLET 1949—55 500 BULLET 1953—55 MAN 8...
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ROYAL ENFIELD WORKSHOP MANUAL Contents 1949-55 350 Bullet and 1953-1955 500 Bullet SECTION A2a 350 TECHNICAL DATA SECTION A2b 500 TECHNICAL DATA SECTION B2 ENGINE SPECIFICATION SECTION C2 SERVICE OPERATIONS WITH ENGINE IN FRAME SECTION D2 SERVICE OPERATIONS WITH ENGINE REMOVED...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION B2 Engine Specification " 350 and 500 Bullet" Models (Standard) 1. Engine The big end has a hardened chrome steel The engine is a 346 or 499 c.c. vertical single bush pressed in and a floating bush made from cylinder four-stroke with separate cylinder head mild steel and whitemetalled.
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ROYAL ENFIELD WORKSHOP MANUAL running at 1/2 engine speed and a dynamo 12. Timing Drive running at 1.1/2 engine speed. The cams are located in the timing chest and are driven at half engine speed from the crankshaft by a positive geared drive.
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ROYAL ENFIELD WORKSHOP MANUAL Seating thereby automatically by-passing the housed in a box bolted to the frame behind the filter so that the big end will not be deprived of carburettor. lubrication, even though the oil may be dirty. 16. Lubrication System 17.
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ROYAL ENFIELD WORKSHOP MANUAL 350 BULLET OIL PUMP DIAGRAMS FEED PUMP FEED PUMP POSITION 1 POSITION 2 The ports in the housing are connected as follows X - delivery to big end. Y - suction from oil tank Z - suction from oil tank Position 1.
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ROYAL ENFIELD WORKSHOP MANUAL 5 0 0 BULLET OI L PUMP DI A GRAMS FEED PUMP FEED PUMP POS I T I O N 1 POS I T I O N 2 Th e p o r t s a r e c o n n e c t e d a s f o l l o w s : X - i n t h e h o u s i n g i s t h e d e l i v e r y t o t h e b i g e n d .
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ROYAL ENFIELD WORKSHOP MANUAL SECTION C2 Service Operations with Engine in Frame 350 Bullet 1949 - 1955 500 Bullet 1953 - 1955 1. Removal of the Timing Cover oil through the relief valve can be seen. It may First place a tray under the engine to catch...
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ROYAL ENFIELD WORKSHOP MANUAL stems and rockers, with the rocker box covers centre on the compression stroke, i.e., with both removed. To remove the rocker box covers the valves closed. petrol tank must be taken off. (See subsection 5.) Insert a piece of thin tissue paper between the...
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ROYAL ENFIELD WORKSHOP MANUAL is being warmed up on the stand, because all the Using a suitable compressing tool, compress cylinder head nuts are not accessible with the the valve springs and remove the split conical proper tank in position.
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ROYAL ENFIELD WORKSHOP MANUAL When reassembling the engine, it is advisable marked the pin so that it, and the piston, may be to fit a new paper washer between the cylinder replaced the same way round, i.e. split skirt to the barrel and the crankcase.
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ROYAL ENFIELD WORKSHOP MANUAL The filter element is removed by unscrewing The oil feed to the big end can be checked by the nut holding the end cap in position. When partially unscrewing the feed plug in the timing reassembling the filter after cleaning, take care cover between the oil pumps while the engine is that no grit or other foreign matter is sticking to it.
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ROYAL ENFIELD WORKSHOP MANUAL the steel plate taking great care to keep it away place a tray under the engine to catch the oil from the discs or their seatings from the chaincase. 350cc. Engine. Unscrew the body of the Beneath the bottom run of the chain is a breather and examine the disc.
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ROYAL ENFIELD WORKSHOP MANUAL The valve is set to open when the oil pressure If the valve is set to give too high a pressure, exceeds about 35 lbs per square inch and when set the pump disc will be forced off its seating.
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ROYAL ENFIELD WORKSHOP MANUAL 500 BULLET RACER 1954...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION D2 Service Operations with Engine Removed “350 and 500 Bullet” Engines 1. Removal of the Engine from the Frame The flywheel assembly may be difficult to Disconnect the battery leads and remove the remove from the driving side of the crankcase battery.
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ROYAL ENFIELD WORKSHOP MANUAL To remove the idler spindles heat the Mount the crankshaft between centres and crankcase as before, hold the spindles in a vice true up to .0005 in. on either side of the shafts. and tap the crankcase lightly with a hide If the readings for the two shafts are high on hammer.
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ROYAL ENFIELD WORKSHOP MANUAL Mount the crankshaft between centres and Lay the thrust washer on the bearing. true up to .0005 in. on either side of the shafts. Assemble the flywheel into the bearing, if If the readings for the two shafts are high on...
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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 Dl or D2. 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.
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ROYAL ENFIELD WORKSHOP MANUAL Section E1 Page 2...
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ROYAL ENFIELD WORKSHOP MANUAL (See Section C1 or C2.) The top gear pinion and If the main shaft top gear pinion and dog dog will come away with the mainshaft. have been removed, make sure that the dog is The layshaft can then be removed and the...
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ROYAL ENFIELD WORKSHOP MANUAL central screw. Tighten locknut after adjustment has been made. The reason for the two points of adjustment is to enable the lever behind the cover to be kept in its proper position whether the need for adjustment is caused by plate wear or cable stretch.
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ROYAL ENFIELD WORKSHOP MANUAL AMAL NEEDLE TYPE CARBURETTER CARB CHOKE MAIN NEEDLE THROTTLE N E E D LE MODEL YEAR NUMBER DIAMETER VALVE PILOT P O S IT IO N 350 BULLET 1948-55 276CX/1A 0.037 350 BULLET 1956-58 376/29 3.1/2 0.25...
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ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 2...
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ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 3...
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ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 4...
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ROYAL ENFIELD WORKSHOP MANUAL Amal Monobloc Carburetter The supply of air to the engine is controlled by a 1. General Description throttle slide which carries a taper needle operating The Amal Monobloc Carburetter has been in the needle jet. The needle is secured to the...
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ROYAL ENFIELD WORKSHOP MANUAL then undesirably fast it can be slowed down by any point will have some effect on the setting unscrewing the throttle stop a fraction of a turn. required at other points; for instance, a change of...
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ROYAL ENFIELD WORKSHOP MANUAL Section F2 Page 3...
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ROYAL ENFIELD WORKSHOP MANUAL also controls the fuel supply via a connecting pipe dirt is present or, of course, the float is punctured. to the right-hand instrument which does not have If it is necessary to remove the jet block note a float chamber in unit with it.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION G1c Lucas Magdyno Model MOIL for Single Cylinder Engines . General. reach the wick, remove the backing spring The Magdyno is a base-fixed magneto and spring arm by withdrawing the single and dynamo unit, the body of the magneto securing screw.
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ROYAL ENFIELD WORKSHOP MANUAL afterwards with a petrol moistened cloth. Refit the spring arm and backing spring. The bent portion of the spring arm must curve outwards. Place a lock washer over the fixing screw and tighten. The main bearings of the Magdynos are...
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ROYAL ENFIELD WORKSHOP MANUAL 2 (f). Contact Breaker Spring (iii) Very occasionally the fault may be correct contact breaker spring due to a cracked or punctured pick-up pressure, measured at the contacts, is 28-36 moulding. This type of fault is not easily detected by inspection and a check should be made by substitution.
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ROYAL ENFIELD WORKSHOP MANUAL Section G1c Page 4...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION G2b Lucas Dynamo Model E3LM Used on all Models fitted with Magdyno 1. General 3. Test Data The dynamo is a shunt-wound two-pole machine, arranged to work in conjunction with a Cutting-in speed (Dynamo Cold) 1,050 –...
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ROYAL ENFIELD WORKSHOP MANUAL (iii) Start the engine and set to run at normal idling speed. (iv) Connect the negative lead of a moving coil voltmeter, calibrated 0-10 volts, to one of the dynamo terminals and connect the positive lead to a good earthing point on the dynamo yoke or engine.
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ROYAL ENFIELD WORKSHOP MANUAL To remedy a badly worn commutator, mount the at the commutator end while unscrewing the armature with or without the drive end bracket bolts and take care not to lose the nuts. in a lathe, rotate at high speed and take a light (v) Draw the drive end bracket complete with cut with a very sharp tool.
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Miller coil ignition sets and rectifier (ii) The second field coil lead must be connected sets on two-stroke machines, all Royal Enfield machines in current production have the positive terminal earthed.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION G3a Control Box Used on Models G, J2, "350 Bullet," "500 Bullet," "500 Twin," "Meteor 700," 1950 onwards MODEL RB107 1. General In Model RB107 control box, the regulator and cut-out contacts are positioned, for ease of access, above their respective armatures.
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ROYAL ENFIELD WORKSHOP MANUAL With the ignition switch in the "OFF" position, heating of the shunt winding will cause false settings start the engine. to be made. Slowly increase the speed of the engine until the Stop the engine. voltmeter needle "flicks" and then steadies. Note this Remake the original connections and replace the value and stop the engine.
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ROYAL ENFIELD WORKSHOP MANUAL Battery Model PUZ7E 1. General The model PUZ7E (see Fig. 1) is a "drycharged" battery and is supplied without electrolyte but with its plates in a charged condition. When the battery is required for service it is only necessary to fill each cell with sulphuric acid of the correct specific gravity.
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ROYAL ENFIELD WORKSHOP MANUAL 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.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION G5a Head and Tail Lamps Used on Models G, J2, " 350 Bullet," " 500 Bullet," " 500 Twin," "Meteor 700," 1950 onwards 1. Headlamp 2. Lucas Light Unit In all the above Models the headlamp incorporates The unit incorporates a combined reflector and the Lucas Light Unit MCF700.
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ROYAL ENFIELD WORKSHOP MANUAL 3. Replacing the Light Unit and Bulb Slacken the securing screw at the top of the headlamp rim. Remove the front rim and Light Unit assembly. Withdraw the adaptor from the Light Unit by twisting it in an anti-clockwise direction and pulling it off.
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ROYAL ENFIELD WORKSHOP MANUAL Recent machines use lamps with red plastic covers, either Type 529 (Fig. 7), which is a tail lamp only; 525 (Fig. 8), which is a combined stop and tail lamp; or 564 (Fig. 9), which is a combined stop and tail lamp and reflector.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION H1 FRAME EXPLODED VIEW OF LATE 1954-1955 350 BULLET AND 500 BULLET FRAME Section H1 Page 1...
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The rubber bushes in the top and bottom eyes can easily be renewed and the spring can be (b) Royal Enfield Units. Mark 1. Enfield removed by pushing down on the top spring rear suspension units, Part Number 34276 or cover so as to release the split collar above it.
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B.P. Energol S.A.E. 20. Wait till the oil has ceased running, then replace the oil filler and level plugs. (c) Royal Enfield Units. Mark II. Enfield rear suspension units, Part No. 38109, are shown in Fig. 4. This type provides positive damping on the rebound stroke and in consequence does not need the spring to be anchored on scrolls.
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ROYAL ENFIELD WORKSHOP MANUAL On the rebound stroke the disc valve in the top bearing tube and plunger head from the plunger head closes under pressure in the bottom bearing tube, bottom casting and outer damper chamber, so that the oil is forced past the tube assembly.
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ROYAL ENFIELD WORKSHOP MANUAL latter and withdraw the stand complete with its towards the wheels, it will be bearing sleeve after disconnecting one end of the possible to ascertain whether or not the frame is stand spring. Note that the position of the stand...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION J1 Front Fork With Casquette and Aluminium Alloy Bottom Tubes 1. Description The telescopic fork consists of two legs each of which comprises main tube chrome molybdenum alloy steel tubing which is screwed into the Casquette fork head at the upper end and securely clamped to the fork crown.
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ROYAL ENFIELD WORKSHOP MANUAL Upward movement of the wheel spindle forces oil Dismantling the Fork to Replace Spring, Oil from the lower chamber "A" through the annular Seal or Bearing Bushes space between the spring stud (38067) and the bore of...
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ROYAL ENFIELD WORKSHOP MANUAL removal of the main tube bush the bottom tube up sharply against the spring until two or three bush, oil seal housing and oil seal can be threads on the stud project beneath the end of removed.In case of difficulty in removing the main...
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ROYAL ENFIELD WORKSHOP MANUAL The leads to the lighting switch and ammeter All that is necessary is to keep sufficient oil in the should be disconnected from the battery, regulator, fork to ensure that the top end of the bottom spring tail lamp, etc.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION J3 Front Fork With Facia Panel and Aluminium Alloy Bottom Tubes Used on " 500 Bullet," 1953 ; "Meteor 700," 1953 1. Description The telescopic fork consists of two legs each of which comprises main...
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ROYAL ENFIELD WORKSHOP MANUAL The fork is filled with a light oil (S.A.E. 20) to a (E4912). The bottom tube can now be withdrawn point above the lower end of the spring so that the completely from the main tube, leaving the bottom damper chamber "B"...
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ROYAL ENFIELD WORKSHOP MANUAL nuts on the fork crown clamp stud, must be loosened 5. Steering Head Races and the sleeves separated (see paragraph 7) thus The steering head bearing consists of two deep permitting the main tubes to slide through the fork groove thrust races each containing nineteen 1/4 in.
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ROYAL ENFIELD WORKSHOP MANUAL 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. 7. Removal of Main Tubes To remove the main tubes first dismantle the...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION J4 Front Fork With Facia Panel and Steel Bottom Tubes Used on "350 Model G," "500 Model J2," 1951 onward: " 350 Bullet," " 500 Twin," 1950-53 inclusive 1. Description steering damper and have stronger springs.
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ROYAL ENFIELD WORKSHOP MANUAL Section J4 Page 2...
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ROYAL ENFIELD WORKSHOP MANUAL tightening the steering stem locknut after After removal of the fork head the lamp loosening the nuts on the three pinch bolts bracket tubes can be lifted straight off and the which secure the fork head to the steering stem springs can be withdrawn from the upper end of and to the two main tubes.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION Kl Front Wheel With Dual 6 in. Brake Fitted to " Meteor 700," 1953 onwards; "500 Twin," "500 Bullet," "350 Bullet," 1955 onwards . Removal of Brake Cover Plate 1. Removal from Fork To remove the front wheel from the fork...
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ROYAL ENFIELD WORKSHOP MANUAL posts in the brake shoes thus allowing the whole having already removed the brake cover plate assembly to fall apart. assemblies, lift out the felt washers, Part No. 4. Replacing Brake Linings 21466, and distance pieces, Part No. 30538.
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ROYAL ENFIELD WORKSHOP MANUAL by locknuts, 7916, which are centre punched as bearing is first fitted to one end of the spindle by an additional precaution. means of the hollow drift; the spindle and The leading shoes (i.e. those towards the rear...
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ROYAL ENFIELD WORKSHOP MANUAL 13. Spokes the tyre is fitting evenly all the way round The spokes are of the single butted type the rim. A line moulded on the wall of the 8-10 gauge with 90° countersunk heads, tyre indicates whether or not the tyre is angle of bend 95°-100°, length 6.5/8 in.,...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION K2 Front Wheel With Single 6 in. Brake Fitted to 250 Clipper, Model S, G, J and J2. Also 350 + 500 Bullet, and 500 Twin up to the end of 1954 1. Removal from Fork...
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ROYAL ENFIELD WORKSHOP MANUAL 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 nuts on the spindle.
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ROYAL ENFIELD WORKSHOP MANUAL cam and the two shoes and so making full nuts on the spindle. Tightening the nuts use of the more efficient leading shoe. should not have any effect on the ease with Owing to the servo action the wear on the which the spindle can be turned.
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ROYAL ENFIELD WORKSHOP MANUAL With the Palmer rim the spokes from the large taken that they are built the right way round into the flange on the brake drum side go to the more steeply wheel. 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.
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ROYAL ENFIELD WORKSHOP MANUAL 16. Tyre Pressures grease on assembly (which is apt to lead to trouble The load which the tyre will carry at different through grease finding its way past the felt seals on to inflation pressures is shown below :...
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ROYAL ENFIELD WORKSHOP MANUAL SECTION L1 Rear Wheel (Detachable Type) manipulating the tyre. If, however, these are too tight 1. Description a fit in the hub to come out easily they may be left in This wheel is of the "detachable" type which place.
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ROYAL ENFIELD WORKSHOP MANUAL Removal and Replacement of Complete same position.* Disconnect Wheel for Access to Brake speedometer driving cable and slide the wheel Place the machine on the centre stand and out of the fork ends, tilting it so as to disengage...
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ROYAL ENFIELD WORKSHOP MANUAL connecting link in the driving chain make sure that the closed end of the spring link points in the direction of travel of the chain. Replace the chain adjuster cams in their original positions or, if...
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ROYAL ENFIELD WORKSHOP MANUAL 8. Removal of Ball Bearings To remove the ball bearings take the complete wheel out of the machine and separate the main portion of the wheel from the sprocket/brake drum cush drive shell assembly as described above. To remove the bearing from...
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ROYAL ENFIELD WORKSHOP MANUAL reassembly into the machine. 12. Reassembly of Brake Shoes, Pivot Pin and Operating Cam into Cover Plate 15. Wheel Rim No difficulty should be experienced in The wheel rim is type WM2-19 in. plunged carrying out these operations. Make sure that the and pierced with forty holes for spoke nipples.
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ROYAL ENFIELD WORKSHOP MANUAL exceeding 280 lb, 18 lb per square inch for loads the bearings is by packing them with grease after up to 320 lb., 20 lb. per square inch for loads up dismantling the hub as described above.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION L2 Rear Wheel (Non-Detachable Type) Part No. 36788 for " 500 Twin" and " 350 Bullet"; Part No. 37278 for "Meteor 700" and " 500 Bullet." 1. Description to lift the wheel clear of the ground. Remove the dual...
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ROYAL ENFIELD WORKSHOP MANUAL the wheel out of the fork ends, tilting it so as to already removed the brake cover plate assembly and disengage the end of the brake shoe pivot pin from speedometer drive gearbox, lift out the felt washers the slot in the fork end.
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ROYAL ENFIELD WORKSHOP MANUAL entered into one end of the hub barrel which is then 9. Removal of Brake Operating Cam and Brake supported on one of the hollow drifts. The other Shoe Pivot Pin bearing is then threaded over the upper end of the...
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ROYAL ENFIELD WORKSHOP MANUAL When reassembling the cush drive the Recommended greases are Castrolease entry of the vanes between the rubbers will (Heavy), Mobilgrease (No. 4), Esso Grease, be facilitated if the latter are fitted into the Energrease C3 or Shell Retinax A. These driving shell first and then tilted.
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ROYAL ENFIELD WORKSHOP MANUAL between the fork ends. The rim should be trued If the correct method of fitting and removal as accurately as possible, the maximum of the tyre is adopted it will be found that the permissible run-out both sideways and radially covers can be manipulated quite easily with the being plus or minus 1/32 in.
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ROYAL ENFIELD WORKSHOP MANUAL through grease finding its way past the felt seals being fitted with a grease nipple. This is done to on to the brake linings) this greasing point is of prevent excessive greasing by over-enthusiastic little value and the best way to grease the owners.
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ROYAL ENFIELD WORKSHOP MANUAL SECTION M2 Special Tools For "Bullet " Models SECTION C2 Sub- Section Page 4, 18 14835 Magdyno Pinion Extractor (Tool Kit) ....1 TE1124 Valve Spring Compressor ........1 Valve Guide Mandrels ....
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ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 2...
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ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 3...
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ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 4...
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ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 6...
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ROYAL ENFIELD WORKSHOP MANUAL SPARES for ROYAL ENFIELD & 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...
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