Royal Enfield G Workshop Maintenance Manual
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Royal Enfield G Workshop Maintenance Manual

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ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL
WORKSHOP
MAINTENANCE MANUAL
FOR THE
ROYAL ENFIELD
350 cc OHV G, 1945 - 1954
G deluxe and 350 Clipper
1955 - 57
and 500 cc OHV J and J2
1945 – 1954
MOTOR CYCLES
HITCHCOCK'S MOTORCYCLES
ROSEMARY COURT
OLDWICH LANE WEST
CHADWICK END
SOLIHULL
B93 0EY
ENGLAND
Telephone 01564 783 192
Fax 01564 783 313
e-mail:
info@hitchcocksmotorcycles.com
Page 1
Web: hitchcocksmotorcycles.com

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  • Page 1 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE ROYAL ENFIELD 350 cc OHV G, 1945 - 1954 G deluxe and 350 Clipper 1955 - 57 and 500 cc OHV J and J2 1945 – 1954 MOTOR CYCLES HITCHCOCK’S MOTORCYCLES...
  • Page 2 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 2...
  • Page 3 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL CONTENTS DESCRIPTION PAGE TECHNICAL DATA, 500 ENGINE TECHNICAL DATA, 350 ENGINE TOOLS SUPPLIED WITH MACHINE 7 – 9 ENGINE; DECARBONISING 9 – 10 ENGINE; TIMING GEAR 11 – 15 ENGINE; CRANKSHAFT ENGINE; CRANKCASE 16 –...
  • Page 4 DATA ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL ROYAL ENFIELD 500 c.c. O.H.V. MOTOR CYCLE TRANSMISSION. ENGINE. Sprockets-Engine ......21 T. in. P. X .305 in. W, Cubic Capacity ... 499 c.c. Clutch ......42 T.
  • Page 5 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL DATA ROYAL ENFIELD 350 c.c. O.H.V. MOTOR CYCLE ENGINE. Cam Spindle .........6245 in. - .6235 in. Idler Pinion Spindle..49925 in. - .49825 in. Cubic Capacity ...
  • Page 6 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL DATA-continued CARBURETTER. Sparking Plug-Size ........14 m.m. in. reach. Carburetter Type ........... Amal. 276 Type ............Lodge C.14 Sintox. Main Jet Size ..............130 ...........
  • Page 7 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL ENGINE conical collars and release the springs, when the valve DECARBONISING. can be withdrawn. Fig. 2 shows a Terry compressor in 1. Removal of Cylinder Head. use, Fig. 3 a special type suitable for a large...
  • Page 8 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 5. Piston and Rings. renewed if worn, using a draw bolt as shown in Fig. 4, If the piston rings are in good condition they can both for withdrawing the old bush and fitting the new be replaced, taking care to fit them in their original one.
  • Page 9 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL TIMING GEAR. the inlet and exhaust valves, as there is a difference of .002 in. in the stem diameter. 10. Valve Timing. Access to the timing gear is obtained by removal of the timing cover after unscrewing the nine nuts securing it.
  • Page 10 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 12. Tappet Adjustment. Access to the tappet adjustment is obtained by removing the inspection cover from the side of the cylinder. The exhaust tappet should have .004 in. clearance; the inlet .002 in., when the engine is cold.
  • Page 11 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL out towards the opposite end) and the bottom stud; also the studs securing the crankcase to the engine plates and the studs and distance pieces securing the engine plates to the bottom of the seat tube of the frame, and to the chainstays and cradle tubes.
  • Page 12 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL From the upper wheel remove the set screw which prevents the crankpin nut from turning and unscrew this nut, using a well-fitting tubular spanner for this purpose. The crankpin is a press fit in the flywheel PUMP WORM EXTRACTOR Fig.
  • Page 13 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL one fitted, this being subsequently ground out to 1.625 in. ±.00025 in. The practice of fitting new ready-ground big-end bushes is not recommended as it is difficult to ensure roundness of the bore if this is done.
  • Page 14 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL centre of the pin must be screwed tight and of tube between the faces of each flywheel and the centre-punched to make sure that it does not come out. vice jaws (see Fig. 19). When assembling the...
  • Page 15 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL necessary. To remove the main bearing race from the driving side of the case, the half case should be inverted over a lighted gas ring until the heat loosens the race so that it falls out on tapping the case.
  • Page 16 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Position 1. Position 2. Plunger A is being drawn out of cylindrical hole in Plunger A is being pushed into cylindrical hole in disc disc C by action of peg B on shaft D. Port T in disc C C.
  • Page 17 20 miles so that to obtain a consumption diagrammatically in Fig. 25. The primary side of the figure of 2,000 m.p.g., the amount of oil lost must not feed pump B draws oil from the tank A through the exceed 1% of that circulated through the engine.
  • Page 18 800-1,000 m.p.g. If the oil consumption is heavier lapping the disc, the flat face up the side must be than this (or is heavier than 1,500-2,000 m.p.g. in an continued right to the top, otherwise the driving pin engine having a cylinder and piston in good on the end of the cross shaft will foul the disc.
  • Page 19 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL TRANSMISSION which secure the cover over the gear operating GEAR BOX. mechanism and lift this cover away. Disconnect the 27. Removal of Gearbox from Frame. clutch control (if in machine) hinge the lever back, and lift out the clutch adjusting screw and sleeve.
  • Page 20 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 20...
  • Page 21 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL To remove the layshaft and final drive sleeve, the countershaft sprocket must first be removed. This, of course, necessitates removal of the inner half of the chain case if the box is still in the frame. The countershaft sprocket nut should be undone before removal of the gearbox end cover.
  • Page 22 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL DETAIL OF FOOT GEAR CHANGE Fig. 35 the three distance tubes inside the springs pass 4. The layshaft high gear and kickstarter pinion through the holes in the pressure plate. Tighten the should be assembled on the layshaft and the spring pins as far as they will go.
  • Page 23 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL CHAINS 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 34. Lubrication. in. When measuring chains for wear, the load applied The front chain is lubricated by filling the oilbath should be 28 lbs.
  • Page 24 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 24...
  • Page 25 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL VARIOUS CARBURETTER SETTINGS POSSIBLE FOR 350 AND 500 OHV CARB CHOKE MAIN NEEDLE THROTTLE N E E D LE MODEL YEAR NUMBER DIAMETER VALVE PILOT P O S IT IO N 350 G Stub fitting...
  • Page 26 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 26...
  • Page 27 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 27...
  • Page 28 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 28...
  • Page 29 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 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.
  • Page 30 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 31 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 32 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 32...
  • Page 33 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 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 –...
  • Page 34 (iii) Take out the screw "J" with spring internal examination. washer from the centre of the black moulded end cap "G." Draw the cap away from the end (vii) If the dynamo is in good order, restore bracket, take off terminal nut "F" and spring the original connections.
  • Page 35 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 36 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL (iii) Fit the new field coil over the pole shoe and place it in position inside the yoke. Take care to ensure that the taping of the field coil is not trapped between the pole shoe and the yoke.
  • Page 37 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Control Box Used on Models G, J and J2, 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. It will be noticed that some of the internal electrical joints are resistance brazed.
  • Page 38 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL With the ignition switch in the "OFF" otherwise heating of the shunt winding will position, start the engine. cause false settings to be made. Slowly increase the speed of the engine until Stop the engine.
  • Page 39 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 40 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 41 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Head and Tail Lamps Used on Models G, J and J2, 1. Headlamp 2. Lucas Light Unit In all the above Models the headlamp The unit incorporates a combined reflector incorporates the Lucas Light Unit MCF700. This and front lens assembly (see Fig.
  • Page 42 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 43 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 44 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 1950 MODELS Page 44...
  • Page 45 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Front Fork With Facia Panel and Steel Bottom Tubes Used on "350 Model G," "500 Model J2," 1951 onward: 1. Description 2. Dismantling Fork to Replace Spring, The telescopic fork consists of two legs...
  • Page 46 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 46...
  • Page 47 ROYAL ENFIELD 350cc and 500cc O.H.V. 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 which secure the fork head to the steering the springs can be withdrawn from the stem and to the two main tubes.
  • Page 48 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 1954 MODEL G 1947 MODEL J Page 48...
  • Page 49 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Front Fork With Casquette and Aluminium Alloy Bottom Tubes Used on Model G deluxe and 350 Clipper 1. Description The telescopic fork consists of two legs each of which comprises a main tube of chrome...
  • Page 50 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL full of oil. Upward movement of the wheel 3. Dismantling the Fork to Replace Spring, spindle forces oil from the lower chamber "A" Oil Seal or Bearing Bushes through the annular space between the spring...
  • Page 51 ROYAL ENFIELD 350cc and 500cc O.H.V. 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...
  • Page 52 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL The leads to the lighting switch and ammeter damping medium. All that is necessary is to should be disconnected from the battery, keep sufficient oil in the fork to ensure that the regulator, tail lamp, etc.
  • Page 53 In the case of Models S, G and J assembly to fall apart. place the machine on the rear stand and place a suitable box or block beneath the 4.
  • Page 54 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 55 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 56 ROYAL ENFIELD 350cc and 500cc O.H.V. 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.
  • Page 57 A greasing point is provided in the centre of the and grease the cam by this means. hub barrel. Unless the barrel is packed full with 350 CLIPPER OTHERWISE KNOW AS MODEL G DELUXE 1956 Page 57...
  • Page 58 (anchor link nut Place the machine on the stand. Remove the in the case of Models "S," "G" and "J2 ") and dual seat, if fitted, and the detachable portion of remove this together with the washer behind it.
  • Page 59 The lighter bearings used in the "250 Brake linings are supplied either in pairs Clipper" and Models "S" and "G"are 5/8 in. i/d x ready drilled complete with rivets, Part No. 1.9/16 in. o/d x 7/16 in. wide. The Skefko Part 37786BX (6 in.
  • Page 60 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 8. Fitting Limits for Bearings bearings and either fit the assembly of brake The fit of the bearings in the hub barrel is cover plate, speedometer gearbox, etc. or make important. The bearings are locked on the spindle up this distance with tubular distance pieces.
  • Page 61 Model " S " is Type WM 1-19 in., internal width No difficulty should be experienced in 1.60 in. The rim for the Model "G" and Model carrying out these operations. Make sure that the "J2" is WM2-19 in., internal width 1.580 in.
  • Page 62 British Standard Model "S" are Dunlop 3.00-19 in. Lightweight Cycle. Reinforced. On the Model "G" the standard tyre is Dunlop 3.25-19 in. Universal tread and on the 16. Wheel Building and Truing Model "J2," Dunlop 3.50-19 in. Universal tread.
  • Page 63 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL of the tyre indicates whether or not the tyre is 19. Lubrication correctly fitted. If the tyre has a white mark, A greasing point is provided in the centre of indicating a balance point, this should be fitted the hub barrel.
  • Page 64 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL SPRING FRAME Model G deluxe and 350 Clipper Page 64...
  • Page 65 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL 1. Description of Frame The frames used on the above models are basically identical, with swinging arm rear suspension, there some small differences in the lugs for engine attachment, the method of attachment of the pivot point for...
  • Page 66 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Units having Part No. 36451 have a spring If the spring has remained attached to the of .264in. diameter wire (Part No. 35494) bottom casting, unscrew the bottom cover tube having a rating of approximately 250lb. per and unscrew the spring from the scroll on the inch.
  • Page 67 ROYAL ENFIELD 350cc and 500cc O.H.V. 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 tube assembly.
  • Page 68 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL latter and withdraw the stand complete with Also towards the top of the wheels, it will be its bearing sleeve after disconnecting one possible to ascertain whether or not the frame end of the stand spring. Note that the...
  • Page 69 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL SPECIAL TOOLS Page 69...
  • Page 70 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 70...
  • Page 71 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 71...
  • Page 72 ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL Page 72...

This manual is also suitable for:

G deluxe350 clipperJJ2

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