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WORKSHOP
MAINTENANCE MANUAL
FOR THE
Royal
Enfield
CONSTELLATION 1958 on
SUPER METEOR 1956 on
MAN11

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Summary of Contents for Royal Enfield CONSTELLATION 1958

  • Page 1 WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield CONSTELLATION 1958 on SUPER METEOR 1956 on MAN11...
  • Page 2: Table Of Contents

    Contents SECTION A4 ENGINE DATA (SUPER METEOR) SECTION A11 ENGINE DATA (CONSTELLATION) SECTION B4 ENGINE SPECIFICATION (SUPER METEOR) SECTION B11 ENGINE SPECIFICATION (CONSTELLATION) SECTION C4 OPERATIONS WITH ENGINE IN FRAME (SUPER METEOR) SECTION C11 OPERATIONS WITH ENGINE IN FRAME (CONSTELLATION) SECTION D10 OPERATIONS WITH ENGINE REMOVED (ALL MODELS) SECTION E4...
  • Page 3 SECTIONAL VIEW OF TYPICAL TWIN CYLINDER ENGINE (EARLY TYPE)
  • Page 4: Section A4

    SECTION A4 Technical Data Super Meteor Engine Cubic Capacity ......692 c.c. Valve Spring Free Length Stroke ..........90 m.m. Inner 2.1/32 (early) 1.1/2 in. (late) Bore ..... .. Nominal 70 m.m.
  • Page 6: Section A11

    SECTION A11 Technical Data Constellation Engine Cubic Capacity ......692 c.c. Valve Spring Free Length Stroke ..........90 m.m. Inner ......1.1/2 in. Bore ..... .. Nominal 70 m.m.
  • Page 8: Section B4

    SECTION B4 Engine Specification " Super Meteor " 1. Engine bolted to the connecting rods by means of high The engine is an even-firing vertical twin tensile socket screws, secured by cotter pins. cylinder, having separate cylinders and heads and fully enclosed pressure-fed overhead valve 6.
  • Page 9 13. Ignition and Lighting System. (See 16. Lubrication System Section G) Lubrication is by the Royal Enfield Dry Separate systems are provided for ignition Sump system which is entirely automatic and and lighting. The former is by the latest type of positive in action.
  • Page 10 end of the pushrod. It flows down the push rod The breather is located on the driving side of into the cam tunnel where it lubricates the cams the crankcase and consists of a small housing and tappets and thence into the timing chest, attached to the crankcase by three screws and lubricating the timing chains.
  • Page 11 The ports in the housing are connected as follows W - delivery to rocker gear. Y - suction from oil tank. X - delivery to big ends. Z - suction from oil tank. Position 1. The plunger A is being drawn out of Position 2.
  • Page 14: Section B11

    SECTION B11 Engine Specification “Constellation” 1. Engine bearings consist The engine is an even-firing vertical twin white-metalled steel liners which are renewable. cylinder, having separate cylinders and heads The detachable bearing caps are bolted to the and fully enclosed pressure-fed overhead valve connecting rods by means of high tensile socket gear.
  • Page 15 11. Valve Gear tachometer if this is required. This drive can be The valves are operated from the camshaft by fixed to an aperture provided in the timing means of large, flat-based, guided tappets, cover, which is otherwise covered by a small tubular alloy push rods with induction hardened plate.
  • Page 16 17. Breather 16. Lubrication System The efficient operation of the breather is of Lubrication is by the Royal Enfield Dry paramount importance to the performance of the Sump system which is entirely automatic and engine. It acts as a non-return valve between the positive in action.
  • Page 17 crankcase pressure to the breather via the hole 19. Clutch drilled through the drive side main journal. A plug screwed into the head of the bolt The clutch has five pressure plates and four retains the disc, and a hole drilled in its centre friction plates, including the sprocket which is allows the crankcase to breathe into the primary lined on both sides with friction material.
  • Page 18 The ports in the housing are connected as follows W - delivery to rocker gear. Y - suction from oil tank. X - delivery to big ends. Z - suction from oil tank. Position 1. The plunger A is being drawn out of Position 2.
  • Page 20: Section C4

    SECTION C4 Service Operations with Engine in Frame "Super Meteor" 1. Removal of Timing Cover The correct valve timing at .012 in. First place a tray under the engine to catch clearance is as follows: the oil which will escape when the cover is Exhaust opens 75°...
  • Page 21 Section C4 Page 2...
  • Page 22 removing the chain case cover, which is held in position by a single nut. Before removing the nut, place a tray under the engine to catch the oil from the chaincase. Beneath the bottom run of the chain is a curved slipper on which the chain rests and which may be raised or lowered by turning the adjusting screw after having first slackened the...
  • Page 23 tool box. Remove the two nuts on either side of the seat attaching it to the frame and lift the seat and mudguard off. 9. Removal of Petrol Tank Turn off the petrol tap. The petrol tank is attached to the frame by a rubber mounted stud at the front, and is clipped at the rear to a rubber sleeve surrounding the top tube.
  • Page 24 should be fitted in order to maintain the interference. It is necessary to re-cut the valve seat and grind in the valve after a guide has been replaced. (See Subsection 18.) A worn exhaust valve guide may give rise to slight smoking from the exhaust pipe due to oil passing down the valve stem on to the hot valve head.
  • Page 25 way round and so that the pistons go back into the same barrels the same way round. Take care not to drop the gudgeon pin circlip into the crankcase. A clean cloth should be put over the mouths of the crankcase to prevent this.
  • Page 26 cylinder base and cylinder head. Two paper gaskets are fitted to the base of each cylinder. Smear clean oil over the pistons, having replaced the rings if these have been removed, lower the piston over the connecting rod and insert the gudgeon pin from the outer side. Fit the circlip and then fit the second piston in a similar manner.
  • Page 27 Check the fit of the plungers in the pump 23. Removal of Pump Worm and Timing discs which should have a minimum of Sprocket clearance but should be able to be moved in and Remove the timing chains (Subsection 22). out by hand.
  • Page 28 Extract the tappet guides, using Special Tool Great care must be taken not to nip the felt No. E.5790, having heated the case first. washer behind the sprocket on re-assembly as The guides are made from Nickel Chrome this would make the engine very stiff to turn Alloy Iron and if a guide should break while over and would damage the washer and allow removing it, it can be withdrawn with a pair of...
  • Page 29 primary chaincase and put the stator in position This is a gauge .015 in. greater in radius than with the coil connections facing outwards. the rotor and fits over the adaptor on the end of Replace the nuts and shakeproof washers the crankshaft in the rotor's place.
  • Page 30: Section C11

    SECTION C11 Service Operations with Engine in Frame Constellation 1. Removal of the Timing Cover Remember that all three timing sprocket fixing First place a tray under the engine to catch bolts have Left Hand Threads. While the oil which will escape when the cover is tightening the camshaft bolts the sprockets removed.
  • Page 31 the magneto sprocket nut and withdraw the sprocket, using Special Tool No. 14835. Set the contact points to .012 in., fully opened, but if they are worn or pitted refer to Section G. Remove the sparking plugs and set the piston in the left-hand cylinder to 3/8 in.
  • Page 32 8. Removal of the Dual Seat and Rear Mudguard Disconnect the leads to the rear lamp by pulling out the plugs in the connectors near the tool box. Loosen the two nuts on either side of the seat attaching the mudguard carrier to the frame and lift the seat, mudguard and carrier off together.
  • Page 33 tube of 9/16 in. internal diameter to prevent damage to the bore of the guide. If a valve guide is removed for any reason, an oversize one should be fitted in order to maintain the interference. It is necessary to re-cut the valve seat and grind in the valve after a guide has been replaced.
  • Page 34 long central cylinder studs which come opposite the gudgeon pins. Use Special Tool No. E.5477 to extract the gudgeon pin or using a rod about 1/4 in. in diameter insert this right through one gudgeon pin and drive the other pin out of its piston, supporting the connecting rod substantially meanwhile to prevent distortion.
  • Page 35 valve guides and these may be damaged if Oil the cylinder bores and lower the barrels suitable apparatus is not employed. over the pistons and seat them gently on their The inlet valve faces and seats can be cut at gaskets.
  • Page 36 Remove the end plates from both pumps. 23. Removal of Pump Worm and Timing Remove the pump discs and plungers. Sprocket Remove the pump spindle which can be Remove the timing chains (Subsection 22). pulled out from the front or return pump end. Unscrew the oil pump worm by means of the Check the fit of the plungers in the pump hexagon head behind it.
  • Page 37 27. Removal of the Tappets and Guides instead of a partial vacuum, giving rise to smoking or over-oiling. It is only necessary to remove the tappets and guides if they have become worn. See that the discs and backplate of the Remove the cylinder heads and barrels.
  • Page 38 aluminium from stripping. The radial air gap between the rotor and the The method of fitting the thread inserts is the poles of the stator should be .020 in. in all same as that used for the sparking plug inserts positions and care must be taken when refitting described in Subsection 14.
  • Page 40: Section D10

    SECTION D10 Service Operations with Engine Removed Super meteor and Constellation Disconnect the clutch cable. 1. Removal of the Engine Gearbox Unit from Remove the footrest bar. the Frame Remove the bottom rear engine bolt. Disconnect the battery leads. Support the engine on a suitable box or Remove the dual seat and petrol tank.
  • Page 41 fouling between the cotter and the crankshaft Turn the crankshaft until the connecting rods web. are at bottom dead centre and the two halves of If it is necessary to replace the big ends, a the crankcase can then be separated, tapping the service crankshaft can be supplied with crankcase with a soft mallet.
  • Page 42 over the crankshaft, making sure to lift the by two screwed aluminium plugs locked by tappets clear of the cams. centre punching. Bolt the two halves of the crankcase If the crankshaft is taken out of the engine together. for any reason, the plugs should be removed and If so desired the heated timing-side crank- the oil passage cleared of sludge.
  • Page 44: Section E4

    SECTION E4 Gearbox and Clutch Super Meteor + 1961 Constellation 1. Removal of Gearbox This is described in section D, subsection 2. 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.
  • Page 45 Section E4 Page 2...
  • Page 46 (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 replaced the right way round or third and top 2nd and 3rd gears drawn off the final drive gears can be engaged simultaneously.
  • Page 47 The other point of adjustment is behind the clutch plate inserts. To make the adjustment, lower inspection cover on the front of the remove the inspection cover, slacken the locknut gearbox and is for compensating for wear on the and turn the central screw. Tighten the locknut after adjustment has been made.
  • Page 48: Section E7

    SECTION E7 Gearbox and Clutch 1958 – 1960 Constellation 1. Description of the Clutch KL engages with two pinions M and N which The clutch is built into the clutch sprocket are free to rotate or slide on the layshaft G. and is mounted on the gearbox mainshaft which The double pinion KL has dogs at each end projects through into the primary chaincase.
  • Page 49 EXPLODED VIEW OF CLUTCH Fig. 2 3. Removal of the Gearbox Note the felt washer in the recess behind the This is described in Section D, Subsection 2. larger mainshaft bearing and the dished The gearbox can, however, be completely pen-steel washer between the bearing and the dismantled with the engine in the frame except felt washer.
  • Page 50 Fig. 3A -Neutral. None of the dogs is engaged so that the mainshaft B and pinions E, F, H, J are rotating but the mainshaft sleeve C and the final drive sprocket are stationary. Fig. 3B-Bottom Gear. The sliding pinions K, L, M, N have moved over so that the dogs on K engage with the dogs on the pinion J.
  • Page 51 See that the mainshaft is pushed right home. The joint between the gearbox and the inner It may tighten in the felt washer inside the final cover should be made with gold size, shellac or drive shaft nut. a similar jointing compound. The layshaft top gear and kickstarter pinion Make sure that all parts are clean before should be assembled on the layshaft and the...
  • Page 52 Section E7 Page 5...
  • Page 53 that there is still clearance in the operating 8. Dismantling and Reassembling the Clutch mechanism. This can conveniently be done by The method of removing the clutch is means of a screwdriver in the slot in the end of described in Section C. the pressure plate withdrawing pin.
  • Page 54: Section F3

    SECTION F3 Amal 10TT9 Carburetter 1. General Description If you look up into the bottom of the mixing This carburetter comprises two main parts, chamber when the jet holder has been removed, the mixing chamber and the float chamber. They the jet choke tube will be seen.
  • Page 55 Section F3 Page 2...
  • Page 56 mixing chamber. The standard needle jet bore is mixture as it passes through the primary choke numbered. can be handlebar regulated by the air control at The Throttle Valve surrounds the choke the side of the carburetter, less air being block in the carburetter, and when it is open admitted to enrich the mixture for starting or leaves a perfectly shaped passage.
  • Page 57 mixture, and anti-clockwise to enrich it. Adjust With more cut-away on the air intake side (or this very gradually until a satisfactory tick-over vice versa if weak). is obtained, but take care that the achievement of (iv) Jet Needle Position.Tuning sequence too slow a tick-over - that is, slower than is (ii) and (iii) will affect carburation up to some- actually necessary-does not lead to a "spot"...
  • Page 58: Section F4

    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 introduced as an improvement on the earlier throttle slide by a spring clip fitting in one of five standard needle type.
  • Page 59 Amal Monobloc Carburetters used on Fifth-The pilot air screw should be checked to Royal Enfield motor cycles. improve the idling if possible. When setting the Both instruments used for the twin carburetter...
  • Page 60 Section F4 Page 3...
  • Page 61 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. that this is withdrawn from the upper end of the It is important that the pilot air screws of both mixing chamber after unscrewing the jet holder.
  • Page 62 Setting of Amal Monobloc carburetters on Royal Enfield Motorcycles Carburetter Choke Type Bore Needle Needle Throttle Number inches Main Jet Position Valve Pilot Jet Machine 250 Clipper 1955 (late) - 375/10 25/32 1958 (early) 250 Crusader 1957 - 1962 250 Clipper 375/16 7/8.
  • Page 64 SECTION G1D Lucas Rotating Magnet Magneto Model SR2 Used on 1956-59 Super Meter 1. General (i) After every 150 running hours (say 5,000 The magneto rotor comprises a permanent miles) remove the moulded cover and add a magnet fitted with two laminated pole shoes. FEW drops of thin machine oil to the visible The stator consists of laminated pole pieces end of the contact breaker pivot post.
  • Page 65: Section G1D

    Clean the electrodes, the spaces between the electrodes and see that the carbon brush is clean and moves freely in its holder. Clean the outside of the cover before replacing it. (ii) Examine the contact breaker. If the contacts are burnt or dirty, clean them by polishing with a very fine carborundum stone or fine emery cloth.
  • Page 66 HOW TO LOCATE AND REMEDY TROUBLE Condition Possible Causes Method of Detection and Remedy ENGINE WILL NOT Controls not set correctly for starting. See that the ignition is switched on, petrol turned START. on and everything is in order for starting. Contact breaker inoperative.
  • Page 68 SECTION G1f Lucas Twin-Cylinder Magneto Models K2F (42369) and K2F (42369B) Wipe away any dirt or grease from the contact with a petrol-moistened cloth. If necessary, use a very fine carborundum stone to polish the contact, re-cleaning afterwards with a petrol-moistened cloth.
  • Page 69: Section G1F

    To do this, slip back the rubber shroud and, 2 (b). Adjustments by means of the hexagon at the base, unscrew Check every 3,000 miles. the control barrel. If the cable and the plunger to (i) Setting contact breaker gap. The contact which it is attached are now pulled upwards, the breaker gap must be set to 0.012-0.015 in.
  • Page 70 SECTION G2h Generator/Rectifier Charging Set 1. General to see that the connections are clean and tight. (a) Constructional Notes The nuts that clamp the rectifier plates together The alternator consists of a spigot mounted must never under any circumstances be 6-coil laminated iron stator with a rotor carried slackened, as the clamping pressure has been on and driven by an extension of the crankshaft.
  • Page 71 for the parking lights load. In the "Head" position of the lighting switch, the output is further increased by all three pairs of coils being connected in parallel. 2. Maintenance (a) Check wiring occasionally to see that all connections are clean and tight. (b) Check tightness of rectifier securing nut.
  • Page 72: Section G2J

    SECTION G2j Lucas A.C. Lighting-Ignition System 1. General permanent magnet keyed to a laminated pole tip. The Lucas A.C. Lighting-Ignition System The pole tips are riveted circumferentially to comprises seven main components brass side plates, the assembly being cast in (1) Alternator with magnet rotor.
  • Page 73 To ensure easy starting in the "EMG" position of the switch, the stator and rotor poles of the A.C. generator must be correctly positioned. This is ensured by: (a) fitting the rotor sleeve so that the keyway is at the top when the engine is at T.D.C.;...
  • Page 74 DISTRIBUTOR MODEL DKX2A (early models) Fig. 5 Examine the contact breaker, the contacts 7. Ignition Coil Model Q6 or MA6 must be free from grease or oil. If they are burnt The ignition coil should be kept clean and the or blackened, clean with fine carborundum stone terminals kept tight.
  • Page 75 and moulded terminal nut from the defective To connect the cable to ignition coil model cable. Thread the new cable through the moulded MA6, pass the cable through the rubber terminal nut and cut back the insulation for about grommet, push the metal clip into the end of the ¼...
  • Page 76: Section G4A

    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 77 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. dirt and moisture from the top of the battery and ensure that the connections are clean and tight.
  • Page 78: Section G5D

    SECTION G5d Head and Tail Lamps 1. Headlamp 3. Replacing the Light Unit and Bulb In all models the headlamp incorporates the Slacken the securing screw at the top of the Lucas Light Unit MCF 700 built into the headlamp rim. Remove the front rim and Light Casquette fork head which also contains twin Unit assembly.
  • Page 79 screw. After removal of the lamp rim the parking lamp lens can be pulled out of the rubber body, after which the bulb will be accessible. 5. Tail Light The Lucas lamp, Type 564 (Fig. 3) is a combined stop and tail light and also incorporates a reflector.
  • Page 80: Section H5

    Section H5 Page 1...
  • Page 81 1. Description of Frame The frame is built throughout of cold drawn weldless steel tubing with brazed or welded joints, liners being fitted where necessary for extra strength. All the main frame members made chromemolybdenum alloy steel tubing which retains its strength and resistance to fatigue after brazing or welding.
  • Page 82 DUAL SEAT – MUDGUARD ASSEMBLY 1961 ONWARDS Fig. 3 Section H5 Page 3...
  • Page 83 If it is necessary to remove the bronze bushes as experience has shown that the provision of these can be driven out by means of a hammer nipples at this point causes trouble through and a suitable drift and new bushes can be fitted chafing and cutting of control and lighting cables.
  • Page 84: Section J1

    SECTION J1 Front Fork With Casquette and Aluminium Alloy Bottom Tubes 1. Description The telescopic fork consists of two legs each of which comprises a main tube of chrome molybdenum alloy steel tubing which is screwed into the Casquette fork head at the upper end and securely clamped to the fork crown.
  • Page 85 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 Place the machine on the centre stand, stud (38067) and the bore of the main tube valve disconnect the front brake control and remove the port (38138) into the damper chamber "B."...
  • Page 86 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 the bottom tube.
  • Page 87 The leads to the lighting switch and ammeter medium. All that is necessary is to keep sufficient should be disconnected from the battery, oil in the fork to ensure that the top end of the regulator, tail lamp, etc. at their lower ends or by bottom spring stud is never uncovered even in the means of the plug and socket connectors when full rebound position.
  • Page 88: Section K6

    SECTION K6 Front Wheel With Dual 6in. Brake 1. Removal from Fork and unscrew the cover plate nuts 31347. The To remove the front wheel from the fork right and left hand cover plate assemblies can place the machine on the centre stand and front then be withdrawn from the respective brake stand, if fitted, or alternatively with sufficient drums.
  • Page 89 the inner edge of the outer race of the bearing When riveting linings to shoes secure the two and the back of the recess in either end of the centre rivets first so as to ensure that the lining hub barrel. To prevent any possibility of lies flat against the shoe.
  • Page 90 9. Reassembly of Brake Shoes to Cover Plates opposite positions. Floating cam brakes are Assemble each pair of shoes with their return self-centering and there is no need to take any springs on to the pivot pin and operating cam, special precautions to see that the two linings putting a smear of grease in the grooves of the are of equal thickness or that the brake shoe...
  • Page 91 When replacing the tyre fit the part by the 17. Lubrication valve last, also with the edge of the cover at the No grease nipple is provided on later hubs. other side of the wheel pushed down into the due to the tendency to over-grease, resulting in well.
  • Page 92: Section L9

    SECTION L9 Rear Wheel (Quickly Detachable Type with 7 in. diameter Brake and Full-Width Hub) EXPLODED VIEW OF QUICKLY DETACHABLE REAR HUB Fig. 1 2. Removal and Replacement of Main 1. Description Portion of Wheel for Tyre Repairs, etc. This wheel is of the "detachable" type, which Place the machine on the centre stand, if enables the main portion of the wheel to be necessary putting packing pieces beneath the...
  • Page 93 adjuster cam, preferably marking it to ensure Make sure also that the speedometer drive that it is replaced in the same position. Now gearbox is correctly positioned so that there is slide the distance collar out of the fork end and no sudden bend in the driving cable.
  • Page 94 liberally with grease where it fits over the hub barrel. 7. 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.
  • Page 95 the trailing or leading shoe first makes contact assemble the bearing into the circlip grooved end with the drum. With the brake assembly of the barrel and fit the circlip. Replace the correctly centred and the screws securing the bearing spacer, the slot in the spacer can be at cam housing correctly tightened wear on both either end of the hubs, and assemble the second linings should be approximately equal.
  • Page 96 17. Tyre indicating a balance point, this should be fitted The standard tyre is Dunlop 3.50-19 in. near the valve. studded tread. When removing the tyre always start close to 18. Tyre Pressures the valve and see that the edge of the cover at The recommended pressures for the rear tyre the other side of the wheel is pushed down into are 20 lb.
  • Page 97: Section M6

    SECTION M6 Special Tools Section M6 Page 1...
  • Page 98 Section M6 Page 2...
  • Page 99 Section M6 Page 3...
  • Page 100 Section M6 Page 4...
  • Page 101 Section M6 Page 5...
  • Page 102: Section P1

    SECTION Pl "Airflow" Fairing 1. Description of the Fairing bridge piece from the bottom of the speedometer, The "Airflow" fairing and front mudguard it may be removed. are fibre glass units and therefore very light, To remove the ammeter it is only necessary to rigid and tough.
  • Page 103 Section P1 Page 2...
  • Page 104 Section P1 Page 3...
  • Page 105 8. Repairs lamp wire, through the hole in the lamp body In the event of damage to the fairing, small shell. Fit the body shell rubber washer between repair kits consisting of a quantity of resin, the fairing and the lamp body shell rim, and line catalyst and glass fibre are available from our up the holes in the shell rim, the washer and the Service Department.
  • Page 106 SPARES for ROYAL ENFIELD & AMAL HITCHCOCK’S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE: 01564 783 192 FAX: 01564 783 313 E-MAIL: info@hitchcocksmotorcycles.com WEB: hitchcocksmotorcycles.com...

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Super meteor 1956

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