Table of Contents
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MAINTENANCE MANUAL
Enfield
250 CLIPPER
CRUSADER SPORTS
CONTINENTAL
250 TRIALS CONTINENTAL GT
Including AIRFLOW model where applicable
HITCHCOCK'S MOTORCYCLES
ROSEMARY COURT
OLDWICH LANE WEST
CHADWICK END
SOLIHULL
B93 0EY
ENGLAND
WORKSHOP
FOR THE
Royal
SPARES for ROYAL ENFIELD & AMAL
250 CRUSADER
SUPER 5
350 NEW BULLET
TELEPHONE: 01564 783 192
FAX: 01564 783 313
E-MAIL: in-
fo@hitchcocksmotorcycles.com
WEB: hitchcocksmotorcycles.com
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Table of Contents
Related Manuals for Royal Enfield 250 CLIPPER
Summary of Contents for Royal Enfield 250 CLIPPER
- Page 1 CRUSADER SPORTS SUPER 5 CONTINENTAL 350 NEW BULLET 250 TRIALS CONTINENTAL GT Including AIRFLOW model where applicable SPARES for ROYAL ENFIELD & AMAL HITCHCOCK’S MOTORCYCLES TELEPHONE: 01564 783 192 ROSEMARY COURT FAX: 01564 783 313 OLDWICH LANE WEST CHADWICK END...
- Page 2 ROYAL ENFIELD WORKSHOP MANUAL 250 CLIPPER CRUSADER PAGE 2...
- Page 3 ROYAL ENFIELD WORKSHOP MANUAL CONTENTS 1957-62 CRUSADER, 1958 on 250 CLIPPER, 1959 on CRUSADER SPORTS 1962-63 CRUSADER SUPER 5, 1962-63 250 TRIALS, 1963-64 CONTINENTAL, 1963-64 350 UNIT BULLET AND 1965 on CONTINENTAL GT SECTION A16a ENGINE DATA (250cc MODELS) SECTION A16b...
- Page 4 ROYAL ENFIELD WORKSHOP MANUAL CONTINENTAL CRUSADER SPORTS PAGE 4...
- Page 5 (Renew piston rings when gap exceeds Clearance in grooves 0.005/0.003” Valve timing with 0.015” clearance Compression ring 0.004/0.002” Scraper ring 250 Clipper and Crusader 0.7501/0.7499” Piston boss internal diameter Exhaust opens 80 degrees before B.D.C. 0.7501/0.7499” Gudgeon pin diameter Exhaust closes 30 degrees after T.D.C...
- Page 6 ROYAL ENFIELD WORKSHOP MANUAL CONTINENTAL GT PAGE 6...
- Page 7 ROYAL ENFIELD WORKSHOP MANUAL TECHNICAL DATA ( 350cc Bullet) Cubic Capacity 346cc Aluminium cylinder head: 0.6275/0.6270” Stroke 90mm Valve guide external diameter 69.876mm (2.751”) Bore Valve guide hole (in cylinder (Rebore to 0.020” when wear exceeds 0.065” 0.626/0.625” head) diameter and again to 0.040”...
- Page 8 ROYAL ENFIELD WORKSHOP MANUAL PAGE 8...
- Page 9 "Super 5" 9.75 to 1 and a one-piece high-strength cast iron crankshaft. 1963 Models " 250 Clipper," " Crusader The design of the engine is such that, except Sports," "Super 5," "Continental", for the crankshaft and connecting rod, it can be "GT"...
- Page 10 Sports," "Super 5," "Continental," "GT" "350 D, Fig. 2.) Bullet," and "250 Trials," differs from that fitted to the "250 Clipper" and "Crusader 250" models in having a greater rate of lift and different 9. Camshaft opening and closing points. There are no silencing The camshaft is machined from case hardened ramps on these models.
- Page 11 It is chain and "250 Trials" have heads of greater diameter driven at half engine speed from the timing than those fitted to the "250 Clipper" and sprocket on the crankshaft, and the tightness of "Crusader 250."...
- Page 12 "Crusader 250," and "250 Trials," but not to the The oil level in the camshaft housing is con- home market "250 Clipper," "Crusader Sports," trolled by a hole through which the oil overflows "Super 5," "Continental" "GT," and "350 Bullet."...
- Page 13 ROYAL ENFIELD WORKSHOP MANUAL Position 2. The plunger A is being pushed into the cylinder hole in Position 1. The plunger A is being drawn out of the back cylinder the disc C. The port P in the disc now registers with the delivery port...
- Page 14 ROYAL ENFIELD WORKSHOP MANUAL All "Super 5," "Continental," "GT" and "350 19. Clutch Bullet" models, and later type "250 Clipper," There are four types of clutch (see Section E). "Crusader Sports," and "250 Trials" models All are of the conventional plate type, having...
- Page 15 ROYAL ENFIELD WORKSHOP MANUAL SECTION C18 Service Operations with Engine in of Frame the petrol feed pipe, the rear of the tank can be 1. Removal of the Primary Chaincase Cover pulled upwards to release the clip and then lifted (Near Side) clear of the frame.
- Page 16 When this is removed the the opening and closing points are given below: chain tension can be checked without removing the chaincase cover. "250 Clipper" and "Crusader 250" Exhaust opens 80° before B.D.C. 8. Timing Chain Adjustment Exhaust closes 30°...
- Page 17 ROYAL ENFIELD WORKSHOP MANUAL In order to obtain access to the push rods and If the contacts are worn or pitted, refer to rockers, remove the rocker box cover by Section G. unscrewing the central nut (Subsection 3). The timing is adjusted by slackening the two...
- Page 18 When fitting the one-piece rocker housing, to be found on later "250 Clipper," "Crusader 250," and "Crusader Sports" models, and on all "Super 5," "Continental," "GT", "350 Bullet" and "250 Trials"...
- Page 19 ROYAL ENFIELD WORKSHOP MANUAL Using a suitable compressing tool, compress any pieces of broken ring do not drop into the the valve springs and remove the split conical crankcase. collets from the ends of the valve stems. Before replacing the cylinder barrel, clean off Slacken back the compressing tool, and release the joint faces and fit a new paper washer.
- Page 20 ROYAL ENFIELD WORKSHOP MANUAL If the valves or their seats are pitted and require recutting, care must taken reproduce the correct profile. The cylinder head should preferably be returned to the Works for the inlet valve seat to be re-cut but, if this is not possible, Special Valve Cutting Tools No.
- Page 21 All later models: The gauze filter fitted inside the Wash all passages, etc., thoroughly with petrol timing case of later "250 Clipper," "Crusader after lapping, in order to remove all traces of Sports" and "250 Trials," and all "Super 5,"...
- Page 22 ROYAL ENFIELD WORKSHOP MANUAL Check the pump disc spring for fatigue by Engage the pump pinion, idler pinion and assembling the pump and placing the cover in camshaft pinion so that the marks are opposite position without tightening up. It should be held one another.
- Page 23 ROYAL ENFIELD WORKSHOP MANUAL All Models tube with a flattened end and very little can go wrong with it. If, however, it is found to be faulty Rocker Feed Relief Valve. The rocker relief it should be replaced with a new one.
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- Page 25 ROYAL ENFIELD WORKSHOP MANUAL Service Operations with Engine out of Frame contact breaker housing leaving the crankshaft in 1. Removal of the Engine from the the near (driving) side half case. Frame Press the crankshaft assembly out of the near Disconnect the battery leads.
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- Page 29 ROYAL ENFIELD WORKSHOP MANUAL Remember to put the two distance pieces on hot fit the crankshaft oil seal and the contact the shaft first with the chamfer towards the breaker spindle oil seal, pressing them in flush flywheel. with the casing. Be sure that the seals are fitted the right way round, i.e., with the open side...
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- Page 31 ROYAL ENFIELD WORKSHOP MANUAL Gearbox and Clutch the top of the gearbox to the generator 1. Description of the Clutch compartment on the offside. Early Models Four-speed Gearbox The clutch is built into the clutch sprocket and is (See Fig. 2 for operation).
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- Page 35 ROYAL ENFIELD WORKSHOP MANUAL Turn the slotted adjusting screw until it begins fork R. The latter is located by a spring plunger S to tighten up, then slacken it back one complete engaging with a notched plate which is part of the turn.
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- Page 38 ROYAL ENFIELD WORKSHOP MANUAL Early Models The top and bottom nuts have right and left hand Plain dished plate (centre outwards). threads respectively. Cork plate. Put the gear box into third gear and adjust the Plain plate. turnbuckle so that when the pawl carrier plates are Cork plate.
- Page 39 ROYAL ENFIELD WORKSHOP MANUAL Note. If the gearbox is to be completely Remove two Allen screws H (Fig. 5) and take dismantled, the final drive sprocket should be off the main shaft end-cap together with the removed before taking off the gearbox cover on clutch operating lever.
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- Page 41 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...
- Page 42 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...
- Page 43 ROYAL ENFIELD WORKSHOP MANUAL PAGE 43...
- Page 44 ROYAL ENFIELD WORKSHOP MANUAL also controls the fuel supply via a connecting pipe with this type of carburetter unless dirt is present to the right-hand instrument which does not have or, of course, the float is punctured. a float chamber in unit with it.
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- Page 47 ROYAL ENFIELD WORKSHOP MANUAL Lucas A.C. Lighting-Ignition System magnet keyed to a laminated pole tip. The pole 1. General tips are riveted circumferentially to brass side The Lucas A.C. Lighting-Ignition System plates, the assembly being cast in aluminium and comprises of seven main components: machined to give a smooth external finish.
- Page 48 ROYAL ENFIELD WORKSHOP MANUAL breaker so that no unwanted sparks can occur on the compression stroke of the engine. Note that, if the battery is removed, the emergency start will not function unless the lead normally connected to the battery negative terminal is earthed. The emergency start system functions better with a discharged battery than with a fully charged one.
- Page 49 ROYAL ENFIELD WORKSHOP MANUAL (ii) Lubricate the automatic timing control mechanism using thin machine oil. Cleaning every 6,000 miles. Examine the contact breaker. The contacts must be free from grease and oil. If they are burnt or blackened, clean with a fine carborundum stone or a very fine emery cloth.
- Page 50 ROYAL ENFIELD WORKSHOP MANUAL WIRING DIAGRAM 1957—1961 MODELS WITH SCREW ON TERMINALS FOR SWITCHES PAGE 50...
- Page 51 ROYAL ENFIELD WORKSHOP MANUAL B = BLACK P = PURPLE Y = YELLOW U = BLUE G = GREEN D = DARK N = BROWN S = SLATE L = LIGHT R = RED W = WHITE M = MEDIUM...
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- Page 53 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.
- Page 54 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.
- Page 55 ROYAL ENFIELD WORKSHOP MANUAL Battery Model MLZ9E Model MLZ9E is a 6-volt unit. The battery The top of the container is so designed that container is moulded in translucent polystyrene when the cover is in position the special anti-spill through which the acid can be seen. A coloured...
- Page 56 ROYAL ENFIELD WORKSHOP MANUAL level line. Thereafter keep the acid just level with Filling and Soaking the MLZ9E Battery Discard the vent hole sealing tapes. the coloured line by topping up with distilled Pour into each cell in one operation pure water.
- Page 57 Head and Tail Lamps 1. Headlamp contacts secures the bulb firmly in position and The "250 Clipper," "Crusader 250," "Crusader carries the supply to the bulb contacts. Sports" and "350 Bullet" have a Lucas Light Unit The outer surface of the lens is smooth to MCF 700 built into the Casquette facilitate cleaning.
- Page 58 ROYAL ENFIELD WORKSHOP MANUAL 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.
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- Page 60 ROYAL ENFIELD WORKSHOP MANUAL right home in the recesses on the inside of the 1. Description of Frame carrier attachment brackets. The frame is built throughout of cold-drawn weldless steel tubing with welded joints, liners 4. Removal of Rear Suspension Unit being fitted where necessary for extra strength.
- Page 61 ROYAL ENFIELD WORKSHOP MANUAL stand spring, and the stand, together with the Mobilgrease MP, Esso Multipurpose grease H, engine plates, can be removed from the frame. Energrease L2, Shell Retinax "A," or Marfak The stand, stand bearing sleeve and engine plates Multipurpose 2.
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- Page 63 " 350 Clipper " and " Crusader Sports " 1959 onwards, " Crusader 250 " 1957 onwards, " 250 Clipper " late 1958 onwards, " 250 Trials " 1962 onwards and " 250 Continental " " 250 Continental GT " and " 350 Bullet " 1963 onwards 1.
- Page 64 ROYAL ENFIELD WORKSHOP MANUAL 5. Steering Head Races The steering head bearing consists of two deep groove thrust races each containing nineteen ¼ in. diameter balls. The bearing is adjusted by tightening the steering stem locknut after loosening the ball head clip screw and both the fork crown clamp bolts.
- Page 65 ROYAL ENFIELD WORKSHOP MANUAL across flats (Unbrako wrench W.11) or the special tool shown in Fig. 4. At the same time unscrew the steering stem locknut from the top of the steering stem, turning each tube and the nut a turn or two at a time.
- Page 66 ROYAL ENFIELD WORKSHOP MANUAL the diameter of chamber "B" is less than that of chamber "A" there is not room in "B" to receive all the oil which must be displaced from "A" as the fork operates. The surplus oil passes through...
- Page 67 ROYAL ENFIELD WORKSHOP MANUAL Front Fork "Crusader Super 5" 1962 onwards The suspension units are located at their upper 1. Description ends by set pins situated under the crown, and The steering stem is integral with the two fork their lower ends fit onto the links, which in turn...
- Page 68 ROYAL ENFIELD WORKSHOP MANUAL each suspension unit with the countersunk headed The leads to the lighting switch and ammeter bolt and nut. Put back the wheel, couple up the should be disconnected from the battery, rectifier, brake anchor arm and cable, and fit the link side tail lamp, alternator and earth points at their lower covers.
- Page 69 ROYAL ENFIELD WORKSHOP MANUAL Front Wheel With Single 6 in. Brake 1. Removal from Fork To remove the front wheel from the fork place the machine on the centre stand with sufficient packing (about 2 in.) beneath each side of the stand to lift the wheel clear off the ground when tilted back on to the rear wheel.
- Page 70 ROYAL ENFIELD WORKSHOP MANUAL In order to make quite sure that there is clearance 6. Hub Bearings between the inner faces of the outer bearing races These are deep-groove single-row journal ball and the bottom of the recesses, fit the distance bearings, in.
- Page 71 ROYAL ENFIELD WORKSHOP MANUAL on the circumference of the rim shoulders where last, also with the edge of the cover at the other the tyre fits being 53.642/53.582 in. The standard side of the wheel pushed down into the well.
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- Page 73 ROYAL ENFIELD WORKSHOP MANUAL Front Wheel With Single 7 in. Brake 1. Removal from Fork To remove the front wheel from the fork place the machine on the centre stand with sufficient packing (about 2 in.) beneath each side of the stand to lift the wheel clear off the ground when tilted back on to the rear wheel.
- Page 74 ROYAL ENFIELD WORKSHOP MANUAL the upper end of the spindle and driven home by latter once more in the hub at the end from which means of the second hollow drift either under a it was removed. Now drive the spindle through...
- Page 75 ROYAL ENFIELD WORKSHOP MANUAL side of the wheel is pushed down into the well in spoke holes are symmetrical, i.e., the rim can be the rim. assembled to the hub either way round. The rim When replacing the tyre fit the part by the diameter after building is 17.062 in., the...
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- Page 77 The gearbox, that the driving dogs inside the wheel incorporates the well-known Royal Enfield gearbox engage with the slots in the end of the cush drive and also a 6 in. internal expanding hub barrel.
- Page 78 ROYAL ENFIELD WORKSHOP MANUAL the rear brake rod adjusting nut completely and direction of travel of the chain. Replace the chain depress the brake pedal so as to disengage the rod adjuster cams in their original positions or, if from the trunnion in the brake operating lever.
- Page 79 ROYAL ENFIELD WORKSHOP MANUAL which secures the operating lever to the splines on the Brake linings are supplied either in pairs ready cam. A sharp tap on the end of the cam spindle will drilled complete with rivets or ready fitted to now free the lever, after which the cam can be service replacement brake shoes.
- Page 80 ROYAL ENFIELD WORKSHOP MANUAL When re-assembling the cush drive, coat the inside of the bore of the sprocket/brake drum liberally with grease where it fits over the hub barrel. 7. Removal of Ball Bearings To remove the ball bearings, take the complete...
- Page 81 ROYAL ENFIELD WORKSHOP MANUAL cap after unscrewing the three screws attaching it 13. Wheel Rim to the hub. Unscrew the six Simmonds nuts and The wheel rim is WM2-17 in., plunged and drive out the pins. pierced with forty holes for spoke nipples. The spoke holes are symmetrical, i.e., the rim can be...
- Page 82 ROYAL ENFIELD WORKSHOP MANUAL up to 230 lb., 20 lb. per square inch for loads up to Note that the brake cam is drilled for a grease 260lb., 24 lb. per square inch for loads up to passage, but the end of this is stopped up with a 320lb., 28 lb.
- Page 83 ROYAL ENFIELD WORKSHOP MANUAL Rear Wheel (Non-Detachable Type) 1. Description brake rod adjusting nut completely and depress the The wheel incorporates a rubber cush drive brake pedal so as to disengage the rod from the and the chain line is 2 in.
- Page 84 ROYAL ENFIELD WORKSHOP MANUAL A number of early "Crusader 250" models were fitted with brake linings bonded to the shoes. These should be returned for servicing when necessary. 7. Removal of Hub Spindle and Bearings To remove the hub spindle and bearings,...
- Page 85 ROYAL ENFIELD WORKSHOP MANUAL plate, speedometer gearbox, etc., or make up this the lock ring, after which the sprocket/brake drum distance with tubular distance pieces. Fit and can be separated from the cush drive shell and the tighten the spindle nuts. Tightening the nuts six cush drive rubbers can be lifted out.
- Page 86 ROYAL ENFIELD WORKSHOP MANUAL 15. Wheel Building and Truing The spoke holes are arranged in groups of three The spokes are laced one over three and the holes on one side of the centre line, then a single wheel must be built central in relation to the faces...
- Page 87 ROYAL ENFIELD WORKSHOP MANUAL 18. Lubrication Note that the brake cam is drilled for a grease A greasing point is provided in the centre of passage but the end of this is stopped up with a the hub barrel. Unless the barrel is packed full...
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- Page 89 ROYAL ENFIELD WORKSHOP MANUAL Special Tools Sub- Section SECTION C 1 and 2 DWU05 Screwdriver E7353 Valve Guide Mandrels E5477 Gudgeon Pin Extractor (Not illustrated) E2178 Inlet Valve Seat Cutter. "Crusader 250," "250 Clipper" T1891 Inlet Valve Seat Cutter. "Crusader Sports,"...
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- Page 92 Legshield (Part Nos. 41399 and 41400) are Each pannier carrier is attached at three points. available for the 1958 to 1963 "250 Clipper" and The forward end is clipped to the mudguard carrier the 1957 to 1962 "Crusader 250." They are made tube with two clips (Part No.
- Page 93 ROYAL ENFIELD WORKSHOP MANUAL "Airflow" Fairing 1. Description of the fairing bridge piece from bottom The "Airflow" fairing and front mudguard are speedometer, it may be removed. fibre glass units and therefore very light, rigid and To remove the ammeter it is only necessary to tough.
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- Page 95 ROYAL ENFIELD WORKSHOP MANUAL wire, through the hole in the lamp body shell. Fit 8. Repairs the body shell rubber washer between the fairing In the event of minor damage to the fairing, and the lamp body shell rim, and line up the holes...
- Page 96 NOTES ROYAL ENFIELD WORKSHOP MANUAL PAGE 96...