Royal Enfield CO Workshop Maintenance Manual
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Royal Enfield CO Workshop Maintenance Manual

Royal Enfield CO Workshop Maintenance Manual

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ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL
WORKSHOP
MAINTENANCE MANUAL
FOR THE
ROYAL ENFIELD
350 c.c. O.H.V.
MOTOR CYCLES
MODELS CO,WD/CO
and WD/CO/B
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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  • Page 1 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE ROYAL ENFIELD 350 c.c. O.H.V. MOTOR CYCLES MODELS CO,WD/CO and WD/CO/B 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 2 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Page 2...

  • Page 3: Table Of Contents

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL CONTENTS Para Page Para. Page LIST OF ILLUSTRATIONS ....CARBURETTOR 51-53 PERIODICAL ATTENTIONS ....Adjusting Slow Running DATA ............5, 6 Dismantling Carburettor LIST OF TOOLS ...........

  • Page 4: List Of Illustrations

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL LIST OF ILLUSTRATIONS Fig. Fig. No..................Page No..................Page Engine. Exploded View ..Section Through Gear Box ........20 Method of Removal of Valve End Caps ....
  • Page 5 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL DATA ROYAL ENFIELD 350 c.c. O.H.V. MOTOR CYCLE TRANSMISSION. ENGINE. Sprockets-Engine ......19 T. in. P. X .305 in. W, Cubic Capacity ... 346 c.c. Clutch ......42 T. in. P. X .305 in. W.
  • Page 6 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL DATA-continued CARBURETTER. Sparking Plug-Size ........14 m.m. in. reach. Type and Number ........Amal. 276 AC/1A Type ............Lodge C.14 Sintox. Main Jet Size ..............130 ...........

  • Page 7: Engine

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL ENGINE DECARBONISING. conical collars and release the springs, when the valve can be withdrawn. Fig. 2 shows a Terry compressor in 1. Removal of Cylinder Head. Decarbonising will normally necessary use, Fig. 3 a special type suitable for a large approximately every 2,000 miles and can be carried workshop.

  • Page 8: Piston And Rings

    ROYAL ENFIELD 350cc 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: Reassembly Of Engine

    ROYAL ENFIELD 350cc 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: Tappet Adjustment

    ROYAL ENFIELD 350cc 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: Dismantling The Crankcase

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 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. Remove both the engine plates and the gearbox. Take...

  • Page 12: Removal Of Tappets And Guides

    ROYAL ENFIELD 350cc 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: Removal Of And Replacing Mainshafts

    ROYAL ENFIELD 350cc 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 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: Removal Of Crankcase Main Bearings

    ROYAL ENFIELD 350cc 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 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: Lubrication System

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL LUBRICATION SYSTEM. bearing, leakage back into the timing gear being prevented by a cork oil seal. A release valve at the inner end of the timing shaft prevents excessive 23. Principle of Operation. pressure developing when the oil is cold. This valve is The lubrication system is of the true dry sump designed to lift at 30-40 lbs.

  • Page 18: Replacing Pump Discs

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL suitable tool for lapping the disc. This can be held in the rate of loss past the rings will increase, so that the the chuck of a brace. If a new disc is fitted it will be oil consumption in a well worn engine may increase found that the top surface is completely circular.

  • Page 19: Transmission

    ROYAL ENFIELD 350cc 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 O.H.V. WORKSHOP MANUAL Page 20...

  • Page 21: Removal Of Ball Races

    ROYAL ENFIELD 350cc 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: Clutch

    ROYAL ENFIELD 350cc 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: Chains

    ROYAL ENFIELD 350cc 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: Rims

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 40. Rims. The brake cam, cam bearing and the pivot pin Rims which are running slightly out of truth can should be lightly smeared with grease before be trued up by tensioning the spokes, but if the rims...

  • Page 25: Cush Drive Rubbers

    Simmonds nuts at the back of the brake drum and knocking out the three shouldered pins which secure drive fitted to the Royal Enfield Side-valve Model the cush drive lock ring, after which the combined WD/C.

  • Page 26: Adjustment Of Steering Head

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL the fork links become unscrewed from the threads on 48. Adjustment of Steering Head. the swivel pins. When replacing the swivel pins, screw To check for play in the steering head, the weight the links on to the front pin an equal distance at each must be taken off the front wheel by placing a suitable side before starting the threads on the back pin.

  • Page 27: Dismantling And Reassembling Steering Head

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL bearings, place one finger across the head races just the head lug, place the upper ball race in position and beneath the ball head clip. The steering head should be knock the ball head clip down on to it, then screw...

  • Page 28: Section Of Amal Carburettor

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL as described in Para. 51 to give the correct mixture full throttle and may make the mixture too weak at when idling. Running with the pilot adjusting screw large throttle openings, thus causing overheating.

  • Page 29: Lighting And Ignition System

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL LIGHTING AND IGNITION SYSTEM MAGNETO (LUCAS Magdyno Model M01-4, Type freely in its holder, being careful not to stretch the L1 or Model M01-6, Type LI). brush spring unduly. While the pick-up is removed, clean the slip ring track and flanges by holding a soft 54.

  • Page 30: Timing Ignition

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 61. Timing Ignition. from the gear centre, which is keyed to the magneto The ignition timing should be such that the shaft, through the fabric gear which is held against the contact breaker points are just about to open when the gear centre under the pressure of a star shaped spring, to the pinion on the dynamo shaft.

  • Page 31: Test And Repair Of Magneto

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Observe that the cam is fitted with its flat side hydraulic press, but in case of emergency they can be towards the armature of the machine. driven in with a mandrel made to the dimensions The contact breaker end shield can now be shown in Fig.

  • Page 32: Reassembling And Testing Slipping Clutch

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Examine fibre ‘tappet.’ See that it slides freely When the spring pressure has been satisfactorily tested, lock the securing nut by bending over one of without having sideplay. See Fig. 49. the tags of the locking washer.
  • Page 33 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Page 33...

  • Page 34: Dynamo 71-81

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL It is most important that the main dynamo and No reading at terminal "A" but a reading at field leads are not interchanged either internally or terminal "B" indicates that the ammeter is open externally at the dynamo or at the voltage control box.

  • Page 35: Treatment Of Badly Worn Commutator

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL EXPLODED VIEW OF DYNAMO Fig. 54 75. Treatment of Badly Worn Commutator. To remedy a badly worn commutator it will be necessary first to remove the armature from the dynamo. (See dismantling, Para. 72).

  • Page 36: Test Of Armature

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL REGULATOR AND CUTOUT. 79. Test of Armature. The testing of the armature requires the use of a (Lucas Model MCR1, Type L33). volt drop test or "growler." If these are not available, check by substitution.

  • Page 37: Adjustment Of Cut-Out

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 89. Ammeter Faults. Press the armature back against the regulator Check for faults in ammeter by substitution. frame and down on to the bobbin core, with the feeler gauges in position and secure the armature by tightening the two fixing screws.

  • Page 38: Charging

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 94. Charging. 97. Cleaning. If the previous tests indicate that the battery is Care must be taken, when handling the reflector merely discharged, and if the acid level is correct, the to prevent it from becoming finger marked. It can, battery must be recharged from an external supply.

  • Page 39: Lighting Switch

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL LIGHTING SWITCH. (Lucas Type U39). If the horn is used repeatedly when badly out of adjustment, due usually to unsuccessful attempts at adjustment, the horn may become damaged, due to the 101. Method of Making Connections.

  • Page 40: Lubrication Chart

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL LUBRICATION CHART MOTOR CYCLE, SOLO, ROYAL ENFIELD, MODELS WD/CO and WD/CO/B, 350 c.c. O.H.V. Lubricant Part Castrol Grand Prix (or XXL).* 1 +2+3 1, ENGINE TOP UP (Capacity 4 pints) Golden Shell (or Triple Shell).* 2, GEARBOX (Capacities: Standard Box, ¾...
  • Page 41 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL SUPPLEMENT ROYAL ENFIELD 350 c.c. O.H.V. MODEL WD/CO/B FITTED WITH BURMAN GEARBOX Contract No. 294/C/13870 Frame and Engine Nos. 14001-17000 inclusive CLUTCH. To obtain first gear the layshaft clutch is moved to the right so that the external teeth on it engage with the internal teeth in the layshaft first gear, thus 104.
  • Page 42 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Page 42...

  • Page 43: Drift For Removing Driving Gear Bearing

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 107. Dismantling the Gearbox (if in the machine). See Fig. 66. Operate the foot control until the gears are in the top gear position. Disconnect the clutch control cable from the clutch lever on the gearbox, unscrew the six...
  • Page 44 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Page 44...

  • Page 45: Drift For Refitting Mainshaft Ball Bearing

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL 109. Reassembling the Gearbox. The drift shown in Fig. 65 is also suitable for inserting new layshaft bushes. Suitable drifts for inserting the ball bearings are shown in Figs. 67 and 68. DRIFT FOR REFITTING MAINSHAFT BALL BEARING Fig.

  • Page 46: Exploded View Of Camshaft

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL EXPLODED VIEW OF CAMSHAFT (1) Camshaft Bush, Shell. (6) Pawl. (2) Camshaft. (7) Pawl Spring Plug. (3) Operating Peg (Camshaft). (8) Camshaft Bush, Kickstart Case. (4) Operating Peg Cotter. (9) Operating Fork (Layshaft). Pawl Spring.

  • Page 47: Exploded View Of Foot Change Mechanism

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL EXPLODED VIEW OF FOOT CHANGE MECHANISM Sector Spindle Bush. (11) Main Spring. Sector Spindle Nut, (12) Pawl Spring. Sector Spindle. (13) Pawl Spring Plate. Control Quadrant. (14) Pawl Operating Peg. Ratchet Sleeve. (15) Pawl Spindle.

  • Page 48: Exploded View Of Kickstarter Mechanism

    ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL EXPLODED VIEW OF KICKSTARTER MECHANISM Kickstart Spindle Bush (Inner). Kickstart Lever Pedal. Kickstart Spindle. Kickstart Lever in. Bolt Nut. Kickstart Spring. Kickstart Lever in. Bolt. Kickstart Spindle Bush. (10) Kickstart Quadrant. Kickstart Lever Spring Clip.
  • Page 49 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL When operating the kickstart lever, ease the pinion to the mainshaft and the nut which secures the quadrant into engagement with the ratchet pinion by driving sprocket to the driving gear. operating the lever slowly with the clutch lifted.
  • Page 50 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL INDEX Para. Page Para. Page Ammeter ....88, 89 DATA .... 5, 6 (Burman Gearbox) ..Ball Valve in Oil Return Passage ..23, 24 Decarbonising ...
  • Page 51 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL INDEX-continued Para. Page Para. Page Joint, Crankcase .... 22 Regulator. (See Voltage Regulator) .. 82-87 Joint Washer, Cylinder Base ..9, 14 9, 11 “ Head ... Rims, Wheel ....
  • Page 52 ROYAL ENFIELD 350cc O.H.V. WORKSHOP MANUAL Page 52...

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