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Related Manuals for Royal Enfield 350 BULLET 1956
Summary of Contents for Royal Enfield 350 BULLET 1956
- Page 1 WORKSHOP ROYAL ENFIELD WORKSHOP MANUAL MAINTENANCE MANUAL FOR THE Royal Enfield 350 BULLET 1956 on 500 BULLET 1956 on 350 CLIPPER 1958 on Including AIRFLOW models And TRIALS WORKS REPLICA MAN7...
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Page 2: Table Of Contents
ROYAL ENFIELD WORKSHOP MANUAL Contents 1956-62 "350 Bullet" and "500 Bullet", 1958--61 "350 Clipper" (including "Airflow" models) and Trials "Works Replica" 1958 onwards SECTION A14a 350 DATA TECHNICAL SECTION A14b 500 DATA TECHNICAL SECTION C14 SERVICE OPERATIONS WITH ENGINE IN FRAME... - Page 3 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 4: Section A14A
ROYAL ENFIELD WORKSHOP MANUAL SECTION A14a Technical Data 350 Bullet 1956-62, 350 Clipper and Trials Works Replica 1958-62 Cubic Capacity ..346 c.c. Guide Hole in Cylinder Head (All Stroke 90 mm. Bullets and Trials; Clipper, Bore ... Nominal .. - Page 5 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 6: Section A14B
ROYAL ENFIELD WORKSHOP MANUAL SECTION A14b Technical Data " 500 Bullet Engine " 1956 onwards Tappet Guide External Diameter .7510/.7505 in. Cubic Capacity ... 499 c.c. Guide Hole in Crankcase ......750/.749 in. Stroke 90 mm. Tappet Clearance with cold engine Bore ... - Page 7 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 8: Section C14
ROYAL ENFIELD WORKSHOP MANUAL SECTION C 14 Service Operations with Engine in Frame " 350 and 500 Bullet," 1956 -62, " 350 Clipper " and Trials "Works Replica" 1958 -62 1. Removal of the Timing Cover through the relief valve can be seen. It may take... - Page 9 ROYAL ENFIELD WORKSHOP MANUAL cover and adjust the contact breaker points to a stems and rockers, with the rocker box covers clearance of .015 in. when fully opened. removed. To remove the rocker box covers the Because of the auto-advance mechanism, the petrol tank must be taken off.
- Page 10 ROYAL ENFIELD WORKSHOP MANUAL 6. Removal of the Cylinder Head "350 Bullet," "350 Clipper," "Works Replica" and early "500 Bullet" Remove the petrol tank (see Subsection 5). Disconnect the engine steady. Disconnect the plug lead and oil pipe. Remove the exhaust pipe.
- Page 11 ROYAL ENFIELD WORKSHOP MANUAL burrs are not removed and the valve is forced out, the guide may be damaged. 8. Removal of the Rockers See Subsection 6. 9. Removal of the Valve Guides To remove the valve guides from the head two special tools are required which can easily be made.
- Page 12 ROYAL ENFIELD WORKSHOP MANUAL spring over the valve stem and beneath the head, insert the valve into its appropriate guide, press it on to the seat using a tool with a suction cup and with a backwards and forwards rotary motion, grind it on to its seat.
- Page 13 ROYAL ENFIELD WORKSHOP MANUAL The silencer of the "350 and 500 Bullet" from element should be taken out and washed in petrol 1961 onwards, may be dismantled for cleaning after the first 500 miles and every subsequent before refitting to the machine.
- Page 14 ROYAL ENFIELD WORKSHOP MANUAL Check the pump disc springs for fatigue by assembling in the timing cover and placing the pump covers in position. The latter should be held 1/8 in. off the timing cover if the springs are correct.
- Page 15 ROYAL ENFIELD WORKSHOP MANUAL retaining ring and the assembly of driving and Remove the rear half of the primary chaincase driven clutch plates. The clutch sprocket can then by taking out three socket screws. be withdrawn from the centre after removal of Remove the grub screw locking the final drive the large circlip which secures it.
- Page 16 ROYAL ENFIELD WORKSHOP MANUAL on later models with the three cheese-headed The magneto on the "Works Replica" is held screws, and shake-proof washers, or, in the case of by a strap and when the nut securing this has been earlier models, place the three distance pieces over released, the magneto may be lifted from its the three chaincase studs.
- Page 17 ROYAL ENFIELD WORKSHOP MANUAL 350 TRIALS WORKS REPLICA 1960—61 350 BULLET 1959...
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Page 18: Section D2
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 driving side inner roller race and the inner Disconnect the battery leads and remove the distance piece will remain on the engine shaft. - Page 19 ROYAL ENFIELD WORKSHOP MANUAL To remove the idler spindles heat the crankcase Mount the crankshaft between centres and true as before, hold the spindles in a vice and tap the up to .0005 in. on either side of the shafts.
- Page 20 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...
- Page 21 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 22: Section E1
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. - Page 23 ROYAL ENFIELD WORKSHOP MANUAL Section E1 Page 2...
- Page 24 ROYAL ENFIELD WORKSHOP MANUAL (See Section C1 or C2.) The top gear pinion and If the main shaft top gear pinion and dog have dog will come away with the mainshaft. been removed, make sure that the dog is replaced...
- Page 25 ROYAL ENFIELD WORKSHOP MANUAL central screw. Tighten the 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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Page 26: Section F4
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 27 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 28 ROYAL ENFIELD WORKSHOP MANUAL Section F4 Page 3...
- Page 29 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.
- Page 30 ROYAL ENFIELD WORKSHOP MANUAL Section F4 Page 5...
- Page 31 ROYAL ENFIELD WORKSHOP MANUAL 1961 350 CLIPPER 1956 350 BULLET...
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Page 32: Section G1E
ROYAL ENFIELD WORKSHOP MANUAL SECTION G I e Lucas Rotating Magnet Magneto Model SR1 Used on 350 Bullet 1956-59; 500 Bullet 1956-59 1. General thus preventing the retention of moisture at the The magneto rotor comprises a permanent terminal connection. The coil and capacitor are magnet fitted with two laminated pole shoes. - Page 33 ROYAL ENFIELD WORKSHOP MANUAL (b) Cleanings screw. The pointed end of this will pierce the (i) Occasionally remove the moulded cover insulation, make contact with the cable core and and wipe the inside of the cover with a soft dry lock the cable in place.
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Page 34: Section G2K
ROYAL ENFIELD WORKSHOP MANUAL SECTION G2K Lucas A.C. Lighting-Ignition System Used on 350 Bullet and 500 Bullet, 350 Clipper and Trials Work Replica 1961 onwards 1. General insulated from the laminations. The rotor has a The Lucas A.C. Lighting-Ignition System... - Page 35 ROYAL ENFIELD WORKSHOP MANUAL the battery. It should be noted that with the ignition switch at EMG and the engine running, the battery receives a charging current, so that its terminal voltage begins to rise. This rising voltage opposes the alternator voltage, and, on single...
- Page 36 ROYAL ENFIELD WORKSHOP MANUAL the fixing bolt has been replaced and the engine 8. Contact Breaker Unit run for a few minutes, the oil will be forced out Early Models: Type CA1A over the automatic advance mechanism by Later Models: Type 15D1 centrifugal force.
- Page 37 ROYAL ENFIELD WORKSHOP MANUAL 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 grommet, terminal nut and cut back the insulation for about push the metal clip into the end of the cable 1/4 in.
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Page 38: Section G4A
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 39 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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Page 40: Section G5D
ROYAL ENFIELD WORKSHOP MANUAL 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. - Page 41 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 42: Section H5
ROYAL ENFIELD WORKSHOP MANUAL Section H5 Page 1... - Page 43 ROYAL ENFIELD WORKSHOP MANUAL 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 are made of chromemolybdenum alloy steel tubing which retains its strength and resistance to fatigue after brazing or welding.
- Page 44 ROYAL ENFIELD WORKSHOP MANUAL DUAL SEAT – MUDGUARD ASSEMBLY 1961 ONWARDS Fig. 3 Section H5 Page 3...
- Page 45 ROYAL ENFIELD WORKSHOP MANUAL 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 and nipples at this point causes trouble through chafing a suitable drift and new bushes can be fitted under and cutting of control and lighting cables.
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Page 46: Section J1
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 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 47 ROYAL ENFIELD 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 Place the machine on the centre stand,...
- Page 48 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...
- Page 49 ROYAL ENFIELD WORKSHOP MANUAL 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...
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Page 50: Section K6
ROYAL ENFIELD WORKSHOP MANUAL 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... - Page 51 ROYAL ENFIELD WORKSHOP MANUAL 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.
- Page 52 ROYAL ENFIELD WORKSHOP MANUAL 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,...
- Page 53 ROYAL ENFIELD WORKSHOP MANUAL 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.
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Page 54: Section K7
ROYAL ENFIELD WORKSHOP MANUAL SECTION K7 Front Wheel With Single Brake 1959-60 "350 Bullet," 7-inch Brake 1958-60 "350 Clipper" and 1958-60 Trials "Works Replica." 6-inch 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... - Page 55 ROYAL ENFIELD WORKSHOP MANUAL between the inner faces of the outer bearing race, 6. Hub Bearings and the bottom of the recesses, fit the distance These are deep-groove single-row journal ball washers, cover plate, dust excluder and the nut, bearings 5/8 in. i/d by 1.9/16 in. o/d by 7/16 in.
- Page 56 ROYAL ENFIELD WORKSHOP MANUAL on the circumference of the rim shoulders where 14. Tyre the tyre fits being 53.642/53.582 in. The standard The standard tyre is Dunlop 3.25-17 in. steel measuring tape for checking rims is 5/16 in. Ribbed. "350 Bullet" up to 1958. "350 Clipper"...
- Page 57 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 58: Section L12
ROYAL ENFIELD WORKSHOP MANUAL SECTION L12 Rear Wheel (Non-Detachable Type) 1958-59 350 Clipper 1. Description the dual seat if fitted, and the detachable portion of These instructions cover the servicing of two the rear mudguard. Disconnect the rear driving different rear wheels, both of the non-detachable... - Page 59 ROYAL ENFIELD WORKSHOP MANUAL When replacing the wheel make sure that the end of the spindle with a copper hammer or mallet dogs on the speedometer drive gearbox are thus driving it out of the hub, bringing one bearing engaged with the slots in the end of the hub with it and leaving the other in position in the hub.
- Page 60 ROYAL ENFIELD WORKSHOP MANUAL are then entered into one end of the hub barrel 9. Removal of Brake Operating Cam and which is then supported on one of the hollow Brake Shoe Pivot Pin drifts. The other bearing is then threaded over the...
- Page 61 ROYAL ENFIELD WORKSHOP MANUAL the cush drive shell and the six cush drive rubbers 13. Final Reassembly of Hub before Replacing can be lifted out. Wheel When reassembling the cush drive the entry of Before replacing the felt washers which form...
- Page 62 ROYAL ENFIELD WORKSHOP MANUAL fork ends. The rim should be trued as accurately valve last, also with the edge of the cover at the as possible, the maximum permissible run-out other side of the wheel pushed down into the both sideways and radially being plus or minus well.
- Page 63 ROYAL ENFIELD WORKSHOP MANUAL trouble through grease finding its way past the felt countersunk screw instead of being fitted with a seals on to the brake linings) this greasing point is grease nipple. This is done to prevent excessive of little value and the best way to grease the greasing by over-enthusiastic owners.
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Page 64: Section L13
ROYAL ENFIELD WORKSHOP MANUAL SECTION L13 Rear Wheel (Quickly Detachable Type with 7 in. diameter Brake and Full-Width Hub) tight a fit in the hub to come out easily they may 1. Description be left in place. The main body of the wheel can This wheel is of the "detachable"... - Page 65 ROYAL ENFIELD WORKSHOP MANUAL REMOVAL OF WHEEL (OFFSIDE VIEW) Fig. 2 the rear driving chain at the spring link and remove of the fork ends, tilting it so as to disengage the the chain from the rear wheel sprocket leaving it in end of the brake shoe pivot pin from the slot in position on the gearbox countershaft sprocket.
- Page 66 ROYAL ENFIELD WORKSHOP MANUAL 4. Removal of Brake Shoes for Replacement, If the cush drive rubbers become worn so that etc. the amount of free movement measured at the tyre Remove the complete wheel as described exceeds 1/2 in. to 1 in the rubbers. should be above, then remove the spindle nut, 28832, chain replaced.
- Page 67 ROYAL ENFIELD WORKSHOP MANUAL Remove this bearing first, then enter the loose applying pressure to both inner and outer races section of the spindle into the spacer and drive out simultaneously to avoid pre-loading the two hub the remaining bearing by means of a hammer and barrel bearings.
- Page 68 ROYAL ENFIELD WORKSHOP MANUAL distance collars, 41373 and 41372, chain adjuster possible, the maximum permissible run-out both cams, the loose section of the spindle and the sideways and radially being plus or minus 1/32 in. spindle nut, 28832. The wheel is then ready for reassembly into the machine.
- Page 69 ROYAL ENFIELD WORKSHOP MANUAL...
- Page 70 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 ....
- Page 71 ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 2...
- Page 72 ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 3...
- Page 73 ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 4...
- Page 74 ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 5...
- Page 75 ROYAL ENFIELD WORKSHOP MANUAL Section M2 Page 6...
- Page 76 ROYAL ENFIELD WORKSHOP MANUAL Section M4 Page 1...
- Page 77 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 78: Section P1
ROYAL ENFIELD WORKSHOP MANUAL 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 79 ROYAL ENFIELD WORKSHOP MANUAL Section P1 Page 2...
- Page 80 ROYAL ENFIELD WORKSHOP MANUAL Section P1 Page 3...
- Page 81 ROYAL ENFIELD WORKSHOP MANUAL 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,...
- Page 82 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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