Related Manuals for Royal Enfield SPRING FRAME O.H.V. 250cc CLIPPER 1954
Summary of Contents for Royal Enfield SPRING FRAME O.H.V. 250cc CLIPPER 1954
- Page 1 ROYAL ENFIELD WORKSHOP MANUAL WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield 1954—1957 SPRING FRAME O.H.V. 250cc CLIPPER...
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Page 2: Table Of Contents
ROYAL ENFIELD WORKSHOP MANUAL Contents SECTION A3 ENGINE DATA SECTION B3 ENGINE SPECIFICATION SECTION C3 SERVICE WITH ENGINE IN FRAME SECTION D3 SERVICE WITH ENGINE REMOVED SECTION E2 GEARBOX AND CLUTCH SECTION Fl CARBURETTER, STANDARD NEEDLE TYPE SECTION F2 CARBURETTER, MONOBLOC SECTION G2c A.C. - Page 3 ROYAL ENFIELD WORKSHOP MANUAL...
- Page 4 ROYAL ENFIELD WORKSHOP MANUAL List of Illustrations Page SECTION B3—ENGINE Exploded “Clipper” Engine Fig. 1A Exploded “Clipper” Engine Fig. lB Fig. 2 Diagram of Lubrication System Fig. 3A Diagram of Oil Pump (Feed) Fig. 3B Diagram of Oil Pump (Return) SECTION C3—ENGINE...
- Page 5 SECTION H1—FRAME Fig. 1 Exploded View “250 Clipper” Frame Fig. 2 Rear Spring Compressor Fig. 3 Mark I Royal Enfield Rear Suspension Unit Fig. 4 Mark II Royal Enfield Rear Suspension Unit SECTION J2—FRONT FORK Fig. 1 Section of Fork Leg Fig.
- Page 6 ROYAL ENFIELD WORKSHOP MANUAL List of Illustrations—contd. SECTION K2—FRONT WHEEL Page Fig. 1 Front Hub Fig. 2 Removal of Brake Shoe Assembly Fig. 3 Drift for Refitting Bearings Fig. 4A Wheel Lacing (Dunlop Rim) Fig. 4B Wheel Lacing (Palmer Rim)1 SECTION L3—REAR WHEEL...
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Page 7: Section A3
SECTION A3 ROYAL ENFIELD WORKSHOP MANUAL Technical Data "250 Clipper" Engine Cubic Capacity 248 c.c. Tappet Guide External Diameter .875/.874 in. Stroke 77 mm Guide Hole in Crankcase .875/.874 in. Bore Nominal 64 mm Actual 63.970 mm/2.5185 in. Tappet Clearance with cold engine- (Rebore to .020 in. -
Page 8: Section B3
ROYAL ENFIELD WORKSHOP MANUAL SECTION B3 Engine Specification 250 Clipper 1. Engine 8. Main Bearings The engine is a 248c.c. vertical single four Heavy duty roller bearings are provided for stroke, with separate cylinder head and fully the engine shafts, the outer races being shrunk enclosed pressure-fed overhead valve gear. - Page 9 ROYAL ENFIELD WORKSHOP MANUAL Section B3 Page 2...
- Page 10 ROYAL ENFIELD WORKSHOP MANUAL Section B3 Page 3...
- Page 11 ROYAL ENFIELD WORKSHOP MANUAL Section B3 Page 4...
- Page 12 16. Lubrication System though the oil may be dirty. Lubrication is by the Royal Enfield dry- sump system which is entirely automatic and 17. Breather positive in action. The oil tank is integral with...
- Page 13 ROYAL ENFIELD WORKSHOP MANUAL "250 CLIPPER" OIL PUMP DIAGRAMS Position 1. The plunger A is being drawn out of the Position 2. The plunger A is being pushed into the cylinder hole in the disc C by the action of the peg B on cylinder hole in the disc C.
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Page 14: Section C3
ROYAL ENFIELD WORKSHOP MANUAL SECTION C3 Service Operations with Engine in Frame 250 Clipper 1. Removal of Timing Cover remove the oil filler cap so that the oil return through First place a tray under the engine to catch the oil the relief valve can be seen. - Page 15 ROYAL ENFIELD WORKSHOP MANUAL To set the ignition timing, remove the 3. Tappet Adjustment contact breaker cam by taking out the centre The tappets are adjusted by the ball and fixing screw using a 5/16 in. bolt as an extractor,...
- Page 16 ROYAL ENFIELD WORKSHOP MANUAL Before replacing the head see that the two ammeter needle returns to zero, indicating that the Hallite washers are in position in the push rod points have opened. holes in the barrel. (2). Remove the sparking plug cap from the...
- Page 17 ROYAL ENFIELD WORKSHOP MANUAL During this operation put a piece of clean rag Slacken back the compressing tool and in the top of the crank case to prevent foreign release the springs. matter getting in. In particular, take care not to Withdraw the valve and place its springs, top drop the circlip in the crankcase.
- Page 18 ROYAL ENFIELD WORKSHOP MANUAL element should be taken out and washed in If the old copper gasket is used for the petrol after the first 500 miles and every cylinder head joint, it should be annealed by subsequent 2,000 miles. Fit a new element every heating to red heat and plunging in water.
- Page 19 ROYAL ENFIELD WORKSHOP MANUAL Wash all passages, etc., thoroughly with petrol Withdraw the timing pinion by means of a flat after lapping, to remove all traces of grinding chisel placed behind the pinion and tapped gently. paste. Check the pump disc springs for fatigue by 18.
- Page 20 ROYAL ENFIELD WORKSHOP MANUAL necessary to dismantle the crankcase and drive the Remove the clutch sprocket as described in tappet and guide out from underneath. Subsection 20. The guide should have an interference fit of To remove the clutch hub, hold the clutch with .0015 to .0025 in.
- Page 21 ROYAL ENFIELD WORKSHOP MANUAL On some early engines with Miller equipment Big End Relief Valve. This is located in the the rotor may have two keyways. In this case care timing-side crankshaft and can only be adjusted should be taken when reassembling to fit the key when the crankshaft has been dismantled.
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Page 22: Section D3
ROYAL ENFIELD WORKSHOP MANUAL SECTION D3 Service Operations with Engine out of Frame 250 Clipper 1. Removal of the Engine from the Frame 4. Main Bearings. Disconnect the battery leads and remove To remove the outer races from the the battery. - Page 23 ROYAL ENFIELD WORKSHOP MANUAL The connecting rod can then be removed. If the readings for the two shafts are high on Turn the crankshaft over in the jig and repeat opposite sides, the error can be corrected by gently with the other side if necessary.
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Page 24: Section E2
ROYAL ENFIELD WORKSHOP MANUAL SECTION E2 Gearbox and Clutch 250 Clipper 3. Removal of the Ball Races 1. Removal of Gearbox The mainshaft ball bearings can be removed This is described in Section D. Subsection 2. by using a stepped drift 1... - Page 25 ROYAL ENFIELD WORKSHOP MANUAL Section E2 Page 2...
- Page 26 ROYAL ENFIELD WORKSHOP MANUAL 5. Reassembling the Gearbox recesses in the gearbox should be packed with The procedure is the reverse of that given in soft grease and the box should be filled up to the Subsection 2, but the following points should be correct level with gear oil.
- Page 27 ROYAL ENFIELD WORKSHOP MANUAL AMAL NEEDLE TYPE CARBURETTER AMAL MONOBLOC CARBURETTER...
- Page 28 ROYAL ENFIELD WORKSHOP MANUAL SECTION F1 AMAL NEEDLE TYPE CARBURETTER CARB CHOKE MAIN NEEDLE THROTTLE N E E D LE MODEL YEAR NUMBER DIAMETER P O S IT IO N VALVE 250 MODEL S 1951-53 274BH/3A 25/32 STUB FITTING 250 MODEL S...
- Page 29 ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 2...
- Page 30 ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 3...
- Page 31 ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 4...
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Page 32: Section F2
ROYAL ENFIELD WORKSHOP MANUAL SECTION F1 AMAL MONOBLOC CARBURETTER Section F2 Page 1... - Page 33 ROYAL ENFIELD WORKSHOP MANUAL Section F2 Page 2...
- Page 34 ROYAL ENFIELD WORKSHOP MANUAL Section F2 Page 3...
- Page 35 ROYAL ENFIELD WORKSHOP MANUAL Section F1 Page 4...
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Page 36: Section G2C
ROYAL ENFIELD WORKSHOP MANUAL SECTION G2c Miller A.C. Generator and Rectifier Lighting and Ignition Set Used on “ 250 Clipper,” 1954 and early 1955 containing six powerful permanent magnets of "Alcomax" arranged to produce six poles, alternatively north and south. - Page 37 ROYAL ENFIELD WORKSHOP MANUAL charge the battery. Current passes through the coil and contact breaker to provide ignition. Rate of charge at normal speeds is about 2 amps., increasing slightly if the battery is in a low state of charge. Speed in top gear to balance ignition load is 17 to 28 m.p.h., depending on the state of...
- Page 38 ROYAL ENFIELD WORKSHOP MANUAL rotor is therefore keyed on the shaft with its pole engine is running at a moderate or high speed pieces in such a position that the "inner" ends of the negative voltage is increased on account of the coils are positive and current is flowing as the connection to the negative (No.
- Page 39 ROYAL ENFIELD WORKSHOP MANUAL Check timing by turning engine with back This period of 100° embraces TWO peaks of wheel until warning light just goes out and see current from the rectifier, the SECOND of which that piston is 1/64 in. before the top of the corresponds approximately with the firing point.
- Page 40 ROYAL ENFIELD WORKSHOP MANUAL Section G2c Page 5...
- Page 41 ROYAL ENFIELD WORKSHOP MANUAL 1954 250 CLIPPER...
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Page 42: Section G2D
ROYAL ENFIELD WORKSHOP MANUAL SECTION G2d Lucas A.C. Lighting-Ignition System Fitted to "250 Clipper," 1955 I. General The Lucas A.C. Lighting-Ignition System comprises seven main components: (1) Alternator with magnet rotor. (2) Bridge-connected rectifier. (3) Ignition coil. (4) Contact breaker unit with automatic timing control. - Page 43 ROYAL ENFIELD WORKSHOP MANUAL Connections to the remaining coils vary If the opening of the contact points is timed to according to the position of the lighting and coincide with one of these pulses there will be ignition switch controls, as shown schematically sufficient energy present in the system to in Fig.
- Page 44 ROYAL ENFIELD WORKSHOP MANUAL If a feeler gauge at least .008 in. thick cannot be burnt blackened, clean with a fine passed between the rotor and each of the stator carborundum stone or a very fine emery cloth. poles the alignment should be checked.
- Page 45 ROYAL ENFIELD WORKSHOP MANUAL Section G2d Page 4...
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Page 46: Section G4A
ROYAL ENFIELD WORKSHOP MANUAL SECTION G4a Battery Model PUZ7E 1. General The model PUZ7E (see Fig. 1) is a "dry Specific gravity of electrolyte for filling " dry charged" battery and is supplied without charged" batteries electrolyte but with its plates in a charged condition. - Page 47 ROYAL ENFIELD WORKSHOP MANUAL The following table shows the state of charge at different values of specific gravities: State of Charge Temperature Temperature under 90°F. over 90°F. Battery fully 1.270 - 1.290 1.210 - 1.230 charged Battery about half 1.190 - 1.210 1.130 - 1.150...
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Page 48: Section G4B
ROYAL ENFIELD WORKSHOP MANUAL SECTION G4b Battery Model PUZ5E "250 Clipper," 1955 (with Lucas Ignition and Lighting) 1. General Specific gravity of electrolyte for filling "dry The model PUZ5E (see Fig. 1) is a "dry charged" batteries charged" battery supplied... - Page 49 ROYAL ENFIELD WORKSHOP MANUAL The following table shows the state of charge at different values of specific gravities: State of Charge Temperature Temperature under 90°F. over 90°F. Battery fully 1.270 - 1.290 1.210 - charged 1.230 Battery about half 1.190 - 1.210 1.130 -...
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Page 50: Section G5B
ROYAL ENFIELD WORKSHOP MANUAL SECTION G5b Miller Lamps For "250 Clipper" 1954 and early 1955 1. Headlamp reflector and bulb holder. Release the wire clip The headlamp (see Fig. 1) is built into the securing the bulb holder, hinge this back and Casquette fork head which also houses the remove the bulb holder. - Page 51 ROYAL ENFIELD WORKSHOP MANUAL disconnecting the reflector completely from the The replacement bulb is 2.5v.-0.3 amp. wires connecting it to the switch. Remove the M.E.S. four spring clips which secure the reflector and lens to the lamp rim and lift away the lens and Note.
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Page 52: Section G5C
ROYAL ENFIELD WORKSHOP MANUAL SECTION G5c Lucas Lamps For "250 Clipper" late 1955 onwards 1. Headlamp The headlamp incorporates Lucas Light Unit MCF.575 (see Fig. 1) which is built into the Casquette fork head which contains also the ammeter and the lighting switch. - Page 53 ROYAL ENFIELD WORKSHOP MANUAL When fitting a new Light Unit make sure that "TOP" moulded on the back corresponding to it is correctly positioned in the rim, i.e. with the the top of the lens. word "TOP" on the lens opposite the tag in the rim through which the securing screw passes.
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Page 54: Section H1
ROYAL ENFIELD WORKSHOP MANUAL Section H1 Page 1... - Page 55 Fig. 2. (b) Royal Enfield Units. Mark 1. 4. Servicing Rear Suspension Units (a) Proprietary Units. The proprietary Enfield rear suspension units, Part Number 34276 or 36451, are shown in Fig.
- Page 56 B.P. Energol S.A.E. 20. Wait till the oil has ceased running, then replace the oil filler and level plugs. (c) Royal Enfield Units. Mark II. Enfield rear suspension units, Part No. 38109, are shown in Fig. 4. This type provides positive damping on the rebound stroke and in consequence does not need the spring to be anchored on scrolls.
- Page 57 ROYAL ENFIELD WORKSHOP MANUAL On the rebound stroke the disc valve in the the bottom bearing tube, bottom casting and plunger head closes under pressure in the outer tube assembly. damper chamber, so that the oil is forced past The spring can now be lifted away. Its original the clearance between the plunger head and the free length is 8.3/4 in.
- Page 58 ROYAL ENFIELD WORKSHOP MANUAL latter and withdraw the stand complete with its towards the top of the wheels, it will be bearing sleeve after disconnecting one end of possible to ascertain whether or not the frame the stand spring. Note that the position of the...
- Page 59 ROYAL ENFIELD WORKSHOP MANUAL 1955 250 CLIPPER...
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Page 60: Section J2
ROYAL ENFIELD WORKSHOP MANUAL SECTION J2 Front Fork With Casquette and Steel Bottom Tubes Used on " 250 Clipper " 1954 onwards 1. Description The telescopic fork consists of two legs each of which comprises a main tube of chrome... - Page 61 ROYAL ENFIELD WORKSHOP MANUAL a soft mallet, thus allowing the remainder of the 5. Steering Head Races oil to escape. The steering head bearing consists of two Pull the bottom tube down as far as it will go, deep groove thrust races each containing thus exposing the gland nut which can be nineteen 1/4 in.
- Page 62 ROYAL ENFIELD WORKSHOP MANUAL 7. Lubrication The lubrication of the fork bearings is effected by the oil which forms the hydraulic damping medium. The oil level is fixed by a cross hole in the spring stud leading to a drilled passage terminating in the oil level plug.
- Page 63 ROYAL ENFIELD WORKSHOP MANUAL...
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Page 64: Section K2
ROYAL ENFIELD WORKSHOP MANUAL SECTION K2 Front Wheel With Single 6 in. Brake Fitted to 250 Clipper, Model S, G, J and J2. Also 350 + 500 Bullet, and 500 Twin up to the end of 1954 1. Removal from Fork... - Page 65 ROYAL ENFIELD 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 66 ROYAL ENFIELD WORKSHOP MANUAL cam and the two shoes and so making full use the nuts on the spindle. Tightening the nuts of the more efficient leading shoe. Owing to the should not have any effect on the ease with servo action the wear on the leading shoe with which the spindle can be turned.
- Page 67 ROYAL ENFIELD WORKSHOP MANUAL With the Palmer rim the spokes from the large 13. Spokes flange on the brake drum side go to the more The spokes are of the single butted type 8-10 steeply angled holes in the rim which must be on gauge with 90°...
- Page 68 ROYAL ENFIELD WORKSHOP MANUAL 16. Tyre Pressures with grease on assembly (which is apt to lead to The load which the tyre will carry at different trouble through grease finding its way past the inflation pressures is shown below: felt seals on to the brake linings) this greasing...
- Page 69 ROYAL ENFIELD WORKSHOP MANUAL 1957 250 CLIPPER...
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Page 70: Section L3
ROYAL ENFIELD WORKSHOP MANUAL SECTION L3 Rear Wheel (Non-Detachable Type) Part No. 38920-250 Clipper; Part No. 36998-250 Model S; Part No. 32832 350 Model G; Part No. 33595-500 Model J2. REAR HUB Fig. 1 1. Description release the slip collar, 38917 (spacing collar These instructions cover the servicing of four 31993 or 32455 for Models "S"... - Page 71 ROYAL ENFIELD WORKSHOP MANUAL tilting it so as to disengage the end of the brake shoe pivot pin from the slot in the fork end in the case of the 250 Clipper. When replacing the wheel make sure that the...
- Page 72 ROYAL ENFIELD 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 73 ROYAL ENFIELD WORKSHOP MANUAL be centered by leaving the screws just short of dead tight. The brake cover plate assembly with the shoes should then be fitted over the spindle into the brake drum and the brake applied as hard as possible by means of the operating lever.
- Page 74 ROYAL ENFIELD WORKSHOP MANUAL on the left, i.e. the inside spokes to the large both use the same length spokes but the method flange cross from the left to the right of the of lacing the wheel is different (see Subsection centre line.
- Page 75 ROYAL ENFIELD 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 indicating a balance point, this should be fitted of the hub barrel.
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Page 76: Section M3
ROYAL ENFIELD WORKSHOP MANUAL SECTION M3 Special Tools For "250 Clipper" SECTION C3 Sub- Section Page E.5477 Gudgeon Pin Extractor E.5425 Pump Disc Lapping Tool E.5451 Pump Worm Spanner 14835 Magneto Sprocket Extractor E.4871 Brake Bar for Clutch Centre E.5414... - Page 77 ROYAL ENFIELD WORKSHOP MANUAL Special Tools for the "250 Clipper" Section M3 Page 2...
- Page 78 ROYAL ENFIELD WORKSHOP MANUAL Special Tools for the " 250 Clipper" TOOLS FOR FITTING BUSHES Section M3 Page 3...
- Page 79 ROYAL ENFIELD WORKSHOP MANUAL Special Tools for the " 250 Clipper " Section M3 Page 4...
- Page 80 ROYAL ENFIELD WORKSHOP MANUAL Special Tools for the "250 Clipper" Section M3 Page 5...
- Page 81 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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