Related Manuals for Royal Enfield METEOR MINOR STANDARD 1958
Summary of Contents for Royal Enfield METEOR MINOR STANDARD 1958
- Page 1 WORKSHOP MAINTENANCE MANUAL FOR THE Royal Enfield 1958—1963 METEOR MINOR STANDARD METEOR MINOR SPORTS METEOR MINOR DELUXE and AIRFLOW MAN10...
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Page 2: Table Of Contents
Contents METEOR MINOR SECTION A13 ENGINE DATA SECTION B13 ENGINE SPECIFICATION SECTION C13 SERVICE OPERATIONS WITH ENGINE IN FRAME SECTION D11 SERVICE OPERATIONS WITH ENGINE REMOVED SECTION E8 GEARBOX AND CLUTCH SECTION F4 MONOBLOC CARBURETTER SECTION G2j LIGHTING/IGNITION SYSTEM SECTION G4a BATTERY SECTION G5d HEAD AND TAIL LAMPS... - Page 3 SECTIONAL VIEW OF 1958 METEOR MINOR ENGINE...
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Page 4: Section A13
SECTION A13 Technical Data Meteor Minor Engine Cubic Capacity ......496 c.c. Valve Timing with .012 in. clearance- Stroke ..........64.5 m.m. Standard and de-luxe models: Bore ..... .. Nominal 70 m.m. -
Page 6: Section B13
SECTION B13 Engine Specification " Meteor Minor " 1. Engine 6. Crankcase The engine is an even-firing vertical twin The combined crankcase and oil tank is cylinder, having separate cylinders and heads die-cast from light alloy in two halves, being and fully enclosed pressure-fed overhead valve split vertically. - Page 7 13. Ignition and Lighting System. (See 16. Lubrication System Lubrication is by the Royal Enfield Dry Section G) Sump system which is entirely automatic and Separate systems are provided for ignition positive in action. The oil tank is integral with and lighting.
- Page 8 end of the pushrod. It flows down the push rod On early models the breather is located on into the cam tunnel where it lubricates the cams the driving side of the crankcase and consists of and tappets and thence into the timing chest, a small housing attached to the crankcase by lubricating the timing chains.
- Page 9 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.
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Page 10: Section C13
SECTION C13 Service Operations with Engine in Frame "Meteor Minor" 1. Removal of the Timing Cover The correct valve timing at .012 in. tappet First place a tray under the engine to catch clearance is as follows: the oil which will escape when the cover is removed. - Page 11 that firing occurs when the piston is 1/32 in. before top dead centre, which is equivalent to 3/8 in. to 7/16 in. when fully advanced. To set the ignition timing, put the gearbox in top gear and turn the engine by means of the back wheel until the left-hand piston is 1/32 in.
- Page 12 jockey sprocket is mounted. Tightening of the chain is effected by moving the quadrant to the left. It is imperative that the quadrant is fitted the right way round and that the eccentric spindle is fitted correctly in the quadrant fork. If the chain tightens when the quadrant is moved to the right, the tensioner has been wrongly assembled and may cause damage to the quadrant (see Fig.
- Page 13 the burrs are not removed and the valve is In replacing the heads, see that the dowels are forced out, the guide may be damaged. in position in the cylinder barrels and that the push rods are the right way up (shallow cups upwards).
- Page 14 until the last coil is 1 to 1.1/2 threads below the top face. Then break off the tag. If the cylinder head has been removed, the fitting of the insert will be facilitated if the tool is put through the hole from the inside and the insert screwed back from the outside.
- Page 15 18. Grinding-in Valves be recut, but, if this is not possible, a special tool To grind a valve, smear the seating with a consisting of an arbor No. T2053 and cutter No. little grinding in compound, place a light, short T2054 is available.
- Page 16 Loosen the chain tensioner locknut and stud. The felt element should be taken out and Lift the adjusting plate clear of the chain washed in petrol after the first 500 miles and tensioner spindle. after every subsequent 2,000 miles. Fit a new Remove the chain tensioner spindle and element every 5,000 miles.
- Page 17 27. Removal of the Tappets and Guides partial vacuum, giving rise to smoking or over- It is only necessary to remove the tappets and oiling. guides if they have become worn. See that the rubber tube of early models is Remove the cylinder heads and barrels clean and if it is damaged or distorted, fit a new (Subsections 10 and 15).
- Page 18 The radial air gap between the rotor and 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.
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Page 20: Section D11
SECTION D11 Service Operations with Engine Removed Meteor Minor 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 21 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 22 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.
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Page 24: Section E8
SECTION E8 Gearbox and Clutch Meteor Minor 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 25 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 26 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 27 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 28 Section E8 Page 5...
- Page 29 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.
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Page 30: 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 31 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 32 Section F4 Page 3...
- Page 33 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 34 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 36 SECTION G2j Lucas A.C. Lighting-Ignition System Meteor Minor 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.
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Page 37: Section G2J
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 38 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 39 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 40 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.
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Page 41: Section G4A
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 42: 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 43 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 44: Section H4
SECTION H4 Frame EXPLODED VIEW OF EARLY "METEOR MINOR" FRAME Fig. I Section H4 Page 1... - Page 45 1. Description of Frame expander E.5431, which will spread the frame sufficiently to enable the spigots on the thrust The frame is built throughout of cold drawn weldless steel tubing with brazed or welded washers to clear the recesses in the pivot lugs joints, liners being fitted where necessary for forming part of the frame.
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Page 46: Section J6
SECTION J6 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 During this stroke the pressure on the underside Knock the rearmost cap stud upwards into the of the valve plate (38073) causes this to lift so fork with a soft mallet, which will allow oil to that oil can also pass from "A" to "B" through run out of the fork.
- Page 48 4. Spring 6. Steering Head Races Solo and Sidecar springs are available. The The steering head bearing consists of two free length of each is 20.1/2 in. The spring deep groove thrust races each containing should be replaced if it has closed by more than nineteen 1/4 in.
- Page 49 8. Lubrication these are provided. The switch and ammeter are The lubrication of the fork bearings is push fits into the rubber bushes in the fork head. effected by the oil which forms the hydraulic damping medium. All that is necessary is to keep Disconnect the speedometer drive from the sufficient oil in the fork to ensure that the top speedometer head.
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Page 50: Section K5
SECTION K5 Front Wheel With Single 6 in. Brake Meteor Minor De-luxe and Standard 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 51 In order to make quite sure that there is 6. Hub Bearings clearance between the inner faces of the outer These are deep-groove single-row journal bearing races and the bottom of the recesses, fit ball bearings, in. i/d by 1. in.
- Page 52 tolerances on the circumference of the rim valve last, also with the edge of the cover at the shoulders where the tyre fits being 53.642/53.582 other side of the wheel pushed down into the in. The standard steel measuring tape for checking well.
- Page 54 SECTION K7a Front Wheel With Single Brake 7-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 to lift the wheel clear of the ground when tilted back on to the rear wheel.
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Page 55: Section K7A
6. Hub Bearings there is clearance between the inner faces of the These are deep-groove single-row journal outer bearing race, and the bottom of the ball bearings 5/8 in. i/d by 1.9/16 in. o/d by 7/16 recesses, fit the distance washers, cover plate, in. - Page 56 tolerance on the circumference of the rim If the correct method of fitting and removal shoulders where tyre fits being of the tyre is adopted it will be found that the 53.642/53.582 in. The standard steel measuring covers can be manipulated quite easily with the tape for checking rims is 5/16 in.
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Page 58: Section L7
SECTION L7 Rear Wheel (Non-Detachable Type) trunnion in the brake operating lever. Unscrew 1. Description the brake cover plate anchor nut and remove this These instructions cover the servicing of two together with the washer behind it. Disconnect different rear wheels, both of the non-detachable the speedometer driving cable, loosen the type incorporating a rubber cush drive and an spindle nuts and mark the chain adjuster cams to... - Page 59 pieces, which in turn are held up by the cover of notches to tension the chain and maintain plate nuts. In order to prevent endways correct wheel alignment. Do not forget to refit pre-loading of the bearings it is essential that the brake rod and adjust the brake so that the there is a small clearance between the inner edge wheel turns freely while the brake is off, while...
- Page 60 should be replaced. To obtain access to them makes the spindle hard to turn this may be taken remove the complete wheel as described above. as proof that the bearings are bottoming in the Remove the brake cover plate complete with the recesses in the hub barrel before they are solid brake shoe assembly, unscrew the three against the shoulders on the spindle.
- Page 61 leading shoe first makes contact with the drum. With the brake assembly correctly centered and the screws securing the cam housing correctly tightened wear on both linings should be approximately equal. 13. Final Reassembly of Hub before Replacing Wheel Before, replacing the felt washers which form the grease seals, pack both bearings with grease.
- Page 62 with grease on assembly (which is apt to lead to 18. Tyre pressures trouble through grease finding its way past the The load which the tyre will carry at different felt seals on to the brake linings) this greasing inflation pressures is shown below point is of little value and the best way to grease the bearings is by packing them with grease after dismantling the hub as described above.
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Page 64: Section L8
SECTION L8 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 REMOVAL OF WHEEL (OFFSIDE VIEW) Fig. 2 the rear driving chain at the spring link and of the fork ends, tilting it so as to disengage the remove the chain from the rear wheel sprocket end of the brake shoe pivot pin from the slot in leaving it in position on the gearbox countershaft the fork end.
- Page 66 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, replaced.
- Page 67 that end. Remove this bearing first, then enter applying pressure to both inner and outer races the loose section of the spindle into the spacer simultaneously to avoid pre-loading the two and drive out the remaining bearing by means of hub barrel bearings.
- Page 68 gearbox, distance collars, 41373 and 41372, When removing the tyre always start close to chain adjuster cams, the loose section of the the valve and see that the edge of the cover at the spindle and the spindle nut, 28832. The wheel is other side of the wheel is pushed down into the then ready for reassembly into the machine.
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Page 69: Section M6
SECTION M6 Special Tools Section M6 Page 1... - Page 70 Section M6 Page 2...
- Page 71 Section M6 Page 3...
- Page 72 Section M6 Page 4...
- Page 73 Section M6 Page 5...
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Page 74: 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 75 Section P1 Page 2...
- Page 76 Section P1 Page 3...
- Page 77 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 78 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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