Related Manuals for Royal Enfield SPRING FRAME O.H.V. 250cc CLIPPER 1957
Summarization of Contents
SECTION B3 Engine Specification
1. Engine
Details the engine's 248c.c. single cylinder, four stroke design.
2. Cylinder Head
Describes the cylinder head construction and cooling system.
3. Cylinder
Details the cylinder barrel, bore, and piston arrangement.
4. Piston
Describes the piston material, construction, and ring arrangement.
SECTION B3 Engine Specification (contd.)
14. Carburettor
Specifies Amal Type 274/BS/3A or 375/10 carburetters.
15. Air Filter
Describes the Vokes Micro-Vee felt and gauze dry filter.
16. Lubrication System
Explains the dry-sump lubrication system with oil pumps.
17. Breather
Details the breather's function and construction.
SECTION C3 Service Operations with Engine in Frame
1. Removal of Timing Cover
Steps for removing and refitting the timing cover.
2. Valve Timing
Details on setting the valve timing using marks on pinions.
SECTION C3 Service Operations (contd.)
3. Tappet Adjustment
Procedure for adjusting tappet clearances.
4. Ignition Timing
Steps for setting ignition timing.
5. Removal of Turn Off
Instructions for removing the petrol supply.
6. Removal of Cylinder Head
Steps for removing the cylinder head.
SECTION C3 Service Operations (contd.)
7. Removal of Valves
Procedure for removing valves from the head.
8. Removal of Rockers
Refers to Subsection 6 for rocker removal.
9. Removal of Valve Guides
Instructions for removing and fitting valve guides.
10. Removal of Cylinder Barrel
Steps for removing the cylinder barrel.
SECTION D3 Service Operations with Engine out of Frame
1. Removal of the Engine from the Frame
Detailed steps for removing the engine from the frame.
2. Removal of Gearbox
Procedure for removing the gearbox.
3. Dismantling the Crankcase
Steps for dismantling the crankcase halves.
4. Main Bearings
Details on removing and replacing main bearings.
SECTION D3 Service Operations (contd.)
5. Replacement of the Cam and Idler Spindles
Procedure for replacing cam and idler spindles.
6. Flywheel Assembly
Details on dismantling the flywheel assembly.
7. Reassembly of the Crankcase
Steps for reassembling the crankcase.
SECTION E2 Gearbox and Clutch
1. Removal of Gearbox
Refers to Section D, Subsection 2 for gearbox removal.
2. To Dismantle the Gearbox
Detailed steps for dismantling the gearbox.
3. Removal of the Ball Races
Procedure for removing gearbox ball races.
4. Change-Gear Mechanism
Details on the change-gear mechanism and its adjustment.
SECTION E2 Gearbox and Clutch (contd.)
5. Reassembling the Gearbox
Steps for reassembling the gearbox.
6. Dismantling and Reassembly of the Clutch
Procedure for dismantling and reassembling the clutch.
7. Adjustment of the Clutch Control
Steps for adjusting the clutch control cable.
SECTION F1 Amal Needle Type Carburetter
Carburetter with Pilot Jet System
Diagram and explanation of the carburettor system.
TWO DESIGNS
Description of two different carburettor designs.
SECTION F1 Amal Needle Type Carburetter (contd.)
HOW IT WORKS AND PART NAMES
Identifies parts and explains carburettor operation.
HINTS AND TIPS
Practical advice for starting and general operation.
SECTION F1 Amal Needle Type Carburetter (contd.)
HINTS AND TIPS (contd.)
More tips on petrol feed, air leaks, and running issues.
HOW TO TUNE UP
Step-by-step guide for tuning the carburettor.
SECTION F1 Amal Needle Type Carburetter (contd.)
HOW TO TUNE UP (contd.)
Continues the tuning procedure for main jet and pilot jet.
TUNING TWIN ENGINES WITH TWIN CARBURETTERS
Specific tuning advice for twin-engine setups.
SECTION F1 Amal Needle Type Carburetter (contd.)
HOW TO TUNE UP (contd.)
Tuning throttle cut-away and needle position.
TUNING TWIN ENGINES WITH TWIN CARBURETTERS (contd.)
Further notes on twin carburettor setup.
SECTION G2c Miller A.C. Generator and Rectifier
1. General Description
Overview of the lighting and ignition system components.
2. Switch Positions
Describes functions of different lighting switch positions.
SECTION G2c Miller A.C. Generator and Rectifier (contd.)
2 (b). Emergency Start
Explains the emergency start function.
2 (c). Off
Describes the 'Off' switch position.
2 (d). Ignition and Charge
Details ignition and battery charging circuits.
2 (e). Head
Circuit for headlamp operation.
SECTION G2c Miller A.C. Generator and Rectifier (contd.)
2 (f). Pilot
Circuit for pilot light operation.
3. Circuits
Refers to wiring diagram for circuit details.
4. Warning Light
Explains the function of the warning light.
5. Timing
Detailed procedure for setting ignition timing.
SECTION G2c Miller A.C. Generator and Rectifier (contd.)
6. Checking for Faults
Troubleshooting guide for charging issues and electrical faults.
SECTION G2d Lucas A.C. Lighting-Ignition System
I. General
Lists the main components of the Lucas system.
1 (a). Alternator Model RM13
Details the RM13 alternator specifications.
1 (b). Circuit Details
Explains the circuit connections for the alternator.
SECTION G2d Lucas A.C. Lighting-Ignition System (contd.)
1 (c). Emergency Starting
Procedure for starting with a discharged battery.
1 (d). Direct Operation
Notes on operating without a battery.
2. Routine Maintenance
Maintenance advice for alternator and rectifier.
SECTION G2d Lucas A.C. Lighting-Ignition System (contd.)
2 (a). Ignition Coil
Maintenance of the ignition coil.
2 (b). Contact Breaker Unit Model 15D1
Lubrication and cleaning of the contact breaker.
2 (c). Contact Breaker Setting
Procedure for checking and adjusting contact breaker gap.
SECTION G4a Battery Model PUZ7E
1. General
Describes the dry-charged battery model.
2. Preparation for Service
Instructions for filling the battery with electrolyte.
SECTION G4a Battery Model PUZ7E (contd.)
3. Routine Maintenance
Advice on checking electrolyte level and cleaning terminals.
SECTION G4b Battery Model PUZ5E
1. General
Describes the dry-charged battery model.
2. Preparation for Service
Instructions for filling the battery with electrolyte.
SECTION G4b Battery Model PUZ5E (contd.)
3. Routine Maintenance
Advice on checking electrolyte level and cleaning terminals.
SECTION G5b Miller Lamps
1. Headlamp
Details of the headlamp assembly and components.
2. Replacing Bulbs
Instructions for replacing headlamp bulbs.
3. Replacing Lens or Reflector
Procedure for replacing headlamp lens or reflector.
SECTION G5b Miller Lamps (contd.)
4. Warning Light
Explains the function of the ignition warning light.
5. Tail Lamp
Details on tail lamp types and bulb replacement.
SECTION G5c Lucas Lamps
1. Headlamp
Details of the Lucas headlamp unit.
2. Lucas Light Unit
Description of the Lucas light unit features.
3. Replacing the Light Unit and Bulbs
Instructions for replacing the light unit and bulbs.
SECTION G5c Lucas Lamps (contd.)
4. Tail Light
Details on replacing the tail lamp bulb.
SECTION H1 Frame
1. Description of Frame
General description of the frame construction.
2. Steering Head Races
Details on steering head races and their fitting.
3. Removal of Rear Suspension Unit
Procedure for removing the rear suspension unit.
4. Servicing Rear Suspension Units
Instructions for servicing rear suspension units.
SECTION H1 Frame (contd.)
5. Removal of Swinging Arm Chain Stays
Procedure for removing swinging arm chain stays.
6. Centre Stand
Instructions for removing the centre stand.
7. Wheel Alignment
Guide to checking and adjusting wheel alignment.
8. Lubrication
Lubrication points for frame components.
SECTION J2 Front Fork
1. Description
Description of the telescopic front fork.
2. Dismantling Fork to Replace Spring, Oil Seal or Bearing Bushes
Steps for dismantling the front fork.
SECTION J2 Front Fork (contd.)
3. Spring
Details on fork springs.
4. Reassembly of Parts
Instructions for reassembling fork components.
5. Steering Head Races
Details on steering head race adjustment.
6. Removal of Complete Fork
Procedure for removing the complete front fork assembly.
SECTION J2 Front Fork (contd.)
7. Lubrication
Lubrication of the front fork bearings and damping system.
SECTION K2 Front Wheel
1. Removal from Fork
Steps for removing the front wheel from the fork.
2. Removal of Brake Cover Plate Assy.
Procedure for removing the brake cover plate.
3. Removal of Brake Shoes and Springs
Steps for removing brake shoes and springs.
4. Replacing Brake Linings
Instructions for replacing brake linings.
SECTION K2 Front Wheel (contd.)
5. Removal of Hub Spindle and Bearings
Procedure for removing hub spindle and bearings.
6. Hub Bearings
Details on hub bearing types and specifications.
7. Fitting Limits for Bearings
Tolerances for fitting wheel bearings.
8. Refitting Ball Bearings
Instructions for refitting wheel bearings.
SECTION K2 Front Wheel (contd.)
9. Reassembly of Brake Shoes to Cover Plate
Steps for reassembling brake shoes.
10. Floating Cam Housing
Details on the floating cam housing.
11. Refitting Brake Cover Plate
Steps for refitting the brake cover plate.
12. Wheel Rims
Information on wheel rim types.
SECTION K2 Front Wheel (contd.)
13. Spokes
Details on wheel spokes.
14. Wheel Building and Truing
Guide to lacing and truing wheels.
SECTION K2 Front Wheel (contd.)
15. Tyres
Information on tyre types and fitting.
16. Tyre Pressures
Table of tyre pressures and loads.
17. Lubrication
Lubrication points for the hub barrel.
SECTION L3 Rear Wheel (Non-Detachable Type)
1. Description
Description of rear wheel types and features.
2. Removal of Inner Tube with Wheel in Position in Frame
Steps for removing inner tube with wheel in frame.
3. Removal and Replacement of Wheel
Procedure for removing and replacing the rear wheel.
SECTION L3 Rear Wheel (contd.)
4. Removal of Brake Shoes for Replacement, Fitting New Linings, etc.
Steps for removing brake shoes and fitting new linings.
5. Replacing Brake Linings
Instructions for fitting brake linings.
SECTION L3 Rear Wheel (contd.)
6. Removal of Hub Spindle and Bearings
Procedure for removing hub spindle and bearings.
7. Hub Bearings
Details on hub bearing types and specifications.
8. Fitting Limits for Bearings
Tolerances for fitting rear wheel bearings.
9. Refitting Ball Bearings
Instructions for refitting rear wheel bearings.
SECTION L3 Rear Wheel (contd.)
10. Cush Drive
Details on the cush drive mechanism.
11. Final Reassembly of Hub before Replacing Wheel
Steps for final hub reassembly.
12. Wheel Rims
Information on wheel rim types.
SECTION L3 Rear Wheel (contd.)
13. Spokes
Details on wheel spokes.
14. Wheel Building and Truing
Guide to lacing and truing rear wheels.
SECTION L3 Rear Wheel (contd.)
15. Tyres
Information on tyre types and fitting.
16. Tyre Pressures
Table of tyre pressures and loads.
17. Lubrication
Lubrication points for the rear hub.
SECTION M3 Special Tools
SECTION C3
List of special tools for Section C3.
SECTION D3
List of special tools for Section D3.
SECTION H1
List of special tools for Section H1.
SECTION J2
List of special tools for Section J2.
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