Royal Enfield J2 Manuals

Manuals and User Guides for Royal Enfield J2. We have 1 Royal Enfield J2 manual available for free PDF download: Workshop Maintenance Manual

Royal Enfield J2 Workshop Maintenance Manual

Royal Enfield J2 Workshop Maintenance Manual (73 pages)

Brand: Royal Enfield | Category: Motorcycle | Size: 3 MB

Table of Contents

Exploded View of Engine
2
Table of Contents
3
Technical Data, 500 Engine
4
Technical Data, 350 Engine
5
- Tool Roll and Contents
  6
- Supplementary Kit
  6
Tools Supplied with Machine
6
- Removal of Cylinder Head
  7
- Removal of Cylinder and Piston
  7
Engine; Decarbonising
7
- Valves, Springs and Guides
  8
- Big End Bearing
  8
- Small End Bearing
  8
- Piston and Rings
  8
- Reassembly of Engine after Decarbonising
  9
- Valve Timing
  9
- Valve Timing Marks
  9
- Magneto Timing
  9
Engine; Timing Gear
9
- Engine Sprocket Extractor
  10
- Removal of Engine from Frame
  10
- Complete Overhaul.
  10
- Tappet Adjustment
  10
- Dismantling the Crankcase
  11
Engine; Crankshaft
11
Engine; Lubrication System
16
- Oil Circulation Diagram
  17
- Lubrication System
  17
- Principle of Operation
  17
- Ball Valve in Oil Return Passage
  17
- Draining the System
  18
- Replacing Pump Discs
  18
- Detail of Felt Oil Cleaner
  18
- Tool for Lapping Pump Discs
  18
- Removal of Gearbox from Frame
  19
- Removal of Gearbox End Cover
  19
- Gear Box
  19
- Transmission
  19
- Removal of Ball Races
  21
- Drift for Refitting Gearbox Ball Race
  21
- Drift for Removing Gearbox Ball Race
  21
- Reassembling the Gearbox
  21
- Detail of Foot Gear Change
  22
- Adjustment of Clutch Control
  22
- Dismantling and Reassembly of Clutch
  22
- Exploded View of Lcutch
  23
- Lubrication
  23
- Removal, Repair and Replacement
  23
Chains
23
- Carburetter with Pilot Jet System
  25
- Two Designs
  25
- How It Works and Part Names
  26
- Hints and Tips
  26
- Fault at Throttle Positions
  27
- To Cure Richness
  27
- Parts to Tune up with
  27
- How to Trace Faults
  27
- How to Tune up
  28
- Main Jet
  28
- Pilot Jet with Thorttle in Positions
  28
- Needle
  28
- Lucas Magdyno
  29
- Model MOIL for Single Cylinder Engines
  29
- Routine Maintenance
  29
- Renewing High Tension Cable
  30
- Renewing Timing Control Cable
  30
- Cleaning
  30
- Contact Breaker Spring
  31
- Testing Magdyno in Position on Engine
  31
- Inspection of Commutator and Brush Gear
  33
- Test Data
  33
- Testing in Position to Locate Fault in Charging Circuit
  33
DYNAMO Type E3LM
33
- Field Coil
  35
- Commutator
  35
- Reassembly
  36
- Dynamo Polarity
  36
- Armature
  36
- Bearings
  36
- Checking the Electrical Setting of the Regulator
  37
- Checking the Wiring between Battery and Regulator
  37
CONTROL BOX, Model RB107
37
Battery Model PUZ7E
39
- Headlamp
  41
- Lucas Light Unit
  41
Head and Tail Lamps
41
- Parking Lights
  42
- Tail Light
  42
- Replacing the Light Unit and Bulb
  42
Front Fork, Early
45
Front Fork, Casquette, (1955 - 1957)
49
- Main Tube Seal Guide
  50
- Dismantling the Fork to Replace Spring
  50
- Main Tube Spanner
  50
- Spring
  51
- Steering Head Races
  51
- Removal of Complete Fork
  51
- Air Vents
  52
- Removal of Hub Spindle and Bearings
  53
- Removal from Fork
  53
- Replacing Brake Linings
  53
Front Wheel
53
- Fitting Limits for Bearings
  54
- Hub Bearings
  54
- Removal of Brake Shoe Assembly
  54
- Refitting Ball Bearings
  54
- Reassembly of Brake Shoes to Cover Plate
  55
- Refitting Brake Cover Plate
  55
- Wheel Rims
  55
- Floating Cam Housing
  55
- Palmer Rim
  56
- Spokes
  56
- Tyres
  56
- Wheel Building and Truing
  56
- Tyre Pressures
  57
- Rear Wheel (Non-Detachable Type)
  58
- Removal and Replacement of Wheel
  58
- Removal of Inner Tube with Wheel in Position in Frame
  58
- Removal of Brake Shoes for Replacement
  59
- Cush Drive
  60
- Reassembly of Cush Drive
  61
Spring Frame (1955 - 1957)
64
- Description of Frame
  65
- Removal of Rear Suspension Unit
  65
- Servicing Rear Suspension Units
  65
- Removal of Swinging Arm Chain Stays
  67
- Centre Stand
  67
- Wheel Alignment
  68
Special Tools
69
- Tools for Fitting Bushes
  70
- Roller Race, Timing Side
  70
- Roller Race to Crankcase, Driving Side
  70
- Locating Plate for Assembly of Cam Spindles
  71
- Flywheel Assembly Pot or Jig
  71
- Frame Expander
  72
- Gland Nut Hand Grips
  72
- Lockring Spanner
  72

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