Royal Enfield SPRING FRAME O.H.V. 250cc CLIPPER 1954 Manual de usuario

ROYAL ENFIELD WORKSHOP MANUAL

WORKSHOP

MAINTENANCE MANUAL

FOR THE

Royal

Enfield

1954—1957

SPRING FRAME O.H.V.

250cc CLIPPER

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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. LIGHTING SYSTEM (MILLER)

SECTION G2d A.C. LIGHTING SYSTEM (LUCAS)

SECTION G4a BATTERY USED WITH MILLER

SECTION G4b BATTERY USED WITH LUCAS

SECTION G5b LAMPS, MILLER

SECTION G5c LAMPS, LUCAS

SECTION H1 FRAME

SECTION J2 FRONT FORK

SECTION K2 FRONT WHEEL

SECTION L3 REAR WHEEL

SECTION M3 SPECIAL TOOLS

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ROYAL ENFIELD WORKSHOP MANUAL

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ROYAL ENFIELD WORKSHOP MANUAL

List of Illustrations

SECTION B3—ENGINE

Page

Fig.

Exploded “Clipper” Engine

Fig.

Exploded “Clipper” Engine

Fig.

Diagram of Lubrication System

Fig.

Diagram of Oil Pump (Feed)

Fig.

Diagram of Oil Pump (Return)

SECTION C3—ENGINE

Fig.

Valve Timing Marks

Fig.

Tappet Adjustment

Fig.

Push Rod Enclosure Tube

Fig.

Valve Spring Compressor

Fig.

Oil Filter

Fig.

Oil Pressure Relief Valve

Fig.

Primary Chain Adjustment

Fig.

Primary Chain Case

SECTION E2—GEARBOX

Fig.

Exploded Gearbox and Clutch

Fig.

Clutch Adjustment

SECTION F1—AMAL NEEDLE TYPE CARBURETTER

Fig.

Sectional View showing Air Valve and Throttle Closed

Fig.

Section through Carburetter

Fig.

Exploded View of Adjusting screws

Fig.

Sequence of Tuning

SECTION F2—AMAL MONOBLOC CARBURETTER

Fig.

Section through Float Chamber

Fig.

Section through Mixing Chamber

Fig.

Section through Carburetter

Fig.

Exploded View of Adjusting screws

Fig.

Sequence of Tuning

SECTION G2c—MILLER A.C. GENERATOR AND RECTIFIER

LIGHTING AND IGNITION SET

Fig.

A.C. Generator, Rear View

Fig.

Full Wave Rectifier

Fig.

Lighting and Ignition Switch

Fig.

Wiring Diagram

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ROYAL ENFIELD WORKSHOP MANUAL

List of Illustrations—contd.

SECTION G2d—LUCAS A.C. LIGHTING-IGNITION SYSTEM

Page

Fig.

Alternator

Fig.

Rectifier

Fig.

Internal Connections of Alternator

Fig.

Emergency Starting

Fig.

Exploded View of Contact Breaker Unit

Fig.

Wiring Diagram

SECTION G4a—BATTERY MODEL PUZ7E

Fig.

Sectioned View of Battery

Fig.

Topping-up with Distilled Water

Fig.

Measuring Specific Gravity with Hydrometer

SECTION G4b—BATTERY MODEL PUZ5E

Fig.

Battery

Fig.

Topping-Up with Distilled Water

Fig.

Measuring Specific Gravity with Hydrometer

SECTION G5b—MILLER LAMPS

Fig.

Headlamp

Fig.

Ammeter and Warning Light

Fig.

Tail Lamp

SECTION G5c—LUCAS LAMPS

Fig.

Headlamp Light Unit

Fig.

Tail Lamp

SECTION H1—FRAME

Fig.

Exploded View “250 Clipper” Frame

Fig.

Rear Spring Compressor

Fig.

Mark I Royal Enfield Rear Suspension Unit

Fig.

Mark II Royal Enfield Rear Suspension Unit

SECTION J2—FRONT FORK

Fig.

Section of Fork Leg

Fig.

Steering Head Adjustment

Fig.

Outer Cover Centralising Bushes

Fig.

Main Tube Spanner

Fig.

Main Tube Seal Guide

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ROYAL ENFIELD WORKSHOP MANUAL

List of Illustrations—contd.

SECTION K2—FRONT WHEEL

Page

Fig.

Front Hub

Fig.

Removal of Brake Shoe Assembly

Fig.

Drift for Refitting Bearings

Fig.

Wheel Lacing (Dunlop Rim)

Fig.

Wheel Lacing (Palmer Rim)1

SECTION L3—REAR WHEEL

Fig.

Rear Hub

Fig.

Removal of Centre Bolt and Slip Collar to Permit Removal of

Inner Tube

Fig.

Drift for Refitting Bearings (“250 Clipper,” “S” and “G”)

Fig.

Drift for Refitting Bearings (“J2”)

Fig.

Re-assembly of Cush Drive

Fig.

Wheel Lacing (Dunlop Rim)

Fig.

Wheel Lacing (Palmer Rim)

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ROYAL ENFIELD WORKSHOP MANUAL

SECTION A3

Technical Data

"250 Clipper" Engine

Cubic Capacity 248 c.c.

Stroke 77 mm

Bore Nominal 64 mm

Actual 63.970 mm/2.5185 in.

(Rebore to .020 in. when wear exceeds 005 in. and

again to .040 in. after a further .005 in. wear.)

Compression Ratio 6.5 to 1

Piston Diameter-

Bottom of Skirt Fore and Aft. 63.926/63.901mm

Top Lands 63.50/63.45 mm

Piston Rings-

Width-Plain Rings (Two) .0625/.0615 in.

Scraper Ring (One) .15625/.15525 in.

Radial Thickness 2.612/2.460 mm

Clearance in Grooves .0035/.0015 in.

Renew Piston Rings when gap exceeds 1/16 in.

Oversize Pistons and Rings available .020 and .040 in.

Piston Boss Internal Diameter .7500/.7498 in.

Gudgeon Pin Diameter .7498/.7495 in.

Con. Rod Small End Diameter .7510/.75025 in.

Con. Rod Big End Diameter 1.6257/1.6252in.

Floating Bush Ext. Diameter 1.6235/1.6230 in.

Floating Bush Int. Diameter 1.2502/1.2498 in.

Floating Bush Width .739/.736 in.

Crank Pin Diameter 1.24900/1.24875in.

Engine Shaft Diameter 1.0000/.9997 in.

Driving Side Main Roller Bearing

Outside Diameter 1.876/1.875 in.

Inside Diameter 1.5002/1.4998 in.

Width 1.437/1.432 in.

No. of Rollers 24 (2 rows)

Timing Side Main Roller Bearings-

Outside Diameter 1.8772/1.8770 in.

Inside Diameter 1.5004/1.5002 in.

Width .4425/4405 in.

No. of Rollers 12 (1 row)

Size of Rollers

Diameter .2500/.2490 in.

Length .328/.327in.

Graded Rollers are available in steps of .0001 in. from

.2490 in.-.2500 in.

Rocker Bearing Inside Diameter .626/.625 in.

Rocker Spindle Diameter .624/.6235 in.

Inlet Valve Stem Diameter .34275/.34175 in.

Exhaust Valve Stem Diameter .34175/.34075 in.

Valve Guide Internal Diameter .3452/.3437 in.

Valve Guide External Diameter .624/623 in.

Guide Hole in Cylinder Head .623/622 in.

Tappet Stem Diameter .375/.374 in.

Tappet Guide Internal Diameter .3765/.3750 in.

Tappet Guide External Diameter .875/.874 in.

Guide Hole in Crankcase .875/.874 in.

Tappet Clearance with cold engine-

Inlet .002 in.

Exhaust. .004 in.

Valve Spring Free Length

Inner 1 13/16 in.

Outer 1 27/32 in.

(Renew when reduced by 3/16 in.).

Valve Timing with .012 in. clearance-

Exhaust Opens 75° before B.D.C.

Exhaust Closes 35° after T.D.C.

Inlet Opens 30° before T.D.C.

Inlet Closes 60° after B.D.C.

Cam Spindle External Diameter .6245/.6235 in.

Cam Bush Internal Diameter .6255/.6250 in.

Cam Lift . .3125 in.

Valve Lift (approximately) .3125 in.

Contact Breaker-

Speed Half Engine Speed

Points .015/.018 in.

Timing 3/8in. before T.D.C.

advanced

1/64 in. before T.D.C.

retarded

Engine Sprocket 17 Teeth.

Clutch Sprocket 42 Teeth.

Final Drive Sprocket 15 Teeth.

Primary Chain

Type 110046 Renold

Length 66 Pitches.

Width .305 in.

Pitch .500 in.

Feed Oil Pump

Speed 1/12 Engine Speed.

Piston Diameter .25 in. (nominal)

Stroke .375 in.

Return Oil Pump-

Speed 1/12 Engine Speed.

Piston Diameter .375 in. (nominal)

Stroke .375 in.

Sparking Plug

Type Lodge H 14.

K.L.G.F70.

Champion L10S.

Diameter 14 mm

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ROYAL ENFIELD WORKSHOP MANUAL

Section B3 Page 1

SECTION B3

Engine Specification

250 Clipper

8. Main Bearings

Heavy duty roller bearings are provided for

the engine shafts, the outer races being shrunk

into the crankcase while internally the rollers run

direct on the shafts.

9. Cams

The cams are integral with the cam pinions

being machined from carbon steel and case

hardened. They have internal bronze bushes

running on fixed spindles in the timing chest.

The cam profiles are produced with silencing

ramps to ensure quiet running.

10. Valves

The inlet valve is machined from a stamping

of silicon-chrome valve steel and the exhaust

valve is of austenitic steel.

11. Valve Gear

The valves are operated from the cams by,

means of large flat based guided tappets, high

quality tubular steel push rods, with steel caps.

and overhead rockers. Two compression springs

are fitted to each valve.

12. Timing Drive

The cams are located in the timing chest and

are driven at half engine speed from the

crankshaft by a positive geared drive.

The contact breaker is driven from the inlet

cam pinion through two idler pinions which also

act as a gear pump to return the oil from the

timing chest to the oil tank.

13. Ignition and Lighting System

Coil ignition and lighting are supplied from a

6volt battery which is charged through a rectifier

from an A.C. alternator mounted on the engine

shaft inside the primary chain case.

The alternator has a permanent magnet rotor

revolving within a six pole wound laminated

stator.

The arrangement is such that in case of

battery failure, the ignition can be supplied direct

from the alternator.

1. Engine

The engine is a 248c.c. vertical single four

stroke, with separate cylinder head and fully

enclosed pressure-fed overhead valve gear. It

has dry sump lubrication with the oil tank

integral with the crankcase and a built-up steel

crankshaft.

2. Cylinder Head

The cylinder head is of cast iron and is

generously finned to ensure adequate cooling. It

has a large bore induction port, stream-lined and

blended to the valve seating.

3. Cylinder

The cylinder barrel is of cast iron, with

internal tunnels enclosing the push rods. The bore

is nominally 64m.m. and the stroke 77m.m.,

giving a cubic capacity of 248 c.c.

4. Piston

The piston is cast from low expansion

aluminium alloy, heat treated and form-turned

oval and having a split skirt. The compression

ratio is 6½ to 1. There are three piston rings, the

top two of which are compression rings. Both are

taper ground and the top, one is chromium plated.

The third ring is for oil control and is slotted.

5. Connecting Rod

The connecting rod is machined from a

manganese-molybdenum steel stamping and has

a carobronze bush in the little end. The big end

has a hardened chrome steel bush pressed in and

a floating bush made from mild steel and white

metalled.

6. Crankcase

The combined crankcase and oil tank are

die-cast from light alloy in two halves, being split

vertically.

7. Crankshaft and Flywheel

The crankshaft is built up from two steel

flywheels bolted to the crankpin and bolted and

keyed to the engine shafts the whole being

carefully balanced.

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ROYAL ENFIELD WORKSHOP MANUAL

Section B3 Page 2

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ROYAL ENFIELD WORKSHOP MANUAL

Section B3 Page 3

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