Royal Enfield 350 BULLET 1956 User manual

ROYAL ENFIELD WORKSHOP MANUAL
WORKSHOP
MAINTENANCE MANUAL
FOR THE
Royal
Enfield
350 BULLET 1956 on
500 BULLET 1956 on
350 CLIPPER 1958 on
Including AIRFLOW models
And TRIALS WORKS REPLICA
MAN7
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ROYAL ENFIELD WORKSHOP MANUAL
Contents
1956-62 "350 Bullet" and "500 Bullet", 1958--61 "350 Clipper" (including
"Airflow" models) and Trials "Works Replica" 1958 onwards
SECTION A14a 350 DATA TECHNICAL
SECTION A14b 500 DATA TECHNICAL
SECTION C14 SERVICE OPERATIONS WITH ENGINE IN FRAME
SECTION D2 SERVICE OPERATIONS WITH ENGINE REMOVED
SECTION E1 GEARBOX AND CLUTCH
SECTION F4 CARBURETTER
SECTION G1e SR1 MAGNETO
SECTION G2k GENERATOR/RECTIFIER CHARGING SET
SECTION G4a BATTERY
SECTION G5d HEAD AND TAIL LAMPS
SECTION H5 FRAME
SECTION J1 FRONT FORK
SECTION K6 FRONT WHEEL (DUAL BRAKE)
SECTION K7 FRONT WHEEL (7” SINGLE BRAKE)
SECTION L12 REAR WHEEL (NON-DETACHABLE)
SECTION L13 REAR WHEEL (QUICKLY DETACHABLE)
SECTION M2 and M4 SPECIAL TOOLS
SECTION P1 AIRFLOW FAIRING
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ROYAL ENFIELD WORKSHOP MANUAL
350 BULLET 1961
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ROYAL ENFIELD WORKSHOP MANUAL
SECTION A14a
Technical Data
350 Bullet 1956-62, 350 Clipper and Trials Works Replica 1958-62
Cubic Capacity ... ... ... ... 346 c.c.
Stroke ... ... ... ... 90 mm.
Bore ... ... ... Nominal .. 70 mm.
Actual 69.874 mm./2.751 in.
(Rebore to .020 in. when wear exceeds .0065 in. and again
to .040 in. after a further .0065 in. wear.)
Compression Ratios:
350 Bullet to 1958, 350 Clipper
to 1959, and all Works Replica
models 7.25 to 1
350 Bullet, 1959 onwards, and
350 Clipper, 1960 onwards ........7.75 to 1
Piston Diameter-
Bottom of Skirt-Fore and Aft 69.811/69.786 mm.
Top Lands ... 69.32/69.27 mm.
Piston Rings
Width-Plain Rings. (Two) .0635/.0625 in.
Scraper Ring. (One) .156/.155 in.
Radial Thickness ......................... .3.085/2.833 mm.
Clearance in Grooves-Plain Rings .003/.001 in.
Scraper Ring .004/.002 in.
(Renew Piston Rings when gap exceeds 1/16 in.)
Oversize Pistons and Rings available up to +0.060 in.
Piston Boss Internal Diameter .7501/.7499 in.
Gudgeon Pin Diameter ........... ......... .7501/.7499 in.
Con. Rod Small End Diameter .7507/.7505 in.
Con. Rod Big End Diameter...........1.62625/1.62575 in.
Crank Pin Diameter ...........1.24900/1.24875 in.
Con. Rod Floating Bush:
Outside Diameter ...................... .1.6235/1.6230 in.
Inside Diameter ......................... .1.2502/1.2498 in.
Width .983/.980 in.
Driving Side Main Ball and Roller Bearings
Later type 350 Bullet and Works Replica, and
350 Clipper, 1960 onwards, use SKF.CRL.8 and
SKF.RLS.8. Up to 1959 350 Clipper, use two
SKF.RLS.8 bearings.
Outside Diameter ...................... ... 2.25 in.
Inside Diameter ......................... ... 1 in.
Width .625 in.
Timing Side Main Roller Bearing-
Outside Diameter ...................... ...1.876/1.875 in.
Inside Diameter ........................ ...1.5002/1.4998 in.
Width ............................... .750 in.
Size of Rollers:
Diameter ........................ .2500/.2490 in.
Length ......................................... .328/.327 in.
Graded rollers are available in steps of .0001 from .2490
to .2500 in.
Rocker Bearing Inside Diameter ... .626/.625 in.
Rocker Spindle Diameter ................. .6240/.6235 in.
Inlet Valve Stem Diameter ................ .3430/.3425 in.
Exhaust Valve Stem Diameter .3410/.3405 in.
Valve Guide Internal Diameter (All
Bullets and Trials; Clipper,
1960 onwards only) ................ .3447/.3437 in.
Valve Guide External Diameter (All
Bullets and Trials; Clipper,
1960 onwards only) .6275/.6270 in.
Valve Guide Internal Dia. (Clipper,
up to 1959) .3452/.3442 in.
Valve Guide External Dia. (Clipper,
up to 1959) ....................... .625/.623 in.
Guide Hole in Cylinder Head (All
Bullets and Trials; Clipper,
1960 onwards only) .622/.623 in.
Guide Hole in Cylinder Head (Clipper
up to 1959) .............................. ...... .622/ .623 in.
Tappet Stem Dia. (all models) .375/.374 in.
Tappet Guide Internal Dia. (all
models) .3760/.3752 in.
Tappet Guide External Dia. (all
models) .7510/.7505 in.
Guide Hole in Crankcase (all models) .750/.749 in.
Tappet Clearance with cold engine-
Inlet ........................................ .................Nil
Exhaust ................................. .................Nil
Valve Spring Free Length-
Inner ...................................... ..... 2.02 in.
Outer .... 2.095 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 ... .6240/.6235 in.
Cam Bush Internal Diameter ........ ... .6255/.6250 in.
Cam Lift ............................................ ... .3125 in.
Valve Lift (approximately) ............. ... .3125 in.
Contact Breaker (Coil Ignition)-
Speed ............................... ... 1/2 Engine Speed
Points ........................ ..... .014/.016 in.
Timing .. ....... 1/2 - 7/16 in. before T.D.C.
Magneto-
Speed ........... .......... .......... 1/2 Engine Speed
Points ........................ .012/.015 in.
Timing ........... ..........1/2 - 7/16 in. before T.D.C.
Engine Sprocket (Bullet and Clipper) 25 teeth
Engine Sprocket (Trials) ................. .............20 Teeth
Clutch Sprocket (all models) ......... .............56 Teeth
Final Drive Sprocket (Bullet) .............20 Teeth
Final Drive Sprocket (Trials) .............17 Teeth
Final Drive Sprocket (Clipper up
to 1959) ............. ..............................15 Teeth
Final Drive Sprocket (Clipper, 1960
onwards) ................ ..............................20 Teeth
Primary Chain-
Type ....... .............. ....................Duplex No. 114038
................. ........... .......... .......... .............Endless
Length .............. ....90 Pitches (Trials 88 Pitches)
Width .............. .................... .628 in.
Pitch .............. .................... .375 in.
Feed Oil Pump
Speed .............................. ....................1/12 Engine Speed
Piston Diameter... ................... .24975/.24950 in.
Stroke .................... .................................5 in.
Return Oil Pump
Speed ..................... ....................1/12 Engine Speed
Piston Diameter... ................... .37475/.37450 in.
Stroke .................... .................................5 in.
Sparking Plug-
Type ..........Lodge H.14, KLG F.70, Champion L10S,
................... (Trials: Lodge HN)
Diameter .............. ...............................14 mm.
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ROYAL ENFIELD WORKSHOP MANUAL
500 BULLET 1956
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