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Royal Enfield 250 CLIPPER User Manual

Royal Enfield 250 CLIPPER
96 pages
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WORKSHOP
MAINTENANCE MANUAL
FOR THE
Royal
Enfield
250 CLIPPER 250 CRUSADER
CRUSADER SPORTS SUPER 5
CONTINENTAL 350 NEW BULLET
250 TRIALS CONTINENTAL GT
Including AIRFLOW model where applicable
SPARES for ROYAL ENFIELD & AMAL
HITCHCOCKS MOTORCYCLES
ROSEMARY COURT
OLDWICH LANE WEST
CHADWICK END
SOLIHULL
B93 0EY ENGLAND
TELEPHONE: 01564 783 192
FAX: 01564 783 313
E-MAIL: in-
fo@hitchcocksmotorcycles.com
WEB: hitchcocksmotorcycles.com
www.hitchcocksmotorcycles.com

Table of Contents

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Royal Enfield 250 CLIPPER Specifications

General IconGeneral
BrandRoyal Enfield
Model250 CLIPPER
CategoryMotorcycle
LanguageEnglish

Summary

TECHNICAL DATA (250cc Models)

TECHNICAL DATA (350cc Bullet)

Engine Specification

Engine Components

Details the core engine parts, construction, and their specific features.

Engine Systems

Explains systems like valve gear, timing, ignition, fuel, and lubrication.

Service Operations with Engine in Frame

Component Removal Procedures

Step-by-step instructions for removing key engine and chassis components.

System Adjustments

Guidance on adjusting critical engine timing, valve clearance, and chain tension.

Amal Monobloc Carburetter

General Description and Tuning

Overview of the Amal Monobloc carburetter's design and tuning procedures.

Carburetter Maintenance and Issues

Instructions for dismantling, common issues, and causes of high petrol consumption.

Lucas A.C. Lighting-Ignition System

System Overview and Circuit Details

Explains the system components, circuit connections, and general operation.

Operation and Maintenance

Covers emergency starting, routine checks, and maintenance for the system.

Battery Models

Battery Model PUZ7E

Details on PUZ7E battery preparation, maintenance, and servicing.

Battery Model MLZ9E

Information on MLZ9E battery specifications, preparation, and soaking.

Head and Tail Lamps

Headlamp and Light Units

Information on headlamp types, Lucas light units, and bulb replacement.

Parking and Tail Lights

Procedures for accessing and maintaining parking and tail lamp assemblies.

Frame

Frame Description and Head Races

Details on frame construction, steering head races, and general servicing.

Suspension and Stand Components

Covers removal and servicing of rear suspension units, swinging arm, and centre stand.

Front Fork

Front Fork Description and Removal

Details on fork design, spring replacement, and component removal procedures.

Front Fork Servicing and Adjustments

Covers steering head races, complete fork removal, and lubrication.

Front Wheel With Single 6 in. Brake

Wheel Removal and Disassembly

Procedures for removing the front wheel and its brake components for servicing.

Wheel Components and Assembly

Details on wheel components, assembly, tyre fitment, and lubrication requirements.

Front Wheel With Single 7 in. Brake

Wheel Removal and Disassembly

Procedures for removing the front wheel and its brake components for servicing.

Wheel Components and Assembly

Details on wheel components, assembly, tyre fitment, and lubrication requirements.

Rear Wheel (Non-Detachable Type)

Wheel Removal and Brake Access

Steps for removing the rear wheel and accessing the brake drum assembly.

Brake Service and Components

Details on servicing brake shoes, cam, cush drive, hub bearings, and wheel components.

Special Tools

Engine Servicing Tools

Specialized tools for engine maintenance, including valve, camshaft, and pump servicing.

Transmission & General Tools

Tools for clutch repair and general workshop tasks like screwdriver use.

Accessories

Legshields

Information on the fitting and attachment of legshields for protection.

Pannier Equipment

Details on fitting pannier bags and carriers for carrying luggage.

"Airflow" Fairing

Fairing Component Removal

Procedures for removing various components associated with the fairing assembly.

Fairing Repair and Reassembly

Instructions for repairing minor damage and reassembling fairing components.

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