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Royal Enfield 350 BULLET 1949 User Manual

Royal Enfield 350 BULLET 1949
102 pages
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ROYAL ENFIELD WORKSHOP MANUAL
WORKSHOP
MAINTENANCE MANUAL
FOR THE
Royal
Enfield
350 BULLET 194955
500 BULLET 195355
MAN 8
www.hitchcocksmotorcycles.com

Table of Contents

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Royal Enfield 350 BULLET 1949 Specifications

General IconGeneral
BrandRoyal Enfield
Model350 BULLET 1949
CategoryMotorcycle
LanguageEnglish

Summary

SECTION B2 Engine Specification

1. Engine

Engine configuration, lubrication, and crankshaft details.

2. Cylinder Head

Cylinder head material, cooling, and valve insert specifications.

3. Cylinder

Cylinder bore and stroke details for 350/500cc models.

4. Piston

Piston material, rings, and compression ratio information.

5. Connecting Rod

Connecting rod material and little end bearing specifications.

6. Crankcase

Crankcase construction and split details.

7. Crankshaft and Flywheel

Crankshaft and flywheel assembly description.

8. Main Bearings

Types of main bearings on driving and timing sides.

9. Cams

Cam material, hardening, and bush specifications.

10. Valves

Inlet and exhaust valve material details.

11. Valve Gear

Valve operation via tappets, push rods, and rockers.

12. Timing Drive

Timing drive mechanism and magdyno drive description.

13. Ignition and Lighting System

Source of ignition and lighting system power.

14. Carburetter

Reference to specific carburetter sections F1 and F2.

15. Air Filter

Air filter type and functional description.

16. Lubrication System

Explanation of the dry-sump lubrication system.

17. Breather

Details on breather function and types.

18. Gearbox

Description of gearbox, speeds, and gear changes.

19. Clutch

Comparison of 350 and 500 Bullet clutch models.

SECTION C2 Service Operations with Engine in Frame

1. Removal of the Timing Cover

Procedure for removing and refitting the timing cover.

2. Valve Timing

Instructions for setting valve timing at a specific clearance.

3. Tappet Adjustment

How to adjust tappets, including cold clearance.

SECTION D2 Service Operations with Engine Removed

1. Removal of the Engine from the Frame

Step-by-step guide to removing the engine from the frame.

2. Removal of the Gear Box

Procedure for removing the gearbox.

3. Dismantling the Crankcase

Steps for separating the crankcase halves.

4. Main Bearings

Instructions for removing and replacing main bearings.

5. Replacement of the Cam and Idler Spindles

Procedure for removing and replacing cam and idler spindles.

SECTION E1 Gearbox and Clutch

1. Removal of Gearbox

Refers to engine removal sections for gearbox removal.

2. To Dismantle the Gearbox

Steps for dismantling the gearbox.

AMAL NEEDLE TYPE CARBURETTER

Carburetter with Pilot Jet System Diagram

Diagram showing carburetter with pilot jet system.

Amal Carburetter Design Variations

Illustrates two designs of Amal carburetters.

Amal Monobloc Carburetter

1. General Description

Overview of the Amal Monobloc Carburetter features.

2. Tuning the Carburetter(s)

Instructions for tuning the Monobloc carburetter.

SECTION G1c Lucas Magdyno

1. General

General description of the Lucas Magdyno.

2. Routine Maintenance

Maintenance schedule for the Magdyno.

SECTION G2b Lucas Dynamo Model E3LM

1. General

General description of the Lucas Dynamo.

2 (a). Lubrication

Lubrication requirements for the dynamo.

2 (b). Inspection of Commutator and Brush Gear

Inspection procedure for commutator and brush gear.

3. Test Data

Technical test data for the dynamo.

4 (a). Testing in Position to Locate Fault in Charging Circuit

Troubleshooting steps for charging circuit faults.

SECTION G3a Control Box

1. General

General description of the Control Box.

2. Setting Data

Specifies cut-in and drop-off voltages for the cut-out.

3. Servicing

Procedure for servicing the control box and regulator.

Battery Model PUZ7E

1. General

General information about the PUZ7E battery.

2. Preparation for Service

Instructions for preparing the battery with electrolyte.

3. Routine Maintenance

Routine checks and maintenance for the battery.

4. Servicing

Servicing procedures for a discharged battery.

SECTION G5a Head and Tail Lamps

1. Headlamp

Description of the headlamp unit and its features.

2. Lucas Light Unit

Details the Lucas Light Unit construction.

3. Replacing the Light Unit and Bulb

Steps for replacing the light unit and bulb.

4. Parking Lights

Information on parking light bulb mounting.

5. Tail Light

Describes earlier and later tail light types.

SECTION H1 FRAME

1. Description of Frame

Describes frame construction and differences.

2. Steering Head Races

Details steering head races and their fitting.

3. Removal of Rear Suspension Unit

Procedure for removing rear suspension units.

4. Servicing Rear Suspension Units

Servicing instructions for proprietary and Royal Enfield rear suspension units.

SECTION J1 Front Fork With Casquette and Aluminium Alloy Bottom Tubes

1. Description

Description of the telescopic front fork.

2. Operation of the Fork

Explains the fork's movement and damping system.

3. Dismantling the Fork to Replace Spring, Oil Seal or Bearing Bushes

Steps for dismantling the fork for part replacement.

SECTION J3 Front Fork With Facia Panel and Aluminium Alloy Bottom Tubes

1. Description

Description of the front fork with facia panel.

2. Operation of Fork

Explains the fork's operation and damping.

3. Dismantling the Fork to Replace Spring, Oil Seal or Bearing Bushes

Steps for dismantling the fork for component replacement.

SECTION J4 Front Fork With Facia Panel and Steel Bottom Tubes

1. Description

Describes the front fork with steel bottom tubes.

2. Dismantling Fork to Replace Spring, Oil Seal or Bearing Bushes

Instructions for dismantling the fork for parts replacement.

3. Spring

Details the front fork spring length and replacement criteria.

4. Steering Head Races

Information on steering head races and adjustment.

SECTION K1 Front Wheel With Dual 6 in. Brake

1. Removal from Fork

Steps for removing the front wheel from the fork.

2. Removal of Brake Cover Plate Assemblies

Procedure for removing brake cover plate assemblies.

3. Removal of Brake Shoes and Springs

Steps for removing brake shoes and springs.

4. Replacing Brake Linings

Information on replacing brake linings.

5. Removal of Hub Spindle and Bearings

Procedure for removing the hub spindle and bearings.

6. Hub Bearings

Details the types and specifications of hub bearings.

7. Fitting Limits for Bearings

Fitting tolerances and considerations for hub bearings.

8. Refitting Ball Bearings

Instructions for refitting ball bearings.

SECTION K2 Front Wheel With Single 6 in. Brake

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 assembly.

3. Removal of Brake Shoes for Replacement, Fitting New Linings, etc.

Steps for brake shoe replacement and lining fitting.

4. Replacing Brake Linings

Information on fitting new brake linings.

5. Removal of Hub Spindle and Bearings

Procedure for removing hub spindle and bearings.

6. Hub Bearings

Details hub bearing types and specifications.

7. Fitting Limits for Bearings

Fitting tolerances for hub bearings.

8. Refitting Ball Bearings

Instructions for refitting ball bearings.

SECTION L1 Rear Wheel (Detachable Type)

1. Description

Description of the detachable rear wheel.

2. Removal and Replacement of Main Portion of Wheel for Tyre Repairs, etc.

Procedure for removing the main portion of the rear wheel.

3. Removal and Replacement of Complete Wheel for Access to Brake

Steps for removing the complete rear wheel for brake access.

SECTION L2 Rear Wheel (Non-Detachable Type)

1. Description

Description of non-detachable rear wheels.

2. Removal and Replacement of Wheel

Procedure for removing the rear wheel.

3. Removal of Brake Shoes for Replacement, Fitting New Linings, etc.

Steps for brake shoe replacement and lining fitting.

4. Replacing Brake Linings

Information on fitting new brake linings.

5. Removal of Hub Spindle and Bearings

Procedure for removing hub spindle and bearings.

6. Hub Bearings

Details hub bearing types and specifications.

7. Fitting Limits for Bearings

Fitting tolerances for hub bearings.

8. Refitting Ball Bearings

Instructions for refitting ball bearings.

SECTION M2 Special Tools

Magdyno Pinion Extractor Use

Tool for extracting the Magdyno pinion.

Valve Spring Compressor Use

Tool for compressing valve springs.

Valve Guide Mandrel Use

Mandrels for valve guide operations.

Gudgeon Pin Extractor Use

Tool for extracting gudgeon pins.

Valve Grinding Tool Use

Tool used for valve grinding.

Pump Disc Lapping Tool Use

Tool for lapping pump discs.

Pump Worm Shaft Spanner Use

Spanner for the pump worm shaft.

Tappet Guide Extractor Use

Tool for extracting tappet guides.

Clutch Centre Extractor Use

Tool for extracting the clutch centre.

Crankshaft Extractor Use

Tool for extracting crankshafts.

Timing Side Roller Race Assembly Tool

Tool for timing side roller race assembly.

Driving Side Bearing Assembly Tool

Tool for driving side bearing assembly.

Cam Spindle Locating Plate Use

Plate for locating cam spindle assemblies.

350 Bullet Crankshaft Jig Use

Jig for 350 Bullet crankshaft.

500 Bullet Crankshaft Jig Use

Jig for 500 Bullet crankshaft.

Frame Expander Tool Use

Tool for expanding frames.

Gland Nut Grips Use

Grips for gland nuts.

Lockring Spanner Use

Spanner for lockrings.

Gland Nut Hand Grips Use

Hand grips for gland nuts.

Outer Tube Hand Grips Use

Hand grips for outer tubes.

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