Name: Royal Enfield CRUSADER SPORTS
Brand: Royal Enfield
Rating: 5 (1 reviews)

To Next Page

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

HITCHCOCK’S 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 Contents3
Vehicle View4
Technical Data5
Engine Exploded View8
Engine Specification9
Lubrication System Operation Diagram10
Lubrication System Schematic Diagram11
Oil Pump Diagrams13
Removal of the Petrol Tank15
Section C1815
- Service Operations with Engine in of Frame15
- Removal of the Generator Cover15
- Removal of the Primary Chaincase Cover15
- Timing Chain Adjustment16
- Valve and Pump Timing16
- Valve Adjustment16
- Ignition Timing17
SECTION G2F17
- Removal of Carburettor18
- Removal of the Cylinder Head18
- Removal of the Valves18
- Dismantling the Rockers19
- Fitting New Valve Guides19
- Removal of the Cylinder Barrel19
- Removal of the Piston19
- Re-Assembly after Decarbonising20
- Cleaning the Oil Filter21
- Changing the Oil21
- Removal of the Timing Chain and Sprockets21
- Overhauling the Oil Pump21
- Dismantling the Cam Gear22
- Removal of the Contact Breaker22
- Removal of the Primary Drive Chain and Sprockets22
- Attention to the Breather22
- Internal Oil Pipes23
- Removal of the Generator23
- Pressure Relief Valves23
- Service Operations with Engine out of Frame25
- Removal of the Engine from the Frame25
- Dismantling the Crankcase25
- Main Bearings25
- Piston, Connector Rod and Crank Assembly View26
- Fitting the Connecting Rod, 250 C.C. Engine29
- Re-Assembly of the Crankcase29
- Crankpin Oil-Way29
Gearbox and Clutch31
- Operation of Four-Speed Gear Box32
- Operation of Five-Speed Gear Box33
- Arrangement of Five-Speed Gears34
- Adjustment of the Clutch35
- Adjustment of the Gear-Change Mechanism35
- View of Engine with Generator Cover Removed35
- Clutch Exploded View36
- Four-Speed Gearbox Cutaway Section View37
- Removal of the Final Drive Sprocket38
- Dismantling the Clutch38
- Reassembly of the Clutch38
- Dismantling the Gearbox39
- Re-Assembling the Gearbox39
- The Kick-Start Mechanism39
- Amal Monobloc Carburetter41
- Tuning the Carburetter(S)41
- Monobloc Carburetor Exploded View43
- Causes of High Petrol Consumption44
- Dismantling Carburetter44
- Settings of AMAL Monobloc Carburetters45
- Lucas A.C. Lighting-Ignition System47
- Emergency Starting48
- Ignition System Direct Operation48
- Ignition System Routine Maintenance48
- Contact Breaker Unit49
- Contact Breaker Setting49
- Wiring Diagram50
- Battery Maintenance53
- Battery Model PUZ7E - Preparation for Service53
Battery Model MLZ9E55
- Filling and Soaking the MLZ9E Battery56
- Headlamp57
- Lucas Light Unit57
- Replacing the Light Unit and Bulb/Parking Lights57
Head and Tail Lamps57
- Tail Light58
- Frame View59
- Servicing Rear Suspension Units60
- Removal and Replacement of Rear Mudguard Unit60
- Steering Head Races60
- Description of Frame60
- Wheel Alignment61
- Lubrication61
- Removal of Petrol Tank61
- Air Cleaner61
- Dismantling Fork to Replace Spring63
Front Fork63
- Removal of Complete Fork64
- Re-Assembly of Front Fork Parts64
- Front Fork Spring64
- Front Fork Lubrication65
- Dismantling the Fork to Replace Spring, Oil Seal or Bearing Bushes66
- Reassembly of Front Fork Parts66
- Dismantling Fork to Replace Suspension Unit67
- Suspension Units67
Front Fork (Super 5)67
Removal of Hub Spindle and Bearings69
Front Wheel (6" Brake)69
- Removal of Brake Shoes for Replacement, Fitting New Linings, Etc.69
- Removal of Brake Operating Cam69
- Front Wheel Removal from Fork69
- Hub Bearings70
- Fitting Limits for Bearings70
- Refitting Ball Bearings70
- Re-Assembly of Brake Shoes and Operating Cam into Cover Plate70
- Tyre Pressures71
- Spokes71
- Tyres71
- Wheel Building and Truing71
- Front Wheel with Single 7 In. Brake - Removal from Fork73
- Removal of Brake Cover Plate Assembly73
- Replacing Brake Linings73
Front Wheel (7" Brake)73
- Final Assembly of Hub before Replacing Wheel74
- Removal and Replacement of Complete Wheel for Access to Brake77
- Removal/Replacement of Main Portion of Wheel, for Tyre Repairs, Etc.77
Rear Wheel (Q/D)77
- Removal of Ball Bearings80
- Removal of Hub Driving Pins80
- Final Re-Assembly of Hub before Replacing Wheel81
- Wheel Rim81
- Rear Wheel (Non-Detachable Type)83
- Removal of Inner Tube with Wheel in Position in Frame83
- Removal and Replacement of Rear Wheel83
- Removal of Brake Shoes for Replacement84
- Cush Drive85
- Final Reassembly of Hub before Replacing Wheel85
- Wheel Rims85
- Reassembly of Brake Shoes, Pivot Pin, Operating Cam into Cover Plate85
Special Tools89
- Legshields92
- Pannier Equipment92
Accessories92
- Removal of the Headlamp Switch, Speedometer and Ammeter93
- Removal of the Windscreen93
- Removal of the Headlamp93
"Airflow" Fairing93
- Exploded View of "Airflow" Fairing Assembly94
- Reassembly of the Fairing95
- Reassembly of Mudguard, Fork Legs and Wheel95
- Reassembly of Headlamp95
- Reassembly of Ammeter, Headlamp Switch and Speedometer95

Royal Enfield CRUSADER SPORTS User Manual

Table of Contents

Other manuals for Royal Enfield CRUSADER SPORTS

Questions and Answers:

Royal Enfield CRUSADER SPORTS Specifications

Related product manuals

Brand	Royal Enfield
Model	CRUSADER SPORTS
Category	Motorcycle
Language	English