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CRUSADER SPORTS
Royal Enfield CRUSADER SPORTS User Manual
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ROYAL ENFIELD WORKSHOP MANUAL
PAGE 8
EXPLODED
VI
EW
OF 250cc ENGINE
www.hitchcocksmotorcycles.com
7
9
Table of Contents
Table of Contents
3
Vehicle View
4
Technical Data
5
Engine Exploded View
8
Engine Specification
9
Lubrication System Operation Diagram
10
Lubrication System Schematic Diagram
11
Oil Pump Diagrams
13
Removal of the Petrol Tank
15
Section C18
15
Service Operations with Engine in of Frame
15
Removal of the Generator Cover
15
Removal of the Primary Chaincase Cover
15
Timing Chain Adjustment
16
Valve and Pump Timing
16
Valve Adjustment
16
Ignition Timing
17
SECTION G2F
17
Removal of Carburettor
18
Removal of the Cylinder Head
18
Removal of the Valves
18
Dismantling the Rockers
19
Fitting New Valve Guides
19
Removal of the Cylinder Barrel
19
Removal of the Piston
19
Re-Assembly after Decarbonising
20
Cleaning the Oil Filter
21
Changing the Oil
21
Removal of the Timing Chain and Sprockets
21
Overhauling the Oil Pump
21
Dismantling the Cam Gear
22
Removal of the Contact Breaker
22
Removal of the Primary Drive Chain and Sprockets
22
Attention to the Breather
22
Internal Oil Pipes
23
Removal of the Generator
23
Pressure Relief Valves
23
Service Operations with Engine out of Frame
25
Removal of the Engine from the Frame
25
Dismantling the Crankcase
25
Main Bearings
25
Piston, Connector Rod and Crank Assembly View
26
Fitting the Connecting Rod, 250 C.C. Engine
29
Re-Assembly of the Crankcase
29
Crankpin Oil-Way
29
Gearbox and Clutch
31
Operation of Four-Speed Gear Box
32
Operation of Five-Speed Gear Box
33
Arrangement of Five-Speed Gears
34
Adjustment of the Clutch
35
Adjustment of the Gear-Change Mechanism
35
View of Engine with Generator Cover Removed
35
Clutch Exploded View
36
Four-Speed Gearbox Cutaway Section View
37
Removal of the Final Drive Sprocket
38
Dismantling the Clutch
38
Reassembly of the Clutch
38
Dismantling the Gearbox
39
Re-Assembling the Gearbox
39
The Kick-Start Mechanism
39
Amal Monobloc Carburetter
41
Tuning the Carburetter(S)
41
Monobloc Carburetor Exploded View
43
Causes of High Petrol Consumption
44
Dismantling Carburetter
44
Settings of AMAL Monobloc Carburetters
45
Lucas A.C. Lighting-Ignition System
47
Emergency Starting
48
Ignition System Direct Operation
48
Ignition System Routine Maintenance
48
Contact Breaker Unit
49
Contact Breaker Setting
49
Wiring Diagram
50
Battery Maintenance
53
Battery Model PUZ7E - Preparation for Service
53
Battery Model MLZ9E
55
Filling and Soaking the MLZ9E Battery
56
Headlamp
57
Lucas Light Unit
57
Replacing the Light Unit and Bulb/Parking Lights
57
Head and Tail Lamps
57
Tail Light
58
Frame View
59
Servicing Rear Suspension Units
60
Removal and Replacement of Rear Mudguard Unit
60
Steering Head Races
60
Description of Frame
60
Wheel Alignment
61
Lubrication
61
Removal of Petrol Tank
61
Air Cleaner
61
Dismantling Fork to Replace Spring
63
Front Fork
63
Removal of Complete Fork
64
Re-Assembly of Front Fork Parts
64
Front Fork Spring
64
Front Fork Lubrication
65
Dismantling the Fork to Replace Spring, Oil Seal or Bearing Bushes
66
Reassembly of Front Fork Parts
66
Dismantling Fork to Replace Suspension Unit
67
Suspension Units
67
Front Fork (Super 5)
67
Removal of Hub Spindle and Bearings
69
Front Wheel (6" Brake)
69
Removal of Brake Shoes for Replacement, Fitting New Linings, Etc.
69
Removal of Brake Operating Cam
69
Front Wheel Removal from Fork
69
Hub Bearings
70
Fitting Limits for Bearings
70
Refitting Ball Bearings
70
Re-Assembly of Brake Shoes and Operating Cam into Cover Plate
70
Tyre Pressures
71
Spokes
71
Tyres
71
Wheel Building and Truing
71
Front Wheel with Single 7 In. Brake - Removal from Fork
73
Removal of Brake Cover Plate Assembly
73
Replacing Brake Linings
73
Front Wheel (7" Brake)
73
Final Assembly of Hub before Replacing Wheel
74
Removal and Replacement of Complete Wheel for Access to Brake
77
Removal/Replacement of Main Portion of Wheel, for Tyre Repairs, Etc.
77
Rear Wheel (Q/D)
77
Removal of Ball Bearings
80
Removal of Hub Driving Pins
80
Final Re-Assembly of Hub before Replacing Wheel
81
Wheel Rim
81
Rear Wheel (Non-Detachable Type)
83
Removal of Inner Tube with Wheel in Position in Frame
83
Removal and Replacement of Rear Wheel
83
Removal of Brake Shoes for Replacement
84
Cush Drive
85
Final Reassembly of Hub before Replacing Wheel
85
Wheel Rims
85
Reassembly of Brake Shoes, Pivot Pin, Operating Cam into Cover Plate
85
Special Tools
89
Legshields
92
Pannier Equipment
92
Accessories
92
Removal of the Headlamp Switch, Speedometer and Ammeter
93
Removal of the Windscreen
93
Removal of the Headlamp
93
"Airflow" Fairing
93
Exploded View of "Airflow" Fairing Assembly
94
Reassembly of the Fairing
95
Reassembly of Mudguard, Fork Legs and Wheel
95
Reassembly of Headlamp
95
Reassembly of Ammeter, Headlamp Switch and Speedometer
95
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Royal Enfield CRUSADER SPORTS Specifications
General
Brand
Royal Enfield
Model
CRUSADER SPORTS
Category
Motorcycle
Language
English
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