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Royal Enfield G - User Manual

Royal Enfield G
72 pages
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ROYAL ENFIELD 350cc and 500cc O.H.V. WORKSHOP MANUAL
WORKSHOP
MAINTENANCE MANUAL
FOR THE
ROYAL ENFIELD
350 cc OHV G, 1945 - 1954
G deluxe and 350 Clipper
1955 - 57
and 500 cc OHV J and J2
1945 1954
MOTOR CYCLES
HITCHCOCK’S MOTORCYCLES
ROSEMARY COURT
OLDWICH LANE WEST
CHADWICK END
SOLIHULL
B93 0EY ENGLAND
Telephone 01564 783 192
Fax 01564 783 313
e-mail: info@hitchcocksmotorcycles.com
Web: hitchcocksmotorcycles.com
www.hitchcocksmotorcycles.com

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Royal Enfield G and is the answer not in the manual?

Summary

Tools Supplied with Machine

Tool Roll and Contents

Lists tools included in the tool roll for the machine.

Engine

Decarbonising

Procedure for removing carbon deposits from the engine.

Timing Gear, Tappets and Lubrication

Adjusting engine timing, tappets, magneto, and lubrication system.

Gearbox

Removal and Dismantling

Procedures for removing and dismantling the gearbox.

Reassembly and Adjustments

Guidance for reassembling and adjusting the gearbox.

Clutch

Dismantling and Reassembly

Steps for dismantling and reassembling the clutch assembly.

Clutch Control Adjustment

How to adjust the clutch control for proper free movement.

Chains

Lubrication, Tensioning and Wear

Instructions for chain lubrication, tensioning, and checking wear limits.

Removal, Repair and Replacement

Procedures for removing, repairing, and replacing chains.

Carburetter

Settings, Systems and Operation

Carburetter settings, pilot jet system, and how it works.

Hints, Fault Finding and Tuning

Tips, fault tracing, parts identification, and tuning procedures.

Lucas Magdyno

General and Routine Maintenance

Overview of the Magdyno unit and its regular maintenance.

Testing and Adjustments

How to test the Magdyno and adjust its components.

Lucas Dynamo Model E3 LM

General and Test Data

Description of the dynamo and its performance specifications.

Fault Location in Charging Circuit

Procedure to identify faults in the dynamo's charging circuit.

Control Box

General, Setting Data and Servicing

Control box overview, setting data, and servicing procedures.

Electrical Setting Checks

How to check and adjust regulator and cut-out electrical settings.

Battery Model PUZ7 E

General and Preparation for Service

Introduction to the battery and its initial preparation.

Routine Maintenance and Servicing

Regular maintenance and servicing procedures for the battery.

Head and Tail Lamps

Headlamp Components and Replacement

Details on headlamp units, bulbs, and their replacement.

Parking and Tail Lights

Information on parking and tail lights, including bulb types.

Front Fork

Fork Description and Dismantling

Description of the telescopic front fork and dismantling steps.

Spring, Steering Races and Removals

Information on fork springs, steering races, and component removals.

Front Fork (Casquette Type)

Description and dismantling of the Casquette type front fork.

Front Wheel

Wheel Removal and Brake Components

Procedure for removing the front wheel and its brake parts.

Hub Spindle, Bearings and Lacing

Details on hub spindle, bearings, fitting limits, and wheel lacing.

Tyres

Information on front wheel tyres and their fitting.

Rear Wheel

Wheel Description and Removal

Description of the rear wheel and procedures for its removal.

Brake Components and Hub Bearings

Details on rear brake parts, hub bearings, and cush drive.

Wheel Lacing and Tyres

Guide to lacing spokes and fitting tyres for the rear wheel.

Spring Frame

Frame Description and Steering Races

Description of the spring frame and steering head races.

Rear Suspension Units and Springs

Procedures for removing and servicing rear suspension units and springs.

Special Tools

Various Special Tools

Illustrations and purposes of various special tools.

Tools for Fitting Bushes and Assembly

Tools for fitting bushes and assembling components.

Frame and Grip Tools

Tools for frame expansion, gland nuts, and lockrings.

Royal Enfield G Specifications

General IconGeneral
Displacement346 cc
Max Power19.8 bhp @ 5250 rpm
Max Torque28 Nm @ 4000 rpm
Kerb Weight195 kg
Engine TypeSingle cylinder, air-cooled, 4-stroke
Transmission5 Speed Constant Mesh
Front SuspensionTelescopic, 130 mm travel
Rear SuspensionTwin shock absorbers
Front Brake280mm Disc

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