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Royal Enfield II Series User Manual

Royal Enfield II Series
60 pages
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Royal Enfield
"Interceptor"
750
Series
!/
Workshop Manual
Page 3
Page
TECHNICAL
DATA
5
ENGINE
SPECIFICATION
6-8
I.
Engine...
6
2.
Cylinder
Heads
6
3.
Cylinders 6
4. Pistons 6
5.
Connecting
Rods
6
6.
Crankcase
6
7.
Crankshaft
and
Flywheel 6
8.
Main
Bearings 6
9.
Camshafts
6
10.
Valves...
6
11. Valve
Gear
. . . 6
12
.
Timing
Drive 6
13.
Ignition
and
Lighting
System 7
14.
Carburettors
. . . 7
15.
Lubrication
System .. . 7
16.
Breather
8
17.
Gearbox
8
Oil
Pump
Diagrams
. . . 8
18.
Clutch
. . . 8
SERVICE
OPERATIONS
WITH
ENGINE
IN
FRAME
9-18
19.
Removal
of
the
Timing
Cover
9
20. Valve Timing 9
21. Tlclppet
Adjustment
.. .
10
22.
Removal
of
the
Camshafts
.. .
JO
23. Ignition Timing
JO
24.
Primary
Chain
Adjustment
. . .
11
25.
Timing
Chain
Adjustment
. . .
11
26.
Removal
of
the Petrol
Tank
...
12
27.
Removal
and
Refitting
of
the
Cylinder
Head
12
28.
Removal
of
the
Valves l 3
29.
Removal
of
the
Rockers
13
30.
Removal
of
the
Valve
Guides
13
31.
Removal
of
Sparking
Plugs
13
32.
Removal
of
the
Cylinders
13
33.
Removal
of
Pistons ... . .. 14
34.
Decarbonising
14
35.
Grinding-in
Valves
14
36. Reassembly
after
Decarbonising
15
37.
Cleaning
the
Oil Filters
15
38.
Overhaul
of
Oil
Pumps
15
39.
RemovaloftheTimingChains
16
40.
Removal
of
Pump
Worm
and
Timing
Sprocket
l 6
41.
Removal
of
Camshaft
Sprockets
16
42.
Removal
of
the
Engine
and
Clutch
Sprockets
l 6
43.
Removal
of
Tappets
and
Guides
16
44.
Crankcase
Breather
.. . I 6
45.
Removal
of
the
Clutch
l 7
46.
Removal
of
Final
Drive
Sprocket
17
47.
OilSealBehindEngineSprocket
17
48. Oil Pipe
Unions
17
49.
Rocker
Oil Feed Relief Valve
18
50.
Fitting
the
Alternator
18
SERVICE
OPERATIONS
WITH
ENGINE
REMOVED
18-20
51.
Removal
of
the Engine
Gear-
box
Unit
from
the
Frame
.. .
52.
Removal
of
the
Gearbox
53.
Dismantling
the
Crankcase
...
54.
Main
Bearings
55.
Fitting
the
Connecting
Rods
56. Reassembly
of
Crankcase
57.
Crankshaft
Plugs
GEARBOX
AND
CLUTCH
58.
Description
of
the
Clutch
59. Description
of
the
Gearbox
.. .
60.
Removal
of
the
Gearbox
61.
To
Dismantle
the
Gearbox
.. .
62.
Removal
of
the
Ball Races .. .
18
19
19
19
19
20
20
20-25
20
21
21
21
21
LIST OF CONTENTS
63
.
Change-Gear
Mechanism
...
Operation
of
Gears
...
64. Reassembling
the
Gearbox
...
Page
21
22
23
65.
Dismantling
and
Reassembling
the
Clutch
23
23
24
25
25
66.
Adjustment
of
Clutch
Control
Exploded view
of
Gearbox
...
67.
Adjustment
of
Neutral
Finder
68.
Gearbox
Oil Level
AMAL
MONOBLOC
CARBURETTOR
69.
General
Description
...
70.
Tuning
the
Carburettor(s)
71.
Tuning
Sequence
with
Two
Carburettors
...
Exploded
View
of
Monobloc
Carburettor
...
72.
Dismantling
Carburettor
73
.
Causes
of
High
Petrol
Con-
sumption
ELECTRICAL
SYSTEM
74
.
Introduction
..
.
75.
General
76.
Routine
Maintenance
77. Technical
Data
Specific
Gravity
of
Electro-
26-30
26
27
28
29
30
30
31-32
31
31
31
lyte
for
Filling the
Battery
. . . 32
COIL
IGNITION
SYSTEM
32-35
78
.
Description
. . . 32
79.
Checking
the
Low
Tension
Circuit
for
Continuity
80.
Fault
Finding
in
the
Low
Tension
Circuit
81. Ignition Coils
82. Bench
Testing
an
Ignition
Coil
83.
Contact
Breaker
84.
Checking
the
High
Tension
Circuit
CAPACITOR
IGNITION
(Model
2MC)
33
33
34
34
34
35
85.
General
35
86. Identification
of
Capacitor
Terminals
35
87.
Storage
Life
of
Model
2MC
Capacitor
36
88
.
Testing
36
89.
Wiring
and
Installation
36
90. Service
Notes
36
CHARGING
SYSTEM
... 37-39
9
I.
Description
3 7
92.
Checking
the
D.C.
Input
to
Battery
37
93
.
Checking
the
Alternator
Output
37
94. Rectifier
Maintenance
and
Testing
37
95
.
Testing
the
Rectifier...
38
96. Bench
Testing
the
Rectifier
38
97.
Checking
the
Charging
Circuit
for
Continuity
38
98.
Constructing
a
One-ohm
Load
Resistor
39
ZENER
DIODE
.. .
99.
Description
.. .
I
00
.
Maintenance
IOI.
Test
Procedure
102
.
Zener
Diode
Location
HORN
103.
Description
...
104.
Horn
Adjustment
LAMP
UNITS
105
.
Description
...
106
.
Beam
Adjustment
40-41
40
40
40
40
41
41
41
41-42
41
41
I 07.
Removing
and
Refitting
the
Page
42
42
Headlamp
I 08.
General
FUSES
109. Description
IGNITION
·
and
Headlamp
Switches
and
Warning
Lights
...
110. Description ...
111.
General
Wiring
Diagram
FRAME
112. Description
of
Frame
113. Steering
Head
Races
114.
Removal
of
Rear
Mudguard
Assembly
I 15.
Removal
of
Rear
Suspension
Unit ...
116. Servicing the
Rear
Suspen-
sion
Units
117.
Chain
Stays ...
118.
Centre
Stand
119. Wheel
Alignment
I
20.
Lubrication
...
FRONT
FORKS
.. .
121.
Lubrication
.. .
122.
To
Drain
the
Fork
...
123. Filling Oil ...
124. Steering
Head
Adjustment
125
.
Dismantling
the
Forks
126.
To
Remove
the
Forks
as a
42
42
43
43
43
44
45-47
45
45
45
46
46
46
47
47
47
47-49
47
47
47
47
48
Unit
...
48
127.
To
Dismantle
a
Fork
Slider 49
128. Assembling
the
Forks
49
FRONT
WHEEL
49-51
129.
To
Remove
the
Front
Wheel 49
130.
To
Refit
the
Front
Wheel...
49
13
I.
To
Dismantle
the
Hub
50
132. Assembling
the
Hub
50
133. Brake
Adjustment
.. . 50
134.
Brake
Dismantling
and
Assembly 50
135. Brake
Re-assemblv.
.. 50
136. Balancing
the
Front
Wheel
51
REAR
WHEEL
...
51-55
137.
Description
...
51
138.
Removal
and
Replacement
of
Main
Portion
of
Wheel
for
Tyre
Repairs,
etc.
139.
Removal
and
Replacement
of
Complete
Wheel for access
to
Brake
140.
Removal
of
Brake Shoes for
Replacement, etc.
141.
Removal
of
Brake
Operating
Cam
.. .
142.
Cush
Drive
...
143
.
Removal
of
Ball Bearings
...
144.
Hub
Bearings
145. Filling Limits for Bearings
146.
Removal
of
Hub
Driving Pins
147. Refitting Ball Bearings
148. Reassembly
of
Brake Shoes
and
Operating
Cam
into
Cover
Plate
...
149. Final Reassembly
of
Hub
before Replacing Wheel .. .
I 50. Wheel Rims ...
151.
Spokes
152. Wheel Building
and
Truing
153
.
Tyre
...
154. Tyre Pressures
155.
Lubrication
...
SPECIAL
TOOLS
51
52
52
52
52
53
53
53
54
54
54
54
54
54
54
55
55
55
56-58

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Royal Enfield II Series Specifications

General IconGeneral
BrandRoyal Enfield
ModelII Series
CategoryMotorcycle
LanguageEnglish

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