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Royal Enfield J2 User Manual

Royal Enfield J2
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

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Royal Enfield J2 Specifications

General IconGeneral
BrandRoyal Enfield
ModelJ2
CategoryMotorcycle
LanguageEnglish

Summary

Workshop Maintenance Manual

Technical Data and Specifications

Engine Specifications

Detailed specifications for engine cubic capacity, bore, stroke, and piston dimensions.

Transmission Specifications

Technical details for engine sprockets, chains, clutch, and gearbox bearings.

Frame and Wheel Specifications

Data on wheel hub ball races, spokes, and rim sizes.

Ignition and Carburetter Data

Specifications for ignition timing, spark plugs, and carburettor settings.

Tools Supplied with Machine

Tool Roll and Contents

List of standard tools included in the tool roll for maintenance.

Supplementary Kit

Details of additional tools provided in the supplementary kit.

Engine Maintenance and Overhaul

Decarbonising the Engine

Procedures for removing cylinder head, piston, valves, and carbon deposits.

Timing Gear and Magneto Timing

Instructions for setting valve and magneto timing for correct engine operation.

Complete Engine Overhaul

Steps for dismantling and reassembling the engine, including crankcase and flywheels.

Lubrication System Operation

Explanation of the dry sump lubrication system and its principle of operation.

Transmission System Maintenance

Gearbox Servicing

Procedures for removing, dismantling, and reassembling the gearbox.

Clutch System Maintenance

Instructions for dismantling, reassembling, and adjusting the clutch.

Chain Maintenance and Adjustment

Guidance on lubricating, tensioning, and replacing front and rear chains.

Carburetter System Tuning and Fault Finding

Carburetter Settings and Operation

Details on various carburetter settings and how the system works.

Carburetter Tuning and Fault Tracing

Tips for adjusting the carburetter and troubleshooting common running faults.

Electrical System Components

Lucas Magdyno Maintenance

Routine maintenance and adjustments for the Magdyno unit.

Lucas Dynamo Model E3LM Servicing

Testing, dismantling, and servicing procedures for the dynamo.

Control Box (Model RB107) Maintenance

Setting data and servicing instructions for the control box regulator.

Battery Maintenance

Battery Preparation and Routine Care

Steps for preparing a dry-charged battery and performing routine checks.

Lighting System Maintenance

Headlamp and Light Unit Servicing

Procedures for replacing the headlamp unit, bulb, and parking lights.

Tail Light Bulb Replacement

Information on replacing bulbs in various tail light configurations.

Front Fork Servicing (Facia Panel & Steel Tubes)

Front Fork Description

Overview of the fork construction and components.

Fork Dismantling and Reassembly

Steps for dismantling and reassembling the fork for repairs.

Steering Head and Wheel Alignment

Adjusting steering head bearings and ensuring wheel alignment.

Front Fork Servicing (Casquette & Alloy Tubes)

Front Fork Description

Overview of the fork construction with casquette and alloy tubes.

Fork Operation and Dismantling

How the fork operates and procedures for dismantling.

Wheel Maintenance

Front Wheel Servicing

Procedures for removing, disassembling, and reassembling the front wheel.

Rear Wheel Servicing

Steps for removing and replacing the rear wheel and brake components.

Frame and Suspension Servicing

Spring Frame Description

Overview of the frame construction and rear suspension units.

Steering Head and Wheel Alignment

Adjusting steering head bearings and ensuring wheel alignment.

Special Tools for Maintenance

Engine and Transmission Tools

Tools for engine spindle extraction, pump servicing, and clutch work.

Chassis and Wheel Tools

Tools for fitting bushes, frame expansion, and gland nut adjustment.

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