CHAPTER 3 - BASIC DAY-TO-DAY MAINTENANCE
- The Troubleshooting Chart
- Quick Reference or Be-Prepared Reading
- - New Bike Prep:
- bad grounds, checking torques and tightnesses, rusty tank, etc.
- - Most Important:Running In A Fresh Engine
- - Long Term Storage - putting Baby to bed
for the winter
|
The Chapter
- - Cleaning
- - Primary Case Oil, Fork Leg Oil
- - Lubrication: Cables, Engine and Gearbox Oils
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CHAPTER 4 - BASIC DAY-TO-DAY MAINTENANCE: CHECKING AND ADJUSTMENTS
- - Clutch Adjustment
- - Brakes Adjustment
- - Checking Spoke Tension
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- - Chains: Checking, Adjustment,
Replacement
- - Chassis Adjustments
- - Chassis electrical
|
- - Carburetor Adjustments
- - Engine Ignition Timing
- - Valves Adjustment
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PART II - PROFESSIONAL SERVICES - WORK
NORMALLY DONE BY
PAID MECHANICS
Chapter 5 - GENERAL CHASSIS WORK
- - Removing Wheels
- - Tire Changing
|
- - Cable Replacement
- - Brake Shoe Replacement, Arcing
- - Broken stud removal
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- Wheel Bearing Service
- Disk Brake Maintenance
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Chapter 6 - ENGINE WORK:
- Engine Exploded View - pre-AVL
- Engine Exploded View - Displayed Vertically
for printing
- Remove and Replacing the Timing Cover
- The Timing Gears
- Checking and Setting Ignition Timing
- Splitting the Crankcase
- Reassembling the Crankcase
|
- Deciding on Top End Work
- Removing Cylinder Head - Pre-AVL
- Removing Cylinder Head - AVL Models
- Removing Cylinder Barrel
- Replacing Cylinder Barrel
- Replacing Cylinder Head - Pre-AVL
- Replacing Cylinder Head - AVL Models
|
CHAPTER 7 - SUSPENSION
- Operation of The Front Suspension
- The Casquette/Fork Crown/Steering Head
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- The Stanchion/Maintube-Slider Assemblies
- The Rear Suspension
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CHAPTER 8 - The Primary Drive
- Diagnosing Clutch Problems
- Removing the Clutch
- Removing the Alternator Rotor
- Replacing the Alternator Rotor
- Removing and Replacing the Countershaft
Sprocket
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- Replacing the Clutch
- Exploded View - the 350 Clutch
- Exploded View - the 500 Clutch
- The Sprag Clutch Starter Drive - ES Models Only
|
CHAPTER 9 - GEARBOX WORK
A. The Enfield 5-Speed
- Overview - Description, Operation,
And
Troubleshooting
| | |
B. The Albion 4-Speed - Bullet Military, Classic, And Deluxe
- Improving and tuning the US Left Shift
- Exploded view of gearbox
- Removing and Replacing Countershaft Sprocket
- Adjusting The Neutral Finder
- Correcting Gear Changing Problems
- Solving Kickstarter Problems
- Make it possible to use SAE 90 in your
gearbox
|
Exploded view of gearbox - displayed Vertically
for Printing
Removing The Gearbox Covers
Complete Strip
Conversion Back to Right Foot Gearshift
Examination of Gearbox Parts
Gearbox Reassembly
|
CHAPTER 10 - THE CARBURETORS
- The VM24 Mikcarb - 350cc models
- The VM28 Mikcarb - 500cc models
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The Bing Carburetor
The Amal Monobloc Carburetor
|
- The MIK CV Carburetor
- The Amal Concentric Carburetor
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CHAPTER 11 - ELECTRICAL WORK
- Testing the Charging System
- Connections - colours and terminals
- The North American Export AC Lighting
- Retrofitting 4 Wire Alternator
to 3-wire systems
|
- Removing the Alternator Rotor
- Replacing the Alternator Rotor
- The ES (Electric Start) Wiring
- Electrical troubleshooting
|
Wiring Diagrams
Colour Drawings
2003 AC Lighting
2004 Electric Start
Pre-'03 UK Models
Pre-'03 Home (Indian) Models
|
Monochrome - For Challenged Printers
- The US/Canada DC Models
- The UK Models
- The Home (Indian) Models
|
- AC Lighting
- Electric Start
|
|
CHAPTER 12:
PERFORMANCE MODIFICATIONS
CHAPTER 13: CLEAN AIR ADDITIONS
- The Pulse Air Valve and Cat
Converter
|
........ |
- The Crankcase Breather Condenser
Tank
|
APPENDIX
1. TABLES
- Tightening Torques
- Service Limits and Clearances
|
- Inch/Metric Conversion Table
- Broken Stud Removal
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- 500 Tech Specs
- 350 Tech Specs
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2. FACTORY TOOLS
The Factory Tools
3. PARTS BOOKS

Excerpts from The REM Factory Parts Book
|

Excerpts: The 1959 Redditch Factory Parts Book
|
4. Miscellaneous Articles
- To Buy, Or not To Buy? - is a Bullet for You?
- Update your manual - this cd is upgradable! - as improvements
to the CD are made, update "patch" files are posted to the promo site
for upgrading.
connect to the internet and click here for more information.
- Caps: Adding a Capacitor To Your Charging System
- Relays 101: Increasing the Capacity of your lighting
system by adding a relay (Halogen Light)
- 4B. Reading Plugs an excellent
article on reading spark plugs by Gordon Jennings -
All you'll ever need to know!
- Choosing Your Oil - An exceptionally clear article on choice
of Lubricating Oils - by Kevin Mahoney
|
- Appreciation Article: The RE Bullet
- Troubleshooting Lights Problems
- Troubleshooting Contact Breaker Points
- After-market boxes
- Checking Your Charging Sytem
- The DRS Cycle RE FAQ - Frequently Asked Questions file from the DRS
Cycle website, by Dan Holmes, of DRS Cycle
- What Year Is My Enfield?- an article on
interpreting your machine's serial number, by Kevin Mahoney, of Classic
Motors, the USA Enfield Distributor.
|
5. Venerated Ancestors: - J and G series
- The Dynamo/Charging System: The Lucas Magdyno
- The Magneto: The Lucas Magdyno
- Theory Dynamo/Generator Theory
- The Magneto: Timing The Lucas Magdyno
- The "two-piece" engine/gearbox - Adjusting The
Primary and Rear Chains
|  "Pip, pip!" - Maj. Golightly as
a lad, off to a function at the Berwickenhamshire Country Club. circa 1947 |
Disclaimer
And finally, a brief word from our solicitor: The author accepts
NO responsibility, expressed or implied, for any and/or all damages to
persons or property as a result of following any of the instructions
laid out in this manual.
Furthermore, no part of the contents of this manual is presented with
any sponsorship in any way - of, and, with, or by any entity connected in
any fashion with any Royal Enfield manufacturer, distributor, dealer, or
agent worldwide, past, present, or future, nor is it intended to speak for
or represent any such entity.
 |
Keep On Scootin'! |