User Manuals: Royal Enfield WD/CO Motorcycle

Manuals and User Guides for Royal Enfield WD/CO Motorcycle. We have 1 Royal Enfield WD/CO Motorcycle manual available for free PDF download: Workshop Maintenance Manual

Royal Enfield WD/CO Workshop Maintenance Manual

Royal Enfield WD/CO Workshop Maintenance Manual (52 pages)

Brand: Royal Enfield | Category: Motorcycle | Size: 2.74 MB

Table of Contents

Table of Contents
3
List of Illustrations

4
List of Tools

7
Data

7
Periodical Attentions

7
Engine

7
- Decarbonising
  
  7
- Timing Gear
  
  9
  - Valve Timing
    9
  - Magneto Timing
    9
  - Detail of Joints in Push Rod Enclosure Tubes
    9
  - Valve Timing Marks
    9
    
    Tappet Adjustment
    10
- Complete Overhaul
  
  10
  - Removal of Engine from Frame
    10
  - Loosening Magneto Pinion
    10
  - Adjusting Tappets
    10
  - Engine Sprocket Extractor
    10
    
    Dismantling the Crankcase
    11
    
    Removal of Tappets and Guides
    12
    
    Dismantling Flywheels
    12
    
    Connecting Rod
    12
  - Pump Worm Extractor
    12
  - Flywheel Assembly Jig
    12
  - Dismantling Flywheels in Vice
    12
    
    Removal of and Replacing Mainshafts
    13
    
    Reassembly of Flywheels
    13
  - Separating Flywheels
    13
    
    Removal of Crankcase Main Bearings
    15
    
    Replacing Crankcase Main Bearings
    15
    
    Reassembly of Crankcase
    15
  - Assembling Flywheels in Vice
    15
  - Mandrel for Fitting Crankcase Main Bearings
    15
- Lubrication System
  
  17
  - Ball Valve in Oil Return Passage
    17
    
    Replacing Pump Discs
    18
    
    Draining System
    18
  - Feed Pump
    17
  - Oil Circulation Diagram
    17
  - Principle of Operation
    17
    
    Reasons for Excessive Consumption
    17
  - Return Pump
    17
  - Detail of Felt Oil Cleaner
    18
  - Tool for Lapping Pump Discs
    18
  - Removal of Gearbox End Cover
    19
    
    Removal of Ball Races
    21
    
    Foot Change Ratchet Mechanism
    21
Transmission

19
- Gearbox
  
  19
- Clutch
  
  22
- Chains
  
  23
  - Dismantling and Reassembly of Clutch
    22
    
    Adjustment of Clutch Control
    22
  - Lubrication
    23
  - Tensioning
    23
    
    Limits of Wear
    23
    
    Removal, Repair and Replacement
    23
Wheels

23
- Removal and Replacement
  23
- Tyres
  23
- Rims
  24
- Spokes
  24
- Brakes
  24
- Wheel Bearings
  24
- Cush Drive Rubbers
  25
Frame and Fork

25
Carburettor

27
- Adjusting Slow Running
  27
- Dismantling Carburettor
  27
- Causes of High Petrol Consumption
  27
- Section of Amal Carburettor
  28
- Contact Breaker Mechanism Cover Removed
  29
  - Timing Ignition
    30
  - Removal and Replacement of Magdyno
    30
  - Slipping Clutch
    30
  - Dismantling Magneto
    30
Lighting and Ignition System

29
Magneto 54-67

29
- Lubrication of Contact Breaker Mechanism
  29
- Cleaning Contact Breaker
  29
- Adjustment of Contact Breaker
  29
- Cable 57
  29
- Pick up
  29
- Suppressor and Immobilizer
  29
- Magneto Drive
  29
- Detail of Magneto Earth Brush
  30
- Exploded View of Magneto
  30
- Use of Jig for Magneto Slipping Clutch
  30
  - Test and Repair of Magneto
    31
  - Reassembly of Magneto
    31
- Contact Breaker Body and Tappet
  31
- Contact Breaker End Plate
  31
  - Reassembling and Testing Slipping Clutch
    32
Sparking Plug

32
- Dismantling, Cleaning and Setting
  32
- Testing
  32
- Connections to Voltage Regulator
  34
  - Treatment of Badly Worn Commutator
    35
  - Sticking Brushes
    35
  - Worn Brushes
    35
  - Test and Replacement of Field Coil
    35
Charging Circuit

32
- Magneto Slipping Clutch
  32
Dynamo 71-81

34
- Removal
  34
- Dismantling
  34
- Cleaning Commutator and Brushes
  34
- Regulator Terminals
  34
- Commutator and Brush Gear
  35
  - Test of Armature
    36
  - Dynamo
    36
  - Reassembly of Dynamo
    36
- Exploded View of Dynamo
  35
- Testing Brush Springs for Tension
  35
- Undercutting Mica
  35
Regulator and Cutout

36
- Description
  36
- Adjustment
  36
- Cleaning Contacts
  36
- Mechanical Setting
  36
- Adjustment of Cut-Out
  37
- Regulators for Use with NIFE Batteries
  37
Ammeter

37
- Removal and Replacement
  37
- Ammeter Faults
  37
Battery

37
- Topping up
  37
- Checking Conditions
  37
- Cleaning
  37
- Earthing Connections
  37
- Charging
  38
- Cables
  38
Headlamp

38
- Removing Lamp Front and Reflector
  38
- Setting and Focussing
  38
- Cleaning
  38
- Bulbs
  38
- Headlamp-Reflector Partially Removed
  38
- Tail Lamp
  38
- Tail Lamp-Cap Removed
  38
- Electric Horn
  39
  - General
    39
  - Method of Adjusting
    39
- Lighting Switch
  39
Lubrication Chart

40

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