Bullet Classic EFI (C5) Bullet Electra EFI (E5) Bullet EFI (G5)
SECTION ONE 01 INTRODUCTION
PREF ACE PREFA We are pleased to release this workshop manual for the new generation of Royal Enfield Motorcycles fitted with unit construction engine, electronically controlled “Engine Management System” and fuel injection technology. We have endeavoured to make this manual user friendly. However, we welcome your valuable suggestions for improvements which you may write to us or email us at vvikram@royalenfield.com. Service Head Quarters, Royal Enfield Chennai.
FOREW ORD FOREWORD PREPARATION FOR SERVICE Good preparation is very important for carrying out correct service job. The motorcycle should be cleaned well before starting a repair job. Cleaning will occasionally uncover sources of trouble. Availability of tools, measuring instruments and parts should be ensured before commensing an overhaul, since Interruption to locate tools or parts can cause distraction and needless delay. Use of special tools will ensure a quality service.
HO W TO USE YOUR HOW SER VICE MANU AL SERVICE MANUAL Pictorial presentation of various activities, make this manual easy to understand and user friendly. This service manual is divided into 10 Sections 01 to 10. Page numbers for each section starts with 01. Thus, page 05-10 indicates 10th page of section 5. Engine breather System Clutch System Inlet manifold & Throttle body Blow up Charts.
SECTION EIGHT 08 SUSPENSION AND STEERING Front fork working principle Front fork removal & reassembly Steering stem removal & reassembly Gas filled shock absorber - Relay starter - Starter motor - IC Flasher - RR Unit - TPS Unit Electrical parts Inspection - Working principle - Clutch switch - Removal and assembly - Starter switch - Adjustment of shock absorber - Switch modules LH & RH - Recharging of shock absorber Swing Arm - Removal - Bush lubrication / replacement - Reassembly Centre Stand Remov
SECTION TWO 02 GENERAL
SALIENT FEA TURES OF THE UNIT CONSTR UCTION FEATURES CONSTRUCTION ENGINE & ENGINE MAN AGEMENT SY STEM MANA SYSTEM • HIGH TORQUE ENGINE • ENHANCED POWER DELIVERY • HYDRAULIC TAPPETS • AUTO DECOMPRESSOR • AUTO CHAIN TENSIONER FOR PRIMARY CHAIN • • IMPROVED ACCELERATION & HIGH SPEED CRUISING • EXCELLENT COLD STARTING ABILITY • ACCURATELY CONTROLLED, AIR FUEL MIXTURE & IGNITION TIMING BY THE ENGINE CONTROL UNIT • IMPROVED PERFORMANCE AND FUEL EFFICIENCY THRO FUEL INJECTION SYSTEM.
BASIC TERMINOL OGY OF AUT OMOBILES TERMINOLOGY AUTOMOBILES ENGINE : The Engine helps to convert Chemical energy availbale in petrol into heat energy then to mechanical energy for motion. It is the heart of the vehicle in which power is generated for moving the vehicle. Fuel Power Air BORE : Bore is the inside diameter of the cyclinder block in which Piston moves up and down. TDC : TDC stands for Top Dead Center. It is the top most position to which the piston can travel in the cylinder barrel.
TOTAL VOLUME : It is the sum of the swept voume (Displacement volume) and Clearance volume. Total Volume = Swept volume + Clerance volume. COMPRESSION RATIO : It is a ratio between total volume in the engine to the clearance volume available at the end of compression stroke. Compression ratio = Total volume of air fuel mixture Clearance volume VOLUMETRIC EFFICIENCY : Volumetric efficiency is the ratio between the volume of air fuel mixture that actually enters the cylinder and Swept volume.
IHP : IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed inside the engine cylinder by combustion process. It is utilised to drive the piston. FHP : 1HP (Horse Power Available after explosion) FHP (Frictional Losses) FHP stands for Frictionl Horse Power. It is the amount of horse power used or lost to overcome the friction between various engine components.
IGNITION TIMING : Ignition timing is the timing at which spark commences so that the spark from the spark plug can ignite the mixture in the combusion chamber at the end of TDC during compression stroke. TDC Position Ignition Timing Position If spark occurs earlier than specified ignition timing, it is called “Advance” timing. If spark occurs after the specified ignition timing, it is called “Retard” timing. IDLING SPEED : Ignition Timing in Degrees It is the speed of the crankshaft (i.e.
TECHNICAL SPECIFICA TIONS SPECIFICATIONS A. ENGINE AND ENGINE SYSTEMS BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 1. Engine Type 4 Stroke Single Cylinder, Air cooled 2. Bore 84mm 3. Stroke 90mm 4. Displacement 499cc 5. Compression ratio 8.5:1 6. Max Power @ rpm 20.3 Kw @ 5250 rpm 7. Max Torque @ rpm 41.3 Nm @ 4500 rpm 8. Idle rpm 9. Starting 10. Air filter element 11. Lubrication 12. Engine oil tank capacity 13. Engine oil grade 14. Cooling B.
C. CHASSIS BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 1. Frame Tubular 2. Front Suspension Telescopic, hydraulic damping, Stroke 130 mm 3. Rear Suspension Swing arm with gas shock absorbers 4. Fr. Fork oil capacity 5. Front fork oil SAE 10W -30 6. Front Brake Hydraulic, Hand operated, 280 mm dia ventilated disc 7. Rear Brake Mechanical, Foot operated, 153 mm internal expanding 8. Brake Oil Capacity 9. Brake Oil Grade 10.
BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 7. Tail / Brake Lamp 12V 5 / 21W 8. Speedometer lamp 9. Hi beam indicator 12V, 2W 10. Neutral lamp Tell tale 12V, 2W 11. Turn Signal Tell Tale 12V, 2W 12. Turn signal 12V, 10W 13. Horn F. WEIGHTS 1. Mass of Vehicle in running order 187 Kg. 2. Max pay load 178 Kgs. 3. Max technical permissible mass 365 Kg. G. DIMENSIONS 1. Length 2. Width 3. Height 4. Wheel base 1370 mm 5. Ground clearance 140 mm 6.
IDENTIFICA TION OF CHASSIS NO ., ENGINE NO IDENTIFICATION NO., NO,, CHASSIS NO. ENGINENO.
LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25128-2 Magneto Puller for TCI Application : Removal of magneto assembly ST 25151-4 Chain case outer puller (TCI) Application :To remove Crank case LH cover ST-25594-4 Clutch spring assy. Application : To compress clutch springs while removing & refitting Clutch plates.
LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST-25591-4 Clutch centre nut Application : To hold Clutch Sprocket while removing / tightening the Clutch & Sprag Sprocket Nut. Oil seal adopter Application : Fitment of gear shaft oil seal on crank case LH cover. ST 25118-4 Cylinder head nut tightening tool Application : To remove and tightening of cylinder head nut.
LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25123-1 Valve Spring compressor Application : To compress the valve spring for removal and fitting of valve. ST 25153-4 Extractor for 5 Speed Gear box Pivot Pin Application : To remove Gear Rocker Shaft top pivot pin and Gear Cam Plate pivot pin. ST 25 FD sprocket removal tool Application : To remove front drive sprocket from Sleeve Gear.
LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST Front fork main tube spanner Application : Loosening and tightening of front fork main tube with fork end ST 25112-4 Expander for front fork oil seal Application : Expander for oil seal while inserting main tube into bottom tube of front fork ST 25114-4 Extractor for Fork oil seal Application : Removal of oil seal in front fork bottom tube 02-13
LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25113-4 Mandrel for oil seal Application : Fitment of oil seal in front fork bottom tube ST 25110-3 Gauge for tightening chain stay Application : Alignment of Swing Arm while tightening ST 25244-4 Adjuster Special Spanner Application :To adjust gas filled shock absorber 02-14
CONTROL CABLES AND WIRING HARNESS ROUTING ALL CONTROL CABLES & WIRING HARNESS ROUTING UNDER TANK AND SEAT TOP VIEW UNDER TANK LH VIEW UNDER TANK RH VIEW 02-15
GENERAL VEHICLE INFORMA TION INFORMATION HARNESS ROUTING STEERING RH MAGNETO WIRES ROUTING PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING 02-16
GENERAL VEHICLE INFORMA TION INFORMATION FUSE CARRIERS ARRANGEMENT (E5 & G5) HORN WIRE ROUTING FUSE CARRIERS ARRANGEMENT (C5) HANDLE BAR WIRES ROUTING 02-17
GENERAL VEHICLE INFORMA TION INFORMATION TAIL LAMP & TRAFFICATOR WIRES ROUTING ECU MOUNTING BULLET ELECTRA EFI (E5 & G5) THROTTLE BODY MOUNTING WITH CABLES ECU MOUNTING BULLET CLASSIC EFI (C5) 02-18
SECTION THREE 03 SERVICE D ATA DA
SER VICE LIMITS OF COMPONENTS SERVICE (All units in mm unless specified) WEAR LIMITS Wear limits are given as new min, new max and service limits. New components must be within the limits specified. Components within service limits may be reused after careful inspection. Use of parts beyond service limit can reduce the operating life of the component and may affect the motorcycle performance seriously. Cylinder bore Cylinder bore : Point of measurement Ring to groove clearance : Comp.
Piston ring end gap : compression From top New Min. New Max. Service Limit 1st 0.20 0.35 0.70 2nd 0.35 0.50 0.85 Piston Pin diameter New Min. 19.992 New Max. 19.997 Service Limit 19.982 Piston ring end gap - Oil Ring Big end axial play New Min. 0.20 New Min. 0.20 New Max. 0.70 New Max. 0.55 Service Limit 0.90 Service Limit 0.65 Small end bore inner diameter Crank shaft : Run out New Min. 20.007 New Min. 0.00 New Max. 20.016 New Max. 0.04 Service Limit 20.
Connecting rod bend Valve stem OD (Inlet) New Min. 0.00 New Min. 6.965 New Max. 0.05 New Max. 6.980 Service Limit 0.08 Service Limit 6.955 Cylinder Head warpage Valve to guide (inlet) clearance New Min. 0.00 New Min. 0.02 New Max. 0.05 New Max. 0.05 Service Limit 0.07 Service Limit 0.08 Valve stem OD (Exhaust) Valve guide bore New Min. 7.00 New Min. 6.945 New Max. 7.015 New Max. 6.960 Service Limit 7.25 Service Limit 6.
Valve to guide (Exhaust) Clearance Hydraulic Tappet OD New Min. 0.04 New Min. 21.387 New Max. 0.07 New Max. 21.405 Service Limit 1.00 Service Limit 21.380 Valve Spring : length Hydraulic Tappet guide bore New Min. 42.80 New Min. 21.417 New Max. 44.80 New Max. 21.438 Service Limit 41.50 Service Limit 21.450 Push rod run out Hydraulic tappet to guide clearance New Min. 0.00 New Min. 0.012 New Max. 0.02 New Max. 0.051 Service Limit 0.05 Service Limit 0.
Main shaft Outer diameter A Location New Min. New Max. Service Limit Selector fork shaft outer diameter B A 19.99 20.00 19.97 B 23.93 23.95 23.90 New Min. 9.96 New Max. 9.98 Service Limit 9.94 Lay shaft Outer diameter X Location New Min. New Max. Service Limit Selector fork inner diameter Y X 17.99 18.00 17.97 Y 23.95 23.97 23.93 New Min. 10.00 New Max. 10.03 Service Limit 9.98 Cam plate inner diameter Selector fork lug thikness New Min. 13.01 New Min. 3.90 New Max. 13.
Lay shaft 1st gear inner diameter Pivot cam plate outside diameter New Min. 18.03 New Min. 12.98 New Max. 18.06 New Max. 13.00 Service Limit 18.09 Service Limit 12.96 Clutch spring Length Lay shaft 2nd gear inner diameter New Min. 24.00 New Min. 64.5 New Max. 24.03 New Max. 65.5 Service Limit 24.06 Service Limit 60.0 Main shaft 3rd & 4th gear inner diameter Friction plate with insert : thickness MS 4 MS 3 New Min. 24.00 New Min. 2.95 New Max. 24.03 New Max. 3.
Clutch steel plate : Distortion Throttle cable free play New Min. 0.00 New Min. - New Max. 0.05 New Max. 1 mm Service Limit 0.10 Service Limit 2 mm Duplex Chain - Length across 21 pins Drive chain : slackness New Min. 190.00 New Min. 20.00 New Max. 191.00 New Max. 30.00 Service Limit 195.00 Service Limit - Rear Sprocket chain pull off Clutch cable -Free play New Min. 2 mm New Min. - New Max. 4 mm New Max. - Service Limit - Service Limit 5.
Brake drum rear : Internal dia. Sprocket GOOD REPLACE New Min. Sharp, bend broken teeth New Max. Service Limit New Min. 152.40 New Max. 152.50 Service Limit 153.50 Drive chain length across 21 pins Wheel rim: Face out / Run out New Min. 320 New Min. 0 New Max. 322 New Max. 1.0 mm Service Limit 328 Service Limit 2.00 mm Axle shaft : run out Brake lining thickness New Min. 3.80 New Min. 0.00 New Max. 4.06 New Max. 0.01 Service Limit 2.00 Service Limit 0.
Caliper Piston Outer Diameter Main tube - run out OD New Min. 0.00 New Min. - New Max. - New Max. - Service Limit 0.04 Service Limit 25.31mm Master Cylinder piston OD Front fork assembly spring : length New Min. 538 New Min. - New Max. 544 New Max. - Service Limit 527 Service Limit 12.64 mm Master Cylinder Bore Caliper Bore Inner Diameter ID New Min. - New Min. - New Max. - New Max. - Service Limit 25.46 mm Service Limit 12.
Tyre tread : Depth New Min. - New Max. - Service Limit 1.00 mm Spark Plug Gap New Min. 0.7 New Max. 0.
PERIODICAL MAINTENANCE The schedule provided herein is based upon average riding conditions and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carried out. The frequency of the maintenance must be shortened depending upon the severity of the driving condition OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water etc., S. No. DESCRIPTION SCHEDULE Kms (x 1000) 0.5 Miles (x 1000) 0.
PERIODICAL MAINTENANC E MAINTENANCE AIR FILTER CLEANING BULLET ELECTRA EFI (E5/G5) Remove the 2 air filter lid mounting screws and take out air filter lid Blow compressed air from outside to inside. Check for cracks, holes, clogging etc. Replace, if defective Assemble in the reverse order of dismantling. SPARK PLUG CLEANING Disconnect suppressor cap and remove spark plug using spark plug spanner. Clean insulator tip and electrodes using a pointed scrapper or plug cleaner.
PERIODICAL MAINTENANC E MAINTENANCE ENGINE OIL OIL LEVEL CHECK Place the motorcycle on the centre stand Before checking the oil level start and warm the engine for few minutes. Switch “OFF” the ignition, wait for two minutes and then check oil level at the inspection window on the RH Crankcase cover DRAINING PROCEDURE : Keep a clean tray under the engine Remove the two Hex Flange Bolts M5 X 16, Sump drain Cap, “O” ring and Suction filter Assy. Remove the Magnetic Plug assy along with its washer.
REMOVAL OF OIL FILTER ELEMENT: The oil filter element is located on the Crankcase Cover RH Remove the oil filter cap mounting screws. Remove the oil filter cap along with gasket (Bullet Electra EFI (E5/G5) “O” ring (Bullet Classic EFI (C5) Remove the washer, spring, spring cap, “O” ring and filter element. NOTE : Always re-check brake lamp after adjustment of brake pedal level and free play.
The tightening torque for M10 lock nut is 2 KG-M. This must be ensured. Over size Cam Spindle (For Spares) 570040 : 0.1 mm Over size Spindle 570041 : 0.2 mm Over Size Spindle CAUTION : - After the first 800 kms (500 miles) the backlash between the cam gears must be checked. If a slight cam noise is observed, then adjustment of the eccentric sleeve has to be carried out as mentioned above.
REAR SHOCK ABSORBERS ADJUSTMENT The rear shock absorber spring preload can be increased or reduced according to road and load conditions. Rotate the wheel and apply brake and tighten all the nuts and lock the split pin. BRAKE CAM GREASING (EVERY 6,000 KMS) Remove the brake cover plate. Clean the brake cam and apply grease. Refit the cover plate. Increase the spring preload for high load operation. Reduce the spring preload for low load operation.
CAUTION -Adjust both left and right shock absorbers to the same notch. FRONT FORK A. OIL LEVEL CHECK (EVERY 6000 KMS) Take out front fork from the vehicle. Remove bolt cap. Fill 265 ml of API SG 10W-30 oil in each leg . Bump the fork several times and then assemble bolt cap with “O” ring (to release air lock if any). Assemble back all removed parts. DISC BRAKE FLUID LEVEL CHECK Check brake fluid is above the ‘Min’ level in master cylinder. MAX MIN Top up if level is below ‘Min’ mark.
If felt, adjust as follows : Loosen crown plate bolts as shown picture ‘A’ Pack grease in the top ball race. Assemble the steering stem. WHEEL ALIGNMENT CHECK Hold the vehicle upright off the stand on level ground. Stretch a string about 100 mm above the ground along the wheels. If the string touches two points on the rear wheel and two points on the front wheel (Four point contact) then the wheels are aligned. B A Tighten stem lock nut as shown picture ‘B’ Check play.
Screw in or out the cable adjuster for setting the required play at lever end (2 to 3 mm). (B ) ADJUSTMENT AT THROTTLE BODY END Loosen the lock nuts on both the cables. Adjust both cables unitform and tighten the lock nuts. After adjustment refix cable boot. PRIMARY CHAIN TENSION ADJUSTMENT This vehicle is fitted with Auto chain tensioner. Hence there is no need for periodic manual adjustment. THROTTLE CABLE PLAY ADJUSTMENT Throttle rotor free play 2-3 mm.
If required, top up with distilled water VALVE TIMING CUM ECCENTRIC CAM SPINDLE Bring piston to TDC so that the key way in the Rotor assembly is at 12o Clock position Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear. SPECIFIC GRAVITY CHECKING : Check specific gravity (SG) with a hydrometer Similarly check position of the inlet cam single punch mark align with the single punch mark on the exhaust cam.
Remove the piston rings carefully. For cleaning the groove in the piston, a piece of broken piston ring thrust into a wooden handle and filed to a chisel point can be used. Standard Service Limit : 0.9 - 1.1 mm : 1.5 mm Valve seat width is not within specification, reface the valve seat. CYLINDER HEAD AND VALVES CAUTION : VALVE SEAT INSPECTION If a valve face is burnt or badly worn or if it contacts the seat unevenly, replace the valve.
VALVE SEAT REFACING Valve Seat cutters, a grinder or equivalent valve seat refacing equipment are recommended to correct worn valve seat. If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60 degree inner cutter. NOTE : Use a 45 degree cutter to remove the roughness or irregularities from the seat. Using 32 degree cutter, remove top 1/4 of the existing valve seat material.
After cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure. NOTE : Excessive lapping pressure may deform or damage the seat. Change the angle of lapping tool frequently to prevent uneven seat wear. Lapping compound can cause damage if it enters between the valve stem and guide. After lapping, wash any residual compound off the cylinder head and valve. NOTE : To avoid damage to the seating face, turn the valve slowly while inserting.
ENGINE COMPRESSION TEST STEP-A Start and warmup the engine to normal running temperature. Remove the spark plug & connect compression gauge. a) Remove spark plug & put few drops of engine oil into the combustion chamber. b) Connect compression gauge & repeat the procedure as explained in the step-A. If compression pressure does not increase, then check for c) Switch “OFF” Ignition and engine stop switch condition.
SECTION FOUR 04 ENGINE
LUBRICA TION SY STEM LUBRICATION SYSTEM 04-1
LUBRICA TION SY STEM LUBRICATION SYSTEM ROCKER PUSH ROD FLY HYDRAULIC OIL PUMP CAM STRAINER CRANK OIL SUMP LUBRICATION SYSTEM : Oil from the oil tank is circulated to various parts through a powerful oil pump, the capacity of which is 4.5 litres per minute @ 2750 rpm. The oil in the sump gets filtered through an oill strainer located in the crankcase and then pumped into the oil filter element located in the RH Cover. From here oil is circulated to 3 main areas.
HYDRA ULIC TAPPETS (ROLLER HYDRA ULIC VAL VE HYDRAULIC HYDRAULIC ALVE LIFTER (RHVL) HYDRAULIC TAPPET : The Hydraulic tappet, (also known as RHVL Roller Hydraulic Valve Lifter) is located between the cam and pushrod in the valve train mechanism. It not only serves as a valve lifter most importantly, it automatically and constantly adjusts itself to compensate for any extra clearance in the valve train mechanism when the engine is running at various RPM.
WORKING PRINCIPLE : Oil enters the hydraulic tappets through a feed hole in the body and flows into the plunger through the plunger feed hole, filling the “low pressure chamber” (E, in Figure) The oil also flows around the check ball and through the slots of the ball retainer to fill the cavity below the plunger, called the “high pressure chamber” (A, in Figure). Oil is forced down into this area by momentary low pressure which occurs once during each cam rotation.
AUT O DECOMPRESSOR AUTO WORKING PRINCIPLE BENEFITS OF AUTO DECOMPRESSOR : The auto decompressor is assembled in the exhaust cam and consists of a flyweight, spring and pin. These are assembled in the cam assembly with a screw 3 Eliminates the need to fix a manual system which will need to be adjusted and serivced periodically.
ELECTRIC ST AR TER SY STEM & SPRA G MECHANISM STAR ARTER SYSTEM SPRAG WORKING PRINCIPLE The sprag is located in the primary sprocket on the crankcase drive side. This provides better rigidity of the sprag mechanism during initial crankin. The auto decompressor mechanism further helps in reducing the load on the sprag during intitial cranking and also prevents reversal phenomenon of the crank shaft.
AUT O CHAIN TENSIONER ASSEMBL Y UTO ASSEMBLY WORKING PRINCIPLE The auto chain tensioner has a spring loaded plunger mechanism with a ratchet arrangement. It eliminates need for manual adjustment of the primary chain tension. It is assembled on the crankcase LH below the chain tensioner pad. The spring loaded plunger applies force on the chain tensioner pad thereby lifting it and holding aginst the primary chain to the required tension.
ENGINE BREA THER SY STEM BREATHER SYSTEM Breather arrangement inside the RH cover WORKING PRINCIPLE The engine breather system is located on the RH cover of the crankcase. A connecting hole directs the engine breathing into a chamber in the RH cover which has an inbuilt deflector to deflect the oil that may come along with the fumes from the crankcase. This oil gets drained through a small hole provided at the bottom of the breather chamber.
CL UT CH SY STEM CLUT UTCH SYSTEM The clutch system has a seven plate construction to achieve increase effective diameter and improved torque carrying capacity. The clutch is operated through a lever on the cover LH.
INLET MANIFOLD & THR OTTLE BOD Y THRO BODY The inlet manifold has the fuel injector located on top portion and the throttle body attach to it. The throttle body has a butterfly valve attached which is operated buy the throttle cables attached to a drum on the right side. A manual Bi starter is located on the left side and is the spring and plunger type arrangement. An idle air bypass screw is provided on the throttle body.
Blow Up Charts 04-11
27 31 30,31,32,33,34 Key Nos. A2 13,14,15,16,17 Key Nos.
CRANK CASE RH - COVER SIDE KEY No. DESCRIPTION A1 CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY A2 OIL PUMP ASSEMBLY 1 TAPPET DOOR BUFFED 2 CSK SOCKET HEAD SCREW M5 X 12 3 ROTOR AND RELUCTOR ASSEMBLY 4 KEY - MAGNETO 5 PLAIN WASHER, 6 HEX. NUT M12 X 1.25 7 HEX. SOCKET HEAD CAP SCREW, M6 X 30 8 HEX.
CRANK CASE LH INSIDE VIEW 04-14
CRANK CASE LH KEY No.
1 2 6 3 7 4 8 5 9 27 30 11 12 29 26 10 28 25 24 21 22 23 20 15 16 17 14 13 19 18 CRANK CASE RH - INSIDE VIEW 04-16
CRANK CASE RH - INSIDE VIEW KEY No. DESCRIPTION KEY No. DESCRIPTION 1 CIRCLIP 18 MACHINED WASHER 6.4 2 DEEP GROOVE BALL BEARING – SLEEVE GEAR 19 HEX. NYLOCK NUT M6 X 1 20 HEX FLANGE BOLT M5 X 16 3 NEEDLE BEARING 21 DRAIN CAP - SUMP 4 SLEEVE GEAR 22 O RING- DRAIN CAP 5 NEEDLE BEARING 23 SUCTION FILTER ASSY 6 HEX. SOCKET HEAD CAP SCREW, M6 X 12 24 STOP PLATE 7 BRACKET - PIN - HYDRAULIC - TAPPET 25 HEX. SCREW M8 X 25, 8 NEEDLE ROLLER 26 OIL THROWER 9 BEARING 27 HEX.
ENGINE COVER - RH 49 27 48 7 04-18
ENGINE COVER - RH KEY No. DESCRIPTION KEY No. DESCRIPTION 1 UCE, RH COVER SUB ASSEMPLY 26 HEX.SCREW, M5X12 2 COVER, RH 27 3 PLUG STATOR & PULSOR COIL ASSY THREE PHASE 4 RESTRICTOR (LEE PLUG) 28 PULSOR COIL FIXING SCREW 5 SEALING WASHER 12X15.5 29 ALLEN SCREW M6X30 6 OIL LEVEL WINDOW 30 HEX.SOCKET HEAD CAP SCREW, M6X85 7 BOLT BREATHER 31 HEX.SOCKET HEAD CAP SCREW, M6X100 8 JET,CRANKSHAFT RH 32 HEX.SOCKET HEAD CAP SCREW, M6X80 9 OIL SEAL , CRANK FEED 24X10X7 33 HEX.
CRANK CASE LH - COVER SIDE 04-20
CRANK CASE LH - COVER SIDE KEY No. DESCRIPTION KEY No. DESCRIPTION 1 CRANK CASE-LH 23 BUSH, C T PAD 2 DOWEL (6MM) 24 CHAIN TENSIONER PAD 3 COLLAR, MAINSHAFT 25 PLAIN WASHER 4 GEAR, - JACK SHAFT 26 HEX.NUT,M8 5 KEY - JACK SHAFT 27 AUTO CHAIN TENSIONER ASSEMBLY 6 CIRCLIP 12 × IN IS 3075 (PART I) (FOR SHAFT) 28 O RING,CHAIN TENSIONER ASSEMBLY. 29 HEX. SOCKET HEAD CAP SCREW, M6X20 7 DOWEL 30 SPRAG CLUTCH ASSEMBLY 8 NEUTRAL SWITCH WITH PACKING 31 ENGINE SPROCKET 9 HEX.
ENGINE COVER - LH 10 8 12 7 11 6 9 15 14 3 5 18 2 4 16 17 19 1 20 13 04-22
ENGINE COVER - LH KEY No. DESCRIPTION 1 LH COVER SUB ASSEMBLY 2 COVER, LH 3 BUSH 4 OIL SEAL 14 X 20 X 3 5 GASKET, COVER LH 6 OIL SEAL INA G 12 X 18 X 5 7 ASSEMBLY, CLUTCH OP 8 CABLE CLEVIS, CLUTCH OPERATING LEVER 9 CLUTCH CABLE ASSEMBLY 10 PIN, CLUTCH OPERATING LEVER 11 LOCK PIN SPRING, CLUTCH OPERATING MECH. 12 SPRING, CLUTCH OP LEVER 13 HEX.
GEAR TRAIN ASSEMBLY 04-24
GEAR TRAIN ASSEMBLY KEY No. DESCRIPTION KEY No.
GEAR SHIFTING KICK STARTER(E5 & G5) 5 04-26
GEAR SHIFTING KEY No. DESCRIPTION 1 SS ROCKER SHAFT ASSEMBLY, 2 PIN PIVOT 3 STRIKER, GEAR CHANGE 4 SPRING 5 SPRING, GEAR CHANGE STRIKER 6 SPACER 7 PIVOT BEARING, ROCKER SHAFT UPPER 8 HEX. SOCKET HEAD CAP SCREW, M6 X 12 9 PIVOT BEARING, ROCKER SHAFT BOTTOM 10 ASSEMBLY, GEAR LEVER SHAFT 11 STOP PIN 12 O-RING 13 HEX. SOCKET HEAD CAP SCREW, M5 X 40 KICK STARTER(E5 & G5) KEY No.
CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT 25 37 36 24 35 23 27 37 38 22 26 37 39 38 39 38 38 19 17 21 18 34 20 15 14 11 10 9 33 6 7 32 3 8 30 29 28 16 2 5 12 CRANK SHAFT ASSY. 4 31 13 PISTON ASSY.
CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT KEY No.
DAMPER PAD POSITION DETAILS Number of damper pads per engine = 15 570482/b INLET SIDE VIEW 570479/b 570478/b 570482/b 570480/b Part No. Description Quantity per engine 570478/b Damper pad-cylinder head LH 2 Damper padcylinder head RH 4 570479/b Image EXHAUST SIDE VIEW 570479/b 570479/b 570482/b 570482/b 570480/b Quantity per engine Part No.
SECTION FIVE 05 TORQUE SPECIFICA TIONS SPECIFICATIONS ENGINE DISMANTLING INSPECTION & ASSEMBL Y ASSEMBLY
TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. ENGINE DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. 1 570013 HEX SOCKET HD CAP SCREW, M5 X 16 RETAINER PLATE / SUCTION FILTER MTG 0.60 6 2 570016 HEX.SOCKET HD.CAP SCREW, M5 X 45 E START HOUSING COVER 0.60 6 3 570094 HEX.SOCKET HD.CAP SCREW, M5 X 25 E START HOUSING COVER 0.60 6 4 570232 HEX.SOCKET HD.CAP SCREW, M6 X 12 STOP PLATE, PIVOT PIN / COVER LH / PIVOT BRG LOWER 1.
TOR QUE SPECIFICA TION - ENGINE TORQ SPECIFICATION S. PART No No. DESCRIPTION LOCATION TORQUE VALUE Kg/M. N/M. 30 570215 BOLT, PAWL (M6 X 1) GEAR BOX INDEX 1.00 10 31 570233 HEX.SOCKET HD.CAP SCREW, M5 X 40 PIVOT BEARING, ROCKER SHAFT LOWER 0.60 6 32 550138 CSK SOCKET HEAD SCREW M5 X 0.8 X 16, COVER, KICKSTART SHAFT 0.60 6 33 145090 HEX SCREW M6 X 16 KICKSTART, SPRING 1.00 10 34 570240 HEX.SOCKET HD.CAP SCREW, M5 X 35 COVER K.S. GEAR 0.60 6 35 142291 HEX SCREW M8 X 22.
ENGINE DISMANTLING , INSPECTION AND ASSEMBL Y ASSEMBLY COMPONENTS THA T CAN BE THAT REMO VED WITH THE ENGINE REMOVED MOUNTED ON THE FRAME. Cylinder head assembly Cylinder barrel & Piston Crank case Cover RH Crank case Cover LH Clutch assembly Inlet and Exhaust Cam assembly Oil pump Assembly ENGINE SHOULD BE REMO VED FR OM THE FRAME REMOVED FROM FOR THE FOLL OWING JOBS: FOLLO Remove the front and rear flange nuts, washer at the front & rear mounting of the fuel tank. Crank case repair/replacement.
SEA T REMO VAL B ULLET SEAT REMOV BULLET ELECTRA EFI (E5/G5) Remove 4 nos. flange bolts from both sides of the seats. Remove the 2 screws, at the bottom of the LH switch module and separate the module from the handle bar. Disconnect the cable from the lever. Remove the pillion holder, lift from the rear end and pull out the seat BULLET CLASSIC EFI (C5) Remove the mounting bolts as shown and remove the seat. Remove cable from the straps in the frame.
CL UT CH CABLE REMO VAL CLUT UTCH REMOV Slacken the adjuster at the clutch cover end and disconnect the cable from the lever. Take out clutch cable from the cover. Remove the clutch cable from the clutch lever at handle bar end. REMO VAL OF THR OTTLE REMOV THRO CABLE Slacken the adjusters at the throttle body end for both cables. REMO VAL OF THR OTTLE REMOV THRO BOD Y BODY Loosen the throttle body flange & bellow clip. Remove the throttle body by pushing towards Air Filter box.
Remove the rear mounting at the pillion foot rest end (C5). Remove the rear mounting at the pillion foot rest end (E5/G5). Remove the flange nut 2 nos. from cylinder head. Remove the Silencer Assembly with Exhaust pipe. Remove the Suppressor Cap NOTE : Loosen the rear brake rod adjuster nut so that the brake pedal can be depressed to allow the exhaust pipe to be removed. Disconnect the Oxygen sensor, loosen and remove from Exhaust pipe.
Remove the battery flap cover Remove the terminal boot & terminal wires . Remove the fuse carrier plate mounting screws 2 nos. FOR BULLET CLASSIC EFI ( C5) Remove battery cover on LH side. Remove the black coupler. Remove the battery holding straps pull the battery out & remove terminals. CAUTION : Always remove earth wire terminal first.
REMO VAL OF E-ST AR T MO TOR REMOV E-STAR ART MOT Remove the cover screw Remove the terminal rubber boot. Remove 4 screws of the starter drive housing and tap gently to free the housing. Gently lift the motor and remove the motor along with the housing. Remove the 2 dowels for the housing drive. Remove the terminal nut & take out the terminal wire lead. Remove the 2 mounting allen screws.
Remove the chain link and the drive chain. REMO VAL OF SIDE ST AND REMOV STAND Disconnect the coupler of the side stand Engine cut off switch from the wiring harness. Slacken the nyloc nuts & remove the brake light switch. Remove the piece mudguard bracket bolt along with 2 plain washers & 1 star washer Remove the mounting nuts and remove the side stand. Remove rider foot rest LH & RH (E5/G5) REMOVAL OF REAR BRAKE SWITCH Disconnect the brake switch spring from brake lever.
Engine oil Drain It is best to drain the engine oil in warm condition. Remove the 2 Flanged hex bolts. Remove the drain cap with ‘O’ ring. Remove suction filter. Remove the magnetic drain plug with washer. CYLINDER HEAD ASSEMBL Y ASSEMBLY Remove the 4 allen screws along with rubber seals from Inlet and exhaust rocker covers. Remove the Inlet & Exhaust Rocker cover, dowel & rubber gasket. Remove the 4 allen screws each on the rocker bearing inlet & exhaust.
Remove inlet and exhaust pushrods Remove the Cylinder head assy. Remove the Spark plug Remove the multi layer steel (MLS) head gasket. REMOVAL OF VALVES Remove the 6 flanged hex nuts, securing the cylinder head. Remove the Inlet & Exhaust valves by using special tool No.
Remove the Inlet Valve spring retainer, split collar and Spring. CYLINDER BARREL SUB ASSEMBLY Remove Inlet Valve as shown NOTE : Ensure piston is at TDC. Gently tap Cylinder barrel and remove along with 2 dowel pins. Remove gudgeon pin and piston. NOTE: Similarly follow the same process to remove Exhaust Valve. Remove Inlet and Exhaust Valve stem seal from valve guides. NOTE : Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel, as shown.
NOTE : Carefully remove the piston rings from Remove oil filter cover bolts. the piston without deforming. Remove Cylinder barrel bottom Gasket. Remove oil filter cap gasket, “O”ring & Spring. Use Special tool No. ST - 25592-4 to hold connecting rod as shown Fig. CAUTION : REMOVAL OF COVER RH SUB ASSEMBLY : Remove kickstarter lever. (only for Bullet Electra EFI - E5/G5) Care must be taken while removing cover due to spring force.
Remove the 11 allen screws securing cover RH. Gently tap & pull out the cover evenly Remove RH cover gasket & 2 dowels. It may be necessary to tap the cover slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove Remove Pulser coil by removing 2 screws CAUTION : Tap only at the places shown to avoid damage to the RH cover Remove Stator assembly by removing 3 mounting screws.
Remove circlip, oil seal and jet crankshaft NOTE : Oil seal recommended to replace at every 20,000 kms interval. Remove Breather bolt and washer Remove 6 Nos. allen screws to remove breather chamber cover Remove oil filler cap and “O” ring Remove breather chamber gasket Remove Ignition Timing check bolt and washer (if not removed earlier).
Remove the 2 oil seals from the Kick Shaft hole (Electra EFI - E5/G5 only) Remove the 3 allen screws & 2 dowels from Cam steady plate. INSIDE OIL SEAL OUTSIDE OIL SEAL COMPONENTS DISMANTLING ON CRANK CASE RH CRANKCASE REMOVAL OF ROTOR ASSEMBLY Remove Cam steady plate and the shims. Loosen and remove magneto lock nut and plain washer. Ensure the connecting rod is locked properly with the special tool resting firmly and evenly on the crankcase top position.
Remove oil pump plastic gear after removing circlip. Observe short boss of pump drive gear should face outwards. Exhaust cam with auto decompressor. DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR Remove Cam gear inlet. Remove mounting allen screw on flyweight sub assembly. Remove Cam gear Exhaust (Auto decompressor sub assy). Remove flyweight along with return spring over actuating pin lever as shown in Fig. NOTE : Ensure spring bend lug being seated inside flyweight hole properly.
Remove the actuating pin in the Exhaust cam. Remove the woodruff key. Remove the Oil pump assembly with “O” ring. CAUTION : Ensure "O" ring must be located on the oil pump body outlet. Remove Gear lever from engine LH cover side. Remove the 4 allen screws to remove Oil pump assy. Remove Gear lever shaft with bush (spacer shaft).
Remove rocker shaft return spring pivot pin with “O” ring by using special No. ST 25123-4 Extractor for 5 speed gear box pivot pin as shown in Fig. Remove the two bolts and remove the rocker shaft upper pivot bearing with “O” ring. Remove the rocker shaft assembly by gently tilting and twisting out. Straighten lock tab and Unlock the FD sprocket nut. Remove nut and lock washer. Remove the two screws holding the lower pivot bearing ..
Remove FD Sprocket Remove kicker shaft cover with oil seal. NOTE : Use special tool No. ST 25 while removing FD sprocket if necessary. Remove Kick starter return spring locking bolt with washer (only for Bulletin Electra EFI (E5/G5). Pull out Sleeve gear Spacer by using monkey / gas plier as shown in Fig. Remove 4 Nos. Kicker Cover screws. (only for Bullet Electra E5 / G5) Remove Kick starter return spring from kickshaft spindle (only for Bullet Electra EFI (E5/G5).
DISMANTLING COVER LH SUB ASSEMBLY : Remove the 11 allen screws holding the cover LH. It may be necessary to tap the cover slightly to remove. Remove lock pin and spring from clutch operating shaft. PULL LOCK PIN Remove inspection plug along with “O” ring Remove clutch operating shaft assy from clutch cover. Tap and remove the Clutch cover. Remove Clutch operating shaft oil seal and 2 Nos. of Dowels.
Remove gear lever shaft bush and oil seal. COMPONENTS DISMANTLING ON CRANK CASE LH CRANKCASE REMOVAL OF CLUTCH ASSY. Use Special tool No. ST - 25591-4 Clutch centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch. Remove nyloc nut & plain washer. Remove clutch push pad, ball bearing & bearing retainer cup. Remove auto chain tensioner bottom pin bolt, “O”ring and spring. Unlock clip and press push rod to slacken duplex chain. Remove 17mm Hex bolt on the Engine sprocket.
Remove Duplex chain along with Sprag clutch and Clutch assembly. Remove Engine sprocket and sprag clutch gear assembly. DISMANTLING OF CLUTCH ASSEMBLY Remove 2 hex bolts at opposite locations Fix Special tool No. ST - 25594-4 Clutch Spring Compressing Tool and tighten the 2 long bolts fully so as to hold the springs down loosen & remove the other 4 bolts. Remove sprag clutch bearing. FLANGE FACE Remove the special tool holding both evenly to release the spring tension.
Remove Spring retainer plate & 6 Springs. Remove clutch drum sprocket with big washer. Remove clutch hub, centre, friction and steel plates. Remove collar on main shaft (distance collar from Crankcase LH). Remove special distance washer sprag clutch on Crankshaft LH. Remove hex nut and washer to remove chain tensioner pad.
Remove Auto chain tensioner body assy. by removing the 2 Nos. allen screws. Remove the rear engine mounting nut along with the washer. Remove double gear shaft and double gear starter drive. Remove the front engine mounting nut Remove the jack gear after removing the circlip.
Remove centre stand & footrest supports. Loosen the crankcase stud nuts and allen screws as per the following sequence. Remove the front and rear engine studs & slide the engine assembly off the frame. Remove Engine Front Mounting Bracket. Remove Mudguard mounting clip & Rear Engine Mounting Bracket. Tap gently and remove the crankcase LH.
Remove special thrust washer (lay shaft ) from Crank case LH & 2 Nos. Dowel pins. Pull out the crank shaft from the crankcase RH. Remove clutch bearing retainer plate holding screws and remove the retainer plate from crankcase LH. Remove clutch ball bearing from crankcase LH. Remove needle roller bearing for lay shaft from crankcase LH. Remove roller bearing NU 305 from crankcase LH.
Remove spacer, circlip, crank shaft bearing 6305 from crankcase LH. Remove circlip and sleeve gear ball bearing 6007 from crankcase RH. Remove lay shaft needle bearing from crankcase RH. Remove last circlip from crankcase LH. Remove crank shaft needle roller bearing from crankcase RH. Remove nyloc nut, machined washer, pawl - camplate, return spring and bolt pawl from crankcase RH.
Remove Tappet cover by dismantling 4 Allen screws. Remove the exhaust and inlet hydraulic tappets carefully from Crankcase top side. EX. tappet INLET tappet Remove the Tappet cover. NOTE: Remove Inlet tappet first and then the exhaust tappet. CAUTION : Store the tappets carefully & right side up as detailed earlier. GEAR TRAIN REMOVAL Remove the Allen screw, and the bracket join - hydraulic tappets. Gently pull out the 2 needle roller pins holding the inlet and exhaust hydraulic tappets.
Pull out cam plate pivot pin with “O” ring by using special tool No. ST 25153-4 Extractor shown below. Remove special thrust washer (Layshaft) from Crank case RH Remove LS 1st gear and thrust washer from the Layshaft. Check that the 4 rollers are in place in the cam plate correctly while removing to avoid damage to the pins or its location in the cam plate. Gently slide out the gear train assembly along with the cam plate, Fork shaft, Forks, Layshaft double gear(LS3 & LS4) and main shaft with all gears.
Remove centre selector fork from the selector shaft and then LH selector fork. DISMANTLING OF LAYSHAFT SUB ASSEMBLY Remove Lay shaft 1st gear and thrust washer. Remove circlip from the selector shaft if required. Remove Double gear (LS 3rd and 4th gear). LA YSHAFT SUB ASSEMBL Y LAY ASSEMBLY Remove the high gear.
Remove 2nd gear and thrust washer. DISMANTLING OF MAINSHAFT SUB ASSEMBLY Remove main shaft 1st gear. Layshaft Remove the main shaft 2nd gear. MAIN SHAFT SUB ASSEMBLY Remove the main shaft 3rd gear.
Remove circlip & 1st. thrust washer. REMOVAL OF SLEEVE GEAR SUB ASSEMBLY Remove open end needle bearing. Remove 4th gear and 2nd thrust washer. Remove closed end needle bearing. Main shaft REMO VAL OF KICK REMOV ST AR TER ASSEMBL Y STAR ARTER ASSEMBLY Only for Bullet Electra EFI (E5/G5) REMO VAL OF SLEEVE REMOV GEAR ASSEMBL Y ASSEMBLY Remove 3 allen screws to take out oil thrower (plastic cap).
Pull out kick starter sub assy. as shown in Fig. REMOVAL OF KICK STARTER SUB ASSEMBLY Remove the Kick pinion gear. Remove the thrust washer from kick spindle. Remove circlip & thrust washer. Remove the Kick pawl, plunger and spring from kickstarter shaft. Remove the thrust washer.
VITAL PARTS I. BEARINGS Sl.No. USAGE 1. NBI 45 × 30 × 20 DESCRIPTION Crankcase RH - Crankshaft bearing QTY 1 2. Ball Bearing 6305 C3 (25×62×17) Crankcase LH - Crankshaft bearing 1 3. Roller Bearing Nu305 C4 (25×62×17) Crankcase LH - Crankshaft bearing 1 4. Ball bearing 6006, C3 Crankcase LH - Main Shaft bearing 1 5. Lay Shaft bearing 550032/a Fitted on Crankcase RH and Crankcase LH 2 6. NRB 3 × 21.8 Locating Pin-Pivot, cam plate 1 7.
UNIDIRECTIONAL FITTINGS LIST Deep groove ball bearing 6007-RSH/C3 in Crankcase RH- Rubber sealed facing FD sprocket side. Cam Gear Inlet- Single punch mark must align with single punch mark of Cam gear exhaust. Gear rocker shaft bottom pivot bearingSmooth machined surface side facing upwards. Oil pump drive pinion - Short boss facing outwards. Main shaft 2nd Gear- Selector fork groove side facing towards M.S. 4th Gear. Special thrust washer Lay shaft RH Profile towards sleeve gear side on RH Crank case.
ENGINE ASSEMBL Y ASSEMBLY Please ensure all the parts are cleaned and stored in a sequence for inspection and reassembly. Lubricate all moving parts prior to reassembly. While fixing bearings or bushes in the crankcases, it is necessary to heat the crankcase for ease of fixing. Cool the crankcases after the fixing the bearings / bushings before further assembly. ASSEMBL Y OF ENGINE ASSEMBLY BEARINGS CRANKCASE LH Assemble Needle roller bearing for lay shaft.
Assemble 6305 - C3 bearing after 1st circlip. Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig. CRANKCASE RH Assemble Needle bearing for lay shaft. Assemble sleeve gear ball bearing (6007 R1/C3) and circlip. NOTE : Ensure the rubber sealed face is facing the FD sprocket side, while assembling the 6007 bearing. Assemble NU 305 big roller bearing after bearing spacer in LH Crank case for crankshaft.
Assemble closed end needle bearing inside sleeve Gear. Insert sleeve Gear into Crankcase RH. NOTE : Do not hammer directly over sleeve Gear. It is recommended to use arbor press. Assemble open end needle bearing. Check bearing seating position and for free rotation. Assemble exhaust and inlet hydraulic tappets carefully into Crank case RH lubricate and check free upward & downward movement inside Crank case RH tunnel. INLET RHVL Assemble bolt pawl (Torque 2.0 KG-M) into Crank Case RH as shown in Fig.
Fit bracket lock clip to hold needle roller pin of hydraulic valve lifter and tighten with allen screw (Torque 1 KG-M). Assemble magnetic drain plug assy. (Torque 2 KG-M) with washer on crankcase RH. DRAIN BOLT NOTE : Assemble cleaned suction filter element into Crank case RH. Apply LOCKTITE 542 thread sealant before assembling the drain plug. ASSEMBLING OF KICK ST AR TER SUB ASSEMBL Y STAR ARTER ASSEMBLY (BULLET ELECTRA E5 & G5) Insert the spring, plunger and pawl in the kick starter spindle.
Assemble the Kick pinion gear over kick pawl mechanism. Fix kickstarter sub assy in to Crankcase RH as shown in Fig. TRIP PLATE Insert the thrust washer above the kick spindle. NOTE : Ensure kick pawl is seated over the trip plate in the Crank case RH. Rotate kick Gear and confirm free wheel movement. Assemble oil thrower under the kickstarter Gear (Torque 0.6 KG-M). Lock the circlip over kick sub assy. Assemble Kick starter return spring by hooking into kickshaft spindle.
Insert spring locking bolt with washer into kick spring eyelet and rotate clockwise to lock Kick starter return spring on the Crank case and tighten (Torque 1 KG-M). Assemble striker spring on rocker shaft assy. NOTE : Ensure striker spring both ends are seated on striker lever rocker shaft. Apply LOCTITE 5699 RTV silicon liquid gasket then assemble kick shaft Cover with oil seal on Crank case RH by 4 screws (Torque 0.6 KG-M). Assemble rocker shaft sub assy.
Assemble lower pivot bearing 2 allen bolts (Torque 0.6 KG-M). Assemble High gear. Assemble Double gear (LS 3rd and 4th gear). NOTE : It is recommended to tighten the upper pivot bearing first and then the bottom pivot bearing to avoid gear shifting problems. Assemble rocker return spring stop pin along with “O” ring by using special tool No. ST 25123-4 as shown in Fig. Assemble thrust washer and then Lay shaft 1st gear.
ASSEMBLING OF MAINSHAFT SUB ASSEMBLY Assemble main shaft 3rd gear. Smear oil and assemble the 1st thrust washer and then the 4th gear on the main shaft. Assemble main shaft 2nd gear as shown. Assemble 2nd thrust washer and fix circlip to lock the 4th Gear. NOTE : Ensure 2nd gear selector fork groove side is facing towards MS 4th gear. Assemble main shaft 1st gear. Smear oil on the 3rd & 4th gear with bush before assembly on Mainshaft.
Assemble circlip on the selector shaft. Assemble selector fork sub assembly over main and Layshaft sub assy. as shown in Fig. Assemble LH selector fork on the selector shaft and then insert centre fork so that the cut shoulders of both the forks are matched. Always assemble the cam plate on selector fork sub assembly in 3rd gear position & ensure the 4 rollers are in good condition and located properly. Assemble RH selector fork as shown in Fig.
Assemble the thrust washer, LS2nd gear & High gear with Lay shaft mounted on the Crank case RH as shown in Fig. Insert cam plate piviot pin with “O” ring with special tool No. ST 25123-4 as shown in Fig. NOTE : Apply LOCTITE 577 thread sealant to pivot pin to avoid oil seepage if any. Hold the cam plate and gear train sub assembly along with Fork shaft, Forks, Lay shaft double gear (LS3 & LS4) and main shaft with all gears (in 3rd gear position). Gently slide inside the crankcase RH.
Assemble “O” ring, cap pivot, copper washer and tighten bolt (Torque 1 KG-M). NOTE : Check Crank shaft big end bearing axial play is within service limit. Check Crank shaft run out is within service limit. Ensure the bearing inner races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembling in the crankcase RH. Assemble the 2 dowel pins on the crankcase and apply LOCKTITE 5699 RTV silicon liquid gasket on the RH Crank case seating surface.
Insert the jack shaft from the crankcase LH inside & fix the woodruf key. Check connecting rod bend as shown in Fig. Assemble the crankcase LH over RH Crank case by tapping gently. Simultaneously holding self motor jack shaft carefully. Assemble Front Engine Mounting Brackets and tighten bolts (Torque 2.5 KG-M). Tighten the crankcase stud nuts and allen screws as per the following sequence. Assemble Rear Engine Mounting Bracket and the piece mudgaurd holding bracket (Torque 2.5 KG-M).
Assemble neutral switch with packing. Locate the crankcase on the frame and fit the front engine mounting stud. Fit the rear engine mounting stud. Fit the centre stand and foot rest supports. Ensure the woodruf key is located correctly on the jack shaft and fix the circlip. NOTE : Ensure step face of jack shaft gear should face inside (Towards Crank case LH) Locate the double gear for starter drive in the crankcase and insert shaft. Ensure cut portion of shaft is facing upwards.
Fix the dowels in the crankcase and carefully fix the motor with housing starter drive. Apply LOCKTITE 5699 RTV silicon liquid gasket on the joint face. NOTE : Apply LOCKTITE 577 thread sealant to mounting bolts to avoid oil seepage if any. Fix the E-Start motor cover. Fix the 4 Allen screws of housing starter drive and tighten (Torque 0.6 KG-M). Assemble spacer (distance washer) on Crankshaft LH. Fix the main cable on the starter motor on tighten. Insert rubber boot properly.
SPRAG CLUTCH ASSEMBLY Assemble Engine primary sprocket and sprag clutch gear assembly. 0.2 to 0.5 mm DETAILS B CAUTION : Lubricate the needle bearing well before assembling on the sprag clutch. Assemble the primary chain auto chain tensioner body assy. with “O” ring and tighten with 2 allen screws (Torque1 KG-M). Ensure the distance between sprag clutch gear end face and engine sprocket end face should be maintained between 0.2 to 0.5 mm as indicated in the above image.
Assemble collar on main shaft (distance collar on Crankcase LH). CAUTION : Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk / slippage. Assemble wheel clutch on clutch hub. ASSEMBL Y OF CL UT CH ASSEMBLY CLUT UTCH Assemble needle roller Bearing ( SCE 228C3) in the clutch sprocket and locate the thrust washer. Assemble clutch friction plate over clutch hub and then clutch plain plate. Similarly follow the same to sub assemble all the clutch plates.
Use Special tool No. ST - 25594-4 Clutch spring compressing tool to compress the clutch springs over spring holder and tighten with 2 long bolts. Assemble the 4 clutch holding bolts bolts and tighten diagonally and evenly. Assemble Duplex chain over Engine sprag clutch sprocket and Clutch assembly. Mount on main shaft. Use Special tool No. ST 25591-4 Clutch centre holding tool to lock Clutch sprocket and engine sprag clutch assy. NOTE : Tighten bolts diagonally and evenly 5 threads each (Torque 1 KG-M).
Fix the washer and nyloc hex nut 24 mm over clutch assembly and tighten. Assemble clutch bearing cup, ball bearing (6001) & clutch push pad. Use Torque wrench to tighten the nyloc nut on Clutch (Torque 4.2 KG-M). Assemble gear lever shaft bush. Assemble gear lever oil seal on cover LH . Fix the spring and bolt with “O” ring for the auto chain tensioner (Torque 1 KG-M).
Assemble Clutch operating shaft oil seal. Assemble clutch operating shaft assembly on cover LH. Assemble spring for clutch operating shaft and lock the pin. Assemble oil filler plug with “O” ring. Assemble the cover LH on Crank case LH. NOTE : Ensure 2 Nos. dowel pins are located properly. Apply LOCKTITE 5699 RTV silicon liquid gasket. Locate 11 allen screws on cover LH and tighten (Torque 1 KG-M).
Assemble clutch cable on Crank case cover LH and fix to clevis. Assemble lock type washer and nut (Torque 7.5 KG-M). Assemble Sleeve gear Spacer over sleeve as shown in Fig. Lock the tab over the FD sprocket nut. Assemble FD Sprocket . Fix Rear Chain master link, plate and lock clip. NOTE : Care to be taken while fixing the FD sprocket direction circular groove index mark, facing outwards.
Assemble oil pump on Crank case RH and tighten with 4 allen screws (Torque 0.35 to 0.6 KG-M). ASSEMBLING PROCEDURE OF AUT O DECOMPRESSOR UTO Locate the actuating pin in the Exhaust cam. CAUTION : Ensure "O" ring is located on the oil pump body outlet. Fix the woodruff key carefully on Crankshaft. Assemble Gear lever shaft assembly into RH Crank case window and then fix gear shaft spacer. Assemble the flyweight along with return spring over activating pin and tighten with allen screw.
VALVE TIMING Bring piston to TDC so that the woodruf key in the timing shaft is at 12’ Clock position. Fix oil pump drive pinion and lock it with the circlip. ASSEMBLY PROCEDURE OF CAM GEARS NOTE : Ensure the short boss of the gear is facing outwards. Locate the exhaust cam on the spindle and ensure the 2 punch marks on the cam aligns with the punch mark on the timing shaft gear. Locate the inlet cam on the spindle and align the single punch marks on the inlet and exhaust cams.
Fix Cam steady plate and check for axial play of Cam Gears to avoid noise problem. Fix oil seal 2 Nos. at Kick Shaft hole on Crank case RH cover. INSIDE OIL SEAL OUTSIDE OIL SEAL Assemble the dowels and allen screws on Cam steady plate and tighten (Torque 1 KG-M). Fix breather chamber gasket. Assemble magneto rotor, plain washer and nut and tighten (Torque 4.8 KG-M). Assemble 6 allen screws to fix breather chamber cover plate (Torque 0.60 KG-M). NOTE : Use special tool No.
Assemble Breather bolt and washer (Torque 2.0 KG-M). Assemble Stator on cover RH and tighten with 3 mounting screws (Torque 1 KG-M). Assemble Pulser coil on cover RH and tighten with 2 screws (Torque 1 KG-M). Assemble Ignition Timing inspection bolt with copper washer (if not assembled earlier) Torque 1.5 KG-M. NOTE : Apply LOCKTITE 595 silicon adhesive sealant to magneto wire cable grommet to avoid oil seepage. Assemble jet Crankshaft, oil seal Crank feed and circlip on cover RH inside.
Assemble cover RH carefully by aligning kickshaft and dowels. Fix cover RH and tighten with 11 allen screws (Torque 1 KG-M). Assemble “O”ring, Spring and gasket oil filter cap. CAUTION : Care must be taken while fixing cover due to spring force and gasket. Assemble oil filter cover (Torque 0.60 KG-M). Assemble the “O” rings, Oil filter element, washer and plate as shown. Assemble kickstarter lever (only for Bullet Electra EFI (E5/G5) (Torque 2.5 KG-M).
Fix Cylinder barrel bottom Gasket. PIST ON SUB ASSEMBL Y PISTON ASSEMBLY Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves. CLEANING Remove piston rings from piston. Check the piston rings end gap at the bottom end of the Cylinder. Scrub the carbon deposits from the piston groove with the help of scrapper. Scrap the carbon deposits from the skirt area and groove area of piston without causing any scratches or scoring.
Check the piston pin for wear. Measure outside dia of piston pin at 3 points. Locate the top ring (Index mark “1 IP” facing upwards). NOTE : Top ring has rectangular cross section with black colour (Nitride coating). Stagger piston rings end gap as shown in Fig. EX IN ASSEMBLY IN EX NOTE : After installation, the ring should rotate freely rotatable in the ring grooves. CAUTION : Ensure the open end of any piston ring does not align with the piston pin boss.
CYLINDER BARREL Assemble the multi layer steel (MLS) head gasket on the barrel & 2 Nos. dowels. CLEANING Scrap the carbon deposit from the top edge of the bore. Clean the barrel with cleaning solvent and dry it with compressed air. INSPECTION Visually check for cracks, scratches, breakage of fins, scoring, seizure mark etc of the Cylinder bore. Check Cylinder liner for wear at 3 locations measure the cylinder ID in X and Y axis.
Check the Cylinder head face for warpage on surface plate as shown in Fig. Check the valve guide for wear with small bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance. Check the valve stem for run out. Check inlet and exhaust valve stem for wear. Check the valve seat to valve head seating as below. Replace valve if the valve head is knife edged.
Make pencil marks on the seating area of valve head as shown in Fig. In case if the pencil marks are not erased, grind the valve to the seat as below - Apply fine grinding paste on to the valve seating area. Assemble valves into the valve seat. WARNING : Do not allow the grinding paste to seep into the valve stem and valve guide. Using a suction valve grinder / valve lapping stick, rotate the valve back and forth several times. Lift and turn the valve by half and grind valve on its seat.
VALVE SEAT INSPECTION : Check and ensure proper seating with pencil marks as explained above. Valve seating on valve seat can also be checked as follows: Assemble the valve assembly in position. Keep the Cylinder head on a table. Fill petrol on top of the valves. Seepage of petrol past the valve seat indicates improper valve seating. NOTE : Please ensure cleaning of the cylinder head with solvent and blow thorough all oil passages with compressed air.
Similarly follow the same process to assemble the exhaust Valve as shown in Fig. NOTE: Tighten the 6 flanged hex nuts diagonally and evenly. Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring. VALVE LEAKAGE TEST Pour solvent into exhaust port and check for valve seat leakage if any. Assemble the spark plug Similarly check for inlet valve seat leakage. Assemble the Cylinder head assy. on the Barrel. Check run out of the push rods.
Assemble inlet and exhaust pushrods. Assemble the inlet and exhaust rocker bearing with dowel and tighten allen screws Assemble the Inlet & Exhaust Rocker covers, dowels & rubber gasket then tighten rocker cover bolt with rubber washer (Torque 1 KG-M)) . Assemble tappet door by applying LOCKTITE 5699 RTV silicon gasket on Crank case RH then tighten screws (Torque 0.60 KG-M). Tighten the swing arm nut to specified torque.
Tighten the front engine mounting stud nuts to the specified torque. Tighten the rear engine stud nuts to the specified torque. Tighten the centre stand and foot rest nuts to the specified torque. Assemble throttle body and connect the throttle cables. Fill recommended the engine oil to the correct level and tighten filler cap with “O” ring. Assemble the exhaust pipe and silencer in the reverse order of disassembly. Fix the oxygen sensor & connect to wiring harness.
SECTION SIX 06 ENGINE MANGEMENT SYSTEM
ENGINE MAN AGEMENT SY STEM MANA SYSTEM The Bullet Electra EFI (E5 & G5) and Bullet Classic EFI (C5) are fitted with an intelligent Engine Management System (EMS).
COMPONENTS DESCRIPTION ELECTRONIC CONTROL UNIT (ECU) ALTERNATOR THROTTLE BODY ASSEMBLY TEMPERATURE SENSOR FUEL INJECTOR ASSEMBLY CRANK POSITION SENSOR FUEL PUMP MODULE ROLLOVER SENSOR LAMBDA (O2) SENSOR MALFUNCTION INDICATOR LAMP (MIL) 06-2
FUNCTIONS OF COMPONENTS ELECTRONIC CONTROL UNIT (ECU) Located under dual seat (Bullet Electra EFI - E5 / G5) Located in LH Electrical Box (Bullet Classic EFI - C5) The ECU consists of a microprocessor. It controls the output devices by giving pulses to the respective devices. It has two memories Flash Memory and E2 PROM. Flash memory is an exclusive recording unit for controlling program and setting data.
FUNCTIONS OF COMPONENTS FUEL INJECTOR Exploded view of fuel injector Assembled between throttle body and cylinder head Specification: Operating Voltage : 10 – 14 V. Operating temperature : –30º C to + 120º C. Fuel Injection pressure : 294 kpa (2.9 bar) Solenoid Operating Resistance : 10.3 ± 0.5 Ohms Fuel Injector is a solenoid operated electromagnetic valve, which atomizes the fuel by forcing it through a small nozzle under high pressure.
FUNCTIONS OF COMPONENTS FUEL PUMP MODULE Specification: Operating Voltage : 6 – 14.5 V. Operating temperature : –20º C to + 60º C. Controlled Pressure Regulator : 294 KPa. Inbuilt Filter Capability : Upto 10 Microns Assembled on the fuel tank bottom left side The fuel pump creates a positive pressure in the fuel lines and pumps gasoline through the injector. The Pump operation is determined by the ECU so that it gives exactly the required volume of fuel.
FUNCTIONS OF COMPONENTS THROTTLE BODY MODULE Specification: Operating Voltage : 5 V. Out Put Voltage : 0 – 5V. Throttle Angle : 0 – 80º Throttle Resistance Maximum : 5 K©. Throttle Out Put Voltage at Idling : 0.6 ± 0.2V. Assembled between air filter and inlet manifold Storage Temperature : –20º C to + 80º C The throttle body is a part of the air induction system. It controls the amount of air flowing into the engine, in response to throttle opening.
Throttle Position Sensor (TPS): TPS is used to monitor the position of the throttle and is located on the butterfly spindle so that it can directly monitor the position of the butterfly throttle valve. The sensor is usually a potentiometer and therefore provides a variable resistance depending upon the position of the butterfly valve and hence throttle position can be sensed by the ECU. The sensor signal is used by the ECU as an input to its control system.
FUNCTIONS OF COMPONENTS ENGINE TEMPERATURE SENSOR Specification: Operating temperature : –30º C to +120º C Operating Voltage : 5 ± 0.5 V. Resistance Value w.r.t. Temperature –20º C –– 18.8 Kilo Ohms + 40º C –– 1.136 Kilo Ohms + 100º C –– 0.1553 Kilo Ohms Assembled on the cylinder head Engine temperature sensor is used to measure the engine oil temperature. It senses the oil temperature and provides the input to the ECU which calculates the average engine temperature.
FUNCTIONS OF COMPONENTS LAMBDA (HEGO O2) SENSOR Specification: Operating Voltage : Upto16 V (Maximum). Operating temperature : 600º C to 950º C. (TIP) Tightening Torque : 24.5 ± 4.9 N-m (2.5 ± 0.5 Kg f-m) Assembled on the exhaust pipe The Lambda Sensor detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected.
There are three levels of identifying a malfunction in the ECU or the sensors. Level 1 Visual This is indicated by the lamp in the MIL glowing continuously. Check for any sensor loose connections and plug in properly. If still MIL GLOWS, then check for the the problem by Test Pin or by DOL TOOL. Level 2 Test pin An open single pole connector is provided close to the UCE.
Level 3 DOL This is done by connecting a DOL tool to the connector near the ECU. This will accurately determine the defective sensor and show the details on the diagnostic screen with the following respective codes as shown below. P Code MAL FUNCTION INDICATION MIL will glow continuous. Engine will start but not perform to its potential.
INSTRUCTIONS (DO’S & DON’TS): 1) DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR the engine is running. 2) DO ensure the battery is in good condition & Fully Charged Battery. 3) DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands retracted. (Engine will NOT Start OR switch OFF if side stand is extended).
TROUBLE SHOOTING S No Symptom Possible Cause Engine stop switch is in OFF position Side stand is ON. 1 MIL does not glow when ignition key switched ON Battery discharged Side stand switch faulty Fuse blown. Sensor couplers / wires loose contact. 2 MIL glows Continuously 3 MIL Glows & Switches OFF but vehicle does not start Battery discharged A E Start related Starter motor cables loose connection. Relay starter not working.
TROUBLE SHOOTING S No Symptom Possible Cause Spark plug Fouled Spark plug cap shorting E Ignition related No output from Magneto Vehicle Starts but Switches Crank sensor loose connections/ off faulty Roll over Sensor Loose connections / Injector holes clogged 5 6 Loose inlet manifold / Leak in inlet manifold Loose connections or problem in manifold pressure sensor High fuel consumption / Stuck butterfly in throttle body / Uneven Idling / Poor Pick up / broken throttle Cables Smoky Exhaust / Engine L
SECTION SEVEN 07 TORQUE SPECIFICA TIONS SPECIFICATIONS CHASSIS WHEELS & BRAKES
TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. CHASSIS DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. Handle Bar 1 146032 Handle Bar Clip Bolts Handle Bar Clip 1.20 12 3 560574 Master Cylinder Cap Screws Master Cylinder Reservoir Cap 0.13 1.5 2 560609 Fr. Brake Lever Pivot Bolt Fr. Brake Lever Pivot 1.20 12 4 560579 Brake Lever Pivot Lock Nut Brake Lever Pivot 1.
TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. CHASSIS DESCRIPTION 2 1 580592 FLANGE HEX. BOLT M8 X 10 LOCATION TORQUE VALUE Kg / M. N / M. CHAIN GUARD MTG. / REAR M.GUARD REAR MTG. 3.00 30 2 2 141051 HEX NUT M8 SEAT MOUNTING REAR C5 3.00 30 2 3 145862 FLANGED HEX BOLT M8 FRONT MUDGUARD STAYS BOTTOM MOUNTING C5 3.00 30 FRONT MUDGUARD STAYS TOP SCREWS MOUNTING C5 0.30 3 2 5 571055 ENGINE TEMPERATURE SENSOR CYLINDER HEAD 1.20 12 2 6 571054 OXYGEN SENSOR EXHAUST PIPE 2.
FR ONT WHEEL REMO VAL FRONT REMOV ✰ Tap the axle gently to remove it out of the fork end and the wheel ✰ Place the vehicle on its center stand. ✰ Place a suitable wooden block below the front end of engine to support the vehicle so that the front wheel is lifted up by 25mm from the ground. ✰ Disconnect speedo cable. ✰ ✰ ✰ ✰ Loosen the pinch bolt on the RH fork end. Tilt the vehicle slightly to the right side and take out the wheel along with the speedo drive and the bush.
✰ Locate the bush on the left side of the wheel (Disc brake side) ✰ Remove the wedge between the brake pads and position the wheel between the fork legs, taking care to ensure the brake disc in seated correctly between the brake pads in the caliper ✰ Fix the wheel axle from the right side fork leg, carefully ensuring that the holes int eh fork legs and the wheel assembly are aligned. Do nto force the axle or tap heavily on the axle as it will damage the bearing inner races and the threads on the axle.
3 3 Remove the Master Cylinder top cover, diaphragm plate & diaphragm. 3 Loosen the bleeder screw by 1 turn approximately 3 Depress brake lever slowly and fully and release. This will force the brake fluid out of the bleeder screw. Repeat this process till the brake fluid drains out completely from the master cylinder and the wheel calliper assembly. Remove the protective boot from the bleeder nipple on the calliper assembly.
3 3 Remove the calliper assembly from the fork leg and drain out the brake fluid 3 Fix the diaphragm, plate and top cover. Do not tighten the screws completely since it may be required to top up fluid during the bleeding process. 3 Depress the brake lever completely and release fully so as to allow the brake fluid to fill up in the brake hose and caliper. 3 When a slight firmness is felt on the lever and it depresses only halfway, hold the lever firmly in that position. DO NOT RELEASE THE LEVER.
3 Loosen the bleeder screw by ½ turn to allow air bubbles in the brake system to escape out. 3 Check the fluid level and top up to “MAX” level and refit the diaphragm and the top cover and tighten with the screws. 3 Check for any leaks at the banjo or the bleeding screw area and ensure all mounting bolts are tightened to the correct torque.
3 When a slight pressure “build up” is felt on the lever, depress and hold. DO NOT RELEASE THE LEVER. The air in the hydraulic system will be expelled upwards during this operation, allowing the fluid to fill up in the calliper and the brake hose completely. 3 Remove the Master Cylinder top cover, diaphragm plate & diaphragm. 3 Place a clean tray or container below the calliper assembly to collect the old brake fluid. 3 Loosen and remove the banjo bolt with the washers from the Caliper assembly.
3 Remove the Rear view mirror RH. 3 Disconnect the Front brake switch wire and remove the switch from the master cylinder. 3 Disconnect the Banjo bolt and the remove the brake hose from the master cylinder end 3 3 Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar. 3 Remove the boot and the Circlip from the master cylinder body.
INSPECTION CAUTION : 3 Check both the rubber seals on the plunger for wear, cracked edges or any other damage. Replace seals whenever the plunger is removed Do not clean the hydraulic disc brake parts with any other cleaning material, solvents or water. USE NEW BRAKE FLUID ONLY. 3 Check the master cylinder housing and piston for any scoring, pitting due to corrosion or any other damages. 3 Check the master cylinder bore for any damages, scoring marks etc.
3 3 Locate the circlip into the groove of the master cylinder. Ensure the circlip is seated correctly inside the groove. 3 Assemble the Brake Switch 3 Fix the master cylinder assembly on the handle bar with the ’UP’ mark facing upwards. 3 Tighten the master cylinder assy. clamp top bolt first and then tighten the bottom bolt. Torque 0.90 KG-M. 3 Assemble the brake lever in the front bracket and tighten with the bolt first and then tighten the lock nut 3 Torque values: Bolt-lever 0.
3 Position the brake hose on the master cylinder such that it is pointing downwards correctly and tighten with the banjo bolt. Replace the banjo bolt sealing washers whenever the bolt is removed. 3 Tighten the banjo bolt firmly Torque 3.5 KG-M. 3 Connect the brake light switch. 3 Fill the brake fluid till “MAX” mark and bleed the system. 3 Assemble the diaphragm, plate and cover. Tighten screws gently Torque 0.15 KG-M. 3 Assemble the rear view mirror.
3 3 3 3 Remove the brake pad tensioner spring plate. 3 Remove the Bellow & Boot. 3 Hold the caliper body with the pistons facing downwards. 3 Blow compressed air with a nozzle at a low pressure, into the oil passage hole on the caliper, so that the pistons can be removed Remove pin bolt. Remove the brake pads from the caliper assembly. Remove mounting bracket from the Caliper assembly.
CAUTION : Measure the caliper piston O.D. Do not use high pressure air or any pliers or sharp objects to remove the pistons as their working surface can get damaged. Service limit – 25.31 mm Ensure the pistons do not fly out of the caliper body due to high air pressure. Support the pistons CAUTION : Enough care should be taken to avoid damages of the piston O.D. while servicing/ handling. 3 Remove the Bleed screw.
3 3 3 Coat the caliper cylinders and Pistons with clean brake fluid and install the Pistons into the caliper body with the dished end facing inwards. 3 Install the Pad tension spring plate into the Caliper body. 3 Assemble Bleed screw with the dust cap on the caliper body. 3 Assemble the Mounting Bracket on the caliper Body. If the Caliper Boot and Bellow are hard or deteriorated, replace them with new ones. Smear fresh brake fluid on the caliper boot and bellow and assemble them as shown.
3 3 3 First install the brake pad at the piston side and then install the other brake pad 3 Tighten the Pin bolts with a torque of 1.5 2.0 KG - M after mounting the caliper assembly on the fork assembly. 3 Fix the Grub screws on the pins and tighten to a torque of 0.2 to 0.3 KG-M. 3 Connect the brake hose to the caliper with New sealing washers and tighten the Banjo bolt. Torque : 3.5 to 3.8 KG -M.
WHEEL DISC INSPECTION Check the wheel disc periodically for any oil or grease stains, slush, grit, scoring marks etc. Keep the disc clean and dry at all times for the brakes to work at peak efficiency. If the Disc is scored heavily, replace the disc. IF the scoring is very mild, remove the same using a mild abrasive paper. 3 Check the Disc thickness and the ‘Run-Out’ of Disc.11 Sl. No. Parameter Service Limit 1 Disc Thickness As described on the disc 2 Disc runout 0.
3 Remove the cush drives (4 Nos.) from the hub. BRAKE DR UM ASSEMBL Y DRUM ASSEMBLY 3 Remove the drive chain from the sprocket. 3 Disconnect the brake operating rod from the cam lever. 3 Remove the cover plate anchor nut from the chain stay. 3 Remove the nut from hub spindle short. CAUTION : The cush drives are locked to the hub with rubber lugs. Pull out the cush rubbers gently to avoid damage to the lugs 3 3 Remove the dust seals. Drive out the bearings (2 Nos) and take out the spacer.
3 3 Remove sprocket drum assy. from the swing arm along with brake shoes and cover plate carefully. Disconnect chain if not removed earlier. 3 Clean the brake shoe & cush drive with dry cloth / cloth wet with solvent. INSPECTION 3 Visually check all parts for breaks, cracks, dents, scoring, glazing or any other damage. 3 Check bearings for free rotation, axial play and radial clearance. Replace if necessary.
SECTION EIGHT 08 SUSPENSION & STEERING
FR ONT FORK WORKING PRINCIPLE - FOR B ULLET FRONT BULLET ELECTRA EFI (E5 & G5) OIL FLOW DURING REBOUND STROKE 08-1
FR ONT FORK WORKING PRINCIPLE - FOR B ULLET EFI FRONT BULLET CLASSIC (C5) FORK STROKE LENGTH : 130 MM FORK MOVEMENT IS CONTROLLED BY THE COMPRESSION SPRING AND HYDRAULIC DAMPING FORCE S.No. Description 1. 2. 3. 4. 5. 6. 7. 8. 15 9 Bolt cap “O” ring Main tube Spacer Seal dust Fork oil seal & circlip One way check valve Fork piston S.No. 9. 10. 11. 12. 13. 14. 15.
FRONT FORK DIS ASSEMBL Y ASSEMBLY Gently tap the fork bottom tube downwards and remove the bottom tube. Place motorcycle on centre stand. Remove the oil control collar from the spring stud. Remove speedo cable, front wheel and mudguard. Using special tool ST 25105-2, remove the valve port. Remove caliper mounting bolts and take out the caliper. Take out spring stud and front fork spring.
REMO VAL OF FORK SEALS REMOV Loosen the pinch bolt on fork crown bottom. Remove the plug screw from the head lamp casing and using special tool ST 25108-3, unscrew and remove the main tubes, cover tubes, bush and washer. INSPECTION Visually inspect all parts for damages, cracks, bends, wear marks or any other damage. Check the main tube for any bend. Measure the spring length. Inspect the other internal parts for any visual damage.
Remove the handle bar clamp bolts and nuts and take out handle bar. Take out ball race from steering stem. CLEANING Clean all the parts carefully for inspection. Remove the stem lock nut and washer carefully. Rub the bearing race balls in a clean cloth. Tap the steering stem downwards, taking care to collect the steering race balls (38 nos) for inspection. INSPECTION Remove head lamp casing. Inspect the balls for marks of wear, corrosion, pitting and damage.
REASSEMBL Y OF STEERING REASSEMBLY Using a hollow drift, fix the bottom ball race the steering stem. Fix the ball race on the frame head tube (top). Locate 19 balls each on the ball races steering stem bottom and frame had tube top. Locate the head lamp casing over the frame down tube such that the centre holes align. Insert the steering stem into the frame head tube slowly and steadily. Till it matches with the frame head tube bottom ball race.
Assemble front forks, mudguard & front wheel in reverse order of disassembly. Assemble the handle bar and other parts. Adjust the steering stem play correctly & tighten the steering stem rinch bolt under the handle bar bracket. REMOVAL AND ASSEMBLY OF REAR SHOCK ABSORBER Remove the top and bottom mounting nuts and washers.
RECHARGING OF SHOCK ABSORBERS Remove the small screw with “O” Ring. Remove the rear wheel sprocket assembly (1). Remove the shock absorbers (2). 2 1 Remove the chain guard. Inject the special purpose needle into the hole provided in the screw (Puncturing the rubber) and start pumping the air into the chamber till the pressure reached to 100 PSI (7 BAR). Tolerance for filling pressure can be 6.7 BAR to 7 BAR. Remove the swing arm cap swing pivot. Fit the small screw with “O” Ring.
Using a mandrel, drive out the plastic bush from either sides of the swing arm and remove the steel spacer. Always use reamer to ream the bush after pressing into swing arm tube. Apply grease inside the bush and then insert spacer as shown in Fig. CAUTION : Do not remove plastic bush, unless it is defective. ASSEMBLY Press the new plastic bush into the swing arm tube. BUSH SPACER Position special tool ST 25110-3 on shock absorber mounting pins.
Place a washer and tighten nut. CENTER ST AND STAND DISASSEMBLY Disconnect the stand return spring two nos. (1) Remove the split pins & washers from the both ends of the centre stand spindle (2). Drive out the centre stand spindle. 2 1 After tightening the swing arm hex nyloc nut. Remove special Tool ST 25110-3. Fix both side caps swing pivot carefully. Assemble both side shock absorbers, washers and dome nuts as shown in Fig.
SECTION NINE 09 ELECTRICALS
ELECTRICAL SYMBOLS 01. Alternating current (AC) ... 02. Direct current (DC) ... 03. Wired across ... 04. Connection ... 05. Switch ... 06. Ground ... 07. Cell ... 08. Battery ...
PRECA UTIONS : PRECAUTIONS 3 Wear rubber gloves while handling a battery. 3 Use only constant current battery charger of correct charging rate, to charge batteries. 3 Remove the filler caps only to fill distilled water OR if the battery is to be charged. Hydration may occur when atmospheric air contacts the plates. 3 Keep all the filler caps removed while charging the battery. 3 Use only distilled water to top up the level after the initial charging.
TEMPERATURE OF ELECTROLYTE : 3 CAUTION : Cool the electrolyte to about 30 deg. C before filling it in the battery, just below the maximum level indicated. Always connect the positive and negative terminals of battery into the positive and negative sockets provided in the constant current battery charger. SOAKING PERIOD: 3 Always disconnect the Negative (-ve) terminal first & then the Positive (+ve).
MAINTENANCE 3 Check the electrolyte level and top up, if necessary to the ‘MAX’ mark with distilled water every week. 3 Protect battery from direct sunlight, heat, rain and dust. 3 Keep exhaust seal cap in place to avoid deterioration of dry charge properties 3 New dry charged batteries need initial charging duration of 8 to 10 hours - Upto 3 months from the date of manufacturing. 3 Beyond 3 months the batteries may need extended duration of initial charging subject to storage conditions.
Specific Gravity Fully charged Carbon deposits on the spark plug establishes a ‘shunt’ between center and earth electrodes, that prevents good sparking and causes misfiring. Clean the deposits off periodically, with a spark plug cleaning tool / machine. 3 Check spark plug for pitted out the earth and center electrodes. If the earth electrode has worn off to a knife edge and center electrode has reduced in height, replace it with new. Requires Recharging 1 .24 3 3 1 .
CHECKING PROCEDURE OF ELECTRICAL COMPONENTS PULSAR COIL 3 SPECIFICATION Stator coil 3 Pulsar coil 3 Ignition coil Resistance mode - Across the wires 3 Suppressor Cap 180 - 240 3 Battery 3 Horn 3 Relay Starter Set the multimeter in resistance mode. 3 Starter motor Check the Resistance between 3 IC Flasher a. Green to white wire. 3 RR Unit 3 c 3 (ohms).
CAUTION : Brown or white/red to core no connectivity. HORN 3 SUPPRESSOR CAP - M14 3 SPECIFICATION Continuity Mode - Beep Sound SPECIFICATION Resistance Mode - 4.5 to 6 K ohms RELA Y ST AR TER RELAY STAR ARTER BA TTER Y BATTER TTERY 3 SPECIFICATION Voltage mode - 11.5 to 13 V 3 SPECIFICATION Resistance 4 to 5 ohms. 3 CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between BATTERY WHEN CHARGING 3 a. Green/white to white wire. SPECIFICATION Voltage mode - 13 to 14.
CAUTION : Never try to repair / tamper IC Flasher. RR UNIT E- ST AR TER MO TOR STAR ARTER MOT 3 SPECIFICATION Resistance 0.3 to 0.5 ohms. 3 3 CHECKING PROCEDURE Set the multimeter in voltage mode (DCV 20). Connect the multimeter to Battery terminals and then check the voltage as shown in Fig. CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between motor terminal & aluminium body. Start and accelerate upto 3000 RPM and then check online voltage inbetween 12.2 to 13.
ELECTRICAL PARTS INSPECTION CLUTCH SWITCH Check the continuity for the following wires Clutch lever in normal condition : Brown and Black ; if no continuity, switch is not ok. Clutch lever in pressed condition : Black and Green; if no continuity, switch is not ok. MODE BROWN GREEN BLACK 3 If the battery is weak (below 10 V), start with the kick starter and do not try to start with self starter. 3 Always maintain correct Engine oil level.
09-10
09-11
09-12
TROUBLE SHOOTING PROBLEMS 1. E-start motor not working. PROBLEM CAUSES 1. Fuse blown. 2. If the battery voltage increases with RPM increase, replace RR Unit. 3. Faulty relay starter. 4. Starter motor cables loose connection. 5. Starter motor failure. 2. Fuse blown when pilot lamp switched ‘ON’ 1. Rear harness cable routing fouling with the tyre. 2. Rear harness cable fouling with taillamp bracket. 3. Fuse blown when Head light high beam ‘ON’ 1. Check the Headlight wiring harness 4.
SECTION TEN 10 TROUBLE SHOO TING SHOOTING
TR OUBLE SHOO TING TROUBLE SHOOTING This section discusses trouble shooting on various performance problems. This following check list can be helpful in locating most of the operating troubles. Observation Causes Remedies Complaint : Engine fails to start Ignition switch in ‘OFF’ Position Switch ‘ON’ ignition Stop switch in ‘OFF’ Position Push stop switch to ‘ON’ position.
Observation Poor Cranking Causes Remedies Loose spark plug Tighten spark plug Loose cylinder head nuts Tighten cylinder head nuts Blown cylinder head gasket Change cylinder head gasket Auto Decompressor mechanism stuck in open position Ensure flyweight in exhaust cam gear assembly in free to operate.
Observation Fuel Related Electricals Related Causes Remedies Fuel is stale due to vehicle being in storage for a long period Clean petrol tank and carburetor and fill the tank with fresh petrol Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Fuel pump pressure low Check and correct Fuel Injector partially blocked Replace fuel injector. Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap.
Observation Electricals Related Causes Remedies Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead.
Observation Smoke through exhaust Causes Remedies Wrong grade/recycled lube oil Replace it with right grade oil Damaged valve stem seal Replace the seal Worn out / scored valve guide / valve stem Check and Replace Vertically aligned piston ring Properly stagger the piston end gaps rings Excessive piston ring end gap Replace the piston rings Wrong fitment of piston rings Refit the piston rings correctly Connecting Rod Bent Replace the crankshaft Clearance Excess between Piston & Cylinder Ba
Observation Causes Remedies Burrs in splined position of the shaft Check and Replace Improper position of the return spring.
2005 Eicher Motors Ltd. (Royal Enfield Motors Unit), Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019, India. Tel : 91 44 4204 3300. Fax : +91-44-4201 1719. www.royalenfield.com All rights reserved.
