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TB TS Service Manual Final 1.pmd

1. _5 50 580887 FLANGED HEX BOLT M10 X75 FUEL TANK REAR MOUNTING 540 50 500355 screw me FUEL PUMP MOUNTING SCREWS 1 580998 FLANGED BOLT 120 ENGINE MOUNTING FRONT TOP 300 30 580341 FLANGED BOLT M8 X 112 ENGINE MOUNTING FRONT BOTTOM 3 00 30 580345 FLANGED BOLT 8 X 00 ENGINE MOUNTING REAR 300 30 580448 FLANGED BOLT MIO X 260 ENGINE MOUNTING BOTTOM 500 50 145865 FLANGED HEX SERRATED NUT M10X1 5 RIDER FOOT REST RH MOUNTING 500 50 300 300 200 20 400 40 581158 HEX SOCKET HEAD CAP SCREW 8 X 352 SILENSER FRONT MOUNTING E5 G5 142182 HEX NUT WITH NYLON INSERT M 8 FOOT REST amp SILENSER REAR MOUNTING E5 G5 5 580349 FLANGED HEX BOLT X 20 HEAR BRAKE PEDAL asks mexmurwnzxias REAR BRAKE COVER ANCHOR PN NUT ralsecseo 9 145881 FLANGED HEX BOLT M8 45 REAR MUDGUARD CARRIER FRONT 1 2 3 A 5 7 10 11 12 13 14 1 1 17 18 1 20 MOUNTING C5 07 1 TORQUE SPECIFICATION CHASSIS PART TORQUE VALUE DESCRIPTION LOCATION Kg M 21 580592 FLANGE HEX BOLT X 10 CHAIN GUARD MTG REAR M GUARD REAR 141051 HEX NUT M8 SEAT MOUNTING REAR C5 00 23 145862 FLANGED HEX BOLT M8 FRONT MUDGUARD STAYS BOTTOM MOUNTING C5 24 141306 HEX NUT WITH NYLOCK INSERT
2. BUSH lt 7 dj 0 Always use reamer to ream the bush after pressing into swing arm tube Apply grease inside the bush then insert spacer as shown in Fig Position specialtool ST 25110 3 on shock absorber mounting pins x Position it on frame and insert the swing arm hex bolt after applying grease 08 9 x Place a washer and tighten nut CENTER STAND OF a x DISASSEMBLY Disconnect the stand return spring two nos 1 x Remove the split pins amp washers from the both ends of the centre stand spindle 2 x Drive out the centre stand spindle After tightening the swing arm hex nyloc nut Remove special Tool ST 25110 3 x Fix both side caps swing pivot carefully Assemble both side shock absorbers washers and dome nuts as shown in Fig ASSEMBLY x Assemble the centre stand in the reverse order of disassemble as shown in Fig Assemble the chain guard x Assemble the rear wheel and adjust drive chain free play 08 10 SECTION NINE 09 ELECTRICALS ELECTRICAL SYMBOLS 06 Ground Resistor z 21 Silicon Controlled Rectifier 44 SCR 17 Transformer BATTERY CONSTRUCTION Positive Plate Negative Plate Electrolyte Separator Container Cover Filling Plugs Gang Piece Terminals Intercell Poles Exhaust Tube Exhaust Seal Cap Porous mass
3. x Remove Engine sprocket and sprag clutch gear assembly X 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 amp remove the other 4 bolts x Remove the special tool holding both evenly to release the spring tension NOTE Flange wide faces of the sprag clutch bearing must face outwards NOTE Loosen bolts in opposite direction simultaneously 5 threads each 05 23 Remove Spring retainer plate amp 6 Springs x Remove collar on main shaft distance collar from Crankcase LH x Remove clutch drum sprocket with big washer Remove special distance washer sprag clutch on Crankshaft LH Remove clutch hub centre friction and steel plates Remove hex nut and washer to remove chain tensioner pad 05 24 x Remove Auto chain tensioner body assy x Remove the rear engine mounting nut by removing the 2 Nos allen screws along with the washer x Remove double gear shaft and double gear starter drive x Remove the jack gear after removing the X circlip 05 25 Remove centre stand amp footrest supports gt x 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 x Remove Mudguard mounting clip amp Rear Engine Mounting Brack
4. gt x Apply grease on steering stem bottom ball race and Top ball races in the frame head tube 08 6 Assemble front forks mudguard amp front wheel in reverse order of disassembly Assemble the handle bar and other parts Adjust the steering stem play correctly amp tighten the steering stem rinch bolt under the handle bar bracket GAS FILLED SHOCK ABSORBER WORKING PRINCIPLE x pressure of the nitrogen Air in the reserve tube of a gas charged shock varies from 75 to 120 psi depending on the amount of fluid in the reserve tube The gas serves several important functions to improve the ride control characteristics of the shock absorbers x main function is to increase the resistance of fluid flow into the reserve tube This improves valving performance during the beginning of rebound stroke Another function is to minimize aeration of the shock absorber s hydraulic fluid The pressure of the nitrogen gas air prevents air bubbles or foam from weakening the hydraulic effectiveness of fluid flow through both the piston and base valve systems Foam affects performance since foam compresses fluid does not This is alternatively called as cavitation The effect of foaming will result in poor riding comfort REMOVAL AND ASSEMBLY OF SHOCK ABSORBER Remove the top and bottom mounting nuts and washers ve Pull out the shock absorber from bottom and slide out from fram
5. x 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 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 INSPECTION x Clean the electrodes and set gap to 0 7 mm to 0 8 mm Clean the plug in a Spark plug cleaner cum Tester x the plug for proper sparking in the tester Light blue solid continuous spark Spark Plug OK seen in the tester Yellow or red spark intermittent or no spark or side spark Spark Plug as seen in the tester Not OK mirror 09 5 CHECKING PROCEDURE OF ELECTRICAL COMPONENTS x Statorcoil PULSAR COIL ve Pulsar coil SPECIFICATION x Ignition Resistance mode Across the wires ve Suppressor Cap 180 240 ohms Battery x CHECKING PROCEDURE x Relay Starter Set the multimeter in resistance mode x Starter motor Check the Resistance between x Flasher a Green to white wire x RRUnit MEASURING INSTRUMENT yc Multimeter STARTER COIL SPECIFICATION Resistance mode Across any two wires Ww CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between wires a Yellow 1 to yellow 2 0 8 to 1 5 ohm
6. In Fig 1 the Gear ratio is 20 1022 1 In Fig 2 the Gearratiois20 20 2 1 1 Gear ratios multiply the engine torque to fulfil various demands for pulling the vehicle like More effort is required during initial movement of the vehicle More effort is required to climb an elevation More effort is required while driving in muddy or sandy surfaces FINAL DRIVE RATIO It is a relative rotation between the engine sprocket and the sprocket on the rear wheel Both the sprockets are connected through drive chain Final drive ratio further multiplies the torque available at the output shaft TDC Position Ignition Timing Position Ignition Timing in Degrees 10 TEETH 02 5 TECHNICAL SPECIFICATIONS A ENGINE AND ENGINE SYSTEMS BULLET ELECTRA EFI E5 BULLET EFI G5 BULLET CLASSIC EFI 2 Engine Type 4 Stroke Single Cylinder Air cooled 84mm 90mm 499cc Compression ratio ax Power rpm 20 3 Kw 5250 rpm 41 3 Nm 4500 rpm 1050 200 rpm Kick amp Electric Start Paper element Max Torque rom 00 Electric Start Air filter element Z Z Z s slal Q lt CO G S D Oo S gt 2 Q O 3 gt lt 3 5 p N ie Lubrication Forced Lubrication Wet Sump 2 75 litres JASO MA 15W 50 API SL Grade ESTER Semi Synthetic Oil
7. O oa N N 10 12 13 14 15 16 17 18 19 20 21 CRANK CASE LH COVER SIDE DESCRIPTION CRANK CASE LH DOWEL 6MM COLLAR MAINSHAFT GEAR JACK SHAFT KEY JACK SHAFT CIRCLIP 12 x IN IS 3075 PART 1 FOR SHAFT DOWEL NEUTRAL SWITCH WITH PACKING HEX SOCKET HD CAP SCREW M6 X 50 STUD M6 X 168 STUD M6 X 106 STUD M6 X 196 STUD M6 X 226 STUD M6 X 80 NUT M6X1 FLANGE NYLOC TYPE SHAFT DOUBLE GEAR DOUBLE GEAR STARTER DRIVE HOUSING STARTER DRIVE HEX SOCKET HD CAP SCREW M5 X 45 HEX SOCKET HD CAP SCREW M5 X 25 DISTANCE WASHER SPRAG CLUTCH STUD CHAIN TENSIONER PAD KEY No 37 39 41 42 DESCRIPTION BUSH C T PAD CHAIN TENSIONER PAD PLAIN WASHER HEX NUT M8 AUTO CHAIN TENSIONER ASSEMBLY RING CHAIN TENSIONER ASSEMBLY HEX SOCKET HEAD CAP SCREW M6X20 SPRAG CLUTCH ASSEMBLY ENGINE SPROCKET SPRAG CLUTCH SPRAG CLUTCH GEAR NEEDLE BEARING WASHER HEX HEAD SCREW M12 CLUTCH ASSEMBLY COMPLETE NYLOCK NUT CLUTCH PUSH PAD BALL BEARING 6001 PRIMARY CHAIN HEX SOCKET HEAD CAP SCREW M6X85 PLAIN WASHER 04 21 ENGINE COVER LH 04 22 KEY No c O a N LL o CO OO N A O N ENGINE COVER LH DESCRIPTION LH COVER SUB ASSEMBLY COVER LH BUSH OIL SEAL 14X20X3 GASKET COVER LH OIL SEAL INA 12 18 5 ASSEMBLY CLUTCH OP CABLE CLEVIS CLUTCH OPERATING LEVER CLUTCH CABLE ASSEMBLY PIN C
8. Remove cutter and inspect the area Install a45 degree finish cutter and cut the seat to proper width SEAT WIDTH xx sure that all printing and irregularities are removed Refinish if necessary Standard seat width 0 9 1 1mm 03 22 After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure NOTE The Parts detail of Cylinder Head assembly eS ea bs 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 Recheck the seat contact after lapping Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air Install the valve spring seats and new valve stem seals Lubricate each valve stem with clean engine oil Insert the intake and exhaust valve into the valve guides CYLINDER HEAD SPLIT COLLAR RETAINER SPRING VALVE SPRING VALVE STEM SEAL SEAT SPRING VALVE GUIDE PLUG VALVE SEAT INSERT EXHAUST VALVE EXHAUST VALVE INLET VALVE SEAT INSERT INLET NOTE To avoid damage to the seating face turn the valve slowly while inserting 03 23 ENGINE COMPRESSION TEST STEP A Start and warmup the engine to normal running tempe
9. SERVICE MANUAL UPDATED ON DECEMBER 2010 Bullet Classic EFI Bullet Electra EE SECTION ONE 01 INTRODUCTION We 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 e mail us at vvikram royalenfield com Service Head Quarters Royal Enfield Chennai Copyright 2009 EICHER MOTORS LIMITED UNIT ROYAL ENFIELD All Rights Reserved No part of this Service technical manual shall be copied distributed or otherwise dealt without the express permission in written from Eicher Motors Limited Unit Royal Enfield who remains the sole owner of this manual Part No 597451 1 Qty 300 Dec 10 01 1 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 USE O
10. spring stop pin to avoid oil seepage ASSEMBLING OF LAYSHAFT SUB ASSEMBLY Assemble thrust washer and then 2nd gear on layshaft x Assemble High gear Assemble Double gear LS 3rd and 4th gear x Assemble thrust washer and then Lay shaft 1st gear ASSEMBLING MAINSHAFT SUB Assemble main shaft 3rd gear ASSEMBLY x 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 xx Assemble main shaft 1st gear x omearoil on the 3rd 8 4th gear with bush before assembly on Mainshaft Assemble on the selector shaft x 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 amp ensure the 4 rollers are in good condition and located properly Fig X Locate special thrust washer Layshaft on Crank case RH and stick using grease NOTE Ensure special thrust washer profile is facing towards sleeve gear 05 45 x Assemble the thrust washer LS2nd gear amp High gear with La
11. the 4Allen screws of housing starter drive and tighten Torque 0 6 KG M x Fixthe main cable on the starter motor on tighten Insert rubber boot properly x Fix the E Start motor with 2 allen bolts Torque 1 KG M along with earthing cable NOTE x Apply LOCKTITE 577 thread sealant to mounting bolts to avoid oil seepage if any Fix the E Start motor cover CAUTION This double stepped face should be inside 05 50 SPRAG CLUTCH ASSEMBLY ee Ld one DETAILSB 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 NOTE Crank the engine gently for ease of assembly CAUTION Do not rotate the starter motor while assembling as it will damage the O ring x Assemble sprag clutch bearing NOTE Ensure wide flanges face of the sprag clutch bearing must face outwards x Assemble Engine primary sprocket and sprag clutch gear assembly CAUTION Lubricate the needle bearing well before assembling on the sprag clutch xx Assemble the primary chain auto chain tensioner body assy with O ring and tighten with 2 allen screws Torque1 KG M Assemble chain tensioner pad washer and hex nut Torque 2 5 KG M 05 51 Assemble collar on main shaft distance collar on Crankcase LH ASSEMBLY OF CLUTCH Assemble
12. Also check and ensure there are no more air bubbles being carried out by the fluid while bleeding the system Ensure the bleeder screw is tightened fully and fix the dust cap v Check the fluid level andtop up to level and refit the diaphragm and the top cover and tighten with the screws Check for any leaks at the banjo or the bleeding screw area and ensure all mounting bolts are tightened to the correct torque BLEEDING PROCEEDURE REVERSE BLEEDING METHOD Ensure the bleeding screw and the brake hose banjo is fully tight Fill the master cylinder with brake fluid from a sealed container till the Max level Depress the brake lever completely and release fully so as to allow the fluid to travel into the brake hose and the wheel caliper 07 7 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 NOTE The brake fluid level will go down when the air escapes out Check level constantly and top up to level Repeat the process detailed above till the brake lever movement is minimal and locks in applied position Also check and ensure there are no more air bubbles coming into the master cylinder Check the fluid level and top up to MAX level Refitt
13. Check and correct No fuel in the tank Fuel pump pressure low Fuel Injector partially blocked Replace fuel injector 10 4 Incorrect Electrode Adjust the gap Spark plug electrode dirty fouled Clean park plug amp Reset gap Wrong specification spark plug Fit the correct Spark Plug Loose HT connections damaged HT lead Fix connections firmly Replace Lead Complaint Poor Pickup Loss of Power Engine Overheating Reduce pay load Inflate to correct pressure Adjust chain tension Adjust brake Clear and clean the fins Replace it with correct plug Change Change the Check and correct Drain and correct the oil level Electricals Related Clean and lubricate the bearings Adjust throttle cable free play Clean Replace cable Tighten replace the hose hose air filter to throttle body Check and correct Air filter Blocked Dirty Torn Check and correct Excessive carbon deposit Decarbonise the engine Fuel is stale due to vehicle being in storage Clean petrol tank and carburetor for a long period and fill the tank with fresh petrol Fuel Related Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Check and correct Replace fuel injector Adjust clutch cable play Clean and free and cable Transmission Related Weak clutch springs Check and Replace Clutch Plates Worn out Glazed Check and Replace Complaint High Oil Consumption Loose drain plug Tighten
14. 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 MALFUNCTION INDICATION MIL will glow continuous Engine will start but not perform to its potential Throttle Position Sensor TPS circuit malfunctioning Manifold Absolute Pressure MAP circuit malfunctioning Engine oil Temperature TE circuit malfunctioning O2 Sensor circuit malfunctioning O2 Sensor heater circuit malfunctioning Engine will NOT Start but will crank MIL will glow continuous Rollover Sensor circuit malfunctioning Injector circuit malfunctioning Ignition Coil circuit malfunctioning Fuel Pump circuit malfunctioning Crankshaft position circuit malfunctioning 06 11 INSTRUCTIONS DO S DON TS 1 DONOT 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 amp Fully Charged Battery 3 DOstartthe engine only when itis 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 4 Switch ON the ignition key engine stop switch to RUN position and retract the side stand completely and wait for approximately 3 seconds for the MIL MALFUNCTION INDICATOR LAMP to switch
15. Switch defective Flasher defective Complaint Electric start not working Battery discharged fully Check amp Recharge Check amp Correct Check amp Correct Bring the vehicle in neutral Check amp Replace Check amp Replace Check amp Replace MIL Glowing Continuously Loose Electrical connections Neutral indicator not glowing Clutch Switch Defective Side Stand Switch Defective E start Motor not working 10 o ROYAL FNFIELD 2005 Eicher Motors Ltd Royal Enfield Motors Unit Thiruvottiyur High Road Thiruvottiyur Chennai 600 019 India Tel 91 44 4223 0400 Fax 91 44 4201 1719 www royalenfield com All rights reserved
16. head x Remove the rear mounting at the pillion h il A ith foot rest end E5 G5 x Remove the Silencer Assembly wit Exhaust pipe x Remove the Suppressor NOTE Loosen the rear brake rod adjuster nut so that the brake pedal can be BATTERY REMOVAL depressed to allow the exhaust pipe to be removed x ignition switch is in OFF position xx Disconnect the Oxygen sensor loosenand FOR BULLET ELECTRA E5 G5 remove from Exhaust pipe Remove side panel LH x Remove the battery cover Remove the fuse carrier plate mounting Screws 2 nos FOR BULLET CLASSIC EFI C5 x Remove battery cover on LH side x Remove the battery holding straps pull the battery out amp remove terminals CAUTION Always remove earth wire terminal first 05 7 REMOVAL OF E START MOTOR Remove 4 screws of the starter drive housing and tap gently to free the housing x Remove cover screw x Gently lift the motor and remove the motor along with the housing Remove the 2 dowels for the housing drive x Remove the terminal nut take out the terminal wire lead x Remove the 2 mounting allen screws REMOVAL OF DRIVE CHAIN Rotate the rear wheel to bring the chain lock to a convenient position and remove the chain lock x Lift the motor upwards and pull out of the housing in the front x Remove the chain link and the drive chain REMOVAL OF SIDE
17. x Torque wrench to tighten the nyloc nut Assemble gear lever shaft bush on Clutch Torque 4 2 KG M xx Fixthe spring and bolt with O ring for the auto chain tensioner Torque 1 KG M 05 54 x Assemble Clutch operating shaft oil seal x Assemble oil filler plug with O ring x Assemble clutch operating shaft assembly on cover LH x Assemble the cover LH on Crank case LH x Assemble spring for clutch operating shaft and lockthe pin NOTE Ensure 2 Nos dowel pins are located properly Apply LOCKTITE 5699 RTV silicon liquid gasket x Locate 11 allen screws on cover LH and tighten Torque 1 KG M x Assemble clutch cable on Crank case Assemble lock type washer and nut cover LH and fix to clevis Torque 7 5 KG M Assemble Sleeve gear Spacer over sleeve X as shown in Fig x 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 05 56 x Assemble oil pump on Crank case RH and tighten with 4 allen screws Torque 0 35 to 0 6 KG M CAUTION Ensure O ring is located on the oil pump body outlet x Fix the woodruff key carefully on Crankshaft x Assemble Gear lever shaft assembly into RH Crank case window and then fix gear shaft spacer ASSEMBLING PROCEDURE OF AUTO DECOMPRESSOR x Locate the actuating pin in the Exha
18. Bi starter Manual Bi starter vent hole clogged plunger stuck in cold position due to extreme cold condition icing No pressure buildup in fuel main line Remedy Switch engine stop switch ON Retract side stand completely Check battery electrolyte level amp Sp gravity Recharge battery Replace side stand switch Check all fuses Assess cause of failure rectify amp replace fuse Check all sensor and wiring harness connections for proper connectivity Check battery electrolyte level amp Sp gravity Recharge battery Check cable connections for proper tightness Check resistance across relay Starter between blue amp white wire Replace relay starter if faulty Check for firm wire connections Check if motor is jammed Replace starter motor Check power relay connection or replace if found to be faulty Check roll over sensor coupler connection Check proper connectivity in wiring harness amp coupler continuity with voltmeter Check fuel pump relay resistance Replace relay if defective Check for proper connectivity in wiring harness amp continuity with voltmeter Check fuel pump resistance Repair electrical connections loose contact Replace pump if defective Hold throttle fully open Hold Manual Bi starter and start engine Release throttle as soon as engine starts Clean Throttle body to ensure vents are clean Check proper working of Bi starter plunger Check fuel pump for proper wor
19. DISC BRAKE FLUID LEVEL CHECK FRONT FORK A OIL LEVEL CHECK EVERY 6000 KMS out front fork from the vehicle Remove bolt cap x Check brake fluid is above the Min level in master cylinder x is below Min mark x Check oil level with a 5 mm dia rod x To up the fluid remove the master x height must be 370 to 380 mm cylinder top cover 2 screws and take out x Topup with API SG 10 W 30 if required cover plate amp diaphragm x brake Fluid DOT 3 or DOT 4 upto B OIL CHANGE level EVERY 12 000 KMS x Hemovethe fork ends from the vehicle CAUTION x Check as detailed in the Section 8 As the brake fluid is highly corrosive take care that it does not spill over other parts Itis suggested to wipe brake fluid immediately if there is any spill over in other parts using a soft cloth preferably a wet cloth For further details Ref page No 07 12 STEERING PLAY ADJUSTMENT EVERY 6 000 KMS x Keep a wooden plank under the stand Hockthefront end and feel the play at stem top end as shown in fig 03 17 If felt adjust as follows Loosen crown plate bolts as shown picture A Tighten stem lock nut as shown picture ve Check play Steering to be free with out any play the screws in reverse order STEERING BALL RACE LUBRICATION EVERY 12 000 KMS x Remove s
20. EFI E5 G5 REMOVAL OF SLEEVE x Remove allen screws to take out oil GEAR ASSEMBLY thrower plastic cap 05 33 Pull out kick starter sub assy as shown in Remove the Kick pinion gear Fig Remove the thrust washer from kick REMOVAL OF KICK STARTER SUB spindle ASSEMBLY x Remove circlip amp thrust washer x Remove the Kick pawl plunger and spring from kickstarter shaft x Remove thrust washer 05 34 VITAL PARTS USAGE DESCRIPTION BI 45 x 30 x 20 Crankcase RH Crankshaft bearing N 72 Roler Bearing 25x62x17 Crankcase LH Cranshatboaring 1_ Balbeamgeooe cs CrarkcasoLH MainStattbeaing 1 Needle Bearing SCE 228 C3 DU ws t Clutch Sprocket drum bearing 10 Ballbearing 6001 C3 11 Connecting rod big end Il GEARS SPROCKETS Nol DESCRIPTION NO OF TEETH PRMARvREDUCTON _ as LL s Primary drive sprocket 26 NRB 3x 21 8 Locating Pin Pivot cam plate s g rsmmrRSYSEM OTS i j om fd J UNIDIRECTIONAL FITTINGS LIST Deep groove ball bearing 6007 RSH C3 in Crankcase RH Rubber sealed facing FD sprocket side Gear rocker shaft bottom pivot bearing Smooth machined surface side facing upwards Main shaft 2nd Gear Selector fork groove side facing towards M S 4th Gear Special thrust
21. 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 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 BDC BDC stands for Bottom Dead Center It is the bottom most position to which the piston can travel in the cylinder barrel STROKE is a distance travelled by piston from TDC to BDC or Vice Versa CUBIC CAPACITY DISPLACEMENT It is a volume generated by piston when it travels from TDC to BDC It is measured as Cubic Centimeter CC It can be mathematically arrived at with the radious of the piston and the stroke of the engine when is the radius of the piston and f is the length of the stroke It is also known as Swept Volume or Displacement volume CLEARANCE VOLUME Itis the nominal volume of the space above the piston in the combustion chamber when piston is at the topmost position TDC BDC POSITIDH 02 2 TOTAL VOLUME It is the sum of the swept voume Displacement volume and Clearance volume Total Volume Swept volume Clerance volume COMPRESSION RATIO lt is a ratio between total volume in the engine to the clearance volume available at the end of compressi
22. FD sprocket if necessary bolt with washer only for Bulletin Electra EFI E5 G5 x Pull out Sleeve gear Spacer by using monkey gas plier as shown in Fig x Remove Kick starter return spring from kickshaft spindle only for Bullet Electra EFI x Remove 4 Nos Kicker Cover screws E5 G5 only for Bullet Electra E5 G5 05 20 DISMANTLING COVER LH SUB x may be necessary to tap the cover ASSEMBLY slightly to remove Remove the 11 allen screws holding the X cover LH Remove lock pin and spring from clutch operating shaft PU x Remove inspection plug along with O Remove clutch operating shaft assy from nng clutch cover Tap and remove the Clutch cover Remove Clutch operating shaft oil seal and 2 Nos of Dowels x Remove gear lever shaft bush and oil seal Use Special tool No ST 25591 4 Clutch centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch COMPONENTS DISMANTLING ON CRANKCASE LH REMOVAL OF CLUTCH ASSY x Remove clutch push pad ball bearing bearing retainer cup x Remove 17mm Hex bolt on the Engine sprocket Remove auto chain tensioner bottom pin bolt O ring and spring Unlock clip and press push rod to slacken duplex chain 05 22 x Remove Duplex chain along with Sprag DISMANTLING OF CLUTCH ASSEMBLY clutch and Clutch assembly x Remove 2 hex bolts at opposite locations
23. MANUFACTURE 2009 9 2010 A 2011 B PRODUCTION MONTH A JAN H AUG K SEP N DEC PRODUCTION SERIAL Nos The engine number is punched on the left hand side Crankcase It is the means of identification of the Engine and its production details After June 2010 Production U5 5 5 9 XXXXXX ENGINE FAMILY i ENGINE CAPACITY TYPE OF START TRANSMISSION FUEL FEED BLANK FOR FUTURE USE YEAR OF MANUFACTURE 2009 9 2010 A 2011 B PRODUCTION MONTH A JAN H AUG K SEP N DEC PRODUCTION SERIAL Nos 02 9 LIST SPECIAL TOOLS AND ITS APPLICATION ST 25128 2 Magneto Puller for TCI ST 25151 4 Chain case outer puller TCI 5 25594 4 Clutch spring assy Application Application To compress clutch springs while removing amp refitting Clutch plates 02 10 LIST SPECIAL TOOLS AND ITS APPLICATION 5 25591 4 Clutch centre nut Oil seal adopter Application Fitment of gear shaft oil seal on crank case LH cover ST 25118 4 Cylinder head nut tightening tool dep Application remove and tightening of cylinder head nut 02 11 LIST SPECIAL TOOLS AND ITS 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 Application Toremove Gear Rocker Shaft top pivot pin and Gear Gear box Pivot Pin Cam Plate pivot
24. Mechanical Efficiency is the ratio between Brake horsepower and Indicated horse power Brake horsepower BHP Indicated Horse power TORQUE Torque is a twisting or turning force or effort It is the product of a distance and force in circular motion In the picture shown the torque applied is the product of distance distance between the center of the bolt and point where force is acting and the amount of force applied With the same force if the distance is increased the torque will also increase and if distance is reduced torque applied will also be reduced CONVERSION 1kg m 7 23 Ib ft 9 81 N m 1lb ft 0 138 Kg m 1 356 N m 1 N m 0 102 Kg m 0 737 Ib ft 02 4 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 If spark occurs earlier than specified ignition timing it is called Advance timing If spark occurs after the specified ignition timing itis called Retard timing IDLING SPEED is the speed of the crankshaft i e RPM of the engine when the throttle is in closed pisition GEAR RATIO The relative rotation between Driven Gear and Driving Gear is known as the Gear Ratio It is determined by number of teeth on the respective gears Gear Ratio No of teeth of Driven Gear No of teeth of Driving Gear
25. STAND x Disconnect the coupler of the side stand Engine cut off switch from the wiring harness x Remove the mounting nuts and remove the side stand REMOVAL OF REAR BRAKE SWITCH x Disconnect the brake switch spring from brake lever Disconnect the rear brake switch coupler from the wiring harness Slacken the nyloc nuts amp remove the brake light switch x Remove the piece mudguard bracket bolt along with 2 plain washers amp 1 star washer 05 9 Engine oil Drain CYLINDER HEAD ASSEMBLY x Remove the 4 allen screws along with rubber seals from Inlet and exhaust rocker covers It is best to drain the engine oil in warm condition Remove the 2 Flanged hex bolts Remove the drain cap with O ring x Remove the Inlet amp Exhaust Rocker cover dowel amp rubber gasket x Remove suction filter x Remove the magnetic drain plug with washer x Remove the inlet and exhaust rocker bearing with dowel and rocker arm x Remove inlet and exhaust pushrods x Remove the Cylinder head assy x Remove the multi layer steel MLS head x Remove the Spark plug gasket REMOVAL OF VALVES x Remove the 6 flanged hex nuts securing the cylinder head x Remove the Inlet amp Exhaust valves by using special tool No ST25123 1 Valve spring compressor as shown x Remove the Inlet Valve spring retainer split CYLINDER BARREL SUB ASSEMBLY collar and Spring X
26. and the castle nut from the rear hub spindle x liltthe vehicle to the right and free it form the sprocket lugs and slid it outwards X Remove the cush drives 4 Nos fromthe BRAKE DRUM ASSEMBLY hub x Remove drive chain from the sprocket Disconnect the brake operating rod from the cam lever CAUTION The cush drives are locked to the hub with rubber lugs Pull out the cush rubbers Remove the cover plate anchor nut from gently to avoid damage to the lugs the chain stay yx Remove dust seals x Remove the nut from hub spindle short x Drive out the bearings 2 Nos and take out the spacer 07 18 x Remove sprocket drum assy from the swing arm along with brake shoes and cover plate carefully Disconnect chain if not removed earlier x Take out sprocket drum brake shoes and spacer pd Remove the oil seal x Drive out the bearing from the hub sprocket CLEANING x Clean all parts except brake shoes cush drive and tyre with solvent and dry with compressed air x Clean the brake shoe amp cush drive with dry cloth cloth wet with solvent INSPECTION v Visually check all parts for breaks cracks dents scoring glazing or any other damage x Check bearings for free rotation axial play and radial clearance Replace if necessary v Lubricate bearing by MP grease and then assemble into sprocket drum by using bearing punch as shown in Fig x
27. care to ensure fuel does not spill Disconnect fuel pump module and low fuel sensor couplers EU a 1 CAUTION Keep cloth on the front end of the fuel tank below the handle bar clamp to avoid damage to the fuel tank while removing 05 3 SEAT REMOVAL BULLET ELECTRA EFI E5 G5 x Remove 4 nos flange bolts from both sides of the seats x Remove the pillion holder lift from the rear end and pull out the seat BULLET CLASSIC EFI C5 x Remove the mounting bolts as shown and remove the seat Remove 2 screws at the bottom of the LH switch module and separate the module from the handle bar x Remove cable from the straps in the frame CLUTCH CABLE REMOVAL REMOVAL OF THROTTLE x Slacken the adjuster at the clutch cover end BODY and disconnect the cable from the lever Loosen the throttle body flange amp bellow x Take out clutch cable from the cover clip Lad x Remove the throttle body by pushing x Remove the clutch cable from the clutch towards Air Filter box lever at handle bar end REMOVAL OF SILENCER AND REMOVAL OF THROTTLE EXHAUST PIPE CABLE x the adjusters at the throttle body end for both cables Remove the centre silencer bracket mounting screw with plain washer Remove the rear mounting at the pillion Remove the flange nut 2 nos from cylinder foot rest end C5
28. cylinder bore for any damages scoring marks etc Measure the inner diameter Service limit 12 76 mm Check the piston outer surface for any damages scoring marks etc Measure the out diameter Service Limit 12 64 mm CLEANING Clean the hydraulic disc brake parts only with clean and new brake fluid as using any other cleaning material can damage the parts and make the brakes ineffective CAUTION Do not clean the hydraulic disc brake parts with any other cleaning material solvents or water USE NEW BRAKE FLUID ONLY REASSEMBLY OF MASTER CYLINDER x Assemble the conical spring compression on the piston Smear the piston seals and cylinder bore with fresh brake fluid x Assemble the piston sub assembly into the master cylinder by gently pushing it into the bore 07 10 x Locate the circlip into the groove of the yx Assemble the Brake Switch master cylinder Ensure the circlip is seated correctly inside the groove x Fix the master cylinder assembly on the handle bar with the UP mark facing upwards x Tighten the master cylinder assy clamp top bolt first and then tighten the bottom bolt Torque 0 90 KG M CAUTION Do not use tools with sharp ends x Assemble the brake lever the front x Silicon grease on the Lever pivot bracket and tighten with the bolt first and hole and on the Piston surface then tighten the lock nut x Torque values Bolt lever 0 6 KG M
29. engine hose air filter to throttle body Tighten replace the hose Poor Compression Check and correct 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 Fill up the tank Clean vent hole Fuel level very low in tank Vent hole clogged in fuel tank cap Fuel Related Fuel Line Clogged Fuel hose cracked resulting in fuel leaking out and not getting supplied to injector Clean the fuel line Check and replace Fuel pump pressure insufficient fuel pump Check fuel pump coupler not working connection Check fuel pump relay for proper working Fuel Injector partially blocked Replace fuel injector Loose damaged throttle body to engine Check and correct hose air filter to throttle body Weak Battery Electrical connections Loose Charge Replace the battery Check amp Correct Incorrect Electrode gap Adjust the gap Electricals Related Spark plug electrode dirty fouled Clean park plug amp Reset gap Wrong specification spark plug Fit the correct Spark Plug Loose HT connections damaged HT lead Fix connections firmly Replace Lead Complaint Engine Misfires amp cuts off 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 Related Fuel adulterated Refill with good fuel Fill up the tank
30. inlet and exhaust rocker bearing with dowel and tighten allen screws x Assemble the Inlet amp Exhaust Rocker covers dowels amp rubber gasket then tighten rocker cover bolt with rubber washer Torque 1 KG M x Assemble tappet door by applying LOCKTITE 5699 silicon gasket on Crank case RH then tighten screws Torque 0 60 KG M Tighten the swing arm nut to specified torque 05 69 lighten the front engine mounting stud nuts Assemble throttle body and connect the to the specified torque throttle cables Fil recommended the engine oil to the correct level and tighten filler cap with O x Tighten the rear engine stud nuts to the ring specified torque Assemble the exhaust pipe and silencer in the reverse order of disassembly Fix the oxygen sensor amp connect to wiring harness Tighten the centre stand and foot rest nuts to the specified torque Fix the clutch cable amp the manual Bi Starter to the handle bar levers Connect all the electrical couplers Connect the brake light switch to the pedal Connect the fuel hose to the pump Assemble the battery amp connect the terminals Check for proper working of all electrical equipments Fix the dual seat Start machine and run in idle RPM for few minutes Switch off amp check oil level add oil to bring level below level Adjust rear brake and chain terminals Align the
31. of a malfunction in EMS Do s amp Dont s Trouble shooting SECTION SEVEN 07 WHEELS amp BRAKES Torque Specification Chassis Front wheel removal amp reassembly Disc brake General instruction Master Cylinder amp Caliper overhauling Bleeding procedure Disc inspection Rear wheel removal amp reassembly Rear Brake removal amp reassembly 01 3 SECTION EIGHT 08 SUSPENSION AND STEERING Front fork working principle Front fork removal amp reassembly Steering stem removal amp reassembly Gas filled shock absorber Working principle Removal and assembly Adjustment of shock absorber Recharging of shock absorber Swing Arm Removal Bush lubrication replacement Reassembly Centre Stand Removal amp Reassembly SECTION NINE 9 ELECTRICALS Electrical symbols Battery Precautions Charging Maintenance Spark plug maintenance amp Inspecton Checking procedure of electrical components Starter coil Pulsar coil Ignition coil Suppressor Cap Battery Horn Relay starter Starter motor Flasher RR Unit TPS Unit Electrical parts Inspection Clutch switch Starter switch Switch modules LH amp RH Do s and Dont s Wiring Diagrams Ignition circuit Starter and charging Complete Wiring diagram Trouble shooting SECTION TEN 10 TROUBLE SHOOTING SAFETY DEFINITIONS Important aspects to be noted are given as follows in the manual NOTE Prov
32. off Start the engine only after this happens 5 DO NOT rev the engine fully immediately after starting OR just before shutting off the engine 6 NOT remove the fuel hose high pressure from the fuel pump to fuel injector when engine is running OR with the ignition switch ON Fuel flows at a very high pressure during these times 7 DONOT use a booster or high voltage charging unit instead of a battery Use only a good correctly charged battery to start OR check the motorcycle 8 DO NOT use high pressure water jet to clean the ECU Throttle Body any of the sensors Keep them well protected while washing the vehicle 06 12 3 MIL does not glow when ignition key switched ON MIL glows Continuously TROUBLE SHOOTING Possible Cause Engine stop switch is in OFF position Side stand is ON Battery discharged Side stand switch faulty Fuse blown Sensor couplers wires loose contact MIL Glows amp Switches OFF but vehicle does not start E Start related Ignition Related Fuel Related Battery discharged Starter motor cables loose connection Relay starter not working Starter motor does not rotate Ignition coil power relay defective loose connections Roll over sensor not connected loose connection Fuel pump relay does not work Fuel pump clogged internal short Fuel air mixture too rich due to extreme cold weather amp repeated cranking without using Manual
33. plate butterfly valve is use for regulating the airflow The throttle body also has a throttle position sensor TPS a manifold pressure sensor MAP anda manual Bi Starter 06 6 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 The ignition timing and fuel injection timing and potentially other parameters are altered depending upon the position of the throttle and also depending on the rate of change of the position The ECU uses the throttle valve position to know The mode in which the engine is operating i e idle part throttle wide open throttle etc Emission controls at wide open Throttle WOT Air fuel ratio correction Power increase correction wow Fuel cutoff control Manifold Pressure Sensor MAP The MAP provides instantaneous manifold pressure information to the ECU This is necessary to calculate air density and determine the engine s air mass flow rate which in turn is used to calculate the appropriate fuel flow to the engine through the injector Manual BI Starter Located in the throttl
34. plunger with respect to the body As cam further rotates the tappets returns to its Original position At this time the plunger spring provides the force to maintain zero back lash in the valve train mechanism and forces the plunger back to its original position This allows engine oil to once again fill the high pressure chamber so that the cycle can be repeated during the next cam rotation The overhead oil supply is accurately metered from the low pressure chamber which is at engine oil pressure by using a flat metal disk metering valve C in Figure which wobbles against a cylindrical radius curved surface on the bottom of the push rod seat D in Figure Oil flows up through the hole in the push rod seat to lubricate the overhead valve train components oil flow path B in Figure The metering valve moves sufficiently to keep the push rod seat hole free and unclogged When the engine is switched off the valve seats on the shoulder of the plunger to minimize drain back of oil If the engine structure or valve train expands or contracts with changes in engine temperature or other differentials the hydraulic tappets will automatically adjust its own internal length to compensate for these changes PRECAUTIONARY MEASURES The hydraulic tappets have minute holes for the oil to circulate and to also act at the hydraulic media hence oil contamination must be at the minumum The oil and the filters in the engine mu
35. tap Cylinder barrel and remove along with 2 dowel pins NOTE Ensure piston is at TDC Remove gudgeon pin and piston NOTE Similarly follow the same process to remove Exhaust Valve NOTE Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel as x Remove Inlet and Exhaust Valve stem seal shown from valve guides Remove gudgeon pin and piston NOTE Always replace valve stem seal in case of removal of valve from Cylinder head 05 12 NOTE Carefully remove the piston rings from x Remove oil filter cover bolts the piston without deforming Remove Cylinder barrel bottom Gasket x Remove oil filter cap gasket O ring amp Spring x Use Special tool No ST 25592 4 to hold connecting rod as shown Fig CAUTION Care must be taken while removing cover due to spring force REMOVAL OF COVER RH SUB ASSEMBLY gt x Remove kickstarter lever only for Bullet Electra EFI E5 G5 x Remove the 3 O rings Oil filter element spring cap washer amp Oil filter element x Remove the 11 allen screws securing X cover RH Gently tap amp pull out the cover evenly RH cover gasket amp 2 dowels x 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 CAUTION Tap only at the places sh
36. the output devices by giving pulses to the respective devices It has two memories Flash Memory and E PROM Flash memory is an exclusive recording unit for controlling program and setting data It collects different inputs from various sensors and calculates optimised values and gives outputs to the respective controlling devices E PROM is an abbreviation for Electronically Erasable Programmable Read Only Memory This is an exclusive recording unit for breakdown information history preservation The main advantage is the system is nonvolatile and stores the data even when the electricity is off While in operation the other breakdown information gets recorded automatically ECU PIN CONFIGURA TION IB Specification Operating Voltage 8 16 V Sensor Supply Voltage 5 V Operating temperature 10 C to 60 C Storage Temperature 20 C to 80 C ECU INTERNAL DIAGRAM 06 3 FUNCTIONS OF COMPONENTS FUEL INJECTOR FRESSURISED FUEL Exploded view of fuel injector Assembled between throttle body and cylinder head Specification Operating Voltage 10 14 V Operating temperature 30 C to 120 C Fuel Injection pressure 294 kpa 2 9 bar Solenoid Operating Resistance 10 3 x 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 The injection system used is a
37. 3 New Max 20 00 23 95 New Max Service Limit 19 97 23 90 Service Limit Lay shaft Outer diameter Selector fork inner diameter Location X Y New Min 17 99 23 95 TO New Max 18 00 23 97 10 03 Cam plate inner diameter Selector fork lug thikness Daf 03 5 Lay shaft 1st gear inner diameter Lay shaft 2nd gear inner diameter Main shaft 3rd amp 4th gear inner diameter Pivot cam plate outside diameter Clutch spring Length 90 Friction plate with insert thickness 03 6 Clutch steel plate Distortion 000 Duplex Chain Length across 21 pins Throttle cable free play Drive chain slackness New Min Service Limit 03 7 Sprocket REPLACE Sharp bend broken teeth Drive chain length across 21 pins Brake drum rear Internal dia Wheel rim Face out Run out Axle shaft run out 03 8 Main tube run out Front fork assembly spring length Caliper Piston Outer Diameter New Min Service Limit Master Cylinder piston OD 03 9 Tyre tread Depth 0 03 10 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
38. AM GEAR INLET 21 HEX SOCKET PAN HEAD SCREW 5 X12 22 OILSEAL KICK STARTER 23 COVER KICK START SHAFT 24 X OILSEAL 25 DISTANCE PIECE 04 13 CRANK CASE LH INSIDE VIEW STAINS 20 3 Rudi RS SW m a WM 4 a y Nat 04 14 O N O Q N 4 N O CRANK CASE LH DESCRIPTION CRANK CASE LH CIRCLIP BALL BEARING 6305 25 X 62 X 17 BEARING SPACER ROLLER BEARING NU305 25 X 62 X 17 BALL BEARING 6006 RETAINER PLATE MAINSHAFT BEARING HEX SOCKET HD CAP SCREW M5 X 16 JACK SHAFT STUD M8 X 128 FLANGE NUT M8 NEEDLE BEARING WASHER THRUST STUD M6 X 133 04 15 rimam 2 2 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 19 NYLOCK NUT M6 X 1 GEAR 20 FLANGE BOLT M5 X 16 21 DRAIN CAP SUMP 22 O RING DRAIN CAP 23 SUCTION FILTER ASSY 24 STOP PLATE 25 SCREW 8 X 25 26 OIL THROWER 27 HEX SOCKET HEAD CAP SCREW M5 X 35 28 LOCATING PIN PIVOT 29 NEEDLE BEARING 30 WASHER THRUST 3 NEEDLE BEARING 4 SLEEVE GEAR 5 NEEDLE BEARING 6 HEX SOCKET HEAD CAP SCREW M6 X 12 7 BRACKET PIN HYDRAULIC TAPPET 8 NEEDLE ROLLER 9 BEARING 10 DOWEL HOLLOW 11 STUD M8 X 128 12 FLANGE NUT M8 13 BOLT PAWL 14 WASHER INSPECTION SCREW 15
39. BOTTOM ASSEMBLY GEAR LEVER SHAFT STOP PIN O RING HEX SOCKET HEAD CAP SCREW M5 X 40 KICK STARTER E5 amp G5 DESCRIPTION KICKSTARTER SHAFT SUB ASSEMBLY KICKSTART SHAFT SPRING PLUNGER PAWL WASHER THRUST KICKSTART GEAR ASSEMBLY KICKSTARTER GEAR 35T BUSH CIRCLIP SPRING HEX SCREW M6 CYLINDER HEAD BARREL PISTON amp CRANKSHAFT PISTON ASSY 04 28 CYLINDER HEAD BARREL PISTON amp CRANKSHAFT KEY No 1 DESCRIPTION CYLINDER HEAD SUB ASSY CYLINDER HEAD VALVE GUIDE VALVE SEATS CYLINDER HEAD ONLY MACHINED HEAD VALVE GUIDE VALVE SEAT INSERT EXHAUST VALVE SEAT INSERT INLET DOWEL 6mm SPARK PLUG M 10 UR5DC SPARK PLUG M 14 W5DC SEAT SPRING VALVE STEM SEAL VALVE SPRING VALVE INLET VALVE EXHAUST RETAINER SPRING SPLIT COLLAR PLUG ROCKER BEARING SET EXHAUST ROCKER ARM INLET HEX SOCKET HD CAP SCREW M6 X 55 ROCKER BEARING SET INLET KEY No 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 DESCRIPTION ROCKER ARM EXHAUST GASKET ROCKER COVER INLET ROCKER COVER INLET WASHER SEAL HEX HEAD SCREW ROCKER COVER GASKET ROCKER COVER EXHAUST ROCKER COVER EXHAUST CYL BARREL ASSY DOWEL PIN DOWEL PIN GASKET CYLINDER BARREL GASKET HEAD MLS PUSH ROD ASSY EXHAUST PUSH ROD ASSY INLET STUD EXHAUST DAMPER PAD CYLINDER HEAD LH DAMPER PAD CYLINDER HEAD RH DAMPER PAD TAPER BARREL DAMPER PAD STRAIGHT BARREL 04 29 DAMPER PAD
40. Check the spindle for bend as shown in Fig ASSEMBLY x Assemble in the reverse order of disassembly x While assembling replace the grease seals and split pin 07 19 SECTION EIGHT 08 SUSPENSION amp STEERING FRONT FORK WORKING PRINCIPLE FOR BULLET ELECTRA EFI E5 amp G5 vs FORK STROKE LENGTH 155 MM r gt FORK MOVEMENT IS CONTROLLED BY THE COMPRESSION SPRING AND HYDRAULIC DAMPING CHAMBER A THRU SPRING STUD HOLES CHAMBER A THRU ANNULAR SPACE BETWEEN SPRING STUD amp VALVE PORT THRU VALVE PORTS 8 HOLES THRU ANNULAR SPACE BETWEEN SPRING STUD amp VALVE PORT THRU SPRING STUD HOLES CHAMBER B CHAMBER C SLIGHT OIL FLOW THRU CHAMBER B CHAMBER C RM OIL FLOW DURING REBOUND STROKE FLOW DURING COMPRESSION STROKE OIL IN CHAMBER PRESSURISED CLOSING BOTH VALVES FLOWS INTO ONLY THRU ANNULAR SPACE LESS OIL PASSAGE AREA HENCE HEAVIER DAMPING MORE OIL PASSAGE AREA FROM CHAMBER W TO CHAMBER HENCE LIGHTER DAMPING AT EXTREME END OF COMPRESSION STROKE OIL COLLAR ENTERS INTO VALVE PORT THIS REDUCES THE PASSAGE AREA AN D CREATES HYDRAULIC CUSHION AT THE END OF REBOUNCE LONG TAPER AT THE SPRING STUD REDUCES THE ANNULAR SPACE GRADUALLY AND INCREASES THE DAMPING RESISTANCE FURTHER f TTD QUICKER EY REDUCED PITCH
41. E DATA SERVICE LIMITS OF COMPONENTS 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 Ring to groove clearance Comp Top rings Point of measurement Piston Piston to bore clearance Ring to groove clearance oil ring Piston ring end gap compression Piston Pin diameter k From top 1st 2nd New Min 0 20 0 35 ee New Max 0 35 0 50 19 997 Service Limit 0 70 0 85 19 982 Piston ring end gap Oil Ring Big end axial play Service Limit Service Limit Crank shaft Run out New Min New Min Service Limit Service Limit 03 2 Connecting rod bend a ow Valve guide bore Valve stem OD Inlet 6 965 New Max 6 980 Service Limit 6 955 Valve to guide inlet clearance Valve stem OD Exhaust 6 945 6 960 6 935 03 3 Valve to guide Exhaust Clearance sil Push rod run out 599000 Hydraulic Tappet OD 21 387 21 405 21 380 Hydraulic tappet to guide clearance F 03 4 Main shaft Outer diameter Selector fork shaft outer diameter New Min 19 99 23 9
42. EDURE Set the multimeter in voltage mode DCV 20 Connect the multimeter to Battery terminals and then check the voltage as shown in Fig Start and accelerate upto 3000 RPM and then check online voltage inbetween 12 2 to 13 5 voltage NOTE Repeat the test with head light ON and OFF condition If RR unit is defective will not fall above specified voltage 09 8 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 Press SS STARTER SWITCH Check the continuity between Red Blue wire and Blue white wire of Switch module RH coupler when switch is pressed MODE RED BLUE BLUE WHITE STARTER RELAY Give 12V DC supply to the starter relay coupler and check for the continuity between the two bolted terminals If continuity shows then component is OK STARTER MOTOR Connect DC supply ve to the motor terminal and ve to the body of the motor Direction of rotation Clockwise DO S AND DON TS DO S x Check battery for electrolyte level periodically and top up with distilled water only x For longer battery life de clutch before starting battery is weak below 10 V start with the kick starter and do not try to start with self starter x Always maintain corre
43. F GENUINE SPARE PARTS Use only genuine Royal Enfield spares whenever replacing parts Use of non genuine parts can seriously affect motorcycle performance and may result in costly rework vehicle down time and above all customer dissatisfaction NOTE Proper service and repair is important for the safe and reliable operation of all mechanical products The service procedures recommended and detailed in this manual will help to carry out correct repairs SAFETY Every care is taken to ensure that the information given in this manual is correct at the time of going to print However Royal Enfield does not assume responsibility for any damage loss or injury caused to the vehicle or to the person carrying out repairs due to errors or omissions in this manual IMPORTANT NOTICE All images shown are only for reference to explain and may not be exactly the same on the motorcycle Technical specifications are subject to change without prior notice Because of changes that may occur in the manufacturing process since this manual was printed it is possible some instructions or illustrations found within this manual may differ from those found on the vehicle However the technical information found within this manual is correct at the time when it was approved for printing Future modifications improvements etc will be communicated to our Authorised Distributors Importers as and when changes are done to the motorcycle 01 2 HOW TO USE YO
44. FRONT MUDGUARD STAYS TOP SCREWS MOUNTING C5 EN TewrenaTUne senson neo s pelsvios4 oxvaEN son 2 25 nurme THROTTLE FLANGE sro ex wee sanoe wr e 560525 HEX NUT WITH NYLOCK INSERT M16x1 5 FRONT WHEEL SPINDLE NUT 5 7 50 70 560546 HEX FLANGE BOLT 8 x 25 FRONT DISC MOUNTING BOLTS 3 70 5 7 BRAKE CALIPER MOUNTING BRAKE CALIPER MOUNTING BRAKET BOLTS 2 27 sosei exeeo sonew oso _ 07 2 FRONT WHEEL REMOVAL the axle gently to remove it out of the fork end and the wheel W h Y 3 L Place the vehicle 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 take out the wheel along with the speedo drive and the bush care to ensure the brake disc does not get damaged while removing the wheel or while storing the wheel x Place a 4 mm thick wooden or plastic wedge between the brake pads to avoid the pistons from coming out too far from the brake caliper if the front brake lever is depressed accidentally CAUTION Do not depr
45. ING COMPRESSION SLOWER REBOUNCE AND Low SHOCK I TRANSFER FORK MOVEMENT NORMAL 08 1 FRONT FORK WORKING PRINCIPLE FOR BULLET EFI CLASSIC C5 x FORK STROKE LENGTH 130 MM x FORK MOVEMENT IS CONTROLLED BY THE COMPRESSION SPRING AND HYDRAULIC DAMPING FORCE Bolt cap Copper washer amp allen bolt O ring Oil control collar Main tube Thorough oil hole Spacer Bottom tube Seal dust Orifices Fork oil seal amp circlip Piston ring One way check valve Washer spring seat Fork piston MAIN CHAMBEH CHAMBER ic i 14 lt 13 0 5 quer det uas 3 UPPER UPPER hk c gt CHAMBER m o CHAMBER n CHAMBER vic FI gt lt 12 IB eal on LOWER P CHAMBER LOWER CHAMBER 11 10 OIL FLOW DURING REBOUND STROKE E 1 D 14 QUICKER JREDUCED PITCHING E COMPRESSION le SLOWER REBOUNCE ano Low SHOCK TIME 55 ges Slp 08 2 FRONT FORK DIS ASSEMBLY Place motorcycle on centre stand Remove speedo cable front wheel and mudguard x Remove caliper mounting bolts and take out the caliper DISMANTLING PROCEDURE BULLET ELECTRA EFI E5 G5 x Remove the cap nut from the fork bottom tube and drain the oil x Gently tap the fork bottom tube downwards and remove the bottom tube Remove the oil control collar fr
46. LUTCH OPERATING LEVER LOCK PIN SPRING CLUTCH OPERATING MECH SPRING CLUTCH OP LEVER HEX SOCKET HEAD CAP SCREW M6 X 201 O RING PLUG OIL FILLER PLUG GEAR LEVER SLEEVE GEAR LEVER HEX SCREW M6 X 25 SEALING WASHER 6 x 10 IS 3175 CU HEX NUT M6 IS 1364 PART 3 8 ZN PL 04 23 GEAR TRAIN ASSEMBLY 04 24 KEY No Al A2 O a amp l OI wo N O GEAR TRAIN ASSEMBLY DESCRIPTION LAY SHAFT SUB ASSEMBLY MAIN SHAFT SUB ASSEMBLY MAIN SHAFT MAIN SHAFT 2ND GEAR WASHER THRUST MAIN SHAFT 4TH GEAR CIRCLIP MAIN SHAFT 3RD GEAR 4TH GEAR MAIN SHAFT 1ST GEAR7 LAY SHAFT WASHER THRUST LAY SHAFT 2ND GEAR LAY SHAFT HIGH GEAR LAY SHAFT 3RD amp 4TH GEARASSY WASHER THRUST ASSEMBLY LAYSHAFT 1ST GEAR LAYSHAFT 1st GEAR KEY No 16 17 18 19 20 21 23 24 25 26 DESCRIPTION BUSH SELECTOR FORK LH SELECTOR FORK CENTRE SELECTOR FORK RH SELECTOR FORK SHAFT CIRCLIP 10N CAM PLATE ASSEMBLY RATCHET PLATE RIVET CAM PLATE RATCHET PLATE ROLLER PIN 04 25 GEAR SHIFTING _ a y 9 o 70 KICK STARTER E5 amp G5 O oa A Oo CO co O oa A Cc N O GEAR SHIFTING DESCRIPTION SS ROCKER SHAFT ASSEMBLY PIN PIVOT STRIKER GEAR CHANGE SPRING SPRING GEAR CHANGE STRIKER SPACER PIVOT BEARING ROCKER SHAFT UPPER HEX SOCKET HEAD CAP SCREW M6 X 12 PIVOT BEARING ROCKER SHAFT
47. MAGNETIC PLUG ASSEMBLY 16 SPRING 17 PAWL 04 17 ENGINE COVER RH 04 18 KEY No N O A MP N N 3 BRS e 6 S 5 G G ENGINE COVER RH DESCRIPTION UCE RH COVER SUB ASSEMPLY COVER RH PLUG RESTRICTOR LEE PLUG SEALING WASHER 12X15 5 OIL LEVEL WINDOW BOLT BREATHER JET CRANKSHAFT RH OIL SEAL CRANK FEED 24X10X7 CIRCLIP 24N WASHER INSPECTION SCREW INSPECTION SCREW IGNITION TIMING O RING OIL FILLER CAP NYLON ELEMENT OIL FILTER SPRING CAP WASHER SPRING O RING O RING FILTER CAP GASKET CAP OIL FILTER CAP OIL FILTER HEX FLANGE BOLT M5x16 GASKET COVER PLATE COVER PLATE BREATHER CHAMBER KEY No 26 27 28 29 31 32 37 39 41 42 amp 47 49 DESCRIPTION HEX SCREW M5X12 STATOR amp PULSOR COILASSY THREE PHASE PULSOR COIL FIXING SCREW ALLEN SCREW M6X30 HEX SOCKET HEAD CAP SCREW M6X85 HEX SOCKET HEAD CAP SCREW 6 100 HEX SOCKET HEAD CAP SCREW 6 80 HEX SOCKET HEAD CAP SCREW M6X60 HEX SOCKET HEAD CAP SCREW 6 40 GASKET COVER RH OIL SEAL KICK SHAFT KICK START CRANKASSY BOSS KICK START CRANK SPRING BALL DIA 6 35 LEVER KICK START CRANK SLEEVE KICK START LEVER WASHER CIRCLIP 10 HEX BOLT M8X40 HEX NUT M8 SEALING WASHER 6 x 10 IS 3175 CU BREATHER PIPE FLYWHEEL MAGNETO 3 PHASE 04 19 CRANK CASE LH COVER SIDE 04 20 KEY No
48. Natural air flow Engine oil tank capacity Engine oil grade TRANSMISSION Wet multiplate Primary drive 3 8 Duplex chain amp sprocket 2 15 1 5 Speed Constant Mesh Primary ratio Overall Ratio 3 063 1 2 013 1 1 522 1 1 212 1 Secondary drive 5 8 Chain amp Sprocket 2 235 1 101 Pitch 2 11 1 102 Pitch Secondary ratio Drive Chain links CHASSIS BULLET ELECTRA EFI E5 BULLET EFI G5 BULLET CLASSIC EFI C5 Tubular Front Suspension Telescopic hydraulic damping Stroke 130 mm Rear Suspension Swing arm with gas shock absorbers Fork oil capacity 265 cc 2 5 cc each leg Front fork oil SAE 10W 30 Front Brake Hydraulic Hand operated 280 mm dia ventilated disc Rear Brake Mechanical Foot operated 153 mm internal expanding Brake Oil Capacity 60 ml Brake Oil Grade DOT 3 or DOT 4 Tyre size Front 90X90 19 51V 90X90 18 51V 3 25X19 Rear 100 90 19 57V 110 80 18 58V 3 5X90 TYRE PRESSURE Front 18 PSI 28 PSI 20 PSI 30 PSI In built 14 5 1 litres 2 75 litres Hear With Pillion Front Rear 2 Steering lock Fuel tank capacity Alternator 12V DC 12V 14 AH Mico WR7 DDC 4 0 7 to 0 8 mm 12V 60 55w Generation Spark plug gap TI TI rooms o om m 2 5 s lt 3 415 3 y 5 5 gt m 0 N BULLET EFI G5 C5 7 ws DIMENSIONS O o ba
49. Nut lever 0 6 KG M 07 11 x 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 x Tighten the banjo bolt firmly Torque 3 5 KG M x Connect the brake light Mh x Filthe brake fluid till MAX mark and bleed the system x Assemble the diaphragm plate and cover Tighten screws gently Torque 0 15 KG M x Assemble the rear view mirror x Loosen and remove the 2 mounting bolts holding the caliper to the fork and remove DISASSEMBLY OF WHEEL the caliper assembly CALIPER x Disconnect the brake Hose by removing the Banjo bolt and sealing washers 07 12 x Remove the brake pad tensioner spring plate x Remove the brake pads from the caliper assembly x Hold the caliper body with the pistons facing downwards x 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 x Remove mounting bracket from the Caliper assembly 07 13 CAUTION Do not use high pressure air or any pliers or sharp objects to remove the pistons as their working surface can get damaged Ensure the pistons do not fly out of the caliper body due to high air pressure Support the pistons Take care not to damage the sides of the piston as it cannot be reused in case it gets damaged Remove he d
50. POSITION DETAILS Number of damper pads per engine 15 INLET SIDE VIEW 570478 b Damper pad cylin der head LH Damper pad cylinder head RH EXHAUST SIDE VIEW a T i d l 1 a 5704790 570480 b at a i L am A Damper pad straight Barrel 570480 b Damper pad taper Barrel SECTION FIVE 05 TORQUE SPECIFICATIONS ENGINE DISMANTLING INSPECTION amp ASSEMBLY TORQUE SPECIFICATION ENGINE PART TORQUE VALUE r Kol DESCRIPTION LOCATION Kg M 570013 SCREW 5 X 16 RETAINER PLATE SUCTION FILTER MTG Sn 5 0016 HEX ER HD CAP SCREW M5 X 45 E START HOUSING COVER 3 570094 HEX SOCKETHD CAP SCREW 5 25 HD CAP SCREW M5 X 25 E ESTARTHOUSNGCOVER 00000 HOUSING COVER 570232 HEX SOCKET HD CAP SCREW M6 X 12 STOP PLATE PIVOT PIN COVER LH 1777 57 BRG LOWER 1 e 1 ry 5 5 570020 FLANGEBOLT BOLT CRANKCASESETASSY 0000002 CASE SET ASSY 2 250 em m www su sane io o s mos owes meroon Pr 77 ars r ia HEX HEXNUTMIBX126 00000000 M12 X 1 25 SIR r r RH EE 570463 HEX SOCKET HD CAP SCREW M6 X 60 E START MOTOR MOUNTING COVER RH 05 1 TORQUE SPECIFICATION ENGINE PART TORQUE VALUE DESC
51. RIPTION LOCATION 57021 5 BOLT PAWL 0000000 BOLT PAWL M6X1 PAWL M6 X 1 GEAR BOX INDEX SS ee 1 wow coeno erar see exsooreTH cnrscnewexse coenam oo om renmen _ 05 2 ENGINE DISMANTLING INSPECTION AND ASSEMBLY COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE MOUNTED ON THE FRAME Cylinder head assembly Cylinder barrel amp Piston Crank case Cover RH Crank case Cover LH Clutch assembly Inlet and Exhaust Cam assembly Oil pump Assembly he e Be ie Ye ENGINE SHOULD BE xx Remove the front and rear flange nuts REMOVED FROM THE FRAME washer at the front amp rear mounting of the FOR THE FOLLOWING J OBS fuel tank x Crank case repair replacement Crank shaft and main bearings replacement ET aby ve Roller Hydraulic Valve Lifter RHVL MEL 4 gt replacement x Transmission parts like Gears Mainshaft P Layshaft repair replacement a A X Kick Starter Gear Pawl Spring Plunger J replacement only for Bullet Electra EFI E5 G5 NOTE Before starting to dismantle engine crank gently amp bring piston to TDC DISMANTLING PROCEDURE x Disconnect fuel hose Take
52. SYSTEM amp SPRAG MECHANISM DETAILS B WORKING PRINCIPLE The sprag is located in the primary sprocket on the crankcase drive side This provides better rigidity ofthe sprag mechanism during initial cranking 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 04 6 AUTO CHAIN TENSIONER 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 The oneway rachet mechanism in the auto chain tensioner ensures that the plunger does not drop down due to the downward force of the chain tensioner pad It does not require any maintenance or service 04 7 ENGINE BREATHER SYSTEM TO AIRFILTER RETURN ROUTE Breather chamber to engine From Engine To Breather Chamber Cover WORKING PRINCIPLE The engine breather system is located on the RH cover of the crankcase Aconnecting 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
53. UR 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 The sections are subdivided into subjects and presented in the following order SECTION ONE INTRODUCTION The manual and its arrangements SECTION TWO 02 GENERAL Salient features of the Unit construction engine amp engine management system Four stroke cycle operation Basic terminology of automobiles Technical specifications Identification of Chassis No Engine List of special tools and its applications Control cables and wiring harness routing SECTION THREE 03 SERVICE DATA Service limits of components Periodical maintenance chart SECTION FOUR 04 ENGINE Lubrication system Roller hydraulic Valve lifter RHVL Auto decompressor Electric starter system amp sprag mechanism Auto Chain Tensioner Assembly Engine breather System Clutch System Inlet manifold amp Throttle body Blow up Charts SECTION FIVE 05 ENGINE DISMANTLING INSPECTION amp ASSEMBLY Torque Specification Engine Engine dismantling procedure Vital parts Description Unidirectional fittings list Engine assembling procedure SECTION SIX 06 ENGINE MANAGEMENT SYSTEM Functional Diagram Components description Function of components Identification
54. YDRAULIC kc Te E TOTAL CESCLITT Fac DER ARM ELE T HEHA AT TIER ATTY CPS Be iL FEED TG FLY He piii CMAR UIN eA HEX HE ARH OL SUME z D o ji S SHAFT FLY WHEEL UPPER CYLINDER LUBRICATION LOWER CYLINDER LUBRICATION INLET SYSTEMI EXHAUST SYSTEMI A ROCKER ARM A ROCKER ARM BEARING SET BEARING SET B PUSH ROD TIP B PUSH ROD TIP C VAVLE STEM TIP C VAVLE STEM TIP PISTON SKIRT SMALL END CYLINDER HEAD CONNECTING ROD I CHANNEL CYLINDER BARREL BIG END BEARING amp PIN CRANK CASE RH GALLERY JET CRANK SHAFT RH CRANK CASE RH COVER GALLERY OIL FILTER PAPER ELEMENT te OIL PUMP 4 OIL SUCTION FILTER IHYDRALIC VALVE LIFTER 4 INLET AND EXHAUST CRANK CASE ORIFICE JET CRANK SHAFT RH ENGINE OIL SUMP LUBRICATION SYSTEM ROCKER ELS ETT eir EET DECADES 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 T
55. anner while tightening the lock nut which prevent the rotation of the sleeve during tightening the lock nut x backlash is first adjusted between pinion to exhaust gear and then exhaust to inlet gear to get effective backlash adjustment tightening torque of M10 lock nut is x Loosen anchor nut 2 KG M This must be ensured x Oversize Cam Spindle For Spares 5 0040 0 1 mm Over Size Spindle 5 0044 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 After adjustment to the required backlash x Loosen the brake rod nut both the Inlet amp Exhaust lock nut in the spindle must be tightened to the specified torque x Ifmoreorless adjust as follows Initially clean then lubricate chain gt EP90 oil and rotate rear wheel Remove split pin and Hex castle nut on the RH side x the adjuster cam on right side till ee 1 ax x Esa sn E un y e j A 1 p NA 7 m F 7 LS d n p Y f c D t 3 25 to 30 mm chain slackness is achieved x Loosen Hex lock nut x Check a ensure the front and rear wheels are aligned If required to align move the adjuster on the LH side without distu
56. ating Angle 60 10 Operating Temperature 20 C to 85 C Assembled under the seat The Roll over sensor is also known as a bank angle sensor If the motorcycle is banking below 60 from the road surface OR in the event of an imminent falling over in a mishap this sensor signals the ECU which in turn will cut off the fuel supply to the injector and the ignition thus stalling the engine to prevent further damage that may be caused if the engine is still running with the throttle stuck wide open and the gears are engaged The Rollover Sensor is located under the seat on the vehicle mounting strip of the frame beside ECU 06 9 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 DOLTOOL Level 2 Test pin An open single pole connector is provided close to the UCE By inserting a piece of wire into this connector and grounding it to an earth the defective sensor can be identified by the following frequency of the MIL blinking MIL will glow continuous Engine will start but not perform to its potential MIL will glow continuous Engine will NOT Start but will crank I wiglow continuous LONG 6 SHORT 6 Crankshaft position circuit malfunctioning 06 10
57. 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 SCHEDULE _ Kms x100 0 5 3 6 9 12 15 18 21 24 27 Miles x 1000 OEA ORE ES 1 EnneO R JR R DE H Check level every 500 Kms or earlier as required Engine oil filter 3 Engine sump fiter c lt el fel ALAA 30 R Magnetic drain plug under gearbox on Crankcase De row IC 5 CCT AL ALA TATA R ALA AJR 6 HTrlead 7 Tt Fuel Pump Check for screw tightness in all services 9 Accelerator cable play CT AL AT AAT A A 10 Rubber hose Air filter to Throttle body 1 1 L t i R ili 11 Rubber hose Inlet manifold 1 1 1 I JR L L TT 12 Airfilterelement c c c c ci c n c 13 Inlet Exhaustvalve seating ss 14 Cylinder l L L L lb 15 Exhaustsystem l1 li li Rear brake pedal pivot 19 Battery Electroytelevel f Li rt t t iL i L i 20 Earth wire eyelet behind battery carrier il I 2h Susu Lubricate every 3000 Kms or earlier as required ema Iud y q 24 R
58. ct Engine oil level x Check for Engine backfire if it exist amp it will damage the sprag clutch amp gears Maintain correct ignition timing the starter switch until the engine starts x Service your bike only at authorized service stations DON TS Never overcharge the battery Never spray water with great force on starter motor RH tool box and other electrical parts x Donotcarry out any repairs on the Starter motor and relay starter or the sprag clutch mechanism 09 9 14 CONNECTORS ECU WITH 09 10 STARTING AND CHARGING CIRCUIT COMPLETE WIRING DIAGRAM s Css 2 doe na HIM u SuOLOSNNOO M 09 12 TROUBLE SHOOTING PROBLEMS PROBLEM CAUSES 1 E start motor not working Fuse blown If the battery voltage increases with RPM increase replace RR Unit Faulty relay starter Starter motor cables loose connection Starter motor failure Fuse blown when pilot lamp switched Rear harness cable routing fouling with ON the tyre Rear harness cable fouling with taillamp bracket Fuse blown when Head light high beam Check the Headlight wirin
59. drained through a small hole provided at the bottom of the breather chamber The emission passes through the deflector chamber and goes to the air filter housing and passes through the inlet manifold back into the cylinder head 04 8 CLUTCH 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 04 9 INLET MANIFOLD amp THROTTLE 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 It is the large brass coloured screw that is accessed from the top of the throttle body The clamps on the throttle body may be loosened and the throttle body rotated outwards from the top to access the screw without removing the fuel tank and to adjust the idle speed with the bike running Turn the screw CLOCKWISE in to DECREASE the idle speed Turn the screw ANTICLOCKWISE out to increase the idle speed Remember that this is an AIR BYPASS screw not a throttle stop screw Turning the screw about turn will result in an approximate 200 RPM change in the idle speed DO NOT adjust
60. e eneee ease Standard 0 9 1 1 Service Limit 1 5 mm Valve seat width is not within specification reface the valve seat CAUTION If a valve face is burnt or badly worn or if it contacts the seat unevenly replace the valve Inspect the valve seat face for x Damage face Replace the valve and reface the valve seat x Uneven seat width Bent or collapsed valve stem Replace the valve and reface the valve seat 2 UNEVEN SEAT WIDTH 1 DAMAGED FACE x Contact area is too high or too low Reface the valve seat 03 21 VALVE SEAT REFACING x Valve Seat cutters a grinder or equivalent valve seat refacing equipment are recommended to correct worn valve seat Ifthe contact area is too high on the valve the seat must be lowered using a 32 degree flat cutter CONTACT TOO HIGH OLD SEAT WIDTH 32 CONTACT TOO LOW OLD SEAT WIDTH x Ifthe contact area is too low on the valve the seat must be raised using a 60 degree inner cutter NOTE Reface the valve seat with a 45 degree cutter when a valve guide is replaced ROUGHNESS 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 OLD SEAT WIDTH Using 60 degree cutter remove the bottom 1 4 of the old seat OLD SEAT WIDTH
61. e x Assemble in the reverse of removal ADJUSTMENT OF SHOCK ABSORBERS x Adjust the Shock absorber using the special tool No ST 25244 4 as shown in Fig This adjustment may be done as per customer road condition requirement NOTE Ensure both side adjustment notch are in same position 08 7 RECHARGING OF SHOCK Remove the rear wheel sprocket ABSORBERS assembly 1 Remove the shock absorbers 2 x Remove the small screw with O Ring Remove the chain guard X Injectthe special purpose needle intothe x lt Remove the swing arm cap swing pivot 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 x X Fitthe small screw with O Ring NOTE The shock absorber needs recharging when the system pressure is less than 5 BAR x Remove the swing arm hex nyloc nut amp SWING ARM washer REMOVAL Remove the chain link and take out the chain Ww Disconnect the brake rod nut x Tap and pull out the swing arm flange hex bolt 08 8 x Using a mandrel drive out the plastic bush from either sides of the swing arm and remove the steel spacer CAUTION Do not remove plastic bush unless it is defective ASSEMBLY Press the new plastic bush into the swing arm tube BUSH SPACER Eu RN m
62. e body and operated manually through a lever on the handle bar LH When the lever is pulled down a cable pulls up the spring loaded piston in the throttle body Helps in providing additional air into the engine during cold start for better idling RPM till the engine operating temperature is attained 06 7 FUNCTIONS OF COMPONENTS ENGINE TEMPERATURE SENSOR Specification Operating temperature 30 C to 120 C Operating Voltage 5 0 5 V Resistance Value w r t Temperature 20 C 18 8 Kilo Ohms 40 C 1 136 Kilo Ohms 100 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 The ECU accordingly operates the injector to optimise the air fuel ratio The engine temperature sensor is located in the cylinder head underneath the inlet manifold and on the oil passage CRANK POSITION SENSOR Specification Output voltage 3 5 VAC Resisitance 200 20 Ohms Assembled on the engine RH cover The crank position sensor is an inductive pulse generator the crank sensor scans 23 short and 1 long protrusion on the alternator The long protrusion is located at 5 before top dead center and is used by the powertrain control module as a reference mark for the crankshaft position The crank position sensor sends an alternating voltage
63. e the bearing Cover motorcycle painted surfaces plastic inner races and the threads on the axle and rubber parts while bleeding a brake system Do not allow brake fluid to come in Position the speedo drive correctly such that contact with any parts of the motorcycle as the cable threads are parallel to the ground brake fluid has highly corrosive properties and the cable will have asmooth bend when 91 fixed on the speedo drive Always replace brake pads as a set only Fix the washer and tighten the nylock nut to Always replace banjo union washers O the specified torque rings diaphragm washers dust seals and Check the wheel for free rotation by spinning piston seals whenever the hydraulic disc it gently and tighten the pinch bolt on the brake system is overhauled Right side to the specified torque Always replace damaged parts like pistons Connect the speedo cable and check the fixing pin etc Do not attempt to repair as it speedo meter for proper working by rotating may render the disc brake to become the wheel ineffective DISC BRAKE DRAINING OLD BRAKE FLUID GENERAL INSTRUCTIONS x Remove the Master Cylinder top cover x Check the system for any fluid leaks at banjo screws union joints damaged brake hose etc Ensure the handle bar is positioned straight and the master cylinder in the handle bar is parallel to the ground whenever checking fluid level Clean master cylinder filler cap before removi
64. earbrakecams L t UT kL 25 Steering ball races t t 26 Spokes tightness fi 27 Wheelrimrunout Jif Ji 28 Te l i evapraiveEissinEqapmentnatertosese 11 11 Ln Dolan n ne A Adjust C Clean D De carbonise I Inspect L Lubricate R Replace Applicable only for Motorcycles sold in the state of California NOTE For maintenance after 30 000 Kms 18 750 miles please repeat the same frequency levels specified above 03 11 PERIODICAL MAINTENANCE AIR FILTER CLEANING x Blow compressed air from outside to BULLET ELECTRA EFI E5 G5 inside Check for cracks holes clogging etc Replace if defective Assemble in the reverse order of dismantling x Remove the 2 airfilter lid mounting screws and take out air filter lid MO SPARK PLUG CLEANING x Disconnect suppressor cap and remove spark plug using spark plug spanner Clean insulator tip and electrodes using a pointed scrapper or plug cleaner x Remove the 3 cover mounting screws amp take out cover BULLET ELECTRA CLASSIC EFI CS x Check and set electrode gap to 0 7 to 0 8 mm Refit the spark plug and connect the lead NOTE A serviceable spark plug produces thick light blue spark across the electrode If spark plug produces yellow red side sparks replace it with new Open filter box cover RH Remove centre
65. ess the front brake lever when the front wheel is removed FRONT WHEEL BEARINGS REMOVAL Remove the dust seals on either sides of the wheel hub Drive out bearings by tapping on the spacer Loosen and remove the axle nut and the using a suitable rod and remove the spacer washer after taking out the bearings REASSEMBLY x Fix the bearing on one side of the hub ensuring that it is seating squarely and fully into the hub spacer and fix the other bearing and fix new dust seals on either side of the hubs Locate the speedo drive on the hub so that the drive lugs of the drive are seated correctly 07 3 X Locate the bush on the left side of the wheel Whenever the disc brake system is Disc brake side overhauled ensure that the old fluid is Remove the wedge between the brake pads drained out completely and then fill with and position the wheel between the fork fresh brake fluid legs taking care to ensure the brake disc in In case the brake fluid is contaminated drain seated correctly between the brake pads in out completely refill with fresh fluid and the caliper bleed ve Fix the wheel axle from the right side fork Use only fresh brake fluid to clean rubber leg carefully ensuring that the holes int eh parts Do not use any petroleum based fork legs and the wheel assembly are cleaning solvents water or detergents etc aligned Do nto force the axle or tap heavily the axle as it will damag
66. et x Remove special thrust washer lay shaft Remove clutch ball bearing from crankcase from Crank case LH amp 2 Nos Dowel pins LH x Pulloutthe crank shaft from the crankcase RH Remove needle roller bearing for lay shaft from crankcase LH x Remove roller bearing NU 305 from Remove clutch bearing retainer plate crankcase LH holding screws and remove the retainer plate from crankcase LH 05 27 Remove spacer circlip crank shaft bearing xx Remove circlip and sleeve gear ball bearing 6305 from crankcase LH 6007 from crankcase RH x Remove lay shaft needle bearing from crankcase RH x Remove last circlip from crankcase LH x Remove nyloc nut machined washer x Remove crank shaft needle roller bearing pawl camplate return spring and bolt from crankcase RH pawl from crankcase RH 05 28 x Remove Tappet cover by dismantling 4 Remove the exhaust and inlet hydraulic Allen screws tappets carefully from Crankcase top side NOTE Remove Inlet tappet first and then the exhaust tappet CAUTION Store the tappets carefully amp right side up as detailed earlier GEAR TRAIN REMOVAL Remove the bolt copper washer cap pivot x Remove the Allen screw and the bracket pin and O ring above the cam plate pivot join hydraulic tappets x x Gently pull out the 2 needle roller pins holding the inlet and exhaust hydraulic tappets x out ca
67. g harness ON Relay starter not working 1 Check the coil resistance If you can hear the sound of relay actuation but starter motor does not rotate change the relay starter Battery discharging frequently Check the alternator o v should be 8 V to 10 V AC Q 1000rpm open circuit across any two of its wire yellow yellow If the voltage is less than this change the alternator Check for battery voltage increase with respect to increase in RPM Otherwise replace the RH unit If alternator is ok Battery cells may be weak 09 13 SECTION TEN 10 TROUBLE SHOOTING 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 Complaint Engine fails to start Ignition switch in OFF Position Switch ON ignition Stop switch in OFF Position Push stop switch to ON position Side stand is ON Switch faulty too Retract side stand much play in side stand replace switch correct side stand play Fuel is stale due to vehicle being in Clean petrol tank and storage for a long period carburetor and fill the tank with fresh petrol Fuel Starvation Fuel hose cracked resulting in fuel Check and replace leaking out and not getting supplied to injector No fuel Supply from Fuel pump Replace fuel pump Fuel pump pressure insufficient fuel Chec
68. he diaphragm and the top cover and tighten with the screws DISASSEMBLY OF MASTER CYLINDER x Remove the Master Cylinder top cover screws Remove the Master Cylinder top cover diaphragm plate amp diaphragm Place a clean tray or container below the calliper assembly to collect the old brake fluid Loosen and remove the banjo bolt with the washers from the Caliper assembly Drain out the entire brake fluid from the master cylinder and brake hose by depressing and releasing the brake lever Remove the calliper assembly fram the fork leg and drain out the brake fluid x the Rear view mirror RH x Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar xx Disconnect the Front brake switch wire and remove the switch from the master cylinder x Remove the boot and the Circlip from the master cylinder body x Disconnect the Banjo bolt and the remove the brake hose from the master cylinder end x Remove the conical spring Piston compression spring x Remove the brake lever pivot lock nut brake lever pivot and the brake lever 07 9 INSPECTION YX OMPENSATORY PORT m Check both the rubber seals on the plunger for wear cracked edges or any other damage Replace seals whenever the plunger is removed Check the master cylinder housing and piston for any scoring pitting due to corrosion or any other damages Check the master
69. he first branch goes to flywheel to lubricate crank shaft as well as barrel piston assembly The second branch goes to hydraulic tappet to maintain the oil pressure constantly The third branch goes to rocker assembly and drains down to RH cover chamber through the push rod tunnel LUBRICATION OIL Specification MOTUL 3000 4T PLUS 15W50 JASO MA SL GRADE ESTER Semi Synthetic Oil capacity 2 75 Initial oil filling through Oil filler Cap 2 56 through Crankcse LH Cover 0 25 Oil pump TROCHOID TYPE Trichoidal high flow oil pump delivers oil with a pressure of 4 5 Bar This provides good lubrication to all the moving parts and enhances the life of the moving parts in the engine 04 2 HYDRAULIC TAPPETS ROLLER HYD 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 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 The automatic adjustment is achieved with the aid of hydraulic pressure inside the hydraulic tappet BENEFITS OF HYDRAULIC TAPPET x Eliminates the need for manual and periodic push rod height adjustments x Compensatesfor clearances in the valve train mechanism due to wear of moving parts OR due to
70. heck 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 table Fill petrol on top of the valves Seepage of petrol past the valve seat indicates improper valve seating Check the free length of valve spring ASSEMBLY We Install the valve spring seats and new valve stem seals NOTE Please ensure cleaning of the cylinder head with solvent and blow thorough all oil passages with compressed air Lubricate each valve stem with fresh engine oil and fix the inlet and exhaust valve into the valve guides Assemble the valve spring retainer and split collars Compress the valve springs using special tool ST 25123 1 valve spring compressor and fix the split collar locks on the inlet valve x Similarly follow the same process to assemble the exhaust Valve as shown in Fig NOTE Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring VALVE LEAKAGE TEST gt x Pour solvent into exhaust port and check for valve seat leakage if any Similarly check for inlet valve seat leakage xx Assemble the Cylinder head assy on the Barrel Tighten the 6 flanged hex nuts diagonally and evenly x Assemble the spark plug 05 68 x Assemble inlet and exhaust pushrods Assemble the
71. hings before further assembly ASSEMBLY OF ENGINE BEARINGS CRANKCASE LH X Fixthe clutch bearing retainer plate with 2 Assemble Needle roller bearing for lay allen bolts Torque 0 60 KG M 6 NM shaft x Assemble clutch ball bearing 6006 X Insert 1stcirclip Crank case LH for main shaft 05 37 Assemble 6305 bearing after 1st CRANKCASE RH circlip Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig Assemble Needle bearing for lay shaft x 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 Insertcirclip and then assemble crankshaft RH side needle roller bearing into Crank case Assemble NU 305 big roller bearing after bearing spacer in LH Crank case for crankshaft x Assemble closed end needle bearing inside sleeve Gear Assemble open end needle bearing Check bearing seating position and for free rotation x Assemble bolt pawl Torque 2 0 KG M into Crank Case RH as shown in Fig Fix cam plate return spring pawl cam plate with machined washer and nyloc nut Torque 1 KG M NOTE Apply LOCKTITE 542 thread sealant before assembling bolt pawl Insert sleeve Gear into Crankcase RH Gear It is recommended to use arbor press x Assemble exhaust and inlet hydraulic tappets carefully in
72. ible tube of length 12 30 Cms firmly on the bleeder nipple and insert the other end into a glass or plastic container containing fresh brake fluid Ensure the tube end is fully immersed in the fluid This will prevent atmospheric air from getting sucked into the caliper unit during the bleeding process Fill the master cylinder with brake fluid from a sealed container till the MAX level 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 Depress the brake lever completely and release fully so as to allow the brake fluid to fill up in the brake hose and caliper 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 07 6 x x Loosen the bleeder screw turn to allow air bubbles in the brake system to escape out When the bleeder screw is loosened and the air escapes out along with the brake fluid through the bleeder nipple the brake lever willfurther depress Allow the lever to depress fully and hold DO NOT RELEASE THE LEVER Tighten the bleeder screw firmly and then only release the brake lever NOTE Check the fluid level in the master cylinder and top up if necessary till the MAX mark Repeat the process detailed above till the brake lever movement is minimal and locks in applied position
73. ides important information that will have to be adhered to while carrying out repairs CAUTION Indicates activities that are important to be noted Non adherance may result in breakage and or functional failures of the assembly SPECIAL TOOLS Contains details of the special tools and its usage These tools have been specially designed for a specific purpose 01 4 SECTION TWO 02 GENERAL SALIENT FEATURES OF THE UNIT CONSTRUCTION ENGINE amp ENGINE MANAGEMENT SYSTEM HIGH TORQUE ENGINE e IMPROVED ACCELERATION amp HIGH SPEED CRUISING ENHANCED POWER DELIVERY EXCELLENT COLD STARTING HYDRAULIC TAPPETS ABILITY AUTO DECOMPRESSOR ACCURATELY CONTROLLED AIR FUEL MIXTURE amp IGNITION TIMING AUTO CHAIN TENSIONER FOR BY THE ENGINE CONTROL UNIT PRIMARY CHAIN IMPROVED PERFORMANCE AND HIGH CAPACITY TRACHOIDAL OIL FUEL EFFICIENCY THRO FUEL PUMP FOR BETTER LUBRICATION INJECTION SYSTEM FOUR STROKE CYCLE OPERATION SUCTION COMPRESSION POWER EXHAUST STROKE STROKE STROKE STROKE niet Valve TDC to BDC BDC to TDC TDC to BDC BDC to TDC Gas Flow Air Petrol Air Petrol Air petrol mixture Exhaust gas mixture is mixture gets burns gas expands flows out drawn into compressed Piston is cylinder Few degrees before pushed down BTDC spark plug produces spark i x Ui 4 4 1 1 d QUU 1 i 18 atroke and sirake BASIC TERMINOLOGY OF AUTOMOBILES ENGINE The
74. ingle punch mark align with the single punch mark on the exhaust cam ECCENTRIC CAM SPINDLE ADJUSTMENT x center distance adjustment of gears is achieved by rotating the eccentric sleeve and locking it on the spindle by using M 10 lock nut once the desired backlash is X Specific Gravity Min 1 22 8 1 24 arrived x Ifless recharge the battery 3 TERMINAL CLEANING x Clean terminal with warm water and apply petroleum jelly x Incase of sulphation clean by zero base emary paper EVERY 30 000 KMS CYLINDER HEAD Remove carbon from the valves ports and combustion chamber by scrapping Take care not to cause any damage to the valve faces or valve seat inserts Scrape gently to avoid scoring the cylinder head For further details please Ref page No 09 3 03 20 x 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 CYLINDER HEAD AND VALVES VALVE SEAT INSPECTION Clean both Inlet Exhaust valves and thoroughly remove the carbon deposits Apply light coating of Prussian blue to the valve seats NOTE Ensure proper valve seat contact by taping the valve in the valve seat without rotating Remove the valve and inspect the width of each seat The seat contact should be within the specified width and even all around the circumference SS Se ae ea e
75. inion gear while pressing down the kick pawl and plunger ve Insert spring locking bolt with washer into Assemble striker spring on rocker shaft kick spring eyelet and rotate clockwise to assy lock Kick starter return spring on the Crank case and tighten Torque 1 KG M NOTE Ensure striker spring both ends are seated on striker lever rocker shaft x Assemble rocker shaft sub assy carefully X Apply LOCTITE 5699 RTV silicon liquid Into Crank case window after fixing the gasket then assemble kick shaft Cover dowel overthe Crank case RH along with with oil seal on Crank case RH by 4 bottom pivot Bearing screws Torque 0 6 KG M NOTE Ensure oil seal is replaced before fixing kick shaft cover 7 NOTE Ensure bottom pivot bearing smooth ASSEMBLING OF GEAR ROCKER machined surface are facing upwards SHAFT SUB ASSEMBLY Assemble rocker shaft upper pivot bearing with O ring with 2 bolts Torque 1 KG M Assemble gear change spring on rocker shaft assy Then assemble spacer inside the spring as shown in Fig 05 42 Assemble lower pivot bearing 2 allen bolts Torque 0 6 KG M NOTE Itis recommended to tighten the upper pivotbearing first and then the bottom pivot bearing to avoid gear shifting problems x Assemble rocker return spring stop pin along with O ring by using special tool No ST 25123 4 as shown in Fig NOTE Apply thread lock sealant before fixing
76. ith auto decompressor removing circlip Observe short boss of pump drive gear should face outwards DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR Remove mounting allen screw on flyweight sub assembly x Remove Cam gear Exhaust Auto decompressor sub x 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 05 17 x Remove the actuating pin in the Exhaust x Remove the Oil pump assembly with cam O ring x Remove the woodruff key CAUTION Ensure O ring must be located on the oil pump body outlet Remove Gear lever from engine LH cover side Remove 4 allen screws to remove Oil pump assy Remove Gear lever shaft with bush spacer shaft x Remove rocker shaft return spring 7 Remove the rocker shaft assembly by with O ring by using special No ST gently tilting and twisting out 25123 4 Extractor for 5 speed gear box pivot pin as shown in Fig x Straighten lock tab and Unlock the FD sprocket nut Remove the two bolts and remove the rocker shaft upper pivot bearing with O ring x Remove the two screws holding the lower pivot bearing 05 19 x Remove FD Sprocket gt x Remove kicker shaft cover with oil seal NOTE Use special tool No ST25 while Remove Kick starter return spring locking removing
77. k fuel pump coupler pump not working connection Check fuel pump relay for proper working Fuel Injector blocked Replace fuel injector MIL glowing continuously Check Sensor connections amp correct Electricals Related Voltage No Spark J Weak spark Side spark Cracked HT lead Replace H T lead 10 1 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 Ensure flyweight in exhaust cam open position gear assembly in free to operate Poor Crankin Valves Leaking due to poor seating burnt Check amp Correct 9 valves or seats Piston Rings Worn out Replace piston rings Worn out scored glazed cylinder barrel Replace cylinder barrel piston Piston rings stuck in piston grooves Clean check and refit replace piston rings Complaint Engine starts but switches OFF Idling RPM low Adjust the idle air bypass screw in the throttle body Fuel is stale due to vehicle being in Clean petrol tank and carburetor storage for a long period and fill the tank with fresh petrol Fuel adulterated Refill with good fuel Fuel level very low in tank Fill up the tank Vent hole clogged in fuel tank cap Clean vent hole Fuel Related Fuel Line Clogged Clean the fuel line Fuel hose cracked resulting in fuel leaking Check and replace out and not getting supplied to injector Fuel pump pressure in
78. king Correct fuel hose if kinked jammed leaking at joints Correct as necessary 06 13 TROUBLE SHOOTING Possible Cause Remedy Spark plug Fouled Spark plug cap shorting Replace spark plug Replace spark plug cap Ignition coil wire loose connection or broken Check for proper wire connection Replace damaged wire connections Check power relay resistance wire connections Replace if faulty Ignition related Faulty HT coil power relay Faulty H T coil Replace H T coil Check pulsar coil Magneto output connections Check Crank sensor its connections No output from Magneto Crank sensor loose connections faulty Vehicle Starts but Switches off Check Roll over sensor amp its connections Roll over Sensor Loose connections Injector holes clogged Replace injector Loose inlet manifold Leak in Check amp correct inlet manifold Loose connections or problem in manifold pressure sensor Stuck butterfly in throttle body broken throttle Cables Loose connections or problem in throttle position Sensor Check continuity and correct Check amp correct High fuel consumption Uneven Idling Poor Pick up Smoky Exhaust Engine runs badly Check continuity and correct Check amp correct Check amp correct Loose connections or problem in Lambda O sensor circuit Check amp correct Defective temperature sensor Poor Output from charging coils Check Output vo
79. led above when a charged battery remains unused for more than 3 weeks check the electrolyte for correct specific gravity top up if required with distilled water up to maximum mark and charge the battery DISTILLED WATER CAUTION Always connect the positive and negative terminals of battery into the positive and negative sockets provided in the constant current battery charger Always disconnect the Negative ve terminal first amp then the Positive ve When re connecting the battery to the vehicle after re charging first connect Positive ve terminal amp then the Negative ve terminal Keep all battery filler caps open while charging CHARGING procedure Switch on the mains ON See that the charger indicator light is glowing x Switch on the charger ON OFF switch Disconnect the battery from the charger when fully charged INDICATION OF FULL CHARGE x Free gassing from electrolyte for more than 90 minutes reading taken in intervals of 30 minutes each to read constantly 1 240 or more of specific gravity x Voltage 12 0 TO 13 2V 09 3 MAINTENANCE x Protect battery from direct sunlight heat rain and dust Check the electrolyte level and top up if necessary to the MAX mark with distilled water every week x Keep exhaust seal cap in place to avoid deterioration of dry charge properties New dry cha
80. lf due to electrical soarks and cause an explosion LOW FUEL SENSOR Specification Operating voltage 9V to 16V DC Fuel level in tank to switch ON 2 5 0 5 Litres Lamp load 12V 4W Max Tightening torque 12 14 N m Operating temperature 10 C to 85 C A low fuel sensor is provided so that an indication appears in the MIL if the fuel in the tank is less than three litres 0 7 US Gallon Specification Operating Voltage 12 V Bulb Rating 12V AW Assembled on the headlamp casing Malfunction or abnormalities in any of the EFI components sensors is indicated by MIL located on the right side on the headlamp casing When the ignition key is switched on the stop switch is in RUN position amp the side stand is retracted the MIL will glow for few seconds which indicates that the ECU is checking the vital functionality of the sensors In case of any fault in the system the MIL will remain ON continuously 06 5 FUNCTIONS OF COMPONENTS THROTTLE BODY MODULE Specification Operating Voltage 5 V Out Put Voltage 0 5V Throttle Angle 0 80 Throttle Resistance Maximum 5 K Throttle Out Put Voltage at Idling 0 6 0 2V Storage Temperature 20 C to 80 C Assembled between air filter and inlet manifold 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 Athrottle
81. ltage in magneto 10V 16v 1000rpm Poor charging by RR Unit Check RR unit amp Replace Weak battery cells Replace the battery Check wiring harness connections amp replace fuse Battery discharging frequently Charging circuit fuse Blown Low or weak electrolyte Cells weak Check battery amp correct Check battery amp replace Battery not Charging No output from RR Unit Poor connection RR unit failed No output from magneto burnt coils in magneto unit Check amp correct replace RR unit Check for loose connections 06 14 SECTION SEVEN 07 TORQUE SPECIFICATIONS CHASSIS WHEELS amp BRAKES TORQUE SPECIFICATION CHASSIS CR as _ T C C C U C U 1l reos nara sar ows rarae sron sr 56574 vaster Oyinder serons masier yinderResowor oas 16 gt 5 Fr tever pror eor Fr Brate tovert 1 12 5A T Replacing new ball races Tighten upto eee Kg M 70 80Nm loosen fully amp retighten to Kg M 70 80Nm loosen fully amp retighten to 5B During removal for greasing Tighten upto During removal for greasing Tighten upto 1 89 Kg M 18 20Nm loosen fully amp 1 89 Kg M 18 20Nm loosen fully amp retighten to retighten to 45863 FLANGE BOLT M8 X 70 Front Fork Pinch Bolts 580335 FLANGED HEX BOLT M10 X 85 FUEL TANK FRONT MOUNTING 10 a NM 145862 FLANGE X 350
82. m plate pivot pin with O ring x Remove special thrust washer Layshaft by using special tool No ST 25153 4 from Crank case RH Extractor shown below ve Remove LS 1st gear thrust washer x Check thatthe 4 rollers are in place in the from the Layshait cam plate correctly while removing to avoid damage to the pins or its location in the cam plate x Gently slide out the gear train assembly along with the cam plate Fork shaft Forks Layshaft double gear LS3 amp LS4 and main shaft with all gears x Remove selector fork sub assembly from main shaft amp lay shaft sliding gears to take out RH selector fork NOTE Turn cam plate to select 3rd gear position before removing for ease of removal reassembly 05 30 Remove centre selector fork from the DISMANTLING OF LAYSHAFT SUB selector shaft and then LH selector fork ASSEMBLY x Remove Lay shaft 1st gear and thrust washer x Remove circlip from the selector shaft if required x Remove Double gear LS 3rd and 4th gear LAYSHAFT SUB ASSEMBLY Remove the high gear 05 31 x Remove 2nd gear and thrust washer DISMANTLING OF MAINSHAFT SUB ASSEMBLY x Remove main shaft 1st gear Layshaft MAIN SHAFT SUB ASSEMBLY 05 32 x Remove circlip amp 1st thrust washer REMOVAL OF SLEEVE GEAR SUB ASSEMBLY x Remove open end needle bearing x Main shaft REMOVAL OF KICK STARTER ASSEMBLY Only for Bullet Electra
83. mounting nut Take out the air filter element Tap off the dirt ow 03 12 PERIODICAL MAINTENANCE ENGINE OIL OIL LEVEL CHECK Place the motorcycle on the centre stand Before checking the oil level startand 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 x level marks are provided on the Oil level window in Cover RH Max amp Min x If oil level is below the Min mark top up till the level in between Max and Min mark Do not overfill NOTE Oil capacity Min to Max mark is approx 350 Max Min OIL CHANGE Refer Periodical Maintenance chart page No 03 10 for frequency Keep vehicle on level ground the engine and warm up sufficiently so that the oil drains faster DRAINING PROCEDURE Keep a clean tray under the engine Remove the two Hex Flange Bolts M5 16 Sump drain Cap O ring and Suction filter Assy Remove the Magnetic Plug assy along with its washer St Nro TILT VEHIGLE RH Y After the oil drains out remove vehicle from centre stand and tilt the vehicle to both LH and RH sides 3 to 4 times to drain out maximum oil Quantity of oil that be drained in 2 35 Litres approximately Tighten the oil drain bolt with washer Assemble the cleaned suction filter element in
84. needle roller Bearing SCE 228 C3 in the clutch sprocket and locate the thrust washer x Assemble clutch friction plate over clutch hub and then clutch plain plate Similarly follow the same to sub assemble all the clutch plates CAUTION Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk slippage x Assemble wheel clutch on clutch hub nsertclutch sub assy into clutch sprocket after placing the thrust washer Assemble clutch springs 6 Nos on clutch sub assy then place clutch spring holder 05 52 x 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 x Assemble the 4 clutch holding bolts bolts and tighten diagonally and evenly NOTE Tighten bolts diagonally and evenly 5 threads each Torque 1 KG M x Remove the 2 long bolts and the special tool Fix the 2 hex bolts Assemble Duplex chain over Engine sprag clutch sprocket and Clutch assembly Mount on main shaft x Use Special tool No ST 25591 4 Clutch centre holding tool to lock Clutch sprocket and engine sprag clutch assy We Fix 17 mm hex head bolt with washer on sprag Clutch assy Torque 4 8 KG M X Fixthe washer andnylochex nut24mm 7 Assemble clutch bearing cup ball bearing over clutch assembly and tighten 6001 amp clutch push pad
85. ng x Use only DOT 3 or DOT 4 grade brake fluid from a sealed container Do not mix different types of brake fluid as they may not be compatible 07 4 x Remove the Master Cylinder top cover x Loosen the bleeder screw by 1 turn diaphragm plate amp diaphragm approximately Depress brake lever slowly and fully and release This will force the brake fluid out Remove the protective boot from the of the bleeder screw Repeat this process bleeder nipple on the calliper assembly till the brake fluid drains out completely from the master cylinder and the wheel calliper assembly OVERHAULING CALIPER AND MASTER CYLINDER x Place a clean tray or container below the calliper assembly to collect the old oil Loosen and remove the banjo bolt with the washers from the Caliper assembly Fixatransparent flexible tube of length 12 30 Cms firmly on the bleeder nipple and insert the other end into a glass or plastic container to collect the old brake fluid Drain out the entire brake fluid from the master cylinder and brake hose by depressing and releasing the brake lever 07 5 Remove calliper assembly from the fork leg and drain out the brake fluid x Reassemble the calliper and refit the banjo bolts after draining out the oil BLEEDING PROCEDURE NORMAL METHOD YX YX Ensure the bleeding screw and the brake hose banjo is fully tight Fix a transparent flex
86. of lead dioxide Pbo Positive active material Porous mass of spongy Lead Pb Negative active material Diluted sulphuric acid H SO Micro porous acid resistant electrical insulator between positive amp negative plates Polypropylene casing to house the plate group amp electrolyte To seal container the battery To facilitate filling of electrolyte and water topping up To vent gases through common manifold and exhaust nozzle To make connections to the electrical loads To connect the cells series internally To discharge the vent gases To protect the dry charged plates from oxidation 09 1 PRECAUTIONS x YX Wear rubber gloves while handling a battery Use only constant current battery charger of correct charging rate to charge batteries 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 Keep all the filler caps removed while charging the battery Use only distilled water to top up the level after the initial charging During charging the electrolyte temperature should not exceed 45 C if necessary discontinue the charging to cool the electrolyte Ensure that the battery is placed on a non metallic surface while charging Keep fire and spark away from battery charging area Never run the motorcycle without connecting the battery as it may lead premat
87. om the spring stud x Using special tool ST 25105 2 remove the valve port Take out spring stud and front fork spring DISMANTLING PROCEDURE BULLET CLASSIC EFI C5 x Remove the allen screw from the bottom tube and drain the oil x Gently tap the fork bottom tube downwards and remove the bottom tube 08 3 REMOVAL FORK SEALS Loosen the pinch bolt on fork crown bottom N x Remove the plug screw from the head lamp casing and using special tool ST 25108 3 unscrew and remove the main k i ry teo s j e 1 r L W 2 4 k d 96 Ws Ce tra x Remove ring clamp and dust cover Bullet Electra EFI E5 G5 x Remove the circlip from the bottom tube and take out the spacer and dust seal x Place special tool ST 25114 4 on bottom tube and lever out the oil seal along with spacer INSPECTION x Visually inspect all parts for damages cracks bends wear marks or any other damage x Check the main tube for any bend x Measure the spring length Inspect the other internal parts for any visual damage FRONT FORK ASSEMBLY xx Assemble the front fork in the reverse order of dis assembly Replace the oil seals and the O rings with new STEERING DISASSEMBLY x Remove the front fork assembly x Disconnect all wires and remove headlamp unit and trafficators Take out cover tube bush and washer x Remove head lamp a
88. on 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 Volumetric Efficiency Volume of air fuel mixture inhaled during suction stroke Swept volume HORSE POWER HP OR PS HP Horse Power PS PFERDESTARKE is German unit of power Horse Power is the ability of the engine to do a certain amount of work in a given time One Horse power is the power required for lifting a weight of 75 Kg through vertical distance of one meter in one second Conversion 1PS 20 986 HP 2 0 735 KW 1 HP 21 014 PS 0 744 KW 1KW z 1 360 PS 2 1 340 HP 02 3 stands for Indicated Horse Power Indicated t 7 Horse Power is the power actually developed dili z 1HP Horse inside the engine cylinder by combustion process Power Available after explosion It is utilised to drive the piston FHP FHP Frictional Losses FHP stands for Friction Horse Power It is the amount of horse power used or lost to overcome the friction between various engine components BHP 1 I BHP Horse Power Avaiable at Crankshaft BHP stands for Brake Horse Power Brake Horse Power is the amount of Power actually available at the crankshaft or output shaft It is calculated by using dynamometer BHP IHP FHP MECHANICAL EFFICIENCY
89. or any other damage 05 64 x 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 x Replace valve if the valve head is knife edged x Check the valve stem for run out Check inlet and exhaust valve stem for Weal Check the valve seat to valve head seating as below m g F L u W w Wk TUUS 05 65 x Make pencil marks on the seating area of x Incase if the pencil marks are not erased valve head as shown in Fig grind the valve to the seat as below Apply fine grinding paste on to the valve seating area x Assemble valves into the valve seat WARNING Do not allow the grinding paste to seep into the valve stem and valve guide x Using a suction valve grinder valve lapping stick rotate the valve back and forth several times x Liftand turn the valve by half and grind valve on its seat Using a suction valve grinder rotate the valve back and forth several times Remove the valve and check for pencil marks Repeat the process of valve lapping as explained several times for ensuring perfect valve seating Proper seating erases all the pencil marks x Clean the valve and valve seat thoroughly 05 66 VALVE SEAT INSPECTION ve x C
90. own to avoid damage to the RH cover x Remove Stator assembly by removing 3 mounting screws NOTE Remove the stator coupler from the wiring harness before removing RH Cover Place a plastic tray below the RH cover for collecting the oil that will drip while removing the cover 05 14 Remove circlip seal and jet crankshaft Remove Breather bolt and washer NOTE Oil seal recommended to replace at every 20 000 kms interval x Remove 6 Nos allen screws to remove breather chamber cover x Remove oil filler cap and O ring x Remove Ignition Timing check bolt and washer if not removed earlier 05 15 Remove the 2 oil seals from the Kick Shaft hole Electra EFI E5 G5 only INSIDE OIL SEAL LT E OUTSIDE OIL SEAL 7 COMPONENTS DISMANTLING ON CRANKCASE RH REMOVAL OF ROTOR ASSEMBLY gt x Loosen and remove magneto lock nut and plain washer x Ensure the connecting rod is locked properly with the special tool resting firmly and evenly on the crankcase top position xx Use Special tool No ST 25128 2 Magneto removing tool to remove rotor assembly Remove the allen screws 8 2 dowels from Cam steady plate NOTE Check the number of shims on inlet and exhaust cams It is important to reduce noise and axial play between the cam gear face and the cam steady plate 05 16 Remove oil pump plastic gear after x Exhaust cam w
91. pin Application To remove front drive sprocket FD sprocket removal tool from Sleeve Gear 02 12 LIST SPECIAL TOOLS AND ITS APPLICATION 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 ST25114 4 Extractor for Fork oil seal Application Removal of oil seal in front fork bottom tube 02 13 LIST SPECIAL TOOLS AND ITS 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 ST 25244 4 Adjuster Special Spanner Application To adjust gas filled shock absorber 02 14 CONTROL CABLES AND WIRING HARNESS ROUTING ALL CONTROL CABLES amp WIRING HARNESS ROUTING UNDER TANK RH VIEW 02 15 GENERAL VEHICLE INFORMATION HE E t k PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING 02 16 GENERAL VEHICLE INFORMATION FUSE CARRIERS HORN WIRE ROUTING ARRANGEMENT E5 amp G5 FUSE CARRIERS HANDLE BAR WIRES ROUTING ARRANGEMENT C5 02 17 GENERAL VEHICLE INFORMATION TAIL LAMP amp TRAFFICATOR ECU MOUNTING BULLET WIRES ROUTING ELECTRA EFI E5 amp G5 THROTTLE BODY MOUNTING ECU MOUNTING BULLET WITH CABLES CLASSIC EFI C5 02 18 SECTION THREE 03 SERVIC
92. play excess Cam plate pivot pin Oversize Cam plate ratchet face rubbing against the face of the pivot pin Replace pivot pin camplate Selector fork face rubbing against the cam plate face Change selector fork Camplate Burr in the cam plate track outer side of the cam plate Remove burr in the cam plate inner track and outer side Ratchet rivet protruding from cam plate Check and Replace Selector fork amp peg edges chipped off Check and Replace Selector fork shaft bent scoring marks in the shaft Check and Replace 10 Remedies Observation Causes Burrs in splined position of the shaft Check and Replace Improper position of the return spring Check and Replace Complaint Brakes Poor Check amp Correct Check amp Correct Check amp Correct Check amp Correct Improperly adjusted brakes Front brake Disc Warped Scored Brake linings worn Uneven wear Brake drum scored Uneven wear Complaint Vehicle Wobbles Check amp Correct Tighten Replace spokes Wheel rim runout Loose Broken spokes Tyres not fitted correctly Refit tyres correctly Wheels misaligned Ensure proper alignment Under inflated tyres Inflate to correct pressure Complaint Electricals Check amp Correct Check amp Correct Check amp Correct Check amp Correct Check amp Correct Check amp Correct Loose improper connection Bulb fused Fuse blown Bulbs do not light Switch defective
93. rature x Remove the spark plug amp connect compression gauge C Switch OFF Ignition and engine stop switch condition Holdthe throttle open fully and kick several times 5 to 6 times x Note down the reading and repeat the above process 3 times Take to average mean reading in 100 x 10 PSI which is the correct compression pressure Specified engine compression pressure STEP B Incase compression pressure is less than 80 PSI then refit spark plug amp start again to warmup the engine Hemove spark plug amp put few drops of engine oil into the combustion chamber Connect compression gauge amp repeat the procedure as explained in the step A If compression pressure does not increase then check for blown out cylinder head gasket improper torque of Rocker bearing bolts or cylinder head nuts valve seat damage leakage valvestem bend cylinder head warpage improper valve timing If compression pressure reading increases then check for Improper alignment of piston ring end gap position piston ring jamed in groove scoring seizure of cylinder barrel piston worn out piston rings worn out cylinder barrel NOTE In case compression pressure is more than 110 PSI then engine requires Decarbonisation of cylinder head piston combustion chamber 03 24 SECTION FOUR 04 LUBRICATION SYSTEM FEED T ROCKER BESRING DL FEED H
94. rbing the RH side chain adjuster up or down by a few notches to align the wheels NOTE The above procedure is to be adopted to achieve correct wheel alignment and to compensate for pin dimension tolerance on the swing arm 03 15 REAR SHOCK ABSORBERS ADJUSTMENT Therearshock 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 x 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 x The adjuster provided on the bottom of the spring has five notches x Tocarry out the adjustment proceed as follows BRAKE PEDAL PLAY ADJUSTMENT Using special tool place it on the slot PEDAL FREE PLAY 20 TO 30 MM provided on the adjuster x Turnin outthe adjuster nut for correct pedal play Turn the adjuster such that the adjuster moves up to increase the spring preload and vice versa to reduce the spring preload 03 16 CAUTION Adjust both left and right shock absorbers to the same notch Fill 265 ml of AP 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
95. rear wheel o o 05 70 SECTION SIX 06 ENGINE MANGEMENT SYSTEM ENGINE MANAGEMENT SYSTEM The Bullet Electra EFI amp G5 and Bullet Classic EFI C5 are fitted with an intelligent Engine Management System EMS It consists of an Electronic Control Unit ECU which constantly takes inputs like engine speed engine temperature throttle position manifold air pressure exhaust oxygen feed back etc from the respective sensors provided in the vehicle and determines both the ignition timing and the ideal amount of fuel to be injected to optimize the air fuel ratio The benefits of EMS x Wo Excellent cold starting ability Better fuel economy Low exhaust emission Good acceleration Sustained high speed cruising and driveability ENGINE MANAGEMENT SYSTEM FUNCTIONAL DIAGRAM THROTTLE MANIFOLD ENGINE ENGINE POSITION PRESSURE TEMP SPEED SENSOR SENSOR SENSOR SENSOR ELECTRONIC CONTROL UNIT ECU FUEL FUEL IGNITION ROLLOYER PUMP INJECTOR COIL SENSOR MODULE 06 1 COMPONENTS DESCRIPTION ELECTRONIC CONTROL UNIT ECU ALTERNATOR THROTTLE BODY ASSEMBLY TEMPERATURE SENSOR LAMBDA O2 SENSOR MALFUNCTION INDICATOR LAMP MIL FUNCTIONS COMPONENTS ELECTRONIC CONTROL UNIT ECU Located under dual seat Located in LH Electrical Box Bullet Electra EFI E5 G5 Bullet Classic EFI C5 The ECU consists of a microprocessor It controls
96. ree play 2 3 mm There are two adjuster provided one at the top near the throttle grip and the other on the throttle body Minor adjustments can be carried out at the top A ADJUSTMENT AT HANDLE BAR END Slide the rubber boot use 10 mm spanner to adjust cable outer and lock the nut Move the rubber boot over the lock nuts B ADJUSTMENT AT THROTTLE BODY END x Loosen the lock nuts on both the cables Adjust both cables unitform and tighten the lock nuts THROTTLE CABLE ASSY REPLACEMENT x X While replacing throttle cable following procedure is recommended A Connect throttle cable to Rotor throttle grip assembly B Connect cable to throttle body and ensure the recommended free play C Route and strap the cable properly BATTERY ELECTROLYTE LEVEL Electrolyte level can be seen through the casing x between max and min marks NOTE of maintenanace free battery following procedure not applicable 03 19 x If required top up with distilled water MSN CUM ECCENTRIC Ww Bring piston to TDC so that the key way in the Rotor assembly is at 12 Clock position Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear DISTILLED WATER SPECIFIC GRAVITY CHECKING x Check specific gravity SG with a hydrometer Similarly check position of the inlet cam s
97. rged batteries need initial charging duration of 8 to 10 hours Upto 3 months from the date of manufacturing x Beyond 3 months the batteries may need extended duration of initial charging subject to storage conditions x Charged batteries if kept idle should be boost charged once in 3 to 4 weeks Itis always a good practice to boost charge the batteries before fitment to ensure full CAUTION state of charge For topping use only distilled water x Check the terminals and cables for corrosion Apply petroleum jelly on x Keep the battery surface clean and dry terminals to prevent corrosion x Check specific gravity of electrolyte The float graduation in level with the electrolyte ve Never over charge the battery it damages in it is the specific gravity of the electrolyte the battery amp plates may buckle Remove the battery from the motorcycle and store it separately when the motorcycle is notin operation for more than one month 09 4 Specific Gravity Fully charged Requires Recharging x Check voltage with voltmeter Fully Discharged SPARK PLUG MAINTENANCE Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark is used for a long period the electrode gradually burns away and carbon builds up along the inside part Once in 3000 kms or earlier the plug should be removed for inspection cleaning and resetting the gap
98. s b Yellow 2 to yellow 3 0 8 to 1 5 ohms IGNITION COIL c Yellow 3 to yellow 1 0 8to 1 5 ohms x SPECIFICATION Resistance mode across a Between Brown to Red white 4 to 8 ohms b Between Brown to HT lead 12 5 to 16 Kilo Ohms CHECKING PROCEDUHE Set the multimeter in resistance mode Check the Resistance between a Brown to Red white Primary b Brown to HT lead Secondary 09 6 CAUTION HORN Brown or white red to core no connectivity ve SPECIFICATION SUPPRESSOR CAP M14 Continuity Mode Beep Sound yx SPECIFICATION Resistance Mode 4 5 to 6 K ohms RELAY STARTER x SPECIFICATION BATTERY Resistance 4 to 5 ohms SPECIFICATION CHECKING PROCEDURE Voltage mode 11 5 to 13 V Set the multimeter in resistance mode Check the Resistance between BATTERY WHEN CHARGING a Green white to white wire x SPECIFICATION Voltage mode 13 to 14 5 V with head light on 3000 RPM 09 7 STARTER MOTOR SPECIFICATION Resistance 0 3 to 0 5 ohms CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between motor terminal amp aluminium body IC FLASHER x CHECKING PROCEDURE Ensure Battery voltage gt 12 V all indicator bulbs are ok Then starts the vehicle and turn the indicator switch to LH or RH mode If indicators not functional replace it by a new IC Flasher CAUTION Never try to repair tamper IC Flasher UNIT CHECKING PROC
99. se r D gt rF gt m m o penromance NOTE 1 Values given above are for your guidelines only 2 Height EM 9 EN e 2 In view of continuous improvements specifications are likely to change without notice 02 8 IDENTIFICATION OF CHASSIS NO ENGINE CHASSIS NO VEHICLE IDENTIFICATION NO USA CANADA The VIN is a 17 digit number punched on the right side steering head tube and in the information plate riveted to the frame down tube Sample VIN ME3 XXX XX X X X XXXXXX Manufacturer Make and Class code x Decipherable information Capacity Horse power Check digit No Year of Manufacture Place of Manufacture Engine No VEHICLE IDENTIFICATION NO REST OF WORLD The VIN is a 17 digit number punched on the right side steering head tube and in the information plate riveted to the frame down tube Sample VIN XX XX X X X X XXXXXX Manufacturers code sd Type of Frame um Variant Version Ignition System Transmission Type Production Year Assembly factory Production Serial No ENGINE NO The engine number is punched on the left hand side Crankcase It is the means of identification of the Engine and its production details Prior to June 2010 Production U5 S XXXXXX ENGINE FAMILY ENGINE CAPACITY TYPE OF START TRANSMISSION FUEL FEED BLANK FOR FUTURE USE YEAR OF
100. 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 X Locate the piston on the connecting rod and insert the piston pin into the piston x Fitthecirclips on either side and ensure they are located properly in the grooves NOTE Carefully fix the piston pin clip into the piston boss while covering Crank case neck by shop towel chamois cloth as shown in Fig 05 63 CYLINDER BARREL CLEANING Scrap 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 x Thoroughly lubricate cylinder bore with fresh engine oil and then assemble over the piston by gently twisting and tilting NOTE Do not use any sharp objects to press piston rings against groove Use thumb finger force to locate rings in its position properly x Assemble the multi layer steel MLS head gasket on the barrel amp 2 Nos dowels CYLINDER HEAD CLEANING x Scrap off the carbon deposit on the face of the Cylinder head and exhaust port INSPECTION xx Visually check for any cracks breaks of Cylinder head fins Check valve stem scoring bent
101. signal to the powertrain control module which is used to determine engine speed and ignition timing Thus the speed of the engine at that instant is known by the ECU lf the engine runs beyond the maximum rated speed 5500 rpm the ECU cuts off the fuel supply to the injector so that the engine will stall and the RPM will reduce to its rated operating RPM This is a safety aspect inbuilt to prevent damage to moving engine parts 06 8 FUNCTIONS OF COMPONENTS LAMBDA HEGO O2 SENSOR Specification Operating Voltage Upto16 V Maximum Operating temperature 600 C to 950 C TIP Tightening Torque 24 5 x 4 9 N m 2 5 0 5 Kg f m The Lambda Sensor detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected The sensor provides feedback to the ECU which in turn will meter the air fuel ratio in order to achieve a near stoichiometric air fuel ratio of 14 7 1 during closed loop engine operation The ideal mixture is the amount of fuel needed to make an engine perform as commanded by the ECU The Lambda sensor is located on the LH side of the exhaust pipe near the cylinder head The Lambda sensor is temperature sensitive and hence takes approximately 90 seconds to get activated whenever the engine is started Till the time the Lambda sensor is activated the ECU gives a preset air fuel mixture ROLL SENSOH Specification Operating Voltage 12V Oper
102. special thrust washer lay shaft on Crank case LH NOTE Ensure special thrust washer profile facing towards Crank shaft bearing side on LH crankcase HH Crank case Assemble the crank shaft into the 05 47 Insert the jack shaft from the crankcase x Check connecting rod bend as shown LH inside amp fix the woodruf key Fig x Assemble the crankcase LH over RH Crank case by tapping gently Simultaneously holding self motor jack Assemble Front Engine Mounting Brackets and tighten bolts Torque 2 5 KG M x Assemble Rear Engine Mounting Bracket and the piece mudgaurd holding bracket Torque 2 5 KG M NOTE Ensure R index mark side is facing towards RH side FD Sprocket of the engine 05 48 Assemble neutral switch with packing Fit the centre stand and foot rest supports Locate the crankcase on the frame and fit the front engine mounting stud 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 Fitthe rear engine mounting stud Locate the double gear for starter drive in the crankcase and insert shaft Ensure cut portion of shaft is facing upwards 05 49 Fix the dowels the crankcase and carefully fix the motor with housing starter drive Apply LOCKTITE 5699 RTV silicon liquid gasket on the joint face x
103. ssembly gt x Loosen the head lamp casing allen screw Remove the handle bar clamp bolts and nuts and take out handle bar Ww Remove the stem lock nut and washer carefully x the steering stem downwards taking care to collect the steering race balls 38 nos for inspection Remove head lamp casing x Drive out ball races and cover from head lamp casing x Using a copper drift tap out ball race and cover from the frame head tube Take out ball race from steering stem CLEANING x Clean all the parts carefully for inspection YX Hub the bearing race balls in a clean cloth INSPECTION We Inspect the balls for marks of wear corrosion pitting and damage Replace if necessary Inspect the races for Grooves Excessive uneven wear Replace if found defective Check all parts for cracks pitting or any other damage 08 5 REASSEMBLY STEERING X Locate 19 balls each on the ball races ie stem bottom and frame had tube Using a hollow drift fix the bottom ball race the steering stem Locate the head lamp casing over the frame down tube such that the centre holes Fix the ball race on the frame head tube align top Insertthe steering stem into the frame head tube slowly and steadily Till it matches with the frame head tube bottom ball race the ball race along with cover on the frame head tube Bottom
104. st be changed periodically as specified Whenever the tappets are removed for service stored in spares they must be kept upright the push rod seating surface pointing upwards and the rollers at the bottom pointing downwards to prevent the oil from draining off 04 4 AUTO DECOMPRESSOR WORKING PRINCIPLE 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 During inital cranking of the engine the cam rotation will be under 350 RPM At this speed the flyweight will be at its resting position which causes the pin to protrude above the base circle of the cam lobe This will cause the hydraulic tappet to raise and will cause the exhaust valve to be open thus letting out the compression form the cylinder head As the engine starts the cam rotation increases beyond 350 RPM which inturn will cause the flyweight to open and force the pin to rotate and its projection will go below the cam lobe This will cause the tappet to return to its resting poisition and will close the exhaust valve thus holding the compression required to start the engine BENEFITS OF AUTO DECOMPRESSOR x Eliminates the need to fix a manual system which will need to be adjusted and serivced periodically easy starting of the engine xx X Helps to reduce high initial load on the electric start motor 04 5 ELECTRIC STARTER
105. sufficient fuel pump Check fuel pump coupler not working connection Check fuel pump relay for proper working hose air filter to throttle body Spark plug electrode dirty fouled Clean park plug amp Reset gap Wrong specification spark plug Fit the correct Spark Plug Loose HT connections damaged HT lead Fix connections firmly Replace Lead Complaint Idling Erratic high Idling RPM High Adjust the idle air bypass screw in the throttle body No throttle cable free play Adjust throttle cable free play Stuck throttle inner cable Clean Replace cable Loose damaged throttle body to engine Tighten replace the hose hose air filter to throttle body Suction leakage Check and correct Electricals Related Remedies Observation Causes Fuel is stale due to vehicle being in storage Clean petrol tank and carburetor for a long period and fill the tank with fresh petrol Fuel adulterated Refill with good fuel Fuel Related 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 amp Reset gap Electricals Related Wrong specification spark plug Fit the correct Spark Plug Loose HT connections damaged HT lead Fix connections firmly Replace m D Complaint Engine stalls gradually Loose damaged throttle body to
106. teering stem assembly Pt x x Clean and check the balls and races thoroughly for damages pittings discolouration Change them if found defective Pack grease and balls on the bottom ball race as shown in Fig x Pack grease in the top ball race x Assemble the steering stem WHEEL ALIGNMENT CHECK Hold the vehicle upright off the stand on level ground x 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 p 22 y MISALIGNED C 007 F n x If string touches only three points on the two wheels the alignment is incorrect x Move the cam adjuster on the LH side of rear wheel up or down by the required notches without disturbing the RH adjuster till the string touches on all four points CLUTCH CABLE FREE PLAY 2 3mm LEVER END Check clutch cable button seating position inside lever and condition of the cable x Screw in or out the cable adjuster for setting the required play at lever end 2 to 3mm After adjustment refix cable boot PRIMARY CHAIN TENSION ADJUSTMENT x This vehicle is fitted with Auto chain tensioner Hence there is no need for periodic manual adjustment THROTTLE CABLE PLAY ADJUSTMENT Throttle rotor f
107. the plugs Loose crankcase joints Tighten fasteners Damaged gaskets Replace the gaskets Damaged sealing surface Face Replace the parts 10 4 External Leaks Replace it with right grade oil Vertically aligned piston ring Properly stagger the piston end gaps rings Excessive piston ring end Replace the piston rings Wrong fitment of piston rings Refit the piston rings correctly Connecting Rod Bent Replace the crankshaft Clearance Excess between Piston amp Check and Replace Cylinder Barrel Glazed cylinder walls Check and Replace Complaint Engine Noisy Incorrect octane rating of fuel Use correct fuel Excessive clearance between piston and Check and Replace cylinder Loose rocker arm spindle in rocker arm Check and Replace Hydraulic valve lifters damaged Check and Replace Excessive small end clearance Check and Replace A humming Howling backlash noise Adjust the Cam spindles to when accelerated achieve correct cam gears meshing Damaged cams Check and Replace Worn out damaged Big end bearings Check and Replace Complaint Premature Wear of Engine Components Cracked or improperly fitted suction Air filter Check and Correct Replace Dirty adulterated fuel Check and Correct Replace Dirty adulterated Wrong Grade oil Replace oil at regular intervals Complaint Gears Hard Not Engaging Weak clutch spring Check and Replace Check and Correct Change to correct size pin Clutch lever free
108. the throttle stop screw on the side ofthe throttle body unless you are using the factory software to recalibrate the base throttle opening 04 10 Blow Up Charts 04 11 CRANK CASE RH COVER SIDE LE OE 04 12 CRANK CASE RH COVER SIDE KEY No DESCRIPTION KEY No DESCRIPTION 1 GEAR ASSEMBLY EXHAUST WITH 26 FD SPROCKET 17 TEETH DECOMPRESSOR ASSY 27 TAB WASHER A2 ASSEMBLY 28 1 TAPPET DOOR BUFFED 29 CSK SOCKET HEAD SCREW M6 X 30 2 CSK SOCKET HEAD SCREW M5 X 12 30 CIRCLIP 3 ROTOR AND RELUCTOR ASSEMBLY 31 PUMP DRIVE PINION GEAR 4 KEY MAGNETO 32 HEX SOCKET HEAD CAP SCREW M6 X 25 5 PLAIN WASHER 33 O RING OIL PUMP OUTLET 6 HEX NUT M12 X 1 25 34 GASKET OIL PUMP 7 HEX SOCKET HEAD CAP SCREW M6 X 30 35 HEX FLANGE BOLT M5 X 12 8 HEX SOCKET HEAD CAP SCREW M6 X 25 36 COPPER WASHER 9 CAM STEADY PLATE 37 CAP PIVOT PIN 10 DOWEL 6 MM 38 O RING 11 NUT CAM SPINDLE 39 O RING N SHIM CAM GEAR 40 13 PIVOT 41 HEX SOCKET HEAD CAP SCREW 6 X 60 14 5 lt 42 STARTER MOTOR ASSEMBLY 15 FLY WEIGHT 43 HYDRAULIC VALVE LIFTER ROLLER 16 TORSION SPRING 44 COVER STARTER MOTOR 17 CAM GEAR SUB ASSEMBLY EXHAUST 45 HEXSOCKET BUTTON HEAD SCREW M5 X 12 18 CAM SLEEVE cO CAM SPINDLE ADJUSTABLE SPINDLE ADJUSTABLE 0 1 OVERSIZE CAM SPINDLE ADJUSTABLE 0 2 OVERSIZE 20 C
109. then install the other brake pad 2 0 KG M after mounting the caliper assembly on the fork assembly x Fixthe Grub screws on the pins and tighten X Apply Silicon grease on the Pin OD and to a torque of 0 2 to 0 3 KG M then assemble the Pin bolt by pressing brake pads into caliper body New sealing washers and tighten the Banjo x Mountthe Caliper assembly on the Fork bolt and tighten the Mounting bolts evenly Torque 3 5 to 3 8 KG M NOTE x Fill fresh brake fluid in the Master cylinder and bleed the air out of the hydraulic brake system Ensure disc plate is in between both brake pads Torque 2 7 to 3 0 KG M 07 16 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 Check the Disc thickness and the Run Out of Disc 11 Disc Thickness As described on the disc REAR WHEEL REMOVAL v out the spindle with the chain adjuster and remove the spacer from Rear wheel can be dismantled without the LH side removing the rear chain and rear wheel sprocket Ww Place the vehicle on its center stand x Ensure the rear wheel is lifted off the ground by placing suitable wedges under the centre stand legs x Remove the split pin
110. timed injection system and the injection is done close to the inlet valve The injector operates based on the pulse width signal given by the ECU The fuel injector is assembled in the inlet manifold located between the inlet port on the cylinder head and air filter It is placed at an angle in the intake manifold so as to give maximum fuel spray and minimum wall wetting The advantages of fuel injection are X Excellent cold starting Consistentidling RPM Good acceleration X Full power output 06 4 FUNCTIONS OF COMPONENTS FUEL PUMP MODULE Specification Operating Voltage 6 14 5 V Operating temperature 20 C to 60 C mom M Controlled Pressure Regulator 294 KPa vi 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 The Pump maintains a uniform 294kPa fuel pressure Any excess pressure is bypased back into the fueltank so that the fuel hose injector etc do not get damaged due to excess pressure The fuel pump module has an inbuilt micro fuel filter which filters even the most minute dust particles to prevent damage to the seat in the injector The pump is located inside the fuel tank so that it is submerged in liquid and hence cannot ignite itse
111. to Crank case RH lubricate and check free upward amp downward movement inside Crank case RH tunnel CAUTION Please ensure the roller should be facing downwards during assembly Fix the needle roller pins into Crank case 05 39 Fit bracket lock clip to hold needle roller pin of hydraulic valve lifter and tighten with allen screw Torque 1 KG M g 1 x Assemble cleaned suction filter element into Crank case RH x Assemble 2 Nos of Flanged hex bolts Torque 0 6 KG M to fix drain cap with O ring x Assemble magnetic drain plug assy Torque 2 KG M crankcase RH with washer on NOTE Apply LOCKTITE 542 thread sealant before assembling the drain plug ASSEMBLING OF KICK STARTER SUB ASSEMBLY BULLET ELECTRA E5 amp G5 x Insert the spring plunger and pawl in the Kick starter spindle Fixthe thrust washer on kick spindle 05 40 x Assemble the Kick pinion gear over kick Fix kickstarter sub assy in to Crankcase pawl mechanism RH as shown in Fig AT Lum 3 NOTE Ensure kick pawl is seated over the trip plate in the Crank case RH Rotate kick Gear and confirm free wheel movement Insert the thrust washer above the kick spindle Assemble oil thrower under the kickstarter Gear Torque 0 6 KG M x Assemble Kick starter return spring by hooking into kickshaft spindle NOTE Ensure free rotation of kick p
112. to Crank case and fix drain cap with O ring Fill up with 15W50 API SL grade Refil oil quantity 2 40 Litres approximately 03 13 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 Replace oil filter element whenever engine oil is changed RE ASSEMBLY Soak new oil filter in oil for 15 minutes the oil filter and other parts in the reverse order of disassembly Start Engine warm up for a few minutes switch off engine and check the oil level Oil level should be just below Max level REAR BRAKE SWITCH ADJUSTMENT Check brake light switch operation Loosen bottom nut and tighten top nut till the brake light comes on when brake pedal is pressed Tighten the bottom nut duly ensuring that the brake lamp is not glowing continously Incase brake light is continously glowing then readjust till correct position in achieved NOTE Always re check brake lamp after adjustment of brake pedal level and free play REAR WHEEL CHAIN SLACKNESS ADJUSTMENT Check slackness It should be in between 25 to 30 mm X Ensure to hold the eccentric sleeve by sp
113. ue 0 60 KG M NOTE Use special tool No ST 25592 4 to lock connecting rod movement during tightening magneto nut 05 59 x Assemble Breather bolt and washer Torque 2 0 KG M xx Assemble Ignition Timing inspection bolt with copper washer if not assembled earlier Torque 1 5 KG M x Assemble jet Crankshaft oil seal Crank feed and circlip on cover RH inside NOTE Replace the oil seal every 20 000 kms interval Assemble Stator on cover RH and tighten with 3 mounting screws Torque 1 KG M x Assemble Pulser coil on cover RH and tighten with 2 screws Torque 1 KG M NOTE Apply LOCKTITE 595 silicon adhesive sealant to magneto wire cable grommet to avoid oil seepage x Assemble 2 dowels and RH Crank case cover gasket 05 60 x Assemble cover RH carefully by aligning x Assemble O ring Spring and gasket oil kickshaft and dowels filter cap x Fix cover RH and tighten with 11 allen CAUTION Care must be taken while fixing screws Torque 1 KG M cover due to spring force and gasket xx Assemble oil filter cover Torque 0 60 KG M x Assemble the O rings Oil filter element washer and plate as shown x Assemble kickstarter lever only for Bullet Electra EFI E5 G5 Torque 2 5 KG M 05 61 x Fix Cylinder barrel bottom Gasket PISTON SUB ASSEMBLY CLEANING x Remove piston rings from piston x Scrub the carbon deposits from the piston groove
114. ure failure of electrical parts CHARGING INITIAL CHARGE NEW BATTERY ELECTROLYTE x Diluted sulphuric acid with distilled water to a specific gravity of 1 240 PREPARATION x x Take required distilled water in a Hydrometer or equivalent container Slowly add sulphuric acid to it CAUTION It is important to ensure that the sulphuric acid is added into the distilled water and not vice versa Stir and check the specific gravity of electrolyte and add sulphuric acid till the specific gravity becomes 1 240 Never add sulphuric acid to battery electrolyte for topping up or increasing specific gravity It would lead to sulphation Stir with a glass rod x specific gravity with hydrometer TEMPERATURE OF ELECTROLYTE x the electrolyte to about deg before filling it in the battery just below the maximum level indicated SOAKING PERIOD battery with electrolyte filled for about half an hour before commencement of charging Top up the level with electrolyte if necessary CHARGING A NEW BATTERY x Connect the battery to the charger and charge as detailed below Battery Duration Charging Current 12V 14AH 10Hrs 1 4 Amps RECHARGING USED BATTERIES When the specific gravity of electrolyte is less than 1 220 drain out the electrolyte and refill with fresh electrolyte of strength 1 240 and charge the battery as detai
115. ust cam x Assemble the flyweight along with return spring over activating pin and tighten with allen screw xx Lubricate and ensure free movement of the returning of the flyweight NOTE Ensure spring eyelet is seated properly inside flyweight hole 05 57 VALVE TIMING Bring piston to TDC so that the woodruf key in the timing shaft is at 12 Clock position ASSEMBLY PROCEDURE OF CAM GEARS 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 X Locate the inlet cam on the spindle and align the single punch marks on the inlet and exhaust cams Fix oil pump drive pinion and lock it with the circlip NOTE Ensure the short boss of the gear is facing outwards Cam NOTE After assembling both cam gears adjust Eccentric cam to reduce gear backlash Torque 2 KG M NOTE reduce axial play in between Cam Gears outer surface and steady late additional shim may be added as per need 05 58 x Fix steady plate and check for axial Fix oil seal 2 Nos at Kick Shaft hole on play of Cam Gears to avoid noise problem Crank case RH cover Assemble the dowels and allen screws on Cam steady plate and tighten Torque 1 KG M Assemble magneto rotor plain washer and X Assemble 6 allen screws to fix breather nut and tighten Torque 4 8 KG M chamber cover plate Torq
116. ust seals and piston seals from the calliper using a blunt tool x Clean the seal grooves with brake fluid CAUTION Care should be taken to avoid any damage on the bore of the sliding surface INSPECTION x Check the caliper cylinder surface and Piston outer surface for scoring or other damages Measure the caliper cylinder Service limit 25 46 mm Measure the caliper piston O D Service limit 25 31 mm CAUTION Enough care should be taken to avoid damages ofthe piston O D while servicing handling pie Remove the Bleed screw CALIPER ASSEMBLY x Coat clean brake fluid on new dust seals and piston seals and install them in the seal grooves of the caliper body Ensure the piston seal are fixed on the inner groove and the dust seals are fixed on the outer groove 07 14 x Coatthe caliper cylinders and Pistons with x Install the Pad tension spring plate into clean brake fluid and install the Pistons into the Caliper body the caliper body with the dished end facing inwards x Assemble Bleed screw with the dust cap on the caliper body x Ifthe Caliper Boot and Bellow are hard or deteriorated replace them with new ones x Assemble the Mounting Bracket on the caliper Body x Smear fresh brake fluid on the caliper boot and bellow and assemble them as shown 07 15 x Firstinstall the brake pad at the piston side x Tighten the Pin bolts with a torque of 1 5 and
117. variations in engine temperature RAULIC VALVE ROLLER HYDRAULIC VALVE LIFTER _ OUTER BODY OIL TRANSFER ANULUS C DISC VALV B OVER FLOW PATH OIL HEAD OIL DELIVERY CON TROL VALVE LOCKING ACTIO 2 nm OILINLET NS A s CHECK BALL A HIGH PRESSURE CHAMBER OIL FLOW PATH ROLLER wie PLUNGER EL CHECK BALL W SEAT we d AIR ESCAPE PATH X THROUGH PLUNGER CLEARANCE HEAD OIL E 4 lr F TRAPPED AIR VOLUME H HIGH PRESURE CHAMBER 04 3 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 As the hydrauilic tappet rises due to the cam rotation the full load of the valve train is applied on the tappet A predetermined and closely held clearance of 0002 0003 inch 0051 0076 mm between the outer diameter of the plunger and the inner diameter of the tappet body allows a controlled amount of oil to escape up from the high pressure chamber This oil compresses the plunger spring and allows a small relative movement of the
118. washer Lay shaft RH Profile towards sleeve gear side on RH Crank case Special thrust washer Lay shaft LH Profile towards Crank shaft bearing side on LH Crank case Rear engine mounting plate R index mark side facing RH FD sprocket side Gear jack shaft Flat face facing outwards Distance washer sprag clutch Double step facing inside should rest on Crankshaft and Crankcase LH side bearing Sprag Clutch Bearing Wide Flanges side facing upwards Clutch plain plate All plates smooth teeth face in same direction while fitting on Clutch hub FD sprocket Side face circular groove facing outwards Oil pump inner and outer trochoid gear Punch mark facing outwards Cam Gear sub assy exhaust The teeth inbetween two punch marks must align with Crankshaft timing pinion gear punch mark Cam Gear Inlet Single punch mark must align with single punch mark of Cam gear exhaust Oil pump drive pinion Short boss facing outwards Piston rings 1 IP and 2 IP facing upwards Piston A or B mark on the crown facing towards throttle body inlet side 05 36 ENGINE 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 bus
119. with the help of scrapper x Scrap the carbon deposits from the skirt area and groove area of piston without causing any scratches or scoring yx Clean piston rings and piston pin with cleaning solvent and dry it with compressed air INSPECTION yx Visually inspect for cracks scratches scoring seizure marks pitting etc x Check for piston wear measure the outside diameter of piston perpendicular to the piston pin hole Ref page No 03 2 x Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves xx Check the piston rings end gap at the bottom end of the Cylinder CAUTION Set each piston ring squarely into the Cylinder barrel at a point 25 mm from the bottom pushing the ring by piston head and then measuring the end gap 05 62 x Check the piston pin for wear Measure outside dia of piston pin at 3 points x Locate the oil ring expander into the oil ring groove Slide the bottom rail to the bottom of the expander Slide top rail to the top of the expander Place the second ring in piston Index mark 2 IP facing upwards NOTE Second ring has a taper edge cross section and is hard chrome plated Locate the top ring Index mark 1 IP facing upwards NOTE Topring has rectangular cross section with black colour Nitride coating Stagger piston rings end gap as shown in Fig NOTE After installation the ring
120. y shaft mounted on the Crank case RH as shown in Fig xx Hold the cam plate and gear train sub assembly along with Fork shaft Forks Lay shaft double gear LS3 amp 154 and main shaft with all gears in 3rd gear position Gently slide inside the crankcase RH NOTE Ensure alignment of main shaft with sleeve gear hole fork shaft with fork hole inside the Crank case RH and sliding gear with lay shaft x Insert 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 x Insert locating pin to lock piviot pin as shown in Fig x Assemble thrust washer and then LS 1st gear on the Layshaft NOTE Check Gear shifting system by rotating Cam plate and Main shaft sub assy while rotating the shafts simultaneously Check for smooth gears engagement 05 46 x Assemble O ring cap pivot copper washer and tighten bolt Torque 1 KG M NOTE Ensure the bearing inner races small one on timing shaft amp big one on drive shaft are fitted on the crank shaft before assembling in the crankcase RH x Check Crank shaft big end bearing axial play is within service limit Assemble the 2 dowel pins on the crankcase and apply LOCKTITE 5699 RTV silicon liquid gasket on the RH Crank case seating surface Check Crank shaft run out is within service T F limit x Assemble

TB TS Service Manual Final 1.pmd

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