Bullet Classic EFI (C5) Bullet Electra EFI (E5) Bullet EFI (G5) SECTION ONE 01 INTRODUCTION PREF ACE PREFA We are pleased to release this workshop manual for the new generation of Royal Enfield Motorcycles fitted with unit construction engine, electronically controlled “Engine Management System” and fuel injection technology. We have endeavoured to make this manual user friendly. However, we welcome your valuable suggestions for improvements which you may write to us or email us at firstname.lastname@example.org. 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 / Qty. 500 / May ‘09 01-1 FOREW ORD FOREWORD PREPARATION FOR SERVICE Good preparation is very important for carrying out correct service job. The motorcycle should be cleaned well before starting a repair job. Cleaning will occasionally uncover sources of trouble. Availability of tools, measuring instruments and parts should be ensured before commensing an overhaul, since Interruption to locate tools or parts can cause distraction and needless delay. Use of special tools will ensure a quality service. USE OF 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 HO W TO USE YOUR HOW SER VICE MANU AL SERVICE MANUAL Pictorial presentation of various activities, make this manual easy to understand and user friendly. This service manual is divided into 10 Sections 01 to 10. Page numbers for each section starts with 01. Thus, page 05-10 indicates 10th page of section 5. Engine breather System Clutch System Inlet manifold & Throttle body Blow up Charts. SECTION FIVE 05 ENGINE DISMANTLING INSPECTION & ASSEMBL Y ASSEMBLY Torque Specification - Engine The sections are subdivided into subjects and presented in the following order. Engine dismantling procedure SECTION ONE O1 INTRODUCTION Unidirectional fittings list Engine assembling procedure The manual and its arrangements SECTION TWO 02 GENERAL Salient features of the Unit construction engine & engine management system Four stroke cycle operation Basic terminology of automobiles Technical specifications Identification of Chassis No., Engine No., List of special tools and its applications Control cables and wiring harness routing. SECTION THREE 03 SER VICE D ATA SERVICE DA Service limits of components Periodical maintenance chart SECTION FOUR 04 ENGINE Lubrication system Roller hydraulic Valve lifter (RHVL) Auto decompressor Electric starter system & sprag mechanism Auto Chain Tensioner Assembly Vital parts - Description SECTION SIX 06 ENGINE MAN AGEMENT MANA SY STEM SYSTEM Functional Diagram Components description Function of components Identification of a malfunction in EMS Do’s & Dont’s Trouble shooting SECTION SEVEN 07 WHEELS & BRAKES Torque Specification - Chassis Front wheel removal & reassembly Disc brake - General instruction - Master Cylinder & Caliper overhauling - Bleeding procedure - Disc inspection Rear wheel removal & reassembly Rear Brake removal & reassembly 01-3 SECTION EIGHT 08 SUSPENSION AND STEERING Front fork working principle Front fork removal & reassembly Steering stem removal & reassembly Gas filled shock absorber - Relay starter - Starter motor - IC Flasher - RR Unit - TPS Unit Electrical parts Inspection - Working principle - Clutch switch - Removal and assembly - Starter switch - Adjustment of shock absorber - Switch modules LH & RH - Recharging of shock absorber Swing Arm - Removal - Bush lubrication / replacement - Reassembly Centre Stand Removal & Reassembly SECTION NINE 9 ELECTRICALS Electrical symbols Battery - Precautions - Charging - Maintenance Spark plug maintenance & Inspecton Checking procedure of electrical components: - Starter coil - Pulsar coil Do’s and Dont’s Wiring Diagrams - Ignition circuit - Starter and charging - Complete Wiring diagram Trouble shooting SECTION TEN 10 TR OUBLE SHOO TING TROUBLE SHOOTING SAFETY DEFINITIONS Important aspects to be noted are given as follows in the manual. NOTE Provides important information that will have to be adhered to while carrying out repairs. CAUTION Indicates activities that are important to be - Ignition coil noted. Non-adherance may result in breakage and or functional failures of the assembly. - Suppressor Cap SPECIAL TOOLS - Battery - Horn 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 FEA TURES OF THE UNIT CONSTR UCTION FEATURES CONSTRUCTION ENGINE & ENGINE MAN AGEMENT SY STEM MANA SYSTEM • HIGH TORQUE ENGINE • ENHANCED POWER DELIVERY • HYDRAULIC TAPPETS • AUTO DECOMPRESSOR • AUTO CHAIN TENSIONER FOR PRIMARY CHAIN • • IMPROVED ACCELERATION & HIGH SPEED CRUISING • EXCELLENT COLD STARTING ABILITY • ACCURATELY CONTROLLED, AIR FUEL MIXTURE & IGNITION TIMING BY THE ENGINE CONTROL UNIT • IMPROVED PERFORMANCE AND FUEL EFFICIENCY THRO FUEL INJECTION SYSTEM. HIGH CAPACITY TRACHOIDAL OIL PUMP FOR BETTER LUBRICATION FOUR STR OKE CY CLE OPERA TION STROKE CYCLE OPERATION SUCTION STROKE COMPRESSION STROKE POWER STROKE EXHAUST STROKE Inlet Valve Open Closed Closed Closed Exhaust Valve Closed Closed Closed Open Piston Movement TDC to BDC BDC to TDC TDC to BDC BDC to TDC Gas Flow Air Petrol mixture gets Air petrol mixture burns, gas expands. Piston is pushed down. Exhaust gas Air Petrol mixture is drawn into cylinder compressed. Few degrees before BTDC, spark plug produces spark. flows out. 02-1 BASIC TERMINOL OGY OF AUT OMOBILES TERMINOLOGY AUTOMOBILES ENGINE : The Engine helps to convert Chemical energy availbale in petrol into heat energy then to mechanical energy for motion. It is the heart of the vehicle in which power is generated for moving the vehicle. Fuel Power Air BORE : Bore is the inside diameter of the cyclinder block in which Piston moves up and down. TDC : TDC stands for Top Dead Center. It is the top most position to which the piston can travel in the cylinder barrel. BDC : BDC stands for Bottom Dead Center. It is the bottom most position to which the piston can travel in the cylinder barrel. STROKE : It 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. (πr²× l, when ‘r’ is the radius of the piston and ‘l’ is the length of the stroke). It is also known as Swept Volume or Displacement volume. CLEARANCE VOLUME : It is the nominal volume of the space above the piston in the combustion chamber when piston is at the topmost position (TDC). 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 : It is a ratio between total volume in the engine to the clearance volume available at the end of compression stroke. Compression ratio = Total volume of air fuel mixture Clearance volume VOLUMETRIC EFFICIENCY : Volumetric efficiency is the ratio between the volume of air fuel mixture that actually enters the cylinder and Swept volume. 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 = 0.986 HP = 0.735 KW 1 HP = 1.014 PS = 0.744 KW 1KW = 1.360 PS = 1.340 HP 02-3 IHP : IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed inside the engine cylinder by combustion process. It is utilised to drive the piston. FHP : 1HP (Horse Power Available after explosion) FHP (Frictional Losses) FHP stands for Frictionl Horse Power. It is the amount of horse power used or lost to overcome the friction between various engine components. BHP : BHP stands for Brake Horse Power BHP (Horse Power Avaiable at Crankshaft) 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 : Mechanical Efficiency is the ratio between Brake horsepower and Indicated horse power. Brake horsepower Indicated Horse power = BHP IHP 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 lb.ft = 9.81 N-m. 1lb.ft = 0.138 Kg-m = 1.356 N-m. 1 N-m = 0.102 Kg-m = 0.737 lb.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. TDC Position Ignition Timing Position If spark occurs earlier than specified ignition timing, it is called “Advance” timing. If spark occurs after the specified ignition timing, it is called “Retard” timing. IDLING SPEED : Ignition Timing in Degrees It is the speed of the crankshaft (i.e. 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. No. of teeth of Driven Gear Gear Ratio = No. of teeth of Driving Gear In Fig. 1, the Gear ratio is 20 ÷ 10 = 2 : 1 In Fig. 2, the Gear ratio is 20 ÷ 20 = 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. 02-5 TECHNICAL SPECIFICA TIONS SPECIFICATIONS A. ENGINE AND ENGINE SYSTEMS BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 1. Engine Type 4 Stroke Single Cylinder, Air cooled 2. Bore 84mm 3. Stroke 90mm 4. Displacement 499cc 5. Compression ratio 8.5:1 6. Max Power @ rpm 20.3 Kw @ 5250 rpm 7. Max Torque @ rpm 41.3 Nm @ 4500 rpm 8. Idle rpm 9. Starting 10. Air filter element 11. Lubrication 12. Engine oil tank capacity 13. Engine oil grade 14. Cooling B. TRANSMISSION 1. Clutch 2. Primary drive 3/8” Duplex chain & sprocket 3. Primary ratio 2.15 : 1 4. Gear box 5. Overall Ratio 1050 ± 200 rpm Kick & Electric Start Electric Start Paper element Forced Lubrication, Wet Sump 2.75 litres JASO MA -15W-50, API SL Grade, ESTER-Semi Synthetic Oil Natural air flow Wet multiplate 5 Speed Constant Mesh 1st 3.063 : 1 2nd 2.013 : 1 3rd 1.522 : 1 4th 1.212 : 1 5th 1:1 6. Secondary drive 5/8” Chain & Sprocket 7. Secondary ratio 2.235 : 1 2.11:1 8. Drive Chain links 101 Pitch 102 Pitch 02-6 C. CHASSIS BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 1. Frame Tubular 2. Front Suspension Telescopic, hydraulic damping, Stroke 130 mm 3. Rear Suspension Swing arm with gas shock absorbers 4. Fr. Fork oil capacity 5. Front fork oil SAE 10W -30 6. Front Brake Hydraulic, Hand operated, 280 mm dia ventilated disc 7. Rear Brake Mechanical, Foot operated, 153 mm internal expanding 8. Brake Oil Capacity 9. Brake Oil Grade 10. Tyre size : 60 ml DOT 3 or DOT 4 Front 90X90 - 19” - 51V 3.25X19 90X90 - 18” 51V Rear 100/90 - 19” - 57V 3.5X90 110/80-18” - 58V D. TYRE PRESSURE 1. Solo : 2. 265 cc + 2.5 cc / each leg Front 18 PSI Rear 28 PSI With Pillion : Front 20 PSI Rear 30 PSI 3. Steering lock In built 4. Fuel tank capacity 5. Reserve E. ELECTRICALS 1. Generation Alternator 2. System 12V - DC 3. Battery 12V - 14 AH 4. Spark plug 5. Spark plug gap 6. Head lamp 14.5 ±1 litres 2.75 litres Mico - WR7 DDC 4 0.7 to 0.8 mm 12V, 60/55w 02-7 BULLET ELECTRA EFI (E5) BULLET EFI (G5) BULLET CLASSIC EFI (C5) 7. Tail / Brake Lamp 12V 5 / 21W 8. Speedometer lamp 9. Hi beam indicator 12V, 2W 10. Neutral lamp Tell tale 12V, 2W 11. Turn Signal Tell Tale 12V, 2W 12. Turn signal 12V, 10W 13. Horn F. WEIGHTS 1. Mass of Vehicle in running order 187 Kg. 2. Max pay load 178 Kgs. 3. Max technical permissible mass 365 Kg. G. DIMENSIONS 1. Length 2. Width 3. Height 4. Wheel base 1370 mm 5. Ground clearance 140 mm 6. Saddle height H. PERFORMANCE 1. Max. speed 12V, 3.4W 12V DC 2200 mm 2160 mm 800 mm 1100 mm 820 mm 1050 mm 800 mm 132 Kmph (83 Miles) NOTE : 1. Values given above are for your guidelines only 2. In view of continuous improvements, specifications are likely to change without notice 02-8 IDENTIFICA TION OF CHASSIS NO ., ENGINE NO IDENTIFICATION NO., NO,, CHASSIS NO. ENGINENO. 02-9 LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25128-2 Magneto Puller for TCI Application : Removal of magneto assembly ST 25151-4 Chain case outer puller (TCI) Application :To remove Crank case LH cover ST-25594-4 Clutch spring assy. Application : To compress clutch springs while removing & refitting Clutch plates. 02-10 LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST-25591-4 Clutch centre nut Application : To hold Clutch Sprocket while removing / tightening the Clutch & Sprag Sprocket Nut. Oil seal adopter Application : Fitment of gear shaft oil seal on crank case LH cover. ST 25118-4 Cylinder head nut tightening tool Application : To remove and tightening of cylinder head nut. 02-11 LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25123-1 Valve Spring compressor Application : To compress the valve spring for removal and fitting of valve. ST 25153-4 Extractor for 5 Speed Gear box Pivot Pin Application : To remove Gear Rocker Shaft top pivot pin and Gear Cam Plate pivot pin. ST 25 FD sprocket removal tool Application : To remove front drive sprocket from Sleeve Gear. 02-12 LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST Front fork main tube spanner Application : Loosening and tightening of front fork main tube with fork end ST 25112-4 Expander for front fork oil seal Application : Expander for oil seal while inserting main tube into bottom tube of front fork ST 25114-4 Extractor for Fork oil seal Application : Removal of oil seal in front fork bottom tube 02-13 LIST OF SPECIAL TOOLS AND ITS APPLICA TION APPLICATION ST 25113-4 Mandrel for oil seal Application : Fitment of oil seal in front fork bottom tube ST 25110-3 Gauge for tightening chain stay Application : Alignment of Swing Arm while tightening ST 25244-4 Adjuster Special Spanner Application :To adjust gas filled shock absorber 02-14 CONTROL CABLES AND WIRING HARNESS ROUTING ALL CONTROL CABLES & WIRING HARNESS ROUTING UNDER TANK AND SEAT TOP VIEW UNDER TANK LH VIEW UNDER TANK RH VIEW 02-15 GENERAL VEHICLE INFORMA TION INFORMATION HARNESS ROUTING STEERING RH MAGNETO WIRES ROUTING PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING 02-16 GENERAL VEHICLE INFORMA TION INFORMATION FUSE CARRIERS ARRANGEMENT (E5 & G5) HORN WIRE ROUTING FUSE CARRIERS ARRANGEMENT (C5) HANDLE BAR WIRES ROUTING 02-17 GENERAL VEHICLE INFORMA TION INFORMATION TAIL LAMP & TRAFFICATOR WIRES ROUTING ECU MOUNTING BULLET ELECTRA EFI (E5 & G5) THROTTLE BODY MOUNTING WITH CABLES ECU MOUNTING BULLET CLASSIC EFI (C5) 02-18 SECTION THREE 03 SERVICE D ATA DA SER VICE LIMITS OF COMPONENTS SERVICE (All units in mm unless specified) WEAR LIMITS Wear limits are given as new min, new max and service limits. New components must be within the limits specified. Components within service limits may be reused after careful inspection. Use of parts beyond service limit can reduce the operating life of the component and may affect the motorcycle performance seriously. Cylinder bore Cylinder bore : Point of measurement Ring to groove clearance : Comp. Top rings A B C New Min. 84.045 New Min. 0.03 New Max. 84.075 New Max. 0.07 Service Limit 84.190 Service Limit 0.11 Piston Ring to groove clearance comp rings - Middle New Min. 83.940 New Min. 0.03 New Max. 83.970 New Max. 0.07 Service Limit 83.890 Service Limit 0.15 Piston to bore clearance Ring to groove clearance : oil ring New Min. 0.095 New Min. 0.06 New Max. 0.115 New Max. 0.15 Service Limit 0.30 Service Limit 0.21 03-1 Piston ring end gap : compression From top New Min. New Max. Service Limit 1st 0.20 0.35 0.70 2nd 0.35 0.50 0.85 Piston Pin diameter New Min. 19.992 New Max. 19.997 Service Limit 19.982 Piston ring end gap - Oil Ring Big end axial play New Min. 0.20 New Min. 0.20 New Max. 0.70 New Max. 0.55 Service Limit 0.90 Service Limit 0.65 Small end bore inner diameter Crank shaft : Run out New Min. 20.007 New Min. 0.00 New Max. 20.016 New Max. 0.04 Service Limit 20.046 Service Limit 0.08 03-2 Connecting rod bend Valve stem OD (Inlet) New Min. 0.00 New Min. 6.965 New Max. 0.05 New Max. 6.980 Service Limit 0.08 Service Limit 6.955 Cylinder Head warpage Valve to guide (inlet) clearance New Min. 0.00 New Min. 0.02 New Max. 0.05 New Max. 0.05 Service Limit 0.07 Service Limit 0.08 Valve stem OD (Exhaust) Valve guide bore New Min. 7.00 New Min. 6.945 New Max. 7.015 New Max. 6.960 Service Limit 7.25 Service Limit 6.935 03-3 Valve to guide (Exhaust) Clearance Hydraulic Tappet OD New Min. 0.04 New Min. 21.387 New Max. 0.07 New Max. 21.405 Service Limit 1.00 Service Limit 21.380 Valve Spring : length Hydraulic Tappet guide bore New Min. 42.80 New Min. 21.417 New Max. 44.80 New Max. 21.438 Service Limit 41.50 Service Limit 21.450 Push rod run out Hydraulic tappet to guide clearance New Min. 0.00 New Min. 0.012 New Max. 0.02 New Max. 0.051 Service Limit 0.05 Service Limit 0.060 03-4 Main shaft Outer diameter A Location New Min. New Max. Service Limit Selector fork shaft outer diameter B A 19.99 20.00 19.97 B 23.93 23.95 23.90 New Min. 9.96 New Max. 9.98 Service Limit 9.94 Lay shaft Outer diameter X Location New Min. New Max. Service Limit Selector fork inner diameter Y X 17.99 18.00 17.97 Y 23.95 23.97 23.93 New Min. 10.00 New Max. 10.03 Service Limit 9.98 Cam plate inner diameter Selector fork lug thikness New Min. 13.01 New Min. 3.90 New Max. 13.03 New Max. 3.95 Service Limit 13.00 Service Limit 3.88 03-5 Lay shaft 1st gear inner diameter Pivot cam plate outside diameter New Min. 18.03 New Min. 12.98 New Max. 18.06 New Max. 13.00 Service Limit 18.09 Service Limit 12.96 Clutch spring Length Lay shaft 2nd gear inner diameter New Min. 24.00 New Min. 64.5 New Max. 24.03 New Max. 65.5 Service Limit 24.06 Service Limit 60.0 Main shaft 3rd & 4th gear inner diameter Friction plate with insert : thickness MS 4 MS 3 New Min. 24.00 New Min. 2.95 New Max. 24.03 New Max. 3.05 Service Limit 24.06 Service Limit 2.60 03-6 Clutch steel plate : Distortion Throttle cable free play New Min. 0.00 New Min. - New Max. 0.05 New Max. 1 mm Service Limit 0.10 Service Limit 2 mm Duplex Chain - Length across 21 pins Drive chain : slackness New Min. 190.00 New Min. 20.00 New Max. 191.00 New Max. 30.00 Service Limit 195.00 Service Limit - Rear Sprocket chain pull off Clutch cable -Free play New Min. 2 mm New Min. - New Max. 4 mm New Max. - Service Limit - Service Limit 5.00 03-7 Brake drum rear : Internal dia. Sprocket GOOD REPLACE New Min. Sharp, bend broken teeth New Max. Service Limit New Min. 152.40 New Max. 152.50 Service Limit 153.50 Drive chain length across 21 pins Wheel rim: Face out / Run out New Min. 320 New Min. 0 New Max. 322 New Max. 1.0 mm Service Limit 328 Service Limit 2.00 mm Axle shaft : run out Brake lining thickness New Min. 3.80 New Min. 0.00 New Max. 4.06 New Max. 0.01 Service Limit 2.00 Service Limit 0.02 03-8 Caliper Piston Outer Diameter Main tube - run out OD New Min. 0.00 New Min. - New Max. - New Max. - Service Limit 0.04 Service Limit 25.31mm Master Cylinder piston OD Front fork assembly spring : length New Min. 538 New Min. - New Max. 544 New Max. - Service Limit 527 Service Limit 12.64 mm Master Cylinder Bore Caliper Bore Inner Diameter ID New Min. - New Min. - New Max. - New Max. - Service Limit 25.46 mm Service Limit 12.76 mm 03-9 Tyre tread : Depth New Min. - New Max. - Service Limit 1.00 mm Spark Plug Gap New Min. 0.7 New Max. 0.8 Service Limit - 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 be shortened depending upon the severity of the driving condition OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water etc., S. No. DESCRIPTION SCHEDULE Kms (x 1000) 0.5 Miles (x 1000) 0.3 3 6 2 3.75 9 12 15 18 21 24 27 30 6 7.5 9.5 11.25 13 15 17 18.75 1 Engine Oil R R R R R R 2 Engine oil filter R R R R R R 3 Engine sump oil strainer C C C C C C 4 Magnetic drain plug under gear box on crankcase RH C C C C C C 5 Spark plug A A A A A R A A A A R 6 HT lead I I I I I I I I I I I 7 Fuel hose I I I I R I I I R I I 8 Fuel Pump Check for screw tightness in all services 9 Accelerator cable play A A A A A A A A A A A 10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I 11 Rubber hose, Inlet manifold I I I I R I I I R I I 12 Air filter element C C C C R C C C R C C 13 Inlet / Exhaust valve seating I I 14 Cylinder head D 15 Exhaust system D 16 Rear brake pedal pivot L L L L L L L L L L L 17 Battery terminals (apply petroleum jelly) C C C C C C C C C C C 18 Battery Electrolyte level I I I I I I I I I I I 19 Earth wire eyelet (behind battery carrier) I 20 Fork oil R 21 Rear brake cams L L L L 23 Spokes tightness I 24 Wheel rim run out 25 Tyre wear C : Clean R L 22 Steering ball races A : Adjust I I D : De-carbonise I : Inspect L L I I I I I I I I I I I I I L : Lubricate I I I I I I R : Replace NOTE : For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above. 03-11 PERIODICAL MAINTENANC E MAINTENANCE AIR FILTER CLEANING BULLET ELECTRA EFI (E5/G5) Remove the 2 air filter lid mounting screws and take out air filter lid Blow compressed air from outside to inside. Check for cracks, holes, clogging etc. Replace, if defective Assemble in the reverse order of dismantling. SPARK PLUG CLEANING Disconnect suppressor cap and remove spark plug using spark plug spanner. Clean insulator tip and electrodes using a pointed scrapper or plug cleaner. Remove the 3 cover mounting screws & take out cover BULLET ELECTRA CLASSIC EFI (CS) Check and set electrode gap to 0.7 to 0.8 mm. Refit the spark plug and connect the H.T. lead Open filter box cover RH Remove centre mounting nut Take out the air filter element Tap off the dirt 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. 03-12 PERIODICAL MAINTENANC E MAINTENANCE ENGINE OIL OIL LEVEL CHECK Place the motorcycle on the centre stand Before checking the oil level start and warm the engine for few minutes. Switch “OFF” the ignition, wait for two minutes and then check oil level at the inspection window on the RH Crankcase cover DRAINING PROCEDURE : Keep a clean tray under the engine Remove the two Hex Flange Bolts M5 X 16, Sump drain Cap, “O” ring and Suction filter Assy. Remove the Magnetic Plug assy along with its washer. TILT VEHICLE RH & LH Two level marks are provided on the Oil level window in Cover RH Max. & Min. 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 ml. 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 can be drained in 2.35 Litres approximately. Tighten the oil drain bolt with washer. Max Min OIL CHANGE : Refer Periodical Maintenance chart (page No. 03-10) for frequency. Keep vehicle on level ground. Start the engine and warm up sufficiently so that the oil drains faster. Assemble the cleaned suction filter element in 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 : 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 NOTE : Replace oil filter element whenever engine oil is changed. RE ASSEMBLY Soak the new oil filter in oil for 15 minutes. Refil 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 Ensure to hold the eccentric sleeve by spanner while tightening the lock nut which prevent the rotation of the sleeve during tightening the lock nut. The backlash is first adjusted between pinion to exhaust gear and then exhaust to inlet gear to get effective backlash 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. In case brake light is continously glowing then readjust till correct position in achieved. 03-14 The tightening torque for M10 lock nut is 2 KG-M. This must be ensured. Over size Cam Spindle (For Spares) 570040 : 0.1 mm Over size Spindle 570041 : 0.2 mm Over Size Spindle CAUTION : - After the first 800 kms (500 miles) the backlash between the cam gears must be checked. If a slight cam noise is observed, then adjustment of the eccentric sleeve has to be carried out as mentioned above. - After adjustment to the required backlash, both the Inlet & Exhaust lock nut in the spindle must be tightened to the specified torque. If more or less adjust as follows Initially clean then lubricate chain > EP90 oil and rotate rear wheel. Remove split pin and Hex castle nut on the RH side. Loosen anchor nut. Loosen the brake rod nut Turn the adjuster cams on both sides till 25 to 30 mm chain slackness is achieved Loosen Hex lock nut. Check and ensure that the number of notches from the punch mark on the cam to the notch resting on the pin are equal on both sides. 03-15 REAR SHOCK ABSORBERS ADJUSTMENT The rear shock absorber spring preload can be increased or reduced according to road and load conditions. Rotate the wheel and apply brake and tighten all the nuts and lock the split pin. BRAKE CAM GREASING (EVERY 6,000 KMS) Remove the brake cover plate. Clean the brake cam and apply grease. Refit the cover plate. Increase the spring preload for high load operation. Reduce the spring preload for low load operation. The adjuster provided on the bottom of the spring has five notches. To carry out the adjustment proceed as follows : BRAKE PEDAL PLAY ADJUSTMENT PEDAL FREE PLAY 20 TO 30 MM -Using special tool, place it on the slot provided on the adjuster. Turn in/out the 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. FRONT FORK A. OIL LEVEL CHECK (EVERY 6000 KMS) Take out front fork from the vehicle. Remove bolt cap. Fill 265 ml of API SG 10W-30 oil in each leg . Bump the fork several times and then assemble bolt cap with “O” ring (to release air lock if any). Assemble back all removed parts. DISC BRAKE FLUID LEVEL CHECK Check brake fluid is above the ‘Min’ level in master cylinder. MAX MIN Top up if level is below ‘Min’ mark. Check oil level with a 5 mm dia rod. The level height must be 370 to 380 mm. Top up, with API SG 10 W-30 oil, if required B. OIL CHANGE (EVERY 12,000 KMS) Remove the fork ends from the vehicle. Check as detailed in the Section 8 To Top up the fluid, remove the master cylinder top cover 2 screws and take out cover, plate & diaphragm. Top up brake Fluid DOT 3 or DOT 4 upto “MAX” level. CAUTION : As the brake fluid is highly corrosive, take care that it does not spill over other parts. It is 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) Keep a wooden plank under the stand. Rock the front 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’ Pack grease in the top ball race. Assemble the steering stem. WHEEL ALIGNMENT CHECK Hold the vehicle upright off the stand on level ground. Stretch a string about 100 mm above the ground along the wheels. If the string touches two points on the rear wheel and two points on the front wheel (Four point contact) then the wheels are aligned. B A Tighten stem lock nut as shown picture ‘B’ Check play. Steering to be free with out any play. Tighten all the screws in reverse order. STEERING BALL RACE LUBRICATION (EVERY 12,000 KMS) Remove steering stem assembly. Clean and check the balls and races thoroughly for damages / pittings / discolouration. If string touches only three points on the two wheels, the alignment is incorrect Adjust the rear wheel, chain adjuster till the string touches four points. CLUTCH CABLE FREE PLAY : (2-3mm) LEVER END Check clutch cable button seating position inside lever and condition of the cable. Change them if found defective. Pack grease and balls on the bottom ball race as shown in Fig. 03-18 Screw in or out the cable adjuster for setting the required play at lever end (2 to 3 mm). (B ) ADJUSTMENT AT THROTTLE BODY END Loosen the lock nuts on both the cables. Adjust both cables unitform and tighten the lock nuts. After adjustment refix cable boot. PRIMARY CHAIN TENSION ADJUSTMENT This vehicle is fitted with Auto chain tensioner. Hence there is no need for periodic manual adjustment. THROTTLE CABLE PLAY ADJUSTMENT Throttle rotor free play 2-3 mm. 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. THROTTLE CABLE ASSY REPLACEMENT 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 Level to be between max and min marks (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. NOTE : Incase of maintenanace free battery following procedure not applicable. 03-19 If required, top up with distilled water VALVE TIMING CUM ECCENTRIC CAM SPINDLE Bring piston to TDC so that the key way in the Rotor assembly is at 12o Clock position Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear. SPECIFIC GRAVITY CHECKING : Check specific gravity (SG) with a hydrometer Similarly check position of the inlet cam single punch mark align with the single punch mark on the exhaust cam. ECCENTRIC CAM SPINDLE ADJUSTMENT Specific Gravity - Min 1.22 & Max 1.24 If less, recharge the battery. The 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 arrived. TERMINAL CLEANING : Clean terminal with warm water and apply petroleum jelly. In case of sulphation clean by zero base emary paper. DECARBONISING (EVERY 30,000 KMS) CYLINDER HEAD ( For further details please Ref. page No.09-3) 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. 03-20 Remove the piston rings carefully. For cleaning the groove in the piston, a piece of broken piston ring thrust into a wooden handle and filed to a chisel point can be used. Standard Service Limit : 0.9 - 1.1 mm : 1.5 mm Valve seat width is not within specification, reface the valve seat. CYLINDER HEAD AND VALVES CAUTION : VALVE SEAT INSPECTION If a valve face is burnt or badly worn or if it contacts the seat unevenly, replace the valve. Clean both Inlet & Exhaust valves and thoroughly remove the carbon deposits Inspect the valve seat face for : Damage face : Replace the valve and reface the valve seat. Uneven seat width : Bent or collapsed valve stem. Replace the valve and reface the valve seat. 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 Contact area is too high or too low. Reface the valve seat. 03-21 VALVE SEAT REFACING Valve Seat cutters, a grinder or equivalent valve seat refacing equipment are recommended to correct worn valve seat. If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60 degree inner cutter. NOTE : Use a 45 degree cutter to remove the roughness or irregularities from the seat. Using 32 degree cutter, remove top 1/4 of the existing valve seat material. Using 60 degree cutter, remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area. Install a 45 degree finish cutter and cut the seat to proper width. Reface the valve seat with a 45 degree cutter when a valve guide is replaced. Make sure that all printing and irregularities are removed. Refinish if necessary. Standard seat width : 0.9 - 1.1 mm 03-22 After cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure. NOTE : Excessive lapping pressure may deform or damage the seat. Change the angle of lapping tool frequently to prevent uneven seat wear. Lapping compound can cause damage if it enters between the valve stem and guide. After lapping, wash any residual compound off the cylinder head and valve. NOTE : To avoid damage to the seating face, turn the valve slowly while inserting. 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. (For further details Ref. page No.05-55) The Parts detail of Cylinder Head assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 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 03-23 ENGINE COMPRESSION TEST STEP-A Start and warmup the engine to normal running temperature. Remove the spark plug & connect compression gauge. a) Remove spark plug & put few drops of engine oil into the combustion chamber. b) Connect compression gauge & repeat the procedure as explained in the step-A. If compression pressure does not increase, then check for c) Switch “OFF” Ignition and engine stop switch condition. - 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 Hold the throttle open fully and kick several times (5 to 6 times). Note down the reading and repeat the above process 3 times. Take to average mean reading in 100 ± 10 PSI which is the correct compression pressure. Specified engine compression pressure. STEP-B In case compression pressure is less than 80 PSI, then refit spark plug & start again to warmup the engine. 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 ENGINE LUBRICA TION SY STEM LUBRICATION SYSTEM 04-1 LUBRICA TION SY STEM LUBRICATION SYSTEM ROCKER PUSH ROD FLY HYDRAULIC OIL PUMP CAM STRAINER CRANK OIL SUMP LUBRICATION SYSTEM : Oil from the oil tank is circulated to various parts through a powerful oil pump, the capacity of which is 4.5 litres per minute @ 2750 rpm. The oil in the sump gets filtered through an oill strainer located in the crankcase and then pumped into the oil filter element located in the RH Cover. From here oil is circulated to 3 main areas. The 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 : 3 Specification: MOTUL 3000 4T PLUS 15W50 API, JASO MA SL - GRADE ESTER-Semi Synthetic 3 Oil capacity: 2.75 l - Initial oil filling: through Oil filler Cap = 2.5 l, through Crankcse LH Cover: 0.25 l 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 HYDRA ULIC TAPPETS (ROLLER HYDRA ULIC VAL VE HYDRAULIC HYDRAULIC ALVE LIFTER (RHVL) HYDRAULIC TAPPET : The Hydraulic tappet, (also known as RHVL Roller Hydraulic Valve Lifter) is located between the cam and pushrod in the valve train mechanism. It not only serves as a valve lifter most importantly, it automatically and constantly adjusts itself to compensate for any extra clearance in the valve train mechanism when the engine is running at various RPM. The automatic adjustment is achieved with the aid of hydraulic pressure inside the hydraulic tappet. BENEFITS OF HYDRAULIC TAPPET : 3 Eliminates the need for manual and periodic push rod height adjustments. 3 Compensates for clearances in the valve train mechanism due to wear of moving parts OR due to variations in engine temperature. ROLLER HYDRAULIC VALVE LIFTER OUTER BODY PUSH ROD OIL ESCAPING OIL OIL TRANSFER ANULUS PLUNGER (D) PUSHROD SEAT (C)DISC VALVE (B) OVER HEAD OIL FLOW PATH OIL INLET (E) LOW PRESSURE CHAMBER CHECK BALL SEAT AIR ESCAPE PATH THROUGH PLUNGER CLEARANCE (F) TRAPPED AIR VOLUME (H) HIGH PRESURE CHAMBER OIL HEAD, OIL DELIVERY CONTROL VALVE, LOCKING ACTION CHECK BALL (A) HIGH PRESSURE CHAMBER OIL FLOW PATH ROLLER 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 plunger with respect to the body. 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, must be changed periodically as specified. Whenever the tappets are removed for service OR 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. 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). 04-4 AUT O DECOMPRESSOR AUTO WORKING PRINCIPLE BENEFITS OF AUTO DECOMPRESSOR : The auto decompressor is assembled in the exhaust cam and consists of a flyweight, spring and pin. These are assembled in the cam assembly with a screw 3 Eliminates the need to fix a manual system which will need to be adjusted and serivced periodically. 3 Helps in easy starting of the engine 3 Helps to reduce high initial load on the electric start motor 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 04-5 ELECTRIC ST AR TER SY STEM & SPRA G MECHANISM STAR ARTER SYSTEM SPRAG WORKING PRINCIPLE The sprag is located in the primary sprocket on the crankcase drive side. This provides better rigidity of the sprag mechanism during initial crankin. The auto decompressor mechanism further helps in reducing the load on the sprag during intitial cranking and also prevents reversal phenomenon of the crank shaft. 04-6 AUT O CHAIN TENSIONER ASSEMBL Y UTO ASSEMBLY WORKING PRINCIPLE The auto chain tensioner has a spring loaded plunger mechanism with a ratchet arrangement. It eliminates need for manual adjustment of the primary chain tension. It is assembled on the crankcase LH below the chain tensioner pad. The spring loaded plunger applies force on the chain tensioner pad thereby lifting it and holding aginst the primary chain to the required tension. 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 BREA THER SY STEM BREATHER SYSTEM Breather arrangement inside the RH cover WORKING PRINCIPLE The engine breather system is located on the RH cover of the crankcase. A connecting hole directs the engine breathing into a chamber in the RH cover which has an inbuilt deflector to deflect the oil that may come along with the fumes from the crankcase. This oil gets drained through a small hole provided at the bottom of the breather chamber. 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 CL UT CH SY STEM CLUT UTCH SYSTEM The clutch system has a seven plate construction to achieve increase effective diameter and improved torque carrying capacity. The clutch is operated through a lever on the cover LH. 04-9 INLET MANIFOLD & THR OTTLE BOD Y THRO BODY The inlet manifold has the fuel injector located on top portion and the throttle body attach to it. The throttle body has a butterfly valve attached which is operated buy the throttle cables attached to a drum on the right side. A manual Bi starter is located on the left side and is the spring and plunger type arrangement. An idle air bypass screw is provided on the throttle body. 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 ¼ turn will result in an approximate 200 RPM change in the idle speed. DO NOT adjust the throttle stop screw on the side of the throttle body unless you are using the factory software to recalibrate the base throttle opening. 04-10 Blow Up Charts 04-11 27 31 30,31,32,33,34 Key Nos. A2 13,14,15,16,17 Key Nos. A1 28 29 30 32 33 26 7 7 25 34 8 9 10 21 24 A2 11 22 10 11 12 23 40 36 37 38 39 35 6 12 5 4 14 13 20 42 15 16 3 41 17 A1 10 2 18 1 19 10 44 45 43 CRANK CASE RH - COVER SIDE 04-12 CRANK CASE RH - COVER SIDE KEY No. DESCRIPTION A1 CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY A2 OIL PUMP ASSEMBLY 1 TAPPET DOOR BUFFED 2 CSK SOCKET HEAD SCREW M5 X 12 3 ROTOR AND RELUCTOR ASSEMBLY 4 KEY - MAGNETO 5 PLAIN WASHER, 6 HEX. NUT M12 X 1.25 7 HEX. SOCKET HEAD CAP SCREW, M6 X 30 8 HEX. SOCKET HEAD CAP SCREW, M6 X 25 9 CAM STEADY PLATE 10 DOWEL 6 MM 11 NUT - CAM SPINDLE 12 SHIM, CAM GEAR 13 PIVOT 14 PIN ASSEMBLY 15 FLY WEIGHT 16 TORSION SPRING 17 CAM GEAR SUB ASSEMBLY- EXHAUST 18 CAM SLEEVE 19 CAM SPINDLE ADJUSTABLE KEY No. DESCRIPTION 26 FD SPROCKET 17 TEETH 27 TAB WASHER 28 NUT 29 CSK SOCKET HEAD SCREW M6 X 30 30 CIRCLIP 31 PUMP DRIVE PINION (GEAR) 32 HEX. SOCKET HEAD CAP SCREW M6 X 25 33 ‘O’ RING, OIL PUMP OUTLET 34 GASKET, OIL PUMP 35 HEX FLANGE BOLT M5 X 12 36 COPPER WASHER 37 CAP, PIVOT PIN 38 ‘O’- RING 39 ‘O’ RING 40 PIVOT, CAMPLATE 41 HEX SOCKET HEAD CAP SCREW, M6 X 60 42 STARTER MOTOR ASSEMBLY 43 HYDRAULIC VALVE LIFTER ROLLER 44 COVER STARTER MOTOR 45 HEX SOCKET, BUTTON HEAD SCREW, M5 X 12 CAM SPINDLE ADJUSTABLE ( 0.1 OVERSIZE ) CAM SPINDLE ADJUSTABLE ( 0.2 OVERSIZE ) 20 CAM, GEAR - INLET 21 HEX SOCKET PAN HEAD SCREW M5 X12 22 OIL SEAL KICK STARTER 23 COVER, KICK START SHAFT 24 OIL SEAL 25 DISTANCE PIECE 04-13 CRANK CASE LH INSIDE VIEW 04-14 CRANK CASE LH KEY No. DESCRIPTION 1 CRANK CASE-LH 2 CIRCLIP 3 BALL BEARING 6305 (25 X 62 X 17) 4 BEARING SPACER 5 ROLLER BEARING NU305 (25 X 62 X 17) 6 BALL BEARING 6006 7 RETAINER PLATE, MAINSHAFT BEARING 8 HEX SOCKET HD CAP SCREW , M5 X 16 9 JACK SHAFT 10 STUD, M8 X 128 11 FLANGE NUT-M8 12 NEEDLE BEARING 13 WASHER, THRUST 14 STUD M6 X 133 04-15 1 2 6 3 7 4 8 5 9 27 30 11 12 29 26 10 28 25 24 21 22 23 20 15 16 17 14 13 19 18 CRANK CASE RH - INSIDE VIEW 04-16 CRANK CASE RH - INSIDE VIEW KEY No. DESCRIPTION KEY No. DESCRIPTION 1 CIRCLIP 18 MACHINED WASHER 6.4 2 DEEP GROOVE BALL BEARING – SLEEVE GEAR 19 HEX. NYLOCK NUT M6 X 1 20 HEX FLANGE BOLT M5 X 16 3 NEEDLE BEARING 21 DRAIN CAP - SUMP 4 SLEEVE GEAR 22 O RING- DRAIN CAP 5 NEEDLE BEARING 23 SUCTION FILTER ASSY 6 HEX. SOCKET HEAD CAP SCREW, M6 X 12 24 STOP PLATE 7 BRACKET - PIN - HYDRAULIC - TAPPET 25 HEX. SCREW M8 X 25, 8 NEEDLE ROLLER 26 OIL THROWER 9 BEARING 27 HEX. SOCKET HEAD CAP SCREW, M5 X 35 10 DOWEL - HOLLOW 28 LOCATING PIN (PIVOT) 11 STUD, M8 X 128 29 NEEDLE BEARING 12 FLANGE NUT-M8 30 WASHER, THRUST 13 BOLT, PAWL 14 WASHER, INSPECTION SCREW 15 MAGNETIC PLUG ASSEMBLY 16 SPRING 17 PAWL, CAMPLATE 04-17 ENGINE COVER - RH 49 27 48 7 04-18 ENGINE COVER - RH KEY No. DESCRIPTION KEY No. DESCRIPTION 1 UCE, RH COVER SUB ASSEMPLY 26 HEX.SCREW, M5X12 2 COVER, RH 27 3 PLUG STATOR & PULSOR COIL ASSY THREE PHASE 4 RESTRICTOR (LEE PLUG) 28 PULSOR COIL FIXING SCREW 5 SEALING WASHER 12X15.5 29 ALLEN SCREW M6X30 6 OIL LEVEL WINDOW 30 HEX.SOCKET HEAD CAP SCREW, M6X85 7 BOLT BREATHER 31 HEX.SOCKET HEAD CAP SCREW, M6X100 8 JET,CRANKSHAFT RH 32 HEX.SOCKET HEAD CAP SCREW, M6X80 9 OIL SEAL , CRANK FEED 24X10X7 33 HEX.SOCKET HEAD CAP SCREW, M6X60 34 HEX. SOCKET HEAD CAP SCREW, M6X40 35 GASKET - COVER RH 36 OIL SEAL, KICK SHAFT 37 KICK START CRANK ASSY. 38 BOSS, KICK START CRANK 39 SPRING 40 BALL DIA 6.35 41 LEVER, KICK START CRANK 42 SLEEVE, KICK START LEVER 43 WASHER 44 CIRCLIP 10 45 HEX. BOLT M8X40 46 HEX. NUT, M8 47 SEALING WASHER 6 × 10 IS : 3175 CU 48 BREATHER PIPE 49 FLYWHEEL MAGNETO 3 PHASE 10 CIRCLIP 24N 11 WASHER, INSPECTION SCREW 12 INSPECTION SCREW, IGNITION TIMING 13 O-RING 14 OIL FILLER CAP, NYLON 15 ELEMENT - OIL FILTER 16 SPRING CAP 17 WASHER 18 SPRING 19 O-RING 20 O-RING, FILTER CAP 21 GASKET, CAP OIL FILTER 22 CAP, OIL FILTER 23 HEX FLANGE BOLT M5x16 24 GASKET, COVER PLATE 25 COVER PLATE, BREATHER CHAMBER 04-19 CRANK CASE LH - COVER SIDE 04-20 CRANK CASE LH - COVER SIDE KEY No. DESCRIPTION KEY No. DESCRIPTION 1 CRANK CASE-LH 23 BUSH, C T PAD 2 DOWEL (6MM) 24 CHAIN TENSIONER PAD 3 COLLAR, MAINSHAFT 25 PLAIN WASHER 4 GEAR, - JACK SHAFT 26 HEX.NUT,M8 5 KEY - JACK SHAFT 27 AUTO CHAIN TENSIONER ASSEMBLY 6 CIRCLIP 12 × IN IS 3075 (PART I) (FOR SHAFT) 28 O RING,CHAIN TENSIONER ASSEMBLY. 29 HEX. SOCKET HEAD CAP SCREW, M6X20 7 DOWEL 30 SPRAG CLUTCH ASSEMBLY 8 NEUTRAL SWITCH WITH PACKING 31 ENGINE SPROCKET 9 HEX.SOCKET HD.CAP SCREW,M6 X 50 32 SPRAG CLUTCH 10 STUD M6 X 168 33 SPRAG CLUTCH GEAR 11 STUD M6 X 106 34 NEEDLE BEARING 12 STUD M6 X 196 35 WASHER 13 STUD M6 X 226 36 HEX.HEAD SCREW M12 14 STUD M6 X 80 37 CLUTCH ASSEMBLY COMPLETE 15 NUT M6X1, FLANGE NYLOC TYPE 38 NYLOCK NUT 16 SHAFT, DOUBLE GEAR 39 CLUTCH PUSH PAD 17 DOUBLE GEAR - STARTER DRIVE 40 BALL BEARING 6001 18 HOUSING STARTER DRIVE 41 PRIMARY CHAIN 19 HEX.SOCKET HD.CAP SCREW,M5 X 45 42 HEX.SOCKET HEAD CAP SCREW, M6X85 20 HEX.SOCKET HD.CAP SCREW,M5 X 25 43 PLAIN WASHER 21 DISTANCE WASHER , SPRAG CLUTCH 22 STUD, CHAIN TENSIONER PAD 04-21 ENGINE COVER - LH 10 8 12 7 11 6 9 15 14 3 5 18 2 4 16 17 19 1 20 13 04-22 ENGINE COVER - LH KEY No. DESCRIPTION 1 LH COVER SUB ASSEMBLY 2 COVER, LH 3 BUSH 4 OIL SEAL 14 X 20 X 3 5 GASKET, COVER LH 6 OIL SEAL INA G 12 X 18 X 5 7 ASSEMBLY, CLUTCH OP 8 CABLE CLEVIS, CLUTCH OPERATING LEVER 9 CLUTCH CABLE ASSEMBLY 10 PIN, CLUTCH OPERATING LEVER 11 LOCK PIN SPRING, CLUTCH OPERATING MECH. 12 SPRING, CLUTCH OP LEVER 13 HEX. SOCKET HEAD CAP SCREW, M6 X 201 14 O-RING (PLUG) 15 OIL FILLER PLUG 16 GEAR LEVER 17 SLEEVE, GEAR LEVER 18 HEX SCREW M6 X 25 19 SEALING WASHER 6 × 10 IS : 3175 CU 20 HEX NUT M6 - IS 1364 (PART 3) - 8 - ZN.PL 04-23 GEAR TRAIN ASSEMBLY 04-24 GEAR TRAIN ASSEMBLY KEY No. DESCRIPTION KEY No. DESCRIPTION A1 LAY SHAFT SUB ASSEMBLY 16 BUSH A2 MAIN SHAFT SUB ASSEMBLY 17 SELECTOR FORK LH 1 MAIN SHAFT 18 SELECTOR FORK CENTRE 2 MAIN SHAFT 2ND GEAR 19 SELECTOR FORK RH 3 WASHER, THRUST 20 SELECTOR FORK SHAFT 4 MAIN SHAFT 4TH GEAR 21 CIRCLIP 10N 5 CIRCLIP 22 CAM PLATE ASSEMBLY 6 MAIN SHAFT 3RD GEAR / 4TH GEAR 23 RATCHET PLATE 7 MAIN SHAFT 1ST GEAR7 24 RIVET, CAM PLATE/RATCHET PLATE 8 LAY SHAFT 25 ROLLER 9 WASHER, THRUST 26 PIN 10 LAY SHAFT 2ND GEAR 11 LAY SHAFT HIGH GEAR 12 LAY SHAFT 3RD & 4TH GEAR ASSY. 13 WASHER, THRUST 14 ASSEMBLY, LAYSHAFT 1ST GEAR 15 LAYSHAFT 1st GEAR 04-25 GEAR SHIFTING KICK STARTER(E5 & G5) 5 04-26 GEAR SHIFTING KEY No. DESCRIPTION 1 SS ROCKER SHAFT ASSEMBLY, 2 PIN PIVOT 3 STRIKER, GEAR CHANGE 4 SPRING 5 SPRING, GEAR CHANGE STRIKER 6 SPACER 7 PIVOT BEARING, ROCKER SHAFT UPPER 8 HEX. SOCKET HEAD CAP SCREW, M6 X 12 9 PIVOT BEARING, ROCKER SHAFT BOTTOM 10 ASSEMBLY, GEAR LEVER SHAFT 11 STOP PIN 12 O-RING 13 HEX. SOCKET HEAD CAP SCREW, M5 X 40 KICK STARTER(E5 & G5) KEY No. A1 DESCRIPTION KICKSTARTER SHAFT SUB ASSEMBLY 1 KICKSTART SHAFT 2 SPRING 3 PLUNGER 4 PAWL 5 WASHER, THRUST 6 KICKSTART GEAR ASSEMBLY 7 KICKSTARTER GEAR 35T 8 BUSH 9 CIRCLIP 10 SPRING 11 HEX SCREW M6 04-27 CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT 25 37 36 24 35 23 27 37 38 22 26 37 39 38 39 38 38 19 17 21 18 34 20 15 14 11 10 9 33 6 7 32 3 8 30 29 28 16 2 5 12 CRANK SHAFT ASSY. 4 31 13 PISTON ASSY. 04-28 CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT KEY No. DESCRIPTION 1 CYLINDER HEAD SUB ASSY (CYLINDER HEAD, VALVE GUIDE, VALVE SEATS) 2 CYLINDER HEAD - ONLY MACHINED HEAD 3 VALVE GUIDE 4 VALVE SEAT INSERT, EXHAUST 5 VALVE SEAT INSERT,INLET 6 DOWEL (6mm) 7 SPARK PLUG - M 10 - (UR5DC) 8 SPARK PLUG - M 14 - (W5DC) 9 SEAT, SPRING 10 VALVE STEM SEAL 11 VALVE SPRING 12 VALVE INLET 13 VALVE EXHAUST 14 RETAINER,SPRING 15 SPLIT COLLAR 16 PLUG 17 ROCKER BEARING SET-EXHAUST 18 ROCKER ARM - INLET 19 HEX.SOCKET HD.CAP SCREW,M6 X 55 20 ROCKER BEARING SET-INLET KEY No. DESCRIPTION 21 ROCKER ARM, EXHAUST 22 GASKET, ROCKER COVER INLET 23 ROCKER COVER - INLET 24 WASHER-SEAL 25 HEX HEAD SCREW-ROCKER COVER 26 GASKET, ROCKER COVER EXHAUST 27 ROCKER COVER - EXHAUST 28 CYL. BARREL ASSY 29 DOWEL PIN 30 DOWEL PIN 31 GASKET CYLINDER BARREL 32 GASKET HEAD(MLS) 33 PUSH ROD ASSY, EXHAUST 34 PUSH ROD ASSY, INLET 35 STUD, EXHAUST 36 DAMPER PAD - CYLINDER HEAD LH 37 DAMPER PAD - CYLINDER HEAD RH 38 DAMPER PAD TAPER- BARREL 39 DAMPER PAD STRAIGHT - BARREL 04-29 DAMPER PAD POSITION DETAILS Number of damper pads per engine = 15 570482/b INLET SIDE VIEW 570479/b 570478/b 570482/b 570480/b Part No. Description Quantity per engine 570478/b Damper pad-cylinder head LH 2 Damper padcylinder head RH 4 570479/b Image EXHAUST SIDE VIEW 570479/b 570479/b 570482/b 570482/b 570480/b Quantity per engine Part No. Description 570480/b Damper pad straight - Barrel 3 570482/b Damper pad taper - Barrel 6 Image 04-30 SECTION FIVE 05 TORQUE SPECIFICA TIONS SPECIFICATIONS ENGINE DISMANTLING INSPECTION & ASSEMBL Y ASSEMBLY TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. ENGINE DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. 1 570013 HEX SOCKET HD CAP SCREW, M5 X 16 RETAINER PLATE / SUCTION FILTER MTG 0.60 6 2 570016 HEX.SOCKET HD.CAP SCREW, M5 X 45 E START HOUSING COVER 0.60 6 3 570094 HEX.SOCKET HD.CAP SCREW, M5 X 25 E START HOUSING COVER 0.60 6 4 570232 HEX.SOCKET HD.CAP SCREW, M6 X 12 STOP PLATE, PIVOT PIN / COVER LH / PIVOT BRG LOWER 1.00 10 5 570020 HEX FLANGE BOLT CRANK CASE SET ASSY 2.50 25 6 145879 FLANGED HEX. BOLT M8 X 112 FRONT ENGINE MTG PLATE 2.50 25 7 145867 FLANGED HEX. NUT M8 X 1.25 FRONT ENGINE MTG PLATE / EXHAUST PIPE MTG 2.50 25 8 570088 STUD 168L (M6) CRANKCASE SET ASSY 1.00 10 9 570090 STUD 106L (M6) CRANKCASE SET ASSY 1.00 10 10 570089 STUD 196L (M6) CRANKCASE SET ASSY 1.00 10 11 570024 HEX.SOCKET HD.CAP SCREW, M6 X 50 CRANKCASE SET ASSY 1.00 10 12 570085 DOWEL, STUD (M6) CRANKCASE SET ASSY 1.00 10 13 570025 HEX.SOCKET HD.CAP SCREW, M6 X 90 CRANKCASE SET ASSY 1.00 10 14 570086 STUD 226L (M6) CRANKCASE SET ASSY 1.00 10 15 570087 STUD 133L (M6) CRANKCASE SET ASSY 1.00 10 16 570091 STUD 80L (M6) CRANKCASE SET ASSY 1.00 10 17 145866 FLANGED HEX. NUT M6 X 1 CRANKCASE SET ASSY 1.00 10 18 570030 HEX.SOCKET HD.CAP SCREW, M6 X 20 AUTO CHAIN TENSIONER ASSY / COVER LH 1.00 10 19 570095 CHAIN TENSIONER STUD, (M8) AUTO CHAIN TENSIONER ASSY 2.50 25 20 141051 HEX.NUTM8 AUTO CHAIN TENSIONER ASSY / KS CRANK 2.50 25 21 570100 NUT (M10 X 1) CAM SPINDLE SLEEVE NUT 2.00 20 22 570421 HEX.SOCKET HD.CAP SCREW, M6 X 30 CAM STEADY PLATE 1.00 10 23 570132 HEX.SOCKET HD.CAP SCREW, M6 X 25 CAM STEADY PLATE 1.00 10 24 500355 HEX.SOCKET HD.CAP SCREW M6 X 16, BRACKET, PIN, HYD, TAPPET / INLET FLANGE 1.00 10 25 570198 CSK SOCKET HEAD SCREW M5 X 0.8 X 12 TAPPET DOOR 0.60 6 26 570051 HEX.SOCKET HD.CAP SCREW, M4 X 30 OIL PUMP HOUSING ASSY 0.60 6 27 570064 HEX.HEAD SCREW M12 X 1.25 X 20 SHAFT LH 4.80 48 28 550025 HEX NUT M12 X 1.25 SHAFT RH 4.80 48 29 570463 HEX.SOCKET HD.CAP SCREW, M6 X 60 E START MOTOR MOUNTING / COVER RH 1.00 10 05-1 TOR QUE SPECIFICA TION - ENGINE TORQ SPECIFICATION S. PART No No. DESCRIPTION LOCATION TORQUE VALUE Kg/M. N/M. 30 570215 BOLT, PAWL (M6 X 1) GEAR BOX INDEX 1.00 10 31 570233 HEX.SOCKET HD.CAP SCREW, M5 X 40 PIVOT BEARING, ROCKER SHAFT LOWER 0.60 6 32 550138 CSK SOCKET HEAD SCREW M5 X 0.8 X 16, COVER, KICKSTART SHAFT 0.60 6 33 145090 HEX SCREW M6 X 16 KICKSTART, SPRING 1.00 10 34 570240 HEX.SOCKET HD.CAP SCREW, M5 X 35 COVER K.S. GEAR 0.60 6 35 142291 HEX SCREW M8 X 22.5 STOP PLATE, KICK PAWL 2.50 25 36 111914 HEX.BOLT M8 X 40 ASSY, KICK START CRANK 2.50 25 37 143498 HEX. SCREW M6 X 25 GEAR LEVER 1.00 10 38 141060 HEX. NUT M6 GEAR LEVER 1.00 10 39 570246 NUT (M35 X 1.5) FD SPROCKET 8.00 80 40 570440 HEX SCREW M6 X 1 X 35 CLUTCH ASSY 1.00 10 41 560525 HEX. NUT WITH NYLOC INSERT M16X1.5, MAIN SHAFT, CLUTCH SIDE 4.80 48 42 570444 BOLT, BREATHER (M12) BREATHER ASSY 2.00 20 43 570422 HEX.SOCKET HD.CAP SCREW, M6 X 100 COVER RH 1.00 10 44 570130 HEX.SOCKET HD.CAP SCREW, M6 X 85 COVER RH 1.00 10 45 570423 HEX.SOCKET HD.CAP SCREW, M6 X 40 COVER RH 1.00 10 46 570021 HEX.SOCKET HD.CAP SCREW, M6 X 80 COVER RH 1.00 10 47 570425 HEX.SOCKET HD.CAP SCREW, M5 X 12 COVER PLATE, BREATHER CHAMBER 0.60 6 48 570431 HEX FLANGE BOLT CAP, OIL FILTER 0.60 6 49 570131 HEX.SOCKET HD.CAP SCREW, M6 X 60 ROCKER BEARING 1.00 10 50 570129 HEX HEAD SCREW ROCKER COVER MTG ROCKER COVER 1.00 10 51 570175 FLANGED HEX. BOLT M8 X 90 STEADY BRACKET CYL. HEAD 2.50 25 52 570177 HEX NUT WITH NYLON INSERT, M8 STEADY BRACKET CYL. HEAD 2.50 25 53 500327 FLANGE NUT M8 CYL.HEAD MOUNTING 2.50 25 54 500104 STUD, M8 X 128 CY.HEAD MOUNTING 2.50 25 55 570304 HEX SOCKET HEAD CAP SCREW M6 X 12 PIVOT BEARING, UPPER 1.0 0 10 56 550095 ALLEN SCREW M6 X 30 STATOR COIL MOUNTING 1.00 10 57 570276 MAGNETIC PLUG ASSY CRANKCASE DRAIN 2.00 20 58 500339 STUD EXHAUST EXHAUST PIPE MTG 0.60 6 59 572025 SPARK PLUG 2.80 28 05-2 ENGINE DISMANTLING , INSPECTION AND ASSEMBL Y ASSEMBLY COMPONENTS THA T CAN BE THAT REMO VED WITH THE ENGINE REMOVED MOUNTED ON THE FRAME. Cylinder head assembly Cylinder barrel & Piston Crank case Cover RH Crank case Cover LH Clutch assembly Inlet and Exhaust Cam assembly Oil pump Assembly ENGINE SHOULD BE REMO VED FR OM THE FRAME REMOVED FROM FOR THE FOLL OWING JOBS: FOLLO Remove the front and rear flange nuts, washer at the front & rear mounting of the fuel tank. Crank case repair/replacement. Crank shaft and main bearings replacement. Roller Hydraulic Valve Lifter (RHVL) replacement. Transmission parts like Gears, Mainshaft, Layshaft, repair / replacement Kick Starter Gear, Pawl, Spring , Plunger replacement. (only for Bullet Electra EFI E5/G5) NOTE : Before starting to dismantle engine, crank gently & bring piston to TDC. Lift the tank from the seat side & remove. DISMANTLING PROCEDURE Disconnect fuel hose. Take care to ensure fuel does not spill. Disconnect fuel pump module and low fuel sensor couplers. CAUTION : Keep a 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 SEA T REMO VAL B ULLET SEAT REMOV BULLET ELECTRA EFI (E5/G5) Remove 4 nos. flange bolts from both sides of the seats. Remove the 2 screws, at the bottom of the LH switch module and separate the module from the handle bar. Disconnect the cable from the lever. Remove the pillion holder, lift from the rear end and pull out the seat BULLET CLASSIC EFI (C5) Remove the mounting bolts as shown and remove the seat. Remove cable from the straps in the frame. Manual Bi starter 05-4 CL UT CH CABLE REMO VAL CLUT UTCH REMOV Slacken the adjuster at the clutch cover end and disconnect the cable from the lever. Take out clutch cable from the cover. Remove the clutch cable from the clutch lever at handle bar end. REMO VAL OF THR OTTLE REMOV THRO CABLE Slacken the adjusters at the throttle body end for both cables. REMO VAL OF THR OTTLE REMOV THRO BOD Y BODY Loosen the throttle body flange & bellow clip. Remove the throttle body by pushing towards Air Filter box. REMO VAL OF SILENCER AND REMOV EXHA UST PIPE EXHAUST Remove the centre silencer bracket mounting screw with plain washer. 05-5 Remove the rear mounting at the pillion foot rest end (C5). Remove the rear mounting at the pillion foot rest end (E5/G5). Remove the flange nut 2 nos. from cylinder head. Remove the Silencer Assembly with Exhaust pipe. Remove the Suppressor Cap NOTE : Loosen the rear brake rod adjuster nut so that the brake pedal can be depressed to allow the exhaust pipe to be removed. Disconnect the Oxygen sensor, loosen and remove from Exhaust pipe. BATTER Y REMO VAL TTERY REMOV Ensure ignition switch is in “OFF” position. FOR BULLET ELECTRA EFI (E5 / G5) Remove side panel LH. 05-6 Remove the battery flap cover Remove the terminal boot & terminal wires . Remove the fuse carrier plate mounting screws 2 nos. FOR BULLET CLASSIC EFI ( C5) Remove battery cover on LH side. Remove the black coupler. Remove the battery holding straps pull the battery out & remove terminals. CAUTION : Always remove earth wire terminal first. 05-7 REMO VAL OF E-ST AR T MO TOR REMOV E-STAR ART MOT Remove the cover screw Remove the terminal rubber boot. Remove 4 screws of the starter drive housing and tap gently to free the housing. Gently lift the motor and remove the motor along with the housing. Remove the 2 dowels for the housing drive. Remove the terminal nut & take out the terminal wire lead. Remove the 2 mounting allen screws. REMO VAL OF DRIVE CHAIN REMOV Rotate the rear wheel to bring the chain lock to a convenient position and remove the chain lock. Lift the motor upwards and pull out of the housing in the front. 05-8 Remove the chain link and the drive chain. REMO VAL OF SIDE ST AND REMOV STAND Disconnect the coupler of the side stand Engine cut off switch from the wiring harness. Slacken the nyloc nuts & remove the brake light switch. Remove the piece mudguard bracket bolt along with 2 plain washers & 1 star washer Remove the mounting nuts and remove the side stand. Remove rider foot rest LH & RH (E5/G5) REMOVAL OF REAR BRAKE SWITCH Disconnect the brake switch spring from brake lever. Remove rider foot rest LH & RH (C5) Disconnect the rear brake switch coupler from the wiring harness 05-9 Engine oil Drain It is best to drain the engine oil in warm condition. Remove the 2 Flanged hex bolts. Remove the drain cap with ‘O’ ring. Remove suction filter. Remove the magnetic drain plug with washer. CYLINDER HEAD ASSEMBL Y ASSEMBLY Remove the 4 allen screws along with rubber seals from Inlet and exhaust rocker covers. Remove the Inlet & Exhaust Rocker cover, dowel & rubber gasket. Remove the 4 allen screws each on the rocker bearing inlet & exhaust. Remove the inlet and exhaust rocker bearing with dowel and rocker arm. Magnetic Drain Bolt 05-10 Remove inlet and exhaust pushrods Remove the Cylinder head assy. Remove the Spark plug Remove the multi layer steel (MLS) head gasket. REMOVAL OF VALVES Remove the 6 flanged hex nuts, securing the cylinder head. Remove the Inlet & Exhaust valves by using special tool No. ST25123-1 Valve spring compressor as shown 05-11 Remove the Inlet Valve spring retainer, split collar and Spring. CYLINDER BARREL SUB ASSEMBLY Remove Inlet Valve as shown NOTE : Ensure piston is at TDC. Gently tap Cylinder barrel and remove along with 2 dowel pins. Remove gudgeon pin and piston. NOTE: Similarly follow the same process to remove Exhaust Valve. Remove Inlet and Exhaust Valve stem seal from valve guides. NOTE : Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel, as shown. 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 Remove oil filter cover bolts. the piston without deforming. Remove Cylinder barrel bottom Gasket. Remove oil filter cap gasket, “O”ring & Spring. Use Special tool No. ST - 25592-4 to hold connecting rod as shown Fig. CAUTION : REMOVAL OF COVER RH SUB ASSEMBLY : Remove kickstarter lever. (only for Bullet Electra EFI - E5/G5) Care must be taken while removing cover due to spring force. Remove the 3 “O” rings, Oil filter element spring cap, washer & Oil filter element. 05-13 Remove the 11 allen screws securing cover RH. Gently tap & pull out the cover evenly Remove RH cover gasket & 2 dowels. It may be necessary to tap the cover slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove Remove Pulser coil by removing 2 screws CAUTION : Tap only at the places shown to avoid damage to the RH cover Remove Stator assembly by removing 3 mounting screws. 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, oil seal and jet crankshaft NOTE : Oil seal recommended to replace at every 20,000 kms interval. Remove Breather bolt and washer Remove 6 Nos. allen screws to remove breather chamber cover Remove oil filler cap and “O” ring Remove breather chamber gasket Remove Ignition Timing check bolt and washer (if not removed earlier). 05-15 Remove the 2 oil seals from the Kick Shaft hole (Electra EFI - E5/G5 only) Remove the 3 allen screws & 2 dowels from Cam steady plate. INSIDE OIL SEAL OUTSIDE OIL SEAL COMPONENTS DISMANTLING ON CRANK CASE RH CRANKCASE REMOVAL OF ROTOR ASSEMBLY Remove Cam steady plate and the shims. Loosen and remove magneto lock nut and plain washer. Ensure the connecting rod is locked properly with the special tool resting firmly and evenly on the crankcase top position. 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. Use Special tool No. ST - 25128-2 Magneto removing tool to remove rotor assembly. 05-16 Remove oil pump plastic gear after removing circlip. Observe short boss of pump drive gear should face outwards. Exhaust cam with auto decompressor. DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR Remove Cam gear inlet. Remove mounting allen screw on flyweight sub assembly. Remove Cam gear Exhaust (Auto decompressor sub assy). Remove flyweight along with return spring over actuating pin lever as shown in Fig. NOTE : Ensure spring bend lug being seated inside flyweight hole properly. 05-17 Remove the actuating pin in the Exhaust cam. Remove the woodruff key. Remove the Oil pump assembly with “O” ring. CAUTION : Ensure "O" ring must be located on the oil pump body outlet. Remove Gear lever from engine LH cover side. Remove the 4 allen screws to remove Oil pump assy. Remove Gear lever shaft with bush (spacer shaft). 05-18 Remove rocker shaft return spring pivot pin with “O” ring by using special No. ST 25123-4 Extractor for 5 speed gear box pivot pin as shown in Fig. Remove the two bolts and remove the rocker shaft upper pivot bearing with “O” ring. Remove the rocker shaft assembly by gently tilting and twisting out. Straighten lock tab and Unlock the FD sprocket nut. Remove nut and lock washer. Remove the two screws holding the lower pivot bearing .. 05-19 Remove FD Sprocket Remove kicker shaft cover with oil seal. NOTE : Use special tool No. ST 25 while removing FD sprocket if necessary. Remove Kick starter return spring locking bolt with washer (only for Bulletin Electra EFI (E5/G5). Pull out Sleeve gear Spacer by using monkey / gas plier as shown in Fig. Remove 4 Nos. Kicker Cover screws. (only for Bullet Electra E5 / G5) Remove Kick starter return spring from kickshaft spindle (only for Bullet Electra EFI (E5/G5). 05-20 DISMANTLING COVER LH SUB ASSEMBLY : Remove the 11 allen screws holding the cover LH. It may be necessary to tap the cover slightly to remove. Remove lock pin and spring from clutch operating shaft. PULL LOCK PIN Remove inspection plug along with “O” ring Remove clutch operating shaft assy from clutch cover. Tap and remove the Clutch cover. Remove Clutch operating shaft oil seal and 2 Nos. of Dowels. 05-21 Remove gear lever shaft bush and oil seal. COMPONENTS DISMANTLING ON CRANK CASE LH CRANKCASE REMOVAL OF CLUTCH ASSY. Use Special tool No. ST - 25591-4 Clutch centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch. Remove nyloc nut & plain washer. Remove clutch push pad, ball bearing & bearing retainer cup. Remove auto chain tensioner bottom pin bolt, “O”ring and spring. Unlock clip and press push rod to slacken duplex chain. Remove 17mm Hex bolt on the Engine sprocket. 05-22 Remove Duplex chain along with Sprag clutch and Clutch assembly. Remove Engine sprocket and sprag clutch gear assembly. DISMANTLING OF CLUTCH ASSEMBLY Remove 2 hex bolts at opposite locations Fix Special tool No. ST - 25594-4 Clutch Spring Compressing Tool and tighten the 2 long bolts fully so as to hold the springs down loosen & remove the other 4 bolts. Remove sprag clutch bearing. FLANGE FACE Remove the special tool holding both evenly to release the spring tension. 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 & 6 Springs. Remove clutch drum sprocket with big washer. Remove clutch hub, centre, friction and steel plates. Remove collar on main shaft (distance collar from Crankcase LH). Remove special distance washer sprag clutch on Crankshaft LH. Remove hex nut and washer to remove chain tensioner pad. 05-24 Remove Auto chain tensioner body assy. by removing the 2 Nos. allen screws. Remove the rear engine mounting nut along with the washer. Remove double gear shaft and double gear starter drive. Remove the front engine mounting nut Remove the jack gear after removing the circlip. Loosen chain stay bolt 05-25 Remove centre stand & footrest supports. Loosen the crankcase stud nuts and allen screws as per the following sequence. Remove the front and rear engine studs & slide the engine assembly off the frame. Remove Engine Front Mounting Bracket. Remove Mudguard mounting clip & Rear Engine Mounting Bracket. Tap gently and remove the crankcase LH. 05-26 Remove special thrust washer (lay shaft ) from Crank case LH & 2 Nos. Dowel pins. Pull out the crank shaft from the crankcase RH. Remove clutch bearing retainer plate holding screws and remove the retainer plate from crankcase LH. Remove clutch ball bearing from crankcase LH. Remove needle roller bearing for lay shaft from crankcase LH. Remove roller bearing NU 305 from crankcase LH. 05-27 Remove spacer, circlip, crank shaft bearing 6305 from crankcase LH. Remove circlip and sleeve gear ball bearing 6007 from crankcase RH. Remove lay shaft needle bearing from crankcase RH. Remove last circlip from crankcase LH. Remove crank shaft needle roller bearing from crankcase RH. Remove nyloc nut, machined washer, pawl - camplate, return spring and bolt pawl from crankcase RH. 05-28 Remove Tappet cover by dismantling 4 Allen screws. Remove the exhaust and inlet hydraulic tappets carefully from Crankcase top side. EX. tappet INLET tappet Remove the Tappet cover. NOTE: Remove Inlet tappet first and then the exhaust tappet. CAUTION : Store the tappets carefully & right side up as detailed earlier. GEAR TRAIN REMOVAL Remove the Allen screw, and the bracket join - hydraulic tappets. Gently pull out the 2 needle roller pins holding the inlet and exhaust hydraulic tappets. Remove the bolt, copper washer, cap pivot pin and “O” ring above the cam plate pivot pin. Remove the 3mm roller locating pin. 05-29 Pull out cam plate pivot pin with “O” ring by using special tool No. ST 25153-4 Extractor shown below. Remove special thrust washer (Layshaft) from Crank case RH Remove LS 1st gear and thrust washer from the Layshaft. Check that the 4 rollers are in place in the cam plate correctly while removing to avoid damage to the pins or its location in the cam plate. Gently slide out the gear train assembly along with the cam plate, Fork shaft, Forks, Layshaft double gear(LS3 & LS4) and main shaft with all gears. NOTE: Turn cam plate to select 3rd gear position before removing for ease of removal / reassembly. Remove selector fork sub assembly from main shaft & lay shaft sliding gears to take out RH selector fork. 3rd GEAR POSITION 05-30 Remove centre selector fork from the selector shaft and then LH selector fork. DISMANTLING OF LAYSHAFT SUB ASSEMBLY Remove Lay shaft 1st gear and thrust washer. Remove circlip from the selector shaft if required. Remove Double gear (LS 3rd and 4th gear). LA YSHAFT SUB ASSEMBL Y LAY ASSEMBLY Remove the high gear. 05-31 Remove 2nd gear and thrust washer. DISMANTLING OF MAINSHAFT SUB ASSEMBLY Remove main shaft 1st gear. Layshaft Remove the main shaft 2nd gear. MAIN SHAFT SUB ASSEMBLY Remove the main shaft 3rd gear. 05-32 Remove circlip & 1st. thrust washer. REMOVAL OF SLEEVE GEAR SUB ASSEMBLY Remove open end needle bearing. Remove 4th gear and 2nd thrust washer. Remove closed end needle bearing. Main shaft REMO VAL OF KICK REMOV ST AR TER ASSEMBL Y STAR ARTER ASSEMBLY Only for Bullet Electra EFI (E5/G5) REMO VAL OF SLEEVE REMOV GEAR ASSEMBL Y ASSEMBLY Remove 3 allen screws to take out oil thrower (plastic cap). 05-33 Pull out kick starter sub assy. as shown in Fig. REMOVAL OF KICK STARTER SUB ASSEMBLY Remove the Kick pinion gear. Remove the thrust washer from kick spindle. Remove circlip & thrust washer. Remove the Kick pawl, plunger and spring from kickstarter shaft. Remove the thrust washer. 05-34 VITAL PARTS I. BEARINGS Sl.No. USAGE 1. NBI 45 × 30 × 20 DESCRIPTION Crankcase RH - Crankshaft bearing QTY 1 2. Ball Bearing 6305 C3 (25×62×17) Crankcase LH - Crankshaft bearing 1 3. Roller Bearing Nu305 C4 (25×62×17) Crankcase LH - Crankshaft bearing 1 4. Ball bearing 6006, C3 Crankcase LH - Main Shaft bearing 1 5. Lay Shaft bearing 550032/a Fitted on Crankcase RH and Crankcase LH 2 6. NRB 3 × 21.8 Locating Pin-Pivot, cam plate 1 7. Needle Bearing SCE 228 (C3) Sprag Clutch & Clutch Sprocket drum bearing 2 8. Ball bearing 6007 C3 Crankcase RH with Sleeve gear 1 9. Needle bearing Hk 2012 & BK 2016 Sleeve gear bearings 2 10. Ball bearing 6001, C3 Clutch pushrod / Lifter plate bearing 1 11. NRB 35 X 42 X 20 Connecting rod - big end 1 II. GEARS / SPROCKETS Sl.No. 1 2 3 ITEM DESCRIPTION NO. OF TEETH 2.15 PRIMARY REDUCTION GEAR BOX ASSY RATIO Clutch outer sprocket Primary drive sprocket 56 26 1st Gear LS / MS 28/16 3.06 2nd Gear 20/23 2.01 3rd Gear 18/26 1.52 4th Gear 23/20 1.21 High Gear 16/28 1.0 SELF STARTER SYSTEM On motor shaft Drive Gear Driven Gear Idler Jack Gear Sprag clutch outer 05-35 UNIDIRECTIONAL FITTINGS LIST Deep groove ball bearing 6007-RSH/C3 in Crankcase RH- Rubber sealed facing FD sprocket side. Cam Gear Inlet- Single punch mark must align with single punch mark of Cam gear exhaust. Gear rocker shaft bottom pivot bearingSmooth machined surface side facing upwards. Oil pump drive pinion - Short boss facing outwards. Main shaft 2nd Gear- Selector fork groove side facing towards M.S. 4th Gear. Special thrust washer Lay shaft RH Profile towards sleeve gear side on RH Crank case. Piston rings -”1 IP” and “2 IP” facing upwards. Piston- “A” or “B” mark on the crown facing towards throttle body / inlet side. 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 gearPunch mark facing outwards. Cam Gear sub assy. exhaust- The teeth inbetween two punch marks must align with Crankshaft timing pinion gear punch mark. 05-36 ENGINE ASSEMBL Y ASSEMBLY Please ensure all the parts are cleaned and stored in a sequence for inspection and reassembly. Lubricate all moving parts prior to reassembly. While fixing bearings or bushes in the crankcases, it is necessary to heat the crankcase for ease of fixing. Cool the crankcases after the fixing the bearings / bushings before further assembly. ASSEMBL Y OF ENGINE ASSEMBLY BEARINGS CRANKCASE LH Assemble Needle roller bearing for lay shaft. Assemble clutch ball bearing (6006- C3) for main shaft. Fix the clutch bearing retainer plate with 2 allen bolts ( Torque 0.60 KG-M/6 NM). Insert 1st circlip in Crank case LH. 05-37 Assemble 6305 - C3 bearing after 1st circlip. Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig. CRANKCASE RH Assemble Needle bearing for lay shaft. Assemble sleeve gear ball bearing (6007 R1/C3) and circlip. NOTE : Ensure the rubber sealed face is facing the FD sprocket side, while assembling the 6007 bearing. Assemble NU 305 big roller bearing after bearing spacer in LH Crank case for crankshaft. Insert circlip and then assemble crankshaft RH side needle roller bearing into Crank case. 05-38 Assemble closed end needle bearing inside sleeve Gear. Insert sleeve Gear into Crankcase RH. NOTE : Do not hammer directly over sleeve Gear. It is recommended to use arbor press. Assemble open end needle bearing. Check bearing seating position and for free rotation. Assemble exhaust and inlet hydraulic tappets carefully into Crank case RH lubricate and check free upward & downward movement inside Crank case RH tunnel. INLET RHVL Assemble bolt pawl (Torque 2.0 KG-M) into Crank Case RH as shown in Fig. Fix cam plate return spring, pawl cam plate with machined washer and nyloc nut (Torque 1 KG-M). EX. RHVL CAUTION : Please ensure the roller should be facing downwards during assembly. Fix the needle roller pins into Crank case RH. NOTE : Apply LOCKTITE 542 thread sealant before assembling bolt pawl 05-39 Fit bracket lock clip to hold needle roller pin of hydraulic valve lifter and tighten with allen screw (Torque 1 KG-M). Assemble magnetic drain plug assy. (Torque 2 KG-M) with washer on crankcase RH. DRAIN BOLT NOTE : Assemble cleaned suction filter element into Crank case RH. Apply LOCKTITE 542 thread sealant before assembling the drain plug. ASSEMBLING OF KICK ST AR TER SUB ASSEMBL Y STAR ARTER ASSEMBLY (BULLET ELECTRA E5 & G5) Insert the spring, plunger and pawl in the kick starter spindle. Assemble 2 Nos. of Flanged hex bolts (Torque 0.6 KG-M) to fix drain cap with “O” ring. Fix the thrust washer on kick spindle. 05-40 Assemble the Kick pinion gear over kick pawl mechanism. Fix kickstarter sub assy in to Crankcase RH as shown in Fig. TRIP PLATE Insert the thrust washer above the kick spindle. NOTE : Ensure kick pawl is seated over the trip plate in the Crank case RH. Rotate kick Gear and confirm free wheel movement. Assemble oil thrower under the kickstarter Gear (Torque 0.6 KG-M). Lock the circlip over kick sub assy. Assemble Kick starter return spring by hooking into kickshaft spindle. NOTE : Ensure free rotation of kick pinion gear while pressing down the kick pawl and plunger. 05-41 Insert spring locking bolt with washer into kick spring eyelet and rotate clockwise to lock Kick starter return spring on the Crank case and tighten (Torque 1 KG-M). Assemble striker spring on rocker shaft assy. NOTE : Ensure striker spring both ends are seated on striker lever rocker shaft. Apply LOCTITE 5699 RTV silicon liquid gasket then assemble kick shaft Cover with oil seal on Crank case RH by 4 screws (Torque 0.6 KG-M). Assemble rocker shaft sub assy. carefully into Crank case window, after fixing the dowel over the Crank case RH along with bottom pivot Bearing. SMOOTH FACE NOTE : Ensure oil seal is replaced before fixing kick shaft cover. ASSEMBLING OF GEAR ROCKER SHAFT SUB ASSEMBLY NOTE : Ensure bottom pivot bearing smooth machined surface are facing upwards. 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). Assemble High gear. Assemble Double gear (LS 3rd and 4th gear). NOTE : It is recommended to tighten the upper pivot bearing first and then the bottom pivot bearing to avoid gear shifting problems. Assemble rocker return spring stop pin along with “O” ring by using special tool No. ST 25123-4 as shown in Fig. Assemble thrust washer and then Lay shaft 1st gear. NOTE : Apply thread lock sealant before fixing spring stop pin to avoid oil seepage. ASSEMBLING OF LAYSHAFT SUB ASSEMBLY Assemble thrust washer and then 2nd gear on layshaft. LA YSHAFT SUB ASSEMBL Y LAY ASSEMBLY 05-43 ASSEMBLING OF MAINSHAFT SUB ASSEMBLY Assemble main shaft 3rd gear. Smear oil and assemble the 1st thrust washer and then the 4th gear on the main shaft. Assemble main shaft 2nd gear as shown. Assemble 2nd thrust washer and fix circlip to lock the 4th Gear. NOTE : Ensure 2nd gear selector fork groove side is facing towards MS 4th gear. Assemble main shaft 1st gear. Smear oil on the 3rd & 4th gear with bush before assembly on Mainshaft. MAIN SHAFT SUB ASSEMBLY 05-44 Assemble circlip on the selector shaft. Assemble selector fork sub assembly over main and Layshaft sub assy. as shown in Fig. Assemble LH selector fork on the selector shaft and then insert centre fork so that the cut shoulders of both the forks are matched. Always assemble the cam plate on selector fork sub assembly in 3rd gear position & ensure the 4 rollers are in good condition and located properly. Assemble RH selector fork as shown in Fig. 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 Assemble the thrust washer, LS2nd gear & High gear with Lay shaft mounted on the Crank case RH as shown in Fig. Insert cam plate piviot pin with “O” ring with special tool No. ST 25123-4 as shown in Fig. NOTE : Apply LOCTITE 577 thread sealant to pivot pin to avoid oil seepage if any. Hold the cam plate and gear train sub assembly along with Fork shaft, Forks, Lay shaft double gear (LS3 & LS4) and main shaft with all gears (in 3rd gear position). Gently slide inside the crankcase RH. Insert 3 mm locating pin to lock piviot pin as shown in Fig. 3rd GEAR POSITION Assemble thrust washer and then LS 1st gear on the Layshaft. 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. 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 Assemble “O” ring, cap pivot, copper washer and tighten bolt (Torque 1 KG-M). NOTE : Check Crank shaft big end bearing axial play is within service limit. Check Crank shaft run out is within service limit. Ensure the bearing inner races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembling in the crankcase RH. Assemble the 2 dowel pins on the crankcase and apply LOCKTITE 5699 RTV silicon liquid gasket on the RH Crank case seating surface. Assemble special thrust washer (lay shaft) on Crank case LH. NOTE : Assemble the crank shaft into the crankcase RH. Ensure special thrust washer profile facing towards Crank shaft bearing side on LH Crank case. 05-47 Insert the jack shaft from the crankcase LH inside & fix the woodruf key. Check connecting rod bend as shown in Fig. Assemble the crankcase LH over RH Crank case by tapping gently. Simultaneously holding self motor jack shaft carefully. Assemble Front Engine Mounting Brackets and tighten bolts (Torque 2.5 KG-M). Tighten the crankcase stud nuts and allen screws as per the following sequence. Assemble Rear Engine Mounting Bracket and the piece mudgaurd holding bracket (Torque 2.5 KG-M). NOTE : Ensure “ R” index mark side is facing towards RH side (FD Sprocket) of the engine. 05-48 Assemble neutral switch with packing. Locate the crankcase on the frame and fit the front engine mounting stud. Fit the rear engine mounting stud. Fit the centre stand and foot rest supports. Ensure the woodruf key is located correctly on the jack shaft and fix the circlip. NOTE : Ensure step face of jack shaft gear should face inside (Towards Crank case LH) Locate the double gear for starter drive in the crankcase and insert shaft. Ensure cut portion of shaft is facing upwards. CUT PORTION 05-49 Fix the dowels in the crankcase and carefully fix the motor with housing starter drive. Apply LOCKTITE 5699 RTV silicon liquid gasket on the joint face. NOTE : Apply LOCKTITE 577 thread sealant to mounting bolts to avoid oil seepage if any. Fix the E-Start motor cover. Fix the 4 Allen screws of housing starter drive and tighten (Torque 0.6 KG-M). Assemble spacer (distance washer) on Crankshaft LH. Fix the main cable on the starter motor on tighten. Insert rubber boot properly. Fix the E-Start motor with 2 allen bolts (Torque 1 KG-M) along with earthing cable. CAUTION: This double stepped face should be inside. 05-50 SPRAG CLUTCH ASSEMBLY Assemble Engine primary sprocket and sprag clutch gear assembly. 0.2 to 0.5 mm DETAILS B CAUTION : Lubricate the needle bearing well before assembling on the sprag clutch. Assemble the primary chain auto chain tensioner body assy. with “O” ring and tighten with 2 allen screws (Torque1 KG-M). Ensure the distance between sprag clutch gear end face and engine sprocket end face should be maintained between 0.2 to 0.5 mm as indicated in the above image. 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. Assemble sprag clutch bearing. FLANGE FACE Assemble chain tensioner pad, washer and hex nut ( Torque 2.5 KG-M). NOTE : Ensure wide flanges face of the sprag clutch bearing must face outwards. 05-51 Assemble collar on main shaft (distance collar on Crankcase LH). CAUTION : Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk / slippage. Assemble wheel clutch on clutch hub. ASSEMBL Y OF CL UT CH ASSEMBLY CLUT UTCH Assemble needle roller Bearing ( SCE 228C3) in the clutch sprocket and locate the thrust washer. Assemble clutch friction plate over clutch hub and then clutch plain plate. Similarly follow the same to sub assemble all the clutch plates. Insert clutch 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 Use Special tool No. ST - 25594-4 Clutch spring compressing tool to compress the clutch springs over spring holder and tighten with 2 long bolts. Assemble the 4 clutch holding bolts bolts and tighten diagonally and evenly. Assemble Duplex chain over Engine sprag clutch sprocket and Clutch assembly. Mount on main shaft. Use Special tool No. ST 25591-4 Clutch centre holding tool to lock Clutch sprocket and engine sprag clutch assy. NOTE : Tighten bolts diagonally and evenly 5 threads each (Torque 1 KG-M). Remove the 2 long bolts and the special tool. Fix the 2 hex bolts. Fix 17 mm hex head bolt with washer on sprag clutch assy. (Torque 4.8 KG-M). 05-53 Fix the washer and nyloc hex nut 24 mm over clutch assembly and tighten. Assemble clutch bearing cup, ball bearing (6001) & clutch push pad. Use Torque wrench to tighten the nyloc nut on Clutch (Torque 4.2 KG-M). Assemble gear lever shaft bush. Assemble gear lever oil seal on cover LH . Fix the spring and bolt with “O” ring for the auto chain tensioner (Torque 1 KG-M). 05-54 Assemble Clutch operating shaft oil seal. Assemble clutch operating shaft assembly on cover LH. Assemble spring for clutch operating shaft and lock the pin. Assemble oil filler plug with “O” ring. Assemble the cover LH on Crank case LH. NOTE : Ensure 2 Nos. dowel pins are located properly. Apply LOCKTITE 5699 RTV silicon liquid gasket. Locate 11 allen screws on cover LH and tighten (Torque 1 KG-M). 05-55 Assemble clutch cable on Crank case cover LH and fix to clevis. Assemble lock type washer and nut (Torque 7.5 KG-M). Assemble Sleeve gear Spacer over sleeve as shown in Fig. Lock the tab over the FD sprocket nut. Assemble FD Sprocket . Fix Rear Chain master link, plate and lock clip. NOTE : Care to be taken while fixing the FD sprocket direction circular groove index mark, facing outwards. 05-56 Assemble oil pump on Crank case RH and tighten with 4 allen screws (Torque 0.35 to 0.6 KG-M). ASSEMBLING PROCEDURE OF AUT O DECOMPRESSOR UTO Locate the actuating pin in the Exhaust cam. CAUTION : Ensure "O" ring is located on the oil pump body outlet. Fix the woodruff key carefully on Crankshaft. Assemble Gear lever shaft assembly into RH Crank case window and then fix gear shaft spacer. Assemble the flyweight along with return spring over activating pin and tighten with allen screw. 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. Fix oil pump drive pinion and lock it with the circlip. ASSEMBLY PROCEDURE OF CAM GEARS NOTE : Ensure the short boss of the gear is facing outwards. Locate the exhaust cam on the spindle and ensure the 2 punch marks on the cam aligns with the punch mark on the timing shaft gear. Locate the inlet cam on the spindle and align the single punch marks on the inlet and exhaust cams. Add one shim each on inlet and exhaust cam. NOTE : To reduce axial play in between Cam NOTE : After assembling both cam gears, adjust Eccentric cam to reduce gear backlash (Torque 2 KG-M). Gears outer surface and steady late, additional shim may be added as per need. 05-58 Fix Cam steady plate and check for axial play of Cam Gears to avoid noise problem. Fix oil seal 2 Nos. at Kick Shaft hole on Crank case RH cover. INSIDE OIL SEAL OUTSIDE OIL SEAL Assemble the dowels and allen screws on Cam steady plate and tighten (Torque 1 KG-M). Fix breather chamber gasket. Assemble magneto rotor, plain washer and nut and tighten (Torque 4.8 KG-M). Assemble 6 allen screws to fix breather chamber cover plate (Torque 0.60 KG-M). NOTE : Use special tool No. ST 25592-4 to lock connecting rod movement during tightening magneto nut. 05-59 Assemble Breather bolt and washer (Torque 2.0 KG-M). Assemble Stator on cover RH and tighten with 3 mounting screws (Torque 1 KG-M). Assemble Pulser coil on cover RH and tighten with 2 screws (Torque 1 KG-M). Assemble Ignition Timing inspection bolt with copper washer (if not assembled earlier) Torque 1.5 KG-M. NOTE : Apply LOCKTITE 595 silicon adhesive sealant to magneto wire cable grommet to avoid oil seepage. Assemble jet Crankshaft, oil seal Crank feed and circlip on cover RH inside. Assemble 2 dowels and RH Crank case cover gasket. NOTE : Replace the oil seal every 20,000 kms interval. 05-60 Assemble cover RH carefully by aligning kickshaft and dowels. Fix cover RH and tighten with 11 allen screws (Torque 1 KG-M). Assemble “O”ring, Spring and gasket oil filter cap. CAUTION : Care must be taken while fixing cover due to spring force and gasket. Assemble oil filter cover (Torque 0.60 KG-M). Assemble the “O” rings, Oil filter element, washer and plate as shown. Assemble kickstarter lever (only for Bullet Electra EFI (E5/G5) (Torque 2.5 KG-M). 05-61 Fix Cylinder barrel bottom Gasket. PIST ON SUB ASSEMBL Y PISTON ASSEMBLY Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves. CLEANING Remove piston rings from piston. Check the piston rings end gap at the bottom end of the Cylinder. Scrub the carbon deposits from the piston groove with the help of scrapper. Scrap the carbon deposits from the skirt area and groove area of piston without causing any scratches or scoring. Clean piston, rings and piston pin with cleaning solvent and dry it with compressed air. INSPECTION Visually inspect for cracks, scratches, scoring, seizure marks, pitting etc., Check for piston wear, measure the outside diameter of piston perpendicular to the piston pin hole (Ref page No. 03-2) 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 Check the piston pin for wear. Measure outside dia of piston pin at 3 points. Locate the top ring (Index mark “1 IP” facing upwards). NOTE : Top ring has rectangular cross section with black colour (Nitride coating). Stagger piston rings end gap as shown in Fig. EX IN ASSEMBLY IN EX NOTE : After installation, the ring should rotate freely rotatable in the ring grooves. CAUTION : Ensure the open end of any piston ring does not align with the piston pin boss. Locate the piston on the connecting rod and insert the piston pin into the piston. Fit the circlips on either side and ensure they are located properly in the grooves. 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. 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 Assemble the multi layer steel (MLS) head gasket on the barrel & 2 Nos. dowels. CLEANING Scrap the carbon deposit from the top edge of the bore. Clean the barrel with cleaning solvent and dry it with compressed air. INSPECTION Visually check for cracks, scratches, breakage of fins, scoring, seizure mark etc of the Cylinder bore. Check Cylinder liner for wear at 3 locations measure the cylinder ID in X and Y axis. CYLINDER HEAD CLEANING A B C Scrap off the carbon deposit on the face of the Cylinder head and exhaust port. Thoroughly lubricate cylinder bore with fresh engine oil and then assemble over the piston by gently twisting and tilting. INSPECTION Visually check for any cracks, breaks of Cylinder head fins. Check valve stem scoring, bent or any other damage. NOTE : Do not use any sharp objects to press piston rings against groove. Use thumb finger force to locate rings in its position properly. 05-64 Check the Cylinder head face for warpage on surface plate as shown in Fig. Check the valve guide for wear with small bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance. Check the valve stem for run out. Check inlet and exhaust valve stem for wear. Check the valve seat to valve head seating as below. Replace valve if the valve head is knife edged. 05-65 Make pencil marks on the seating area of valve head as shown in Fig. In case if the pencil marks are not erased, grind the valve to the seat as below - Apply fine grinding paste on to the valve seating area. Assemble valves into the valve seat. WARNING : Do not allow the grinding paste to seep into the valve stem and valve guide. Using a suction valve grinder / valve lapping stick, rotate the valve back and forth several times. Lift and turn the valve by half and grind valve on its seat. 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. Clean the valve and valve seat thoroughly. 05-66 VALVE SEAT INSPECTION : Check and ensure proper seating with pencil marks as explained above. Valve seating on valve seat can also be checked as follows: Assemble the valve assembly in position. Keep the Cylinder head on a table. Fill petrol on top of the valves. Seepage of petrol past the valve seat indicates improper valve seating. NOTE : Please ensure cleaning of the cylinder head with solvent and blow thorough all oil passages with compressed air. 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. Check the free length of valve spring. ASSEMBLY Install the valve spring seats and new valve stem seals. Compress the valve springs using special tool ST 25123-1, valve spring compressor and fix the split collar locks on the inlet valve. 05-67 Similarly follow the same process to assemble the exhaust Valve as shown in Fig. NOTE: Tighten the 6 flanged hex nuts diagonally and evenly. Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring. VALVE LEAKAGE TEST Pour solvent into exhaust port and check for valve seat leakage if any. Assemble the spark plug Similarly check for inlet valve seat leakage. Assemble the Cylinder head assy. on the Barrel. Check run out of the push rods. 05-68 Assemble inlet and exhaust pushrods. Assemble the inlet and exhaust rocker bearing with dowel and tighten allen screws Assemble the Inlet & Exhaust Rocker covers, dowels & rubber gasket then tighten rocker cover bolt with rubber washer (Torque 1 KG-M)) . Assemble tappet door by applying LOCKTITE 5699 RTV silicon gasket on Crank case RH then tighten screws (Torque 0.60 KG-M). Tighten the swing arm nut to specified torque. 05-69 Tighten the front engine mounting stud nuts to the specified torque. Tighten the rear engine stud nuts to the specified torque. Tighten the centre stand and foot rest nuts to the specified torque. Assemble throttle body and connect the throttle cables. Fill recommended the engine oil to the correct level and tighten filler cap with “O” ring. Assemble the exhaust pipe and silencer in the reverse order of disassembly. Fix the oxygen sensor & connect to wiring harness. Fix the clutch cable & 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 & 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 & check oil level add oil to bring level below “Max” level. Adjust rear brake and chain terminals. Align the rear wheel. 05-70 SECTION SIX 06 ENGINE MANGEMENT SYSTEM ENGINE MAN AGEMENT SY STEM MANA SYSTEM The Bullet Electra EFI (E5 & G5) and Bullet Classic EFI (C5) are fitted with an intelligent Engine Management System (EMS). 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 are : 3 Excellent cold starting ability. 3 Better fuel economy. 3 Low exhaust emission. 3 Good acceleration. 3 Sustained high speed cruising and driveability. ENGINE MANAGEMENT SYSTEM - FUNCTIONAL DIAGRAM 06-1 COMPONENTS DESCRIPTION ELECTRONIC CONTROL UNIT (ECU) ALTERNATOR THROTTLE BODY ASSEMBLY TEMPERATURE SENSOR FUEL INJECTOR ASSEMBLY CRANK POSITION SENSOR FUEL PUMP MODULE ROLLOVER SENSOR LAMBDA (O2) SENSOR MALFUNCTION INDICATOR LAMP (MIL) 06-2 FUNCTIONS OF COMPONENTS ELECTRONIC CONTROL UNIT (ECU) Located under dual seat (Bullet Electra EFI - E5 / G5) Located in LH Electrical Box (Bullet Classic EFI - C5) The ECU consists of a microprocessor. It controls the output devices by giving pulses to the respective devices. It has two memories Flash Memory and E2 PROM. Flash memory is an exclusive recording unit for controlling program and setting data. It collects different inputs from various sensors and calculates optimised values and gives outputs to the respective controlling devices. E2PROM 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 CONFIGURATION Specification Operating Voltage : 8 – 16 V. Sensor Supply Voltage : 5 V. Operating temperature : –10º C to + 60º C. Storage Temperature : –20º C to + 80º C. ECU INTERNAL DIAGRAM 06-3 FUNCTIONS OF COMPONENTS FUEL INJECTOR Exploded view of fuel injector Assembled between throttle body and cylinder head Specification: Operating Voltage : 10 – 14 V. Operating temperature : –30º C to + 120º C. Fuel Injection pressure : 294 kpa (2.9 bar) Solenoid Operating Resistance : 10.3 ± 0.5 Ohms Fuel Injector is a solenoid operated electromagnetic valve, which atomizes the fuel by forcing it through a small nozzle under high pressure. The injection system used is a 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 : 3 Excellent cold starting 3 Consistent idling RPM 3 Good acceleration 3 Full power output 06-4 FUNCTIONS OF COMPONENTS FUEL PUMP MODULE Specification: Operating Voltage : 6 – 14.5 V. Operating temperature : –20º C to + 60º C. Controlled Pressure Regulator : 294 KPa. Inbuilt Filter Capability : Upto 10 Microns Assembled on the fuel tank bottom left side The fuel pump creates a positive pressure in the fuel lines and pumps gasoline through the injector. The Pump operation is determined by the ECU so that it gives exactly the required volume of fuel. The Pump maintains a uniform (294kPa) fuel pressure. Any excess pressure is bypased back into the fuel tank 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 itself due to electrical sparks 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. Assembled in fuel tank bottom RH side 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). MALFUNCTION INDICATOR LAMP (MIL) Specification: Operating Voltage : 12 V. Bulb Rating : 12V, 4W. 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 & 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 – 80º Throttle Resistance Maximum : 5 K©. Throttle Out Put Voltage at Idling : 0.6 ± 0.2V. Assembled between air filter and inlet manifold Storage Temperature : –20º C to + 80º C The throttle body is a part of the air induction system. It controls the amount of air flowing into the engine, in response to throttle opening. A throttle plate (butterfly valve is use for regulating the airflow) The throttle body also has a throttle position sensor (TPS), a manifold pressure sensor (MAP) and a 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: 3 The mode in which the engine is operating. i.e. idle, part throttle, wide-open throttle etc. 3 Emission controls at wide-open Throttle (WOT). 3 Air-fuel ratio correction. 3 Power increase correction. 3 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 throttle 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 : –30º C to +120º C Operating Voltage : 5 ± 0.5 V. Resistance Value w.r.t. Temperature –20º C –– 18.8 Kilo Ohms + 40º C –– 1.136 Kilo Ohms + 100º C –– 0.1553 Kilo Ohms Assembled on the cylinder head Engine temperature sensor is used to measure the engine oil temperature. It senses the oil temperature and provides the input to the ECU which calculates the average engine temperature. 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 V AC. 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 5º 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 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. If 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 : 600º C to 950º C. (TIP) Tightening Torque : 24.5 ± 4.9 N-m (2.5 ± 0.5 Kg f-m) Assembled on the exhaust pipe The Lambda Sensor detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. 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 OVER SENSOR Specification: Operating Voltage : 12V. Operating 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 DOL TOOL. 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 BLINK MAL FUNCTION INDICATION MIL will glow continuous. Engine will start but not perform to its potential. LONG 0 SHORT 6 Throttle Position Sensor (TPS) circuit malfunctioning LONG 0 SHORT 9 Manifold Absolute Pressure (MAP) circuit malfunctioning LONG 1 SHORT 1 Engine oil Temperature (TE) circuit malfunctioning LONG 1 SHORT 7 O2 Sensor circuit malfunctioning LONG 4 SHORT 5 O2 Sensor heater circuit malfunctioning MIL will glow continuous. Engine will NOT Start but will crank. LONG 1 SHORT 5 Rollover Sensor circuit malfunctioning LONG 3 SHORT 3 Injector circuit malfunctioning LONG 3 SHORT 7 Ignition Coil circuit malfunctioning LONG 4 SHORT 1 Fuel Pump circuit malfunctioning LONG 6 SHORT 6 Crankshaft position circuit malfunctioning 06-10 Level 3 DOL This is done by connecting a DOL tool to the connector near the ECU. This will accurately determine the defective sensor and show the details on the diagnostic screen with the following respective codes as shown below. P Code MAL FUNCTION INDICATION MIL will glow continuous. Engine will start but not perform to its potential. P0120 Throttle Position Sensor (TPS) circuit malfunctioning P0105 Manifold Absolute Pressure (MAP) circuit malfunctioning P0195 Engine oil Temperature (TE) circuit malfunctioning P0130 O2 Sensor circuit malfunctioning P0135 O2 Sensor heater circuit malfunctioning Engine will NOT Start but will crank. MIL will glow continuous P1630 Rollover Sensor circuit malfunctioning P0201 Injector circuit malfunctioning P0351 Ignition Coil circuit malfunctioning P0230 Fuel Pump circuit malfunctioning P0335 Crankshaft position circuit malfunctioning 06-11 INSTRUCTIONS (DO’S & DON’TS): 1) DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR the engine is running. 2) DO ensure the battery is in good condition & Fully Charged Battery. 3) DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands retracted. (Engine will NOT Start OR switch OFF if side stand is extended). 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 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) DO 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) DO NOT 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 TROUBLE SHOOTING S No Symptom Possible Cause Engine stop switch is in OFF position Side stand is ON. 1 MIL does not glow when ignition key switched ON Battery discharged Side stand switch faulty Fuse blown. Sensor couplers / wires loose contact. 2 MIL glows Continuously 3 MIL Glows & Switches OFF but vehicle does not start Battery discharged A E Start related Starter motor cables loose connection. Relay starter not working. Starter motor does not rotate B Ignition Related C Fuel Pump D Fuel Related Ignition coil power relay defective / loose connections Roll over sensor not connected / loose connection. Remedy Switch engine stop switch ON Retract side stand completely Check battery electrolyte level & Sp. gravity. Recharge battery Replace side stand switch Check all fuses. Assess cause of failure, rectify & replace fuse Check all sensor and wiring harness connections for proper connectivity Check battery electrolyte level & Sp. gravity. Recharge battery Check cable connections for proper tightness. Check resistance across relay starter (between blue & 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 & coupler continuity with Fuel pump relay does not work voltmeter. Check fuel pump relay resistance. Replace relay if defective Check for proper connectivity in wiring harness & continuity with voltmeter. Fuel pump clogged / internal short Check fuel pump resistance. Repair electrical connections/loose contact. Replace pump if defective Fuel air mixture too rich due to Hold throttle fully open. Hold Manual extreme cold weather & repeated Bi starter and start engine. Release cranking without using Manual throttle as soon as engine starts. 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 Clean Throttle body to ensure vents are clean. Check proper working of Bi starter plunger. Check fuel pump for proper working. Correct fuel hose if kinked /jammed / leaking at joints. Correct as necessary. 06-13 TROUBLE SHOOTING S No Symptom Possible Cause Spark plug Fouled Spark plug cap shorting E Ignition related No output from Magneto Vehicle Starts but Switches Crank sensor loose connections/ off faulty Roll over Sensor Loose connections / Injector holes clogged 5 6 Loose inlet manifold / Leak in inlet manifold Loose connections or problem in manifold pressure sensor High fuel consumption / Stuck butterfly in throttle body / Uneven Idling / Poor Pick up / broken throttle Cables Smoky Exhaust / Engine Loose connections or problem in runs badly throttle position Sensor. Loose connections or problem in Lambda (O2) sensor circuit. Battery discharging frequently Battery not Charging Replace H T coil Check pulsar coil / Magneto output connections Check Crank sensor & its connections Check Roll over sensor & its connections Replace injector. Check & correct Check continuity and correct Check & correct Check continuity and correct Check & correct Check & correct Defective temperature sensor. Poor Output from charging coils in magneto Check & correct Check Output voltage (10V -16v AC @ 1000rpm) Poor charging by RR Unit Weak battery cells Check RR unit & Replace Replace the battery. Check wiring harness connections & replace fuse Charging circuit fuse Blown 7 Replace spark plug Replace spark plug cap Ignition coil wire loose connection Check for proper wire connection. or broken. Replace damaged wire connections Check power relay resistance / wire Faulty HT coil power relay. connections. Replace if faulty. Faulty H T coil 4 Remedy Low or weak electrolyte. Cells weak Check battery & correct Check battery & replace No output from RR Unit. Poor connection/RR unit failed No output from magneto burnt coils in magneto unit Check & correct / replace RR unit Check for loose connections / 06-14 SECTION SEVEN 07 TORQUE SPECIFICA TIONS SPECIFICATIONS CHASSIS WHEELS & BRAKES TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. CHASSIS DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. Handle Bar 1 146032 Handle Bar Clip Bolts Handle Bar Clip 1.20 12 3 560574 Master Cylinder Cap Screws Master Cylinder Reservoir Cap 0.13 1.5 2 560609 Fr. Brake Lever Pivot Bolt Fr. Brake Lever Pivot 1.20 12 4 560579 Brake Lever Pivot Lock Nut Brake Lever Pivot 1.00 10 5 110116 Steering Stem Top 5A 5B Steering Stem Top Nut - Replacing new ball races-Tighten upto 7-8 Replacing new ball races - Tighten upto 7-8 Kg.M(70-80Nm), loosen fully & retighten to Kg.M(70-80Nm), loosen fully & retighten to 0.15-0.35 2-4 During removal for greasing - Tighten upto During removal for greasing - Tighten upto 1.89 Kg.M(18-20Nm), loosen fully & 1.89 Kg.M(18-20Nm), loosen fully & retighten to retighten to 0.15-0.35 2 - 4 Chassis 1 145863 FLANGE BOLT M8 X 70 Front Fork Pinch Bolts 3.30 33 2 580335 FLANGED HEX. BOLT M10 X 85 FUEL TANK FRONT MOUNTING 5.00 50 3 580337 FLANGED HEX. BOLT M10 X 75 FUEL TANK REAR MOUNTING 5.00 50 4 500355 SCREW M6 FUEL PUMP MOUNTING SCREWS 0.10 1 5 580342 FLANGED HEX BOLT ½” X 120 ENGINE MOUNTING FRONT 7.00 70 6 580338 FLANGED HEX BOLT M8 X 120 ENGINE MOUNTING FRONT TOP 3.00 30 7 580341 FLANGED HEX BOLT M8 X 112 ENGINE MOUNTING FRONT BOTTOM 3.00 30 8 580114 FLANGED HEX BOLT M10 X 270 ENGINE MOUNTING REAR 7.00 70 9 580345 FLANGED HEX BOLT M8 X 100 ENGINE MOUNTING REAR 3.00 30 ENGINE MOUNTING BOTTOM 5.00 50 11 145865 FLANGED HEX SERRATED NUT M10X1.5 RIDER FOOT REST RH MOUNTING 5.00 50 1 2 580343 HEX. NYLOCK NUT SWING ARM MOUNTING 7.00 70 1 3 581158 HEX SOCKET HEAD CAP SCREW M8 X 35 2 SILENSER FRONT MOUNTING E5/G5 3.00 30 1 4 142182 HEX NUT WITH NYLON INSERT, M 8 FOOT REST & SILENSER REAR MOUNTING E5/G5 5.00 50 1 5 580349 FLANGED HEX BOLT, M8 X 20 REAR BRAKE PEDAL 3.00 30 1 6 146434 HEX NUT M12 X 1.25 REAR BRAKE COVER ANCHOR PIN NUT 2.00 20 1 7 580366 NUT REAR BRAKE LEVER NUT 3.00 30 1 8 580360 HEX. CASTLE NUT REAR WHEEL SPINDLE NUT 7.00 70 1 9 170352 DOMED NUT REAR SHOCK ABSORBER TOP & BOTTOM 4.00 40 2 0 145881 FLANGED HEX BOLT M8 X 45 REAR MUDGUARD CARRIER FRONT MOUNTING C5 3.00 30 1 0 580448 FLANGED HEX BOLT M10 X 260 07-1 TOR QUE SPECIFICA TION TORQ SPECIFICATION S. PART No No. CHASSIS DESCRIPTION 2 1 580592 FLANGE HEX. BOLT M8 X 10 LOCATION TORQUE VALUE Kg / M. N / M. CHAIN GUARD MTG. / REAR M.GUARD REAR MTG. 3.00 30 2 2 141051 HEX NUT M8 SEAT MOUNTING REAR C5 3.00 30 2 3 145862 FLANGED HEX BOLT M8 FRONT MUDGUARD STAYS BOTTOM MOUNTING C5 3.00 30 FRONT MUDGUARD STAYS TOP SCREWS MOUNTING C5 0.30 3 2 5 571055 ENGINE TEMPERATURE SENSOR CYLINDER HEAD 1.20 12 2 6 571054 OXYGEN SENSOR EXHAUST PIPE 2.50 25 2 7 550086 NYLOCK NUT M6 FUEL INJECTOR ASSEMBLY, THROTTLE FLANGE 0.10 1 FUEL INJECTOR ASSEMBLY 0.10 1 2 4 141306 HEX NUT WITH NYLOCK INSERT 2 8 570091 STUD 80L Front Wheel / Hydraulic Disc Brake : 1 560525 HEX NUT WITH NYLOCK INSERT (M16×1.5) FRONT WHEEL SPINDLE NUT 5-7 50-70 2 560546 HEX FLANGE BOLT M8 × 25 FRONT DISC MOUNTING BOLTS 1.50 15 2.70 27 3 BRAKE CALIPER MOUNTING BRAKET BOLTS BRAKE CALIPER MOUNTING 4 560591 BLEED SCREW BRAKE CALIPER BLEEDER SCREW 0.60 6 5 560594 PIN BOLT BRAKE CALIPER 2.30 23 BRAKE CALIPER 1.80 18 BRAKE HOSE BANJO 3.50 35 6 7 BRAKE PAD PIN BOLT 560534 BANJO BOLT 07-2 FR ONT WHEEL REMO VAL FRONT REMOV ✰ Tap the axle gently to remove it out of the fork end and the wheel ✰ Place the vehicle on its center stand. ✰ Place a suitable wooden block below the front end of engine to support the vehicle so that the front wheel is lifted up by 25mm from the ground. ✰ Disconnect speedo cable. ✰ ✰ ✰ ✰ Loosen the pinch bolt on the RH fork end. Tilt the vehicle slightly to the right side and take out the wheel along with the speedo drive and the bush. Take care to ensure the brake disc does not get damaged while removing the wheel or while storing the wheel. 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 depress the front brake lever when the front wheel is removed. FRONT WHEEL BEARINGS REMO VAL REMOV ✰ Loosen and remove the axle nut and the washer ✰ Remove the dust seals on either sides of the wheel hub. ✰ Drive out bearings by tapping on the spacer using a suitable rod and remove the spacer after taking out the bearings. REASSEMBL Y REASSEMBLY ✰ Fix the bearing on one side of the hub ensuring that it is seating squarely and fully into the hub. ✰ Fit the 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 ✰ Locate the bush on the left side of the wheel (Disc brake side) ✰ Remove the wedge between the brake pads and position the wheel between the fork legs, taking care to ensure the brake disc in seated correctly between the brake pads in the caliper ✰ Fix the wheel axle from the right side fork leg, carefully ensuring that the holes int eh fork legs and the wheel assembly are aligned. Do nto force the axle or tap heavily on the axle as it will damage the bearing inner races and the threads on the axle. ✰ Position the speedo drive correctly such that the cable threads are parallel to the ground and the cable will have a smooth bend when fixed on the speedo drive. ✰ Fix the washer and tighten the nylock nut to the specified torque. ✰ Check the wheel for free rotation by spinning it gently and tighten the pinch bolt on the Right side to the specified torque. ✰ Connect the speedo cable and check the speedo meter for proper working by rotating the wheel. 3 Whenever the disc brake system is overhauled, ensure that the old fluid is drained out completely and then fill with fresh brake fluid. 3 In case the brake fluid is contaminated, drain out completely, refill with fresh fluid and bleed. 3 Use only fresh brake fluid to clean rubber parts. Do not use any petroleum based cleaning solvents, water or detergents etc. 3 Cover motorcycle painted surfaces, plastic and rubber parts while bleeding a brake system. Do not allow brake fluid to come in contact with any parts of the motorcycle as brake fluid has highly corrosive properties. 3 Always replace brake pads as a set only. 3 Always replace banjo union washers, ‘O’ rings, diaphragm washers, dust seals and piston seals whenever the hydraulic disc brake system is overhauled. 3 Always replace damaged parts like pistons, fixing pin etc. Do not attempt to repair as it may render the disc brake to become ineffective. DISC BRAKE DRAINING OLD BRAKE FL UID FLUID GENERAL INSTRUCTIONS 3 3 Check the system for any fluid leaks at banjo union joints, damaged brake hose etc. 3 Ensure the handle bar is positioned straight and the master cylinder in the handle bar is parallel to the ground, whenever checking fluid level. 3 Clean master cylinder filler cap before removing. 3 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. Remove the Master Cylinder top cover screws. 07-4 3 3 Remove the Master Cylinder top cover, diaphragm plate & diaphragm. 3 Loosen the bleeder screw by 1 turn approximately 3 Depress brake lever slowly and fully and release. This will force the brake fluid out of the bleeder screw. Repeat this process till the brake fluid drains out completely from the master cylinder and the wheel calliper assembly. Remove the protective boot from the bleeder nipple on the calliper assembly. OVERHA ULING CALIPER VERHAULING AND MASTER CYLINDER 3 3 Place a clean tray or container below the calliper assembly to collect the old oil. 3 Loosen and remove the banjo bolt with the washers from the Caliper assembly. 3 Drain out the entire brake fluid from the master cylinder and brake hose by depressing and releasing the brake lever. Fix a transparent 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. 07-5 3 3 Remove the calliper assembly from the fork leg and drain out the brake fluid 3 Fix the diaphragm, plate and top cover. Do not tighten the screws completely since it may be required to top up fluid during the bleeding process. 3 Depress the brake lever completely and release fully so as to allow the brake fluid to fill up in the brake hose and caliper. 3 When a slight firmness is felt on the lever and it depresses only halfway, hold the lever firmly in that position. DO NOT RELEASE THE LEVER. Reassemble the calliper and refit the banjo bolts after draining out the oil BLEEDING PROCEDURE NORMAL METHOD 3 Ensure the bleeding screw and the brake hose banjo is fully tight. 3 Fix a transparent flexible 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. 3 Fill the master cylinder with brake fluid from a sealed container, till the “MAX” level. 07-6 3 Loosen the bleeder screw by ½ turn to allow air bubbles in the brake system to escape out. 3 Check the fluid level and top up to “MAX” level and refit the diaphragm and the top cover and tighten with the screws. 3 Check for any leaks at the banjo or the bleeding screw area and ensure all mounting bolts are tightened to the correct torque. BLEEDING PROCEEDURE REVERSE BLEEDING METHOD: 3 When the bleeder screw is loosened and the air escapes out along with the brake fluid through the bleeder nipple, the brake lever will further depress. Allow the lever to depress fully and hold. DO NOT RELEASE THE LEVER. 3 Tighten the bleeder screw firmly and then only release the brake lever. 3 Ensure the bleeding screw and the brake hose banjo is fully tight. 3 Fill the master cylinder with brake fluid from a sealed container, till the “Max” level. 3 Depress the brake lever completely and release fully so as to allow the fluid to travel into the brake hose and the wheel caliper. NOTE: Check the fluid level in the master cylinder and top up if necessary till the “MAX” mark. 3 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 being carried out by the fluid while bleeding the system. 3 Ensure the bleeder screw is tightened fully and fix the dust cap. 07-7 3 When a slight pressure “build up” is felt on the lever, depress and hold. DO NOT RELEASE THE LEVER. The air in the hydraulic system will be expelled upwards during this operation, allowing the fluid to fill up in the calliper and the brake hose completely. 3 Remove the Master Cylinder top cover, diaphragm plate & diaphragm. 3 Place a clean tray or container below the calliper assembly to collect the old brake fluid. 3 Loosen and remove the banjo bolt with the washers from the Caliper assembly. 3 Drain out the entire brake fluid from the master cylinder and brake hose by depressing and releasing the brake lever. 3 Remove the calliper assembly from the fork leg and drain out the brake fluid NOTE: The brake fluid level will go down when the air escapes out. Check level constantly and top up to “MAX” level. 3 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. 3 Check the fluid level and top up to “MAX” level. Refit the diaphragm and the top cover and tighten with the screws. DISASSEMBL Y OF MASTER DISASSEMBLY CYLINDER 3 Remove the Master Cylinder top cover screws. 07-8 3 Remove the Rear view mirror RH. 3 Disconnect the Front brake switch wire and remove the switch from the master cylinder. 3 Disconnect the Banjo bolt and the remove the brake hose from the master cylinder end 3 3 Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar. 3 Remove the boot and the Circlip from the master cylinder body. 3 Remove the conical spring (Piston compression spring) Remove the brake lever pivot lock nut, brake lever pivot and the brake lever 07-9 INSPECTION CAUTION : 3 Check both the rubber seals on the plunger for wear, cracked edges or any other damage. Replace seals whenever the plunger is removed Do not clean the hydraulic disc brake parts with any other cleaning material, solvents or water. USE NEW BRAKE FLUID ONLY. 3 Check the master cylinder housing and piston for any scoring, pitting due to corrosion or any other damages. 3 Check the master cylinder bore for any damages, scoring marks etc. Measure the inner diameter - Service limit: 12.76 mm 3 Check the piston outer surface for any damages, scoring marks etc. Measure the out diameter - Service Limit: 12.64 mm 3 CLEANING 3 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. REASSEMBL Y OF MASTER REASSEMBLY CYLINDER 3 Assemble the conical spring (compression) on the piston. Smear the piston, seals and cylinder bore with fresh brake fluid. 3 Assemble the piston sub-assembly into the master cylinder by gently pushing it into the bore COMPENSATORY PORT 07-10 3 3 Locate the circlip into the groove of the master cylinder. Ensure the circlip is seated correctly inside the groove. 3 Assemble the Brake Switch 3 Fix the master cylinder assembly on the handle bar with the ’UP’ mark facing upwards. 3 Tighten the master cylinder assy. clamp top bolt first and then tighten the bottom bolt. Torque 0.90 KG-M. 3 Assemble the brake lever in the front bracket and tighten with the bolt first and then tighten the lock nut 3 Torque values: Bolt-lever 0.6 KG-M Nut-lever 0.6 KG-M Assemble the rubber Boot. CAUTION : Do not use tools with sharp ends. 3 Apply Silicon grease on the Lever pivot hole and on the Piston surface. 07-11 3 Position the brake hose on the master cylinder such that it is pointing downwards correctly and tighten with the banjo bolt. Replace the banjo bolt sealing washers whenever the bolt is removed. 3 Tighten the banjo bolt firmly Torque 3.5 KG-M. 3 Connect the brake light switch. 3 Fill the brake fluid till “MAX” mark and bleed the system. 3 Assemble the diaphragm, plate and cover. Tighten screws gently Torque 0.15 KG-M. 3 Assemble the rear view mirror. DISASSEMBL Y OF WHEEL DISASSEMBLY CALIPER 3 3 Remove the Grub screws. 3 Loosen both the pin bolts 3 Loosen and remove the 2 mounting bolts holding the caliper to the fork and remove the caliper assembly Disconnect the brake Hose by removing the Banjo bolt and sealing washers. 07-12 3 3 3 3 Remove the brake pad tensioner spring plate. 3 Remove the Bellow & Boot. 3 Hold the caliper body with the pistons facing downwards. 3 Blow compressed air with a nozzle at a low pressure, into the oil passage hole on the caliper, so that the pistons can be removed Remove pin bolt. Remove the brake pads from the caliper assembly. Remove mounting bracket from the Caliper assembly. 07-13 CAUTION : Measure the caliper piston O.D. Do not use high pressure air or any pliers or sharp objects to remove the pistons as their working surface can get damaged. Service limit – 25.31 mm Ensure the pistons do not fly out of the caliper body due to high air pressure. Support the pistons CAUTION : Enough care should be taken to avoid damages of the piston O.D. while servicing/ handling. 3 Remove the Bleed screw. Take care not to damage the sides of the piston as it cannot be reused in case it gets damaged. Remove he dust seals and piston seals from the calliper using a blunt tool. CALIPER ASSEMBLY 3 3 Coat clean brake fluid on new dust seals and piston seals and install them in the seal grooves of the caliper body. Clean the seal grooves with brake fluid. CAUTION : Care should be taken to avoid any damage on the bore of the sliding surface. INSPECTION 3 Check the caliper cylinder surface and Piston outer surface for scoring or other damages. Measure the caliper cylinder I.D. Service limit – 25.46 mm NOTE : ID Ensure the piston seal are fixed on the inner groove and the dust seals are fixed on the outer groove. OD 07-14 3 3 3 Coat the caliper cylinders and Pistons with clean brake fluid and install the Pistons into the caliper body with the dished end facing inwards. 3 Install the Pad tension spring plate into the Caliper body. 3 Assemble Bleed screw with the dust cap on the caliper body. 3 Assemble the Mounting Bracket on the caliper Body. If the Caliper Boot and Bellow are hard or deteriorated, replace them with new ones. Smear fresh brake fluid on the caliper boot and bellow and assemble them as shown. 07-15 3 3 3 First install the brake pad at the piston side and then install the other brake pad 3 Tighten the Pin bolts with a torque of 1.5 2.0 KG - M after mounting the caliper assembly on the fork assembly. 3 Fix the Grub screws on the pins and tighten to a torque of 0.2 to 0.3 KG-M. 3 Connect the brake hose to the caliper with New sealing washers and tighten the Banjo bolt. Torque : 3.5 to 3.8 KG -M. 3 Fill fresh brake fluid in the Master cylinder and bleed the air out of the hydraulic brake system. Apply Silicon grease on the Pin OD and then assemble the Pin bolt by pressing brake pads into caliper body. Mount the Caliper assembly on the Fork and tighten the Mounting bolts evenly. NOTE : 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. 3 Check the Disc thickness and the ‘Run-Out’ of Disc.11 Sl. No. Parameter Service Limit 1 Disc Thickness As described on the disc 2 Disc runout 0.3mm REAR WHEEL REMO VAL REMOV 3 Pull out the spindle with the chain adjuster and remove the spacer from the LH side. 3 Tilt the vehicle to the right and free it form the sprocket lugs and slid it outwards Rear wheel can be dismantled without removing the rear chain and rear wheel sprocket. 3 Place the vehicle on its center stand 3 Ensure the rear wheel is lifted off the ground by placing suitable wedges under the centre stand legs 3 Remove the split pin and the castle nut from the rear hub spindle Inspection method 07-17 3 Remove the cush drives (4 Nos.) from the hub. BRAKE DR UM ASSEMBL Y DRUM ASSEMBLY 3 Remove the drive chain from the sprocket. 3 Disconnect the brake operating rod from the cam lever. 3 Remove the cover plate anchor nut from the chain stay. 3 Remove the nut from hub spindle short. CAUTION : The cush drives are locked to the hub with rubber lugs. Pull out the cush rubbers gently to avoid damage to the lugs 3 3 Remove the dust seals. Drive out the bearings (2 Nos) and take out the spacer. 07-18 3 3 Remove sprocket drum assy. from the swing arm along with brake shoes and cover plate carefully. Disconnect chain if not removed earlier. 3 Clean the brake shoe & cush drive with dry cloth / cloth wet with solvent. INSPECTION 3 Visually check all parts for breaks, cracks, dents, scoring, glazing or any other damage. 3 Check bearings for free rotation, axial play and radial clearance. Replace if necessary. 3 Lubricate bearing by MP grease and then assemble into sprocket drum by using bearing punch as shown in Fig. 3 Check the spindle for bend as shown in Fig. Take out sprocket drum, brake shoes, and spacer 3 Remove the oil seal. 3 Drive out the bearing from the hub sprocket. ASSEMBLY CLEANING 3 Clean all parts except brake shoes, cush drive and tyre, with solvent and dry with compressed air. 3 Assemble in the reverse order of disassembly. 3 While assembling replace the grease seals and split pin. 07-19 SECTION EIGHT 08 SUSPENSION & STEERING FR ONT FORK WORKING PRINCIPLE - FOR B ULLET FRONT BULLET ELECTRA EFI (E5 & G5) OIL FLOW DURING REBOUND STROKE 08-1 FR ONT FORK WORKING PRINCIPLE - FOR B ULLET EFI FRONT BULLET CLASSIC (C5) FORK STROKE LENGTH : 130 MM FORK MOVEMENT IS CONTROLLED BY THE COMPRESSION SPRING AND HYDRAULIC DAMPING FORCE S.No. Description 1. 2. 3. 4. 5. 6. 7. 8. 15 9 Bolt cap “O” ring Main tube Spacer Seal dust Fork oil seal & circlip One way check valve Fork piston S.No. 9. 10. 11. 12. 13. 14. 15. Description Copper washer & allen bolt Oil control collar Thorough oil hole Bottom tube Orifices Piston ring Washer spring seat OIL FLOW DURING REBOUND STROKE 08-2 FRONT FORK DIS ASSEMBL Y ASSEMBLY Gently tap the fork bottom tube downwards and remove the bottom tube. Place motorcycle on centre stand. Remove the oil control collar from the spring stud. Remove speedo cable, front wheel and mudguard. Using special tool ST 25105-2, remove the valve port. Remove caliper mounting bolts and take out the caliper. Take out spring stud and front fork spring. DISMANTLING PROCEDURE BULLET ELECTRA EFI (E5 / G5) DISMANTLING PROCEDURE BULLET CLASSIC EFI (C5) Remove the allen screw from the bottom tube and drain the oil. Remove the cap nut from the fork bottom tube and drain the oil. Gently tap the fork bottom tube downwards and remove the bottom tube. 08-3 REMO VAL OF FORK SEALS REMOV Loosen the pinch bolt on fork crown bottom. Remove the plug screw from the head lamp casing and using special tool ST 25108-3, unscrew and remove the main tubes, cover tubes, bush and washer. INSPECTION Visually inspect all parts for damages, cracks, bends, wear marks or any other damage. Check the main tube for any bend. Measure the spring length. Inspect the other internal parts for any visual damage. FR ONT FORK ASSEMBL Y FRONT ASSEMBLY Assemble the front fork in the reverse order of dis-assembly. Replace the oil seals and the ‘O’rings with new. Remove ring clamp and dust cover. (Bullet Electra EFI (E5 / G5) STEERING DISASSEMBL Y DISASSEMBLY Remove the front fork assembly. Remove the circlip from the bottom tube and take out the spacer and dust seal. Disconnect all wires and remove headlamp unit and trafficators. Place special tool ST 25114-4 on bottom tube and lever out the oil seal along with spacer. Take out cover tube, bush and washer. Remove head lamp assembly. Loosen the head lamp casing allen screw. 08-4 Remove the handle bar clamp bolts and nuts and take out handle bar. Take out ball race from steering stem. CLEANING Clean all the parts carefully for inspection. Remove the stem lock nut and washer carefully. Rub the bearing race balls in a clean cloth. Tap the steering stem downwards, taking care to collect the steering race balls (38 nos) for inspection. INSPECTION Remove head lamp casing. Inspect the balls for marks of wear, corrosion, pitting and damage. Drive out ball races and cover from head lamp casing. Replace if necessary. Using a copper drift, tap out ball race and cover from the frame head tube. Inspect the races for - Grooves - Excessive / uneven wear. Replace if found defective. Check all parts for cracks, pitting or any other damage. 08-5 REASSEMBL Y OF STEERING REASSEMBLY Using a hollow drift, fix the bottom ball race the steering stem. Fix the ball race on the frame head tube (top). Locate 19 balls each on the ball races steering stem bottom and frame had tube top. Locate the head lamp casing over the frame down tube such that the centre holes align. Insert the steering stem into the frame head tube slowly and steadily. Till it matches with the frame head tube bottom ball race. Fix the ball race along with cover on the frame head tube (Bottom). Tighten the stem with lock nut with washer. Apply grease on steering stem bottom ball race and Top ball races in the frame head tube. 08-6 Assemble front forks, mudguard & front wheel in reverse order of disassembly. Assemble the handle bar and other parts. Adjust the steering stem play correctly & tighten the steering stem rinch bolt under the handle bar bracket. REMOVAL AND ASSEMBLY OF REAR SHOCK ABSORBER Remove the top and bottom mounting nuts and washers. GAS FILLED SHOCK ABSORBER WORKING PRINCIPLE The 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. Pull out the shock absorber from bottom and slide out from frame. Assemble in the reverse of removal. ADJUSTMENT OF SHOCK ABSORBERS 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). The 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. NOTE : Ensure both side adjustment notch are in same position. 08-7 RECHARGING OF SHOCK ABSORBERS Remove the small screw with “O” Ring. Remove the rear wheel sprocket assembly (1). Remove the shock absorbers (2). 2 1 Remove the chain guard. Inject the special purpose needle into the hole provided in the screw (Puncturing the rubber) and start pumping the air into the chamber till the pressure reached to 100 PSI (7 BAR). Tolerance for filling pressure can be 6.7 BAR to 7 BAR. Remove the swing arm cap swing pivot. Fit the small screw with “O” Ring. NOTE: The shock absorber needs recharging when the system pressure is less than 5 BAR. SWING ARM Remove the swing arm hex nyloc nut & washer. REMOVAL Remove the chain link and take out the chain. Disconnect the brake rod nut. Tap and pull out the swing arm flange hex bolt. 08-8 Using a mandrel, drive out the plastic bush from either sides of the swing arm and remove the steel spacer. Always use reamer to ream the bush after pressing into swing arm tube. Apply grease inside the bush and then insert spacer as shown in Fig. CAUTION : Do not remove plastic bush, unless it is defective. ASSEMBLY Press the new plastic bush into the swing arm tube. BUSH SPACER Position special tool ST 25110-3 on shock absorber mounting pins. BUSH Position it on frame and insert the swing arm hex bolt after applying grease. 08-9 Place a washer and tighten nut. CENTER ST AND STAND DISASSEMBLY Disconnect the stand return spring two nos. (1) Remove the split pins & washers from the both ends of the centre stand spindle (2). Drive out the centre stand spindle. 2 1 After tightening the swing arm hex nyloc nut. Remove special Tool ST 25110-3. Fix both side caps swing pivot carefully. Assemble both side shock absorbers, washers and dome nuts as shown in Fig. ASSEMBLY Assemble the centre stand in the reverse order of disassemble as shown in Fig. Assemble the chain guard. Assemble the rear wheel and adjust drive chain free play. 08-10 SECTION NINE 09 ELECTRICALS ELECTRICAL SYMBOLS 01. Alternating current (AC) ... 02. Direct current (DC) ... 03. Wired across ... 04. Connection ... 05. Switch ... 06. Ground ... 07. Cell ... 08. Battery ... BA TTER Y BATTER TTERY CONSTRUCTION Positive Plate - Porous mass of lead dioxide (Pbo2) (Positive active material) Negative Plate - Porous mass of spongy Lead (Pb) (Negative active material) Electrolyte - Diluted sulphuric acid (H2SO4) Separator - Micro porous, acid resistant electrical insulator between positive & negative plates Container - Polypropylene casing to house the plate group & electrolyte Cover - To seal the battery container Filling Plugs - To facilitate filling of electrolyte and water topping up. Gang Piece - To vent gases through common manifold and exhaust nozzle Terminals - To make connections to the electrical loads. 09. Bulb ... 10. Coil ... 11. Resistor ... 12. Capacitor ... 13. Armature and brush ... 14. Fuse ... 15. Volt meter ... 16. Ammeter ... Intercell Poles - To connect the cells in series internally. 17. Transformer ... Exhaust Tube - To discharge the vent gases. 18. Transistor ... Exhaust Seal Cap - To protect the dry charged plates from oxidation. 19. Rectifier / Diode ... 20. Zener Diode ... 21. Silicon Controlled Rectifier ... SCR 09-1 PRECA UTIONS : PRECAUTIONS 3 Wear rubber gloves while handling a battery. 3 Use only constant current battery charger of correct charging rate, to charge batteries. 3 Remove the filler caps only to fill distilled water OR if the battery is to be charged. Hydration may occur when atmospheric air contacts the plates. 3 Keep all the filler caps removed while charging the battery. 3 Use only distilled water to top up the level after the initial charging. 3 During charging, the electrolyte temperature should not exceed 45ºC if necessary, discontinue the charging to cool the electrolyte. 3 Ensure that the battery is placed on a nonmetallic surface while charging. 3 Keep fire and spark away from battery charging area. 3 Never run the motorcycle without connecting the battery as it may lead premature failure of electrical parts. 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. 3 Stir with a glass rod. 3 Check the specific gravity with hydrometer. CHARGING INITIAL CHARGE (NEW BATTERY) ELECTROLYTE : 3 Diluted sulphuric acid with distilled water to a specific gravity of 1.240 PREPARATION : 3 Take required distilled water in a Hydrometer or equivalent container. 3 Slowly, add sulphuric acid to it. 09-2 TEMPERATURE OF ELECTROLYTE : 3 CAUTION : Cool the electrolyte to about 30 deg. C before filling it in the battery, just below the maximum level indicated. Always connect the positive and negative terminals of battery into the positive and negative sockets provided in the constant current battery charger. SOAKING PERIOD: 3 Always disconnect the Negative (-ve) terminal first & then the Positive (+ve). When re-connecting the battery to the vehicle after re-charging first connect Positive(+ve) terminal & then the Negative(ve) terminal. Keep the battery with electrolyte filled for about half an hour before commencement of charging. Top up the level with electrolyte if necessary. C HAR GING A NEW B ATTER Y: HARGING BA TTERY 3 Connect the battery to the charger and charge as detailed below.. Battery Duration Charging Current 12V 14AH 10Hrs 1.4 Amps RECHARGING USED B ATTERIES TTERIES:: 3 3 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 detailed 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. Keep all battery filler caps open while charging. CHARGING procedure: 3 Switch on the mains ‘ON’. See that the charger indicator light is glowing 3 Switch on the charger ON/OFF switch 3 Disconnect the battery from the charger when fully charged. INDICATION OF FULL CHARGE: 3 Free gassing from electrolyte for more than 90 minutes. 3 3 consecutive reading taken in intervals of 30 minutes each to read constantly 1 .240 or more of specific gravity. 3 Voltage: 12.0 TO 13.2V 09-3 MAINTENANCE 3 Check the electrolyte level and top up, if necessary to the ‘MAX’ mark with distilled water every week. 3 Protect battery from direct sunlight, heat, rain and dust. 3 Keep exhaust seal cap in place to avoid deterioration of dry charge properties 3 New dry charged batteries need initial charging duration of 8 to 10 hours - Upto 3 months from the date of manufacturing. 3 Beyond 3 months the batteries may need extended duration of initial charging subject to storage conditions. 3 Charged batteries, if kept idle should be boost charged once in 3 to 4 weeks 3 It is always a good practice to boost charge the batteries before fitment to ensure full state of charge. 3 Check the terminals and cables for corrosion. Apply petroleum jelly on terminals to prevent corrosion. 3 Check specific gravity of electrolyte. The float graduation in level with the electrolyte in it, is the specific gravity of the electrolyte. CAUTION : For topping, use only distilled water. 3 Keep the battery surface clean and dry. 3 Never over charge the battery - it damages the battery & plates may buckle. 3 Remove the battery from the motorcycle and store it separately when the motorcycle is not in operation for more than one month. 09-4 Specific Gravity Fully charged Carbon deposits on the spark plug establishes a ‘shunt’ between center and earth electrodes, that prevents good sparking and causes misfiring. Clean the deposits off periodically, with a spark plug cleaning tool / machine. 3 Check spark plug for pitted out the earth and center electrodes. If the earth electrode has worn off to a knife edge and center electrode has reduced in height, replace it with new. Requires Recharging 1 .24 3 3 1 .15 Check voltage with voltmeter Voltage Fully charged 13 .2 Fully Discharged 10.8 SP ARK PL UG MAINTEN ANCE SPARK PLUG MAINTENANCE INSPECTION 3 3 Clean the electrodes and set gap to 0.7 mm to 0.8 mm 3 Clean the plug in a ‘Spark plug cleaner cum Tester’ 3 Test the plug for proper sparking in the tester 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. Light blue, solid, continuous spark seen in the tester Yellow or red spark; intermittent or no spark; or side spark as seen in the tester mirror Spark Plug OK Spark Plug Not OK 09-5 CHECKING PROCEDURE OF ELECTRICAL COMPONENTS PULSAR COIL 3 SPECIFICATION Stator coil 3 Pulsar coil 3 Ignition coil Resistance mode - Across the wires 3 Suppressor Cap 180 - 240 3 Battery 3 Horn 3 Relay Starter Set the multimeter in resistance mode. 3 Starter motor Check the Resistance between 3 IC Flasher a. Green to white wire. 3 RR Unit 3 c 3 (ohms). CHECKING PROCEDURE MEASURING INSTRUMENT 3 Multimeter ST AR TER COIL STAR ARTER 3 SPECIFICATION Resistance mode - Across any two wires 3 CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between wires a. Yellow 1 to yellow 2 - 0.8 to 1.5 ohms b. Yellow 2 to yellow 3 - 0.8 to 1.5 ohms IGNITION COIL c. Yellow 3 to yellow 1 - 0.8 to 1.5 ohms 3 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. 3 CHECKING PROCEDURE 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 : Brown or white/red to core no connectivity. HORN 3 SUPPRESSOR CAP - M14 3 SPECIFICATION Continuity Mode - Beep Sound SPECIFICATION Resistance Mode - 4.5 to 6 K ohms RELA Y ST AR TER RELAY STAR ARTER BA TTER Y BATTER TTERY 3 SPECIFICATION Voltage mode - 11.5 to 13 V 3 SPECIFICATION Resistance 4 to 5 ohms. 3 CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between BATTERY WHEN CHARGING 3 a. Green/white to white wire. SPECIFICATION Voltage mode - 13 to 14.5 V with head light on @ 3000 RPM 09-7 CAUTION : Never try to repair / tamper IC Flasher. RR UNIT E- ST AR TER MO TOR STAR ARTER MOT 3 SPECIFICATION Resistance 0.3 to 0.5 ohms. 3 3 CHECKING PROCEDURE Set the multimeter in voltage mode (DCV 20). Connect the multimeter to Battery terminals and then check the voltage as shown in Fig. CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between motor terminal & aluminium body. Start and accelerate upto 3000 RPM and then check online voltage inbetween 12.2 to 13.5 voltage. NOTE: IC FLASHER 3 CHECKING PROCEDURE Repeat the test with head light ON and OFF condition. If RR unit is defective will not fall above specified voltage. Ensure Battery voltage > 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. 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. MODE BROWN GREEN BLACK 3 If the battery is weak (below 10 V), start with the kick starter and do not try to start with self starter. 3 Always maintain correct Engine oil level. 3 Check for Engine backfire, if it exist & it will damage the sprag clutch & gears. Maintain correct ignition timing. 3 Hold the starter switch until the engine starts. 3 Service your bike only at authorized service stations. Normal Press STARTER SWITCH DON’TS Check the continuity between Red/Blue wire and Blue/white wire of Switch module RH coupler when switch is pressed. 3 Never overcharge the battery. 3 Never spray water with great force on starter motor, RH tool box and other electrical parts. 3 Do not carry out any repairs on the Starter motor, and relay starter or the sprag clutch mechanism. MODE RED / BLUE BLUE / WHITE ON OFF 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 3 Check battery for electrolyte level periodically and top up with distilled water only. 3 For longer battery life, de-clutch before starting. 09-9 09-10 09-11 09-12 TROUBLE SHOOTING PROBLEMS 1. E-start motor not working. PROBLEM CAUSES 1. Fuse blown. 2. If the battery voltage increases with RPM increase, replace RR Unit. 3. Faulty relay starter. 4. Starter motor cables loose connection. 5. Starter motor failure. 2. Fuse blown when pilot lamp switched ‘ON’ 1. Rear harness cable routing fouling with the tyre. 2. Rear harness cable fouling with taillamp bracket. 3. Fuse blown when Head light high beam ‘ON’ 1. Check the Headlight wiring harness 4. Relay starter not working. 1. Check the coil resistance. 2. If you can hear the sound of relay actuation but starter motor does not rotate, change the relay starter. 5. Battery discharging frequently. 1. Check the alternator. o/v – should be 8 V to 10 V AC @ 1000rpm (open circuit, across any two of its wire yellow-yellow), If the voltage is less than this, change the alternator. 2. Check for battery voltage increase with respect to increase in RPM. Otherwise replace the RR unit (If alternator is ok) 3. Battery cells may be weak. 09-13 SECTION TEN 10 TROUBLE SHOO TING SHOOTING TR OUBLE SHOO TING TROUBLE SHOOTING This section discusses trouble shooting on various performance problems. This following check list can be helpful in locating most of the operating troubles. Observation Causes Remedies Complaint : Engine fails to start Ignition switch in ‘OFF’ Position Switch ‘ON’ ignition Stop switch in ‘OFF’ Position Push stop switch to ‘ON’ position. Side stand is “ON” / Switch faulty / too much play in side stand Retract side stand / replace switch /correct side stand play Fuel is stale due to vehicle being in storage for a long period Clean petrol tank and carburetor and fill the tank with fresh petrol Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Vent hole clogged in fuel tank cap Clean vent hole. Fuel Line Clogged Clean the fuel line. Fuel hose cracked resulting in fuel leaking out and not getting supplied to injector Check and replace No fuel Supply from Fuel pump Replace fuel pump. Fuel pump pressure insufficient/fuel pump not working Check fuel pump coupler connection/ Check fuel pump relay for proper working Fuel Injector blocked Replace fuel injector. MIL glowing continuously Check Sensor connections & correct Weak Battery / Dead Battery Charge / Replace the battery Electrical connections Loose Check & Correct Electrode Gaps incorrect Adjust the gap Wrong specification spark plug Replace with right plug Defective spark plug Change Spark Plug Spark plug electrode dirty / fouled Clean park plug & Reset gap. Spark plug cap / lead not connected Fix cap / lead firmly. Spark plug insulation cracked Replace Spark plug. General Fuel Starvation Electricals Related (No Voltage/No Spark / Weak spark /Side spark / intermittent spark Wrong Spark Plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead Defective plug cap Change the cap Cracked spark plug insulator Change the spark plug Loose connections Tighten connections Fouled Spark plug Clean and adjust the gap Cracked HT lead Replace H.T. lead 10-1 Observation Poor Cranking Causes Remedies Loose spark plug Tighten spark plug Loose cylinder head nuts Tighten cylinder head nuts Blown cylinder head gasket Change cylinder head gasket Auto Decompressor mechanism stuck in open position Ensure flyweight in exhaust cam gear assembly in free to operate. Valves Leaking due to poor seating/burnt valves or seats Check & Correct 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 General Fuel Related Electricals Related Idling RPM low Adjust the idle air bypass screw in the throttle body 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 Fuel level very low in tank Fill up the tank Vent hole clogged in fuel tank cap Clean vent hole. Fuel Line Clogged Clean the fuel line. Fuel hose cracked resulting in fuel leaking out and not getting supplied to injector Check and replace Fuel pump pressure insufficient/fuel pump not working Check fuel pump coupler connection/ Check fuel pump relay for proper working Fuel Injector partially blocked Replace fuel injector. Loose / damaged throttle body to engine hose / air filter to throttle body Check and correct Weak Battery Charge / Replace the battery Electrical connections Loose Check & Correct Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead. Complaint : Idling Erratic / high General 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 hose / air filter to throttle body Tighten / replace the hose Suction leakage Check and correct 10-2 Observation Fuel Related Electricals Related Causes Remedies Fuel is stale due to vehicle being in storage for a long period Clean petrol tank and carburetor and fill the tank with fresh petrol Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Fuel pump pressure low Check and correct Fuel Injector partially blocked Replace fuel injector. Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead. Complaint : Engine stalls gradually General Fuel Related Electricals Related Loose / damaged throttle body to 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 Fuel level very low in tank Fill up the tank Vent hole clogged in fuel tank cap Clean vent hole. Fuel Line Clogged Clean the fuel line. Fuel hose cracked resulting in fuel leaking out and not getting supplied to injector Check and replace Fuel pump pressure insufficient/fuel pump not working Check fuel pump coupler connection/ Check fuel pump relay for proper working Fuel Injector partially blocked Replace fuel injector. Loose / damaged throttle body to engine hose / air filter to throttle body Check and correct Weak Battery Charge / Replace the battery Electrical connections Loose Check & Correct Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead. Complaint :Engine Misfires & cuts off Fuel Related Fuel is stale due to vehicle being in storage for a long period Clean petrol tank and carburetor and fill the tank with fresh petrol Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Fuel pump pressure low Check and correct Fuel Injector partially blocked Replace fuel injector. 10-3 Observation Electricals Related Causes Remedies Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead. Complaint :Poor Pickup/ Loss of Power/ Engine Overheating General Fuel Related Transmission Related Excessive pay load Reduce pay load Under inflated tyres Inflate to correct pressure Rear Chain Adjusted too tight Adjust chain tension Brakes are Binding Adjust brake Dirty / Blocked cooling fins Clear and clean the fins Wrong spark plug specification Replace it with correct plug Torn / damaged air filter element Change Wrong grade Lubrication oil Change the oil Lube oil I starvation Check and correct Engine Oil level Excess Drain and correct the oil level Wheel Bearings Sticky Clean and lubricate the bearings Throttle Cable Free play excess Adjust throttle cable free play Stuck throttle inner cable Clean / Replace cable Loose / damaged throttle body to engine hose / air filter to throttle body Tighten / replace the hose Suction leakage 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 for a long period Clean petrol tank and carburetor and fill the tank with fresh petrol Fuel adulterated Refill with good fuel No fuel in the tank Fill up the tank Fuel pump pressure low Check and correct Fuel Injector partially blocked Replace fuel injector. No clutch cable free play. Adjust clutch cable play Stuck clutch cable Clean and free and cable Weak clutch springs Check and Replace Clutch Plates Worn out/Glazed Check and Replace Complaint :High Oil Consumption External Leaks Loose drain plug Tighten the plugs Loose crankcase joints Tighten fasteners Damaged gaskets Replace the gaskets Damaged sealing surface Face / Replace the parts 10-4 Observation Smoke through exhaust Causes Remedies Wrong grade/recycled lube oil Replace it with right grade oil Damaged valve stem seal Replace the seal Worn out / scored valve guide / valve stem Check and Replace Vertically aligned piston ring Properly stagger the piston end gaps rings Excessive piston ring end gap Replace the piston rings Wrong fitment of piston rings Refit the piston rings correctly Connecting Rod Bent Replace the crankshaft Clearance Excess between Piston & Cylinder Barrel Check and Replace Glazed cylinder walls Check and Replace Incorrect octane rating of fuel Use correct fuel Excessive clearance between piston and cylinder Check and Replace 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 when accelerated Adjust the Cam spindles to achieve correct cam gears meshing Damaged cams Check and Replace Worn-out/damaged Big end bearings Check and Replace Complaint :Engine Noisy Engine 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 Clutch lever free play excess Check and Correct Cam plate pivot pin Oversize Change to correct size pin. 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 & peg edges chipped off Check and Replace Selector fork shaft bent / scoring marks in the shaft. Check and Replace 10-5 Observation Causes Remedies Burrs in splined position of the shaft Check and Replace Improper position of the return spring. Check and Replace Improperly adjusted brakes Check & Correct Front brake Disc Warped/Scored Check & Correct Brake linings worn / Uneven wear Check & Correct Brake drum scored / Uneven wear Check & Correct Complaint : Brakes Poor Complaint : Vehicle Wobbles Wheel rim runout Check & Correct Loose / Broken spokes Tighten / Replace spokes Tyres not fitted correctly Refit tyres correctly Wheels misaligned Ensure proper alignment Under inflated tyres Inflate to correct pressure Loose / improper connection Check & Correct Bulb fused Check & Correct Fuse blown Check & Correct Switch defective Check & Correct Switch defective Check & Correct Flasher defective Check & Correct Complaint : Electricals Bulbs do not light Complaint : Electric start not working Battery discharged fully Check & Recharge MIL Glowing Continuously Check & Correct Loose Electrical connections Check & Correct Neutral indicator not glowing Bring the vehicle in neutral Clutch Switch Defective Check & Replace Side Stand Switch Defective Check & Replace E start Motor not working Check & Replace 10-6 2005 Eicher Motors Ltd. (Royal Enfield Motors Unit), Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019, India. Tel : 91 44 4204 3300. Fax : +91-44-4201 1719. www.royalenfield.com All rights reserved.