Royal Enfield Bullet EFI Service Manual
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Royal Enfield Bullet EFI Service Manual

Euro iv vehicle
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EURO IV - VEHICLE SERVICE MANUAL
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Summary of Contents for Royal Enfield Bullet EFI

  • Page 1 EURO IV - VEHICLE SERVICE MANUAL Classic Bullet EFI Bullet EFI Continental GT KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 2 “FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction. Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy trouble free performance at all times.
  • Page 3 EURO IV BIKES – VEHICLE VIEWS ROYAL ENFIELD ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 4: Table Of Contents

    Handle Bar ............60 12.4 Wiring Diagram ..........277 Front Fork ............70 13. Trouble Shooting ............286 Steering Stem ..........87 ROYAL ENFIELD ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 5: Technical Specifications

    SECTION 01 - TECHNICAL SPECIFICATION BULLET TECH SPEC POINT CONTINENTAL GT BULLET EFI CLASSIC EFI ENGINE Engine 4 Stroke, air cooled, single cylinder 4 Stroke, air cooled, single cyl., OHV, SI Capacity 499 cc (Displacement) 535 cc Bore 84 mm...
  • Page 6 BULLET TECH SPEC POINT CONTINENTAL GT BULLET EFI CLASSIC EFI CHASSIS Frame Tubular Frame Tubular steel double cradle Fr : 90 / 90-19”-52 V 3.25 X 19” 110/90-18 M/C 56H Tyre size Rr : 110 / 80-18”-58 V 3.50 x 19"...

  • Page 7: Periodical Maintenance

    If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required. Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice. DESCRIPTION SCHEDULE Kms (x 1000) 0.5...
  • Page 8 If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required. Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice. DESCRIPTION SCHEDULE Kms (x 1000) 0.5...

  • Page 9: Special Tools Usage List

    Front Fork Oil Seal Driver Fitment of slide bush and fork oil seal (Dia 41mm) into front fork bottom case. ROYAL ENFIELD ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 10: Engine Removal From Frame

    SECTION 04 - ENGINE REMOVAL FROM FRAME Bullet Classic EFI / Bullet EFI / Continental GT Disconnect alternator leads.  Disconnect the spark plug suppressor cap.  Disconnect the fuel pipe.  Remove throttle body along with throttle cable. ...
  • Page 11 SECTION 05 - VEHICLE AGGREGATES ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 12: Cables

    SECTION 5.1 CABLES EXPLODED VIEWS BULLET CLASSIC EFI / BULLET EFI / CONTINENTAL GT S. NO. DESCRIPTION QTY. Throttle Cable Assembly (Twin Cable) BI Starter Cable Clutch Cable Assembly ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 13 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.1 Clutch Cable Assembly Bullet Classic EFI/ Bullet EFI/ Continental GT Dismantling  Slacken the adjuster at the clutch cover end and disconnect the cable from the lever.  Gently pull out part of the clutch cable from the cover.
  • Page 14 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.1 Bi Starter Cable Bullet Classic EFI/ Bullet EFI/ Continental GT Dismantling  Slacken the adjuster at the Bi starter cable end and disconnect the cable from the lever.
  • Page 15 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.1 Clutch Cable Assembly Bullet Classic EFI/ Bullet EFI/ Continental GT Assembling  Locate the clutch cable in clutch lever at handle bar end.  Locate part of clutch cable in the cover.
  • Page 16 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.1 Bi Starter Cable Bullet Classic EFI/ Bullet EFI/ Continental GT Assembling  Locate the Bi starter cable in the clutch lever at handle bar end.  Locate the part of Bi starter cable.

  • Page 17: Airfilter Paper Element

    SECTION 5.2 - AIR FILTER PAPER ELEMENT EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Air Filter Box Assembly with sticker Inlet Bellow Air filter element 500cc Clip Hose - Inlet Bellow Cover Filter element Hexagon Socket Head Cap screw-M5X.8X20 2...
  • Page 18 Pan Head Screw M5 X 12 Clamp Inlet Cover Pipe Outlet Seal TA Sensor Element Air Filter Hex Socket Head Cap Screw M5 X 16 Drain Pipe Clip ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 19 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.2 Air Filter Element Bullet Classic EFI/ Bullet EFI CAUTION:  Unlock and open the Ensure the pillion footrest is Filter box RH. in extended position to avoid damage to filter box lid ...
  • Page 20  Remove airfilter element NOTE: from the housing. Remove rubber seal from the cover. CAUTION: Ensure Purge valve is placed safely to prevent from damage. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 21 Using low pressure compressed air :  blow air from INSIDE to OUTSIDE for Bullet EFI, Bullet Classic EFI Models. blow air from OUTSIDE to INSIDE for Continental GT Models. to remove the fine dust particles. DO NOT WASH THE ELEMENT IN WATER, GASOLINE OR ANY SOLVENTS.
  • Page 22 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.2 Air Filter Element Bullet Classic EFI/ Bullet EFI CAUTION:  Locate the Air filter Ensure the pillion footrest element inside filter box is in extended position to avoid damage to filter box lid.
  • Page 23 Locate side panel RH in the frame, ensuing the pegs in the frame are seated in the grommets.  Tighten the RH side panel at the bottom using pan head screw. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 24 SECTION 5.3 - FUEL TANK ASSEMBLY EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI 12 10 S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Fuel Tank With Sticker - Black Washer Cap-Fuel Tank Washer Thigh Pad R H Clamp Plate - Fuel Pump...
  • Page 25 Punched Washer-Fuel Gauge Mtg Rear Damper-Tank Fuel Gauge Unit O Ring O’ Ring-Fuel Gauge Fuel Pump Quick Connector Clamp Plate - Fuel Pump Fuel Hose (PA Tube) Washer Cap, Injector ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 26: Fuel Tank

    Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.3 Fuel tank - Dismantling Bullet Classic EFI/ CAUTION: Bullet EFI Drain the fuel completely  Remove Seat Assembly. from the fuel tank.  Disconnect fuel hose CAUTION: from the Fuel tank.
  • Page 27  Slide fuel tank onwards rear to release front Prevent damage to locking clamp from the EVAP hose. rubber supports frame. Remove tank from frame carefully. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 28  Do not smoke or allow open flame or sparks in the vicinity.  Store the fuel carefully to avoid spillage. TORQUE CHART Torque Range Aggregate Component Fastener Kg-M Fuel Tank Fuel tank Mounting Flanged hex bolt M6 * 30 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 29 Instructions 5.3 Fuel tank - Assembly Bullet Classic EFI/ Place a piece of cloth on the Bullet EFI top, front portion of the fuel tank to avoid damage Ensure the handle bar is due to touching of the held at straight ahead handle bar clamp on fuel position.
  • Page 30 Fuel tank.  Install 2 Hex bolts at the rear end of fuel tank along with washers,seals and rear dampers.  Assemble Seat.  Fill fuel sufficiently. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 31: Seat Assembly

    SECTION 5.4 - SEAT ASSEMBLY EXPLODED VIEWS BULLET EFI S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Complete Seat Assy Stud M8 Flanged Hex. Bolt M 6 X 20 Plain Washer M8 Pillion Handle Rubber Support Seat Front Hex Nut With Nylon Insert, M6 Flanged Hex.
  • Page 32 Flanged Hex Bolt M8 X 1.25 X 16 Washer (Classic Models) Hexagonal Nut M6 X 1 X 7 Plain Washer (Chrome) Pillion Handle for Rear Seat - Black Spring Bush ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 33 S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Single Seat Assembly with Cowl - Red Rubber Support-Middle Plain Washer Rubber Support-Front Cross Recessed Pan Head Screw M6X14 Rubber Support-Rear ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 34  Gently remove the rider seat from the frame. Rear Seat Removal  Hold nut and remove Flange Hex Bolt M8 long mounting bolt from Socket Spanner 13 mm the sub frame. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 35 Flange hex Bolt M8 under the rear seat to Socket Spanner 13 mm remove seat from Sub frame. Bullet EFI  Remove front Hex nut Hex Flange Bolt M8 mounted on LH & RH side Socket Spanner 13 mm of the seats.
  • Page 36 Instructions 5.4 Seat -Dismantling Continental GT  Unlock & Remove Side panel LH.  Gently pull seat latch to release seat. SEAT LATCH  Remove the seat assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 37 RH side. Rear Seat Assembly  Tighten the 2 hex bolt Flange Hex Bolt M8 under the rear seat to Socket Spanner 13 mm assemble seat into Sub frame. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 38 Domed hex Double end ring spanner nut & Bolt from LH & RH 17 mm side. Bullet EFI  Locate the seat in to Hex Flange Bolt M8 front end tighten rear Socket Spanner 13 mm hex bolt on LH & RH side of the seats.
  • Page 39  Gently press the seat rear end to lock the seat.  Locate the Side panel LH and lock in the seat. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 40 SECTION 5.5 - EXHAUST PIPE & SILENCER EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI, CONTINENTAL GT Bullet & Classic EFI Continental GT S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Flanged Hex. Nut M8 X 1.25 Bracket -Silencer Mounting /Bracket Silencer Exhaust Pipe -Guard Gasket - Exhaust pipe &...
  • Page 41 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.5 Exhaust System Bullet Classic EFI/ Bullet EFI  Disconnect HEGO sensor connector from the exhaust pipe by loosen- ing the nut.  Remove the center Hex Flange Bolt M8...
  • Page 42 / exhaust pipe.  Gently remove the Flange Hex Nut M8 silencer assembly with Socket Spanner 10 mm Exhaust pipe. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 43 Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder  head. Copper gasket in HEGO sensor whenever exhaust pipe / hego sensor is dismantled.  ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 44 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 5.5 Exhaust System- Assembling Bullet Classic EFI/ Bullet EFI  Locate gasket Exhaust pipe.  Position exhaust pipe on the cylinder head assembly. Hex Flange Bolt M8  Tighten two flange hex...
  • Page 45 Hex Flange Bolt M8 Mounting nut at the pillion foot rest end. Socket Spanner 10 mm Torque 25 Nm  Connect HEGO sensor connector from the exhaust pipe. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 46: Front Suspension

    SECTION 06 - FRONT SUSPENSION ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 47: Front Wheel

    SECTION 6.1 - FRONT WHEEL EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Hex Socket Button Head Screw M6*1.0 Spokes Front Toner Front Wheel 90/90 - 19 52 V Front Tyre Import Spindle Tube(Tyre) 3.25X19...
  • Page 48 Rim Tape Front Disc Spindle-Front Wheel Grease Seal,25 X 40 X 7 Wheel Speed Sensor Assy Deep Groove Ball Bearing 6203 (17X40X12) Bearing Spacer Assy Hub-Front Spokes Front ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 49 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.1 Front Wheel Dismantling Bullet Classic EFI/ Bullet EFI / Continental GT  Place the motorcycle on its center stand on a firm and flat surface.  Provide suitable...
  • Page 50 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.1 Front Wheel Dismantling Bullet Classic EFI/ Bullet EFI / Continental GT  Remove the axle nut and Hex Socket Screw M8 washer. Allen Key 6mm Torque 25 Nm (2.5 Kg-m) ...
  • Page 51 Inspect Toner ring for any damage.  Axle & nut for thread damage.  Inspect wheel rim for run out / “jump” it should not exceed 2 mm.  ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 52 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.1 Front Wheel Assembling Bullet Classic EFI/ Bullet EFI / Continental GT  Remove the wooden piece / card board sheet placed between the brake pads.  Locate spacer & speedo drive on the right side in the hub.
  • Page 53 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.1 Front Wheel Assembling Bullet Classic EFI/ Bullet EFI /  Ensure the peg in the Speedo drive is correctly positioned in the slot in the right side fork end. Continental GT ...
  • Page 54  Hold the pinch bolt and tighten the nylock nut on the right side fork end. (Only Bullet Classic EFI / Bullet EFI)  Tighten hex socket Torque 25Nm screw on fork end RH. (Only for Continental ...
  • Page 55 SECTION 6.2 - FRONT MUDGUARD EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI LH side RH side S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Front Mudguard-Black Spring Washer Mudguard Stay Front Black Mod Cable Guide Mudguard Stay Center LH Black New Clamp - Front Caliper Brake Hose Hex Flanged Bolt M8 X 1.25 X 38...
  • Page 56 Front Mudguard Hex. Nut M8 Mud - Flap Front Hex. Socket HD. Cap Screw M6X20 Stainless Steel Fork Brace Hex. Socket Button Head Screw M6X1 Lock Washer Internal Teeth ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 57: Front Mudguard

    Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.2 Front Mudguard Bullet Classic EFI / Bullet EFI  Remove Front wheel as described in Front Wheel section  Release Brake hose Flanged Hex bolt: M8 grommet from...
  • Page 58 RH Allen Key : 5 mm & LH.  Gently lift up and remove mudguard from the fork legs. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 59 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.2 Front Mudguard Bullet Classic EFI / Bullet EFI CAUTION:  Locate Mudguard stays Ensure mudguard does along with mudguard not get scratched while and slide into the fork assembling.
  • Page 60 Allen Key : 5 mm between the fork legs RH & LH.  Locate Front wheel as described in Front Wheel section. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 61: Handle Bar

    SECTION 6.3 – HANDLE BAR EXPLODED VIEWS BULLET CLASSIC EFI / BULLET EFI S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Handle Bar Assembly Complete Lever & Holder Assy. LH Hex Socket Head Screw M8 X 50 Clutch Lever Damper Weight...
  • Page 62 Pan Head Screw M5 X 10 Counter Weight Assy. Add On Lead, Brake Switch Mirror Dummy Ring Clutch Switch Handle Grip - LH Add On Lead, Clutch Switch ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 63 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.3 Handle Bar Bullet Classic EFI / Bullet EFI  Remove Headlamp from Philips head screw driver the headlamp casing and disconnect wire terminals.  Disconnect wire couplers Double end spanner...
  • Page 64 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.3 Handle Bar Bullet Classic EFI / Bullet EFI  Remove the 2 hex bolts Hex bolts: M6 on the clamp holding Socket spanner: 10 mm Front brake master cylinder to handle bar.
  • Page 65  Disconnect all control Double end spanner cables from the handle 15mm bar.  Remove the 2 hex bolts on the clamp holding Front brake master cylinder to handle bar. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 66 2 hex socket Allen Key: 6 mm head cap screws. Hex. Socket Head Screw:  Remove handle bar LH & RH form the fork main Allen Key: 5 mm tubes. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 67 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.3 Handle Bar Bullet Classic EFI / Bullet EFI  Locate handle bar clip on Hex SS Bolt : M12 studs headlamp casing and the Socket spanner: 14 mm handle bar.
  • Page 68 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.3 Handle Bar Bullet Classic EFI / Bullet EFI  Connect all control cables on the handle bar.  Locate Rear view mirrors LH & RH.  Connect wire couplers...
  • Page 69 LH & RH to the fork main tubes.  Locate master cylinder assembly on the handle bar and support suitably to prevent hydraulic oil leak from master cylinder. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 70  Connect handle bar LH & RH wire couplers inside the head lamp housing.  Locate Headlamp on the Philips head screw driver headlamp housing and Connect wire terminals. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 71 SECTION 6.4 – FRONT FORK EXPLODED VIEWS BULLET CLASSIC EFI / BULLET EFI Key Nos. 1 to 3, 5 to 20 Key Nos. 1, 2, 4 to 20 Key Nos. Qty 2 Nos. 2, 7, 9, 11, 15 & 20 Key Nos.
  • Page 72 Circlip (Snap - Ring) Plain Washer Dust Seal Lock Washer, M6 Spindle Taper Reflex Reflector Amber Gasket Wheel Speed Sensor-ABS Bolt M10X1 Hex.Socket Button Head Screrw M6 X 1X 16 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 73 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.4 Front Fork LH & RH Bullet EFI / Bullet Classic EFI  Remove Front wheel as described in Front Wheel section 6.1.  Remove front mud- guard as detailed in Section 6.2.
  • Page 74 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.4 Front Fork LH & RH Bullet EFI / Bullet Classic EFI  Loosen and remove 2 Hex socket screws from the top of the front forks on the head lamp casing.
  • Page 75  Loosen the 2 hex socket screws inside the head lamp holder RH & LH. Ensure the head lamp holders are free on the front fork main tube. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 76 LH & Support the head lamp RH from the steering holders with the trafficators stem and top yoke. while removing the forks LH & RH from the steering stem. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 77 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.4 Front Fork LH & RH Bullet EFI / Bullet Classic EFI Hex Screw M10  Gently rotate and locate Allen Key 8 mm the fork assembly LH &...
  • Page 78 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.4 Front Fork LH & RH Bullet EFI / Bullet Classic EFI  Ensure wheel speed sensor is located in the fork end LH.  Locate front mudguard as detailed above.
  • Page 79 RH & LH. Hex Socket Screw M8  Locate Headlamp in the headlamp housing and Allen key 6 mm connect all electrical connections inside headlamp housing. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 80  Ensure front brake caliper is located in the fork LH.  Locate front mudguard as detailed above.  Assemble Front wheel as described in Front Wheel section 6.1. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 81 Replace all Rubber parts, , plastic bushes, O rings, washers whenever they are removed.  Remove long spring from inner tube. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 82  Gently pump main tube into the bottom tube to drain completely.  Repeat the above process to drain oil from the other fork assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 83  Locate washer, spacer NOTE: and washer spring top in the inner tube. Replace all Rubber parts, , plastic bushes, O rings, washers whenever they are removed. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 84  Locate fork top nut with Hex nut M16 washer, allowing spring to compress slowly. Double end spanner 24 mm  Repeat above process to fill oil and assemble the other fork assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 85: Front Fork

     Pull out the inner tube from the outer tube sharply to remove the inner tube along with the guide bush, seat pipe assembly, rebound spring and cap oil lock. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 86 Hex bolt & nut: M6  Locate the pinch bolt Ring spanners: 10mm and nut on Fork RH. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 87 Spring Length ------ mm Long Pitch Short Pitch Fork spring short  Length New Spring: --------mm Service Limit: -------mm Main tube straightness Service Limit: 0.15 mm Guide Bush ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 88: Steering Stem

    SECTION 6.5 – STEERING STEM EXPLODED VIEWS BULLET CLASSIC EFI / BULLET EFI 15 16 S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Cover Washer Ball Race, Head Lamp Casing Steering Stem Ball Cage Clip, Handle Bar Ball Race, Frame...

  • Page 89: Ks Motorcycles - Http://Ksmotorcycles.com

    Steering Stem Assembly Ring Nut Ball Race - Bottom Yoke Dust Cap - Top Yoke Dust Seal - Bottom Yoke Ball Race - Top Yoke Steering stem - Ball Cage ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 90: Ks Motorcycles - Http://Ksmotorcycles.com

    Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.5 Steering Play Adjustment Bullet Classic EFI / Bullet EFI  Rock the front end and NOTE: feel the play at stem top end. Every 6,000 KMS, Steering Ball race adjustment should...

  • Page 91: Ks Motorcycles - Http://Ksmotorcycles.com

    Hex Socket Screw M5  Loosen the steering Allen Key 6mm dome nut with long extension rod.  Loosen the pinch bolts in bottom yoke on LH and then RH side. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 92: Ks Motorcycles - Http://Ksmotorcycles.com

    Dome Lock Nut M24 then tighten Dome nut Socket Spanner – 30 mm to Torque. Torque – 50 Nm  Again check and confirm the steering free play. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 93: Ks Motorcycles - Http://Ksmotorcycles.com

    Take a small test ride to turning extreme Left to ensure that Right side. - Steering free movement. - No dragging. - No sound from steering stem / mounting area. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 94: Ks Motorcycles - Http://Ksmotorcycles.com

    Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.5 Headlamp Casing & Steering Stem Bullet Classic EFI / Bullet EFI  Disconnect speedometer cable from speedometer.  Disconnect wiring couplers of the speedo- meter, meter, ignition switch and parking lamps from the main wiring harness.

  • Page 95: Ks Motorcycles - Http://Ksmotorcycles.com

    Aggregate to Dismantle/ Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.5 Headlamp Casing & Steering Stem Bullet Classic EFI / Bullet EFI  Gently lower steering stem remove from the frame.  Remove the Headlamp casing from the frame.  Remove the top and bottom ball cage from the ball races.

  • Page 96: Ks Motorcycles - Http://Ksmotorcycles.com

    Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.5 Headlamp Casing & Steering Stem Bullet Classic EFI / Bullet EFI  Using a short chisel, drive in the ball race along with dust headlamp casing and the ball race in steering stem.

  • Page 97: Ks Motorcycles - Http://Ksmotorcycles.com

    Fastener, Size, Tool Usage, Precautions, Photos Instructions 6.5 Headlamp Casing & Steering Stem Bullet Classic EFI / Bullet EFI  Locate the fork cover tubes LH & RH along with the rubber spacers and plastic bushes.  Locate and install the...

  • Page 98: Ks Motorcycles - Http://Ksmotorcycles.com

     Support steering stem and the bottom and loosen and remove the top ring nut first and the second ring nut next. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 99: Ks Motorcycles - Http://Ksmotorcycles.com

     Using a short chisel, drive out the ball race along with dust cap from the top yoke and the ball race from steering stem. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 100: Ks Motorcycles - Http://Ksmotorcycles.com

     Locate the top and bottom ball cage in the ball races.  Locate steering stem and assemble on the frame. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 101: Ks Motorcycles - Http://Ksmotorcycles.com

     Locate the top lock nut on the top yoke.  Locate speed sensor wire coupler from wiring harness.  Connect wiring couplers instrument cluster to main wiring harness. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 102: Ks Motorcycles - Http://Ksmotorcycles.com

    Inspect the steering ball cages and ball races for any rusting, pitting and damaged balls/ races Inspect steering stem for any damages / run out as these will affect the stability and steer ability for the motorcycle ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV...

  • Page 103: Rear Suspension

    SECTION 07 - REAR SUSPENSION ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 104: Rear Wheel

    SECTION 7.1 - REAR WHEEL EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI 23 24 25 21 22 6 7 8 S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Socket Head Bolt M8 X1.25 X20 Cush Rubber Toner-Rear Wheel Adaptor-Rd Sprocket...
  • Page 105 Final Drive Sprocket 17T Cushion Rubber Chain Rear (100 Pitches O-ring type) Tyre-Rear 130/70 – 18” Connecting Link ‘O’ Ring Drive Chain - LGB Tube-Rear (130 /80 – 18") ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 106 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.1 Rear Wheel Dismantling Bullet Classic EFI/ Bullet EFI / Continental GT  Place the motorcycle on its center stand, on a firm and flat surface such that the rear wheel is about 4 inches (10 cms) above the ground.
  • Page 107 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.1 Rear Wheel Dismantling Bullet Classic EFI/ Bullet EFI / Continental GT CAUTION :  Remove the caliper assembly by gently Do not press the rear brake pulling out from the...
  • Page 108  Inspect wheel rim for run out / “jump” it should not exceed 2 mm.  Inspec cush rubbers for wear or deterioration and replace only as set if required. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 109 New Max. Flatness 0.10 mm Service Limit : Run out - disc Rear Disc Thickness (BBI) CON. GT 5.00 (only GT) New Min. New Max. 4.5 mm Service Limit ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 110 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.1 Rear Wheel Assembling Bullet Classic EFI/ Bullet EFI  Remove the wooden piece / card board sheet placed between the brake pads.  Ensure the four Cushion rubbers are in position in the rear wheel hub.
  • Page 111 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.1 Rear Wheel Assembling Bullet Classic EFI/ Bullet EFI  Ensure Chain tensioner is correctly located inside the swing arm on the left side & firmly seated against swing arm.
  • Page 112 Swing Arm Reference Mark Lock nut  To reduce the free play, turn the drive chain slack adjusting nut at each end of the swing Clockwise direction. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 113 It leads to chain slippage or breakage. It is recommended to maintain drive chain slack within the specified limits. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 114 Hex Bolt - 3/8"X45 (For RH Side Only) Flanged Hex. Bolt M10 x 44 Hex Bolt - 3/8" BSF x 2" (For LH Side Only) Spring - Shock Absorber Plain Washer (M10) Plain Washer (M10) ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 115 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.3 Rear Shock absorber Adjustment Bullet Classic EFI / Bullet EFI / Continental GT  The Pre-loaded spring CAUTION: C5/B5 tension shockabsorber is of adjustable type i.e., Riding the motorcycle with...

  • Page 116: Rear Shockers

    Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.3 Rear Shockers Bullet Classic EFI / Bullet EFI Dismantling  Refer Rear Mudguard Section 7.4.  Loosen 2 domed nuts Domed Nut M10 mounted on top end of...
  • Page 117 LH & RH sides along plain washer  Gently remove the Rear Shock Absorbers from LH & RH side. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 118 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.3 Rear Shockers Bullet Classic EFI / Bullet EFI  Locate Rear Shock A b s o r b e r s ( C h r o m e plated) on LH &...
  • Page 119  Install 2 hex bolts on top end of Rear shock absorbers on both LH & RH sides along with single coil spring lock washers plain washers. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 120: Rear Mudguard / Rear Number Plate

    SECTION 7.4 - REAR MUDGUARD EXPLODED VIEWS BULLET EFI 6 28 S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Rear Mudguard With Sticker Std BVI Hex Nut M6X1 Mudguard Carrier RH Mod Black Lock Washer Internal Teeth M6 Flanged Hex. Bolt M8 X 20 Piece Mudguard Hex.
  • Page 121 Flanged Hex. Bolt M8 X 1.25 X 45 Lock Washer,Internal Teeth Dome Cap Bolt M8 X 45 (Special) Hex Bolt, M6 X 35 Plug Carrier End Washer Plain Grommet Hex. Nut M6 Beading ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 122 Trafficator Assy With Bulb-Rear LH Punched Washer M6 Trafficator Assy With Bulb-Rear RH Hex.Nut With Nylon Insert M6 Reflector Flange Hex Bolt M6 X 20 Flanged Hex.Bolt, M8 X 1 X 20 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 123 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.4 Rear Mudguard Bullet Classic EFI / Bullet EFI  Loosen 2 hex bolts Flanged Hex Bolt M8 mounted on top end of Mudguard Carrier on Socket spanner 13 mm both LH &...
  • Page 124 Cross recessed pan head mounted on rear end of screw M6 Rear mudguard along with punched washers Allen Key 5 mm  Gently remove the Rear mudguard from position ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 125 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.4 Rear Mudguard Bullet Classic EFI / Bullet EFI  Gently locate the Rear Hex Socket head cap Mudguard assembly Screw M8 along with Mudguard carriers. Allen Key 5 mm ...
  • Page 126  Install 2 hex bolts on top Flanged Hex Bolt M8 end of Rear mudguard along with Hex nuts Socket Spanner 13 mm  Refer Section 5.4 for assembling Seat dis- mantling . ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 127 SECTION 7.5 - REAR SWING ARM EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Swing Arm Sub Assembly Black Black-Powder Coated Swing Arm Bush - Celcon Flange Bolt with Collar - M6 X 1...
  • Page 128 Slotted Head Screw M6 X 13 Clip - Rear Disc Hose Cover - ABS Modulator Philips Pan Head Screw M6X6 Flanged Hexagonal Bolt M6 X 1 X 20 Chain Tensioner Comp. - LH ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 129: Swing Arm

    Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.5 Rear Swing Arm Bullet Classic EFI / Bullet EFI  Place the motorcycle on its center stand, on a firm and flat surface such that the rear wheel is about 4 inches (10 cms) above the ground.
  • Page 130 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.5 Rear Swing Arm Bullet Classic EFI / Bullet EFI  Ensure the spacer is removed and stored carefully  Gently pull rear wheel towards the left so that...
  • Page 131 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 7.5 Rear Swing Arm Bullet Classic EFI / Bullet EFI  Locate the swing arm assembly from frame.  Install the Hex bolt on Hex Nut M16 the other end of the...
  • Page 132  Gently remove the swing Index mark arm assembly from the frame. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 133  Install the Hex bolt on the other end of the swing arm along with needle bearings, oil seals, spacers, end cups, spacer swing arm, hex nut. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 134: Abs

    SECTION 08 - ABS (ANTILOCK BRAKING SYSTEM) EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI - ANTILOCK BRAKE SYSTEM S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION ABS System Brake Hose Assy-ABS To Rear Master Cylinder Front Caliper Master Cylinder Assy Comp -Rear...
  • Page 135 BULLET EFI & CLASSIC MODELS - ABS MOUNTING TO FRAME S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. ABS System Bracket Assy - ABS & Cover Clamp Brake Hose Wheel Speed Sensor Clamp Front Caliper Hose Hex Button Head Screw M6 X 1 X 16...
  • Page 136 Master Cylinder Assy Comp -Rear Hex.Socket Button Head Screrw M6X1 Rear Brake Switch Pad- Rear Disc Brake Hose Assy-Abs To Rear Caliper Pad-Piston Side - Rear Disc Caliper Assy-Rear ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 137 Clamp LH - Brake Hose Flanged Hex Bolt M8X20 Clamp Front - Brake Hose Hex. Socket Button Head Screw M6X1x16 Flanged Hexoganal Bolt M6X1X20 Wheel Speed Sensor - ABS ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 138 Anti-Lock Braking System (ABS) fitted in Royal Enfield motorcycles, is a safety system to help the front and rear wheels maintain traction with the road surface in the event of sudden application of brakes by the rider at high speeds.
  • Page 139 8.1 LOCATION OF THE ABS SYSTEM PARTS 1. ABS INDICATOR Bullet EFI and Classic EFI  Located inside the small meter in the head lamp casing alongside the EMS MIL and low fuel warning lamp. CONTINENTAL GT  Located in the RPM meter in instrument cluster 2.
  • Page 140  Located on Handle bar RH side 5. FRONT WHEEL CALIPER.  Located on the fork end LH side 6. WHEEL SPEED SENSOR - FRONT  Located on the fork end LH side ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 141 7. TONER RING - FRONT WHEEL.  Located on front Hub centre (below brake disc) 8. REAR BRAKE MASTER CYLINDER Bullet EFI and Classic EFI  Located on the frame bottom on RH side (underneath engine) CONTINENTAL GT  Located on the frame right side near brake pedal 9.
  • Page 142 11. WHEEL SPEED SENSOR - REAR  Located on the rear caliper assembly mounting bracket 12.TONER RING – REAR WHEEL  Located on the rear hub left side below the brake disc ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 143 8.1 LOCATION OF THE ABS SYSTEM PARTS BULLET EFI / BULLET CLASSIC EFI CONTINENTAL GT ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 144 IF FOR ANY REASON THE BRAKE HOSES OR THE MODULATOR HAS TO BE SERVICED, THEN THE ENTIRE HYDRAULIC FLUID SYSTEM BLEEDING HAS TO BE CARRIED OUT AND THE ECU HAS TO BE REPROGRAMMED. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV...
  • Page 145  Loosen and remove the 4 banjo bolts holding 4 brake hoses to the modulator.  Ensure Ignition switch and engine stop switch is in OFF position. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 146 Hex Bolt: M6 the sides and 1 hex bolt at the bottom, holding Double end spanner: modulator to the mount- 10mm ing bracket.  Remove ABS assembly from the bracket. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 147 ECU.  Ensure Ignition switch and engine stop switch is in OFF position.  Locate and install the 4 banjo bolts holding 4 brake hoses to the modulator. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 148  Locate the ABS cover on Hex Bolt: M6 the RH side (Bullet & Classic Models Only) by Double end spanner: installing 2 Hex bolts on 10mm the sides. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 149  Remove the worn out brake pad from the caliper assembly. Pad Service Limit 3.8mm  Clean caliper assembly by dry / clean cloth. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 150  Insert the clip hanger in caliper assembly.  Place the wooden piece / card board sheet in between the brake pads. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 151 Double end spanner 13mm.  After adjustment tighten NOTE : the lock nut in master cylinder push Please connect Rear Brake assembly. pedal returns spring to Master Cylinder. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 152  Fill the Master cylinder with ‘Fresh brake fluid’ from a sealed container till “MAX” level.  Open the bleed screw to ½ a turn. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 153  Relocate & tighten the CAUTION : Master Cylinder assembly Don’t Mix DOT 4 & Above to the original location Brake Fluid together of the handle bar and tighten the Bolt clamp ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 154 Hex nut M8 expelled, then tighten Double end spanner 14 mm the screw.  Remove the rear view mirror.  Disconnect the Brake Switch coupler. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 155 Ring Spanner 8mm handlebar. Hex Bolt M7 Spanner 12 mm Hex Bolt M5 Ring Spanner 8mm  Remove the wire from the coupler by pressing projection terminal ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 156 Circlip from the parts with petrol or any Master cylinder body. other gasoline product or water. USE BRAKE FLUID ONLY.  Remove the Conical spring (piston compression spring). ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 157  Assemble the rubber CAUTION: Boot. Do not use tools with sharp ends.  Apply Silicon grease on the Lever pivot hole and on the Piston surface ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 158 Bolt-lever 6 Nm then tighten the bottom Nut-lever 6 Nm Bolt. Hex Bolt M5 Ring Spanner 8mm  Assemble the Lever, Bolt - lever and Nut-lever and tighten. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 159 Double end spanner 14 mm bleed the system. Then assemble the Diaphragm, Torque 15 Nm diaphragm plate and Cover. Tighten screws gently.  Assemble the rear view mirror. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 160 Check periodically whether the Disc has been contaminated with oil, brake fluid or grease and clean contaminated  Disc with a high quality brake-degreasing agent. Always keep the disc clean and dry at all times for the brakes to work at peak efficiency.  ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 161 Hex Bolt 12 mm C5/B5 mounting bolts on the Socket Spanner – 13mm/ fork end and remove the 12mm caliper.  Remove the Grub screw Screw 11 mm on the brake caliper ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 162 Hex Bolt 13 mm GT Hex Bolt 12 mm C5/B5 Socket Spanner – 13mm/ 12mm  Remove the brake pad from Caliper Assembly.  Remove tensioner spring plate. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 163 O.D. while fluid inlet hole to remove servicing / handling. the Pistons. Remove the Bleed Screw ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 164  Coat the caliper cylinders and Pistons withSilicon grease or clean brake fluid and Install the pistons into the caliper body with the dished facing inwards. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 165  Assemble Bleed screw into caliper body.  Assemble the Mounting Bracket with caliper Body.  First install the pad near to the piston and then assemble other pad. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 166 Torque 35 Nm to the caliper with New sealing copper washer and then Tighten the Banjo bolt.  Fill the brake fluid and bleed the hydraulic brake system. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 167 VarCode EEPROM Out Of Range 5331 H Front Wheel Pressure sensor ohmic fault 5332 H Front wheel pressure sensor offset/Test Pulse/POT fault 5333 H External Supply for Pressure sensor failure ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 168: Evap

    SECTION 09 - EVAP EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY. Hose Purge Valve To Tank Canister Hose T Connector To Throttle Body Hose Canister Vent T Connector Bush Pav Hose T Connector To Canister Hex.Socket Hd.Cap Screw,M6 X 20...
  • Page 169 Hose T-Connector To Canister(GT) Hose-T-Connector To Throttle(GT) T – Connector Adaptor Purge Valve LH Hose -Purge Valve To T-Connector(GT) Canister Assy Adaptor Purge Valve RH Grommet Purge Valve Sleeve ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 170 As soon as the engine is started, these vapours are purged from the canister, into the combustion chamber. The system consists of a canister, purge valve, rubber hoses, connectors and a sealed fuel tank cap. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV...
  • Page 171 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 172 Inspect rubber hoses and joints periodically for any cuts cracks or fractures. Replace if damaged. Inspect Canister periodically for any damage to its body cuts or cracks. Replace all rubber hoses and connectors every 12,000 Kms. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 173 Aggregate to Dismantle/ Fastener, Size, Tool Usage, Precautions, Photos Instructions Canister Bullet Classic EFI / Bullet EFI  Remove 2 bolts mounted on the Piece mudguard.  Remove the canister along with the tubes and connectors. Canister Continental GT  Remove 2 bolts mounted on the Frame additional bracket.
  • Page 174 Aggregate to Assemble/ Fastener, Size, Tool Usage, Precautions, Photos Instructions Canister Bullet Classic EFI / Bullet EFI  Locate Cannister in the piece mudguard bracket such that it can be tightened with 2 hex bolts.  Tighten the 2 bolts.
  • Page 175 SECTION 10 - ENGINE MANAGEMENT SYSTEM (EMS) Royal Enfield Motorcycles being supplied to the European Union are fitted with an intelligent Engine Management System (EMS). The EMS consists of an Electronic Control Unit (ECU) which constantly receives inputs like engine temperature,...
  • Page 176 SPECIFICATIONS / FUNCTIONS OF THE VARIOUS EMS PARTS 1. ELECTRONIC CONTROL UNIT (ECU) The Electronic Control Unit (ECU) is located inside the Electricals box on the Left side (Bullet EFI/ Classic EFI models) and under the seat (Continental GT models).
  • Page 177 Engine Temp. Sensor SSTAND Side Stand Switch ROLL Roll Sensor Manifold Pressure Sensor EXAJ Exhaust Air Injection NLSW Neutral Switch K-LINE Diagnostic Tool HEGO HT HEGO Sensor Heater ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 178 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 179 In addition to the Hego sensor, the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the cylinder head, primarily during idling RPM so as to meet exhaust emission specifications. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV...
  • Page 180 ECU. This helps the ECU to regulate the fuel injector opening duration to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV...
  • Page 181 9. AMBIENT AIR (TA) SENSOR The TA sensor is located on the rear side of the filter box assembly in Bullet EFI / Classic EFI models and on the outlet pipe of the air filter housing in Continental GT models.
  • Page 182 The fuel injector operation and duration to deliver vaporized fuel is controlled by the ECU based on the critical operating inputs received from the crank position sensor, EOT sensor, ambient air temperature sensor, throttle position sensor, manifold pressure sensor and HEGO sensor. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 183 12. EFI ECU POWER & SIDE STAND RELAYS There are two identical relays located inside the Electricals box LH side (on Bullet EFI & Classic EFI models) and on the battery bracket inside the LH panel (on Continental GT models).
  • Page 184 In the event of any malfunction the MIL will glow continuously. The EMS should be checked using either the test pin method OR the Royal Enfield NACS II diagnostic tool connected to the socket in the wiring harness of the motorcycle.
  • Page 185 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Electronic Control 10.1 Unit (ECU) A. Bullet EFI / CAUTION: Bullet Classic EFI  Ensure both Ignition  The ECU is located inside and Engine kill switch the Electricals Box on the...
  • Page 186 Bolt M5 X 0.8 X 16, holding Pulsar coil to cover RH inside.  Remove 3 Hex Socket Head Cap Screw M5 X 30, holding stator coil to cover RH inside. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 187  Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor.  Gently Loosen engine temperature sensor and remove along with ‘O’ ring. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 188 OFF position.  Disconnect wiring harness coupler from the sensor.  Loosen Hego sensor and remove along with copper washer from the exhaust down pipe. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 189 EXAI solenoid.  Remove socket head cap NOTE: screw holding the EXAI Ensure spacer between the solenoid to the reed EXAI solenoid. & bracket is valve bracket. removed. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 190 (MAP) are not serviceable cylinder head. and hence should not be  Remove throttle body removed from the throttle by gently sliding it out of body. the inlet bellow and adaptor. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 191  Using a long reach Philips head screw driver, loosen and remove the 2 screws, holding TA sensor to pipe outlet.  Remove TA sensor along with gasket, from pipe outlet. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 192 Screws: M6 X 12  Pull out fuel pump from Socket spanner: 8mm the fuel tank.  Take care to remove the O ring from the fuel tank. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 193 “O” ring.  Remove the spacer from the stud.  Gently pull out the Injector from cylinder head. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 194 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions EFI ECU Power & 10. 1 0 Side Stand Relays A. Bullet EFI & Classic EFI Models  Two identical relays are located inside electricals box LH.  Ensure Ignition switch and stop switch are in OFF position.
  • Page 195 OFF position.  Disconnect the wiring coupler from the sensor.  Loosen and remove the hex socket screw holding the sensor to the frame and remove the sensor. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 196 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Malfunction 10. 1 2 Indicator Lamp A. Bullet EFI & Classic EFI Models  Located in the small meter on Headlamp casing which also has the low fuel warning and ABS indication.
  • Page 197 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Electronic Control 10.13 Unit (ECU) A. Bullet EFI & Classic EFI  Locate ECU inside the CAUTION: Electricals box on LH  Ensure both Ignition side. and Engine kill switch are ...
  • Page 198  Install and tighten 2 Hex Flange Bolt M6 X 1 X 85 on cover RH front.  Connect Magneto wiring coupler in the electrical harness.  Fill engine oil. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 199 ‘O’ ring on the cylinder head right side below the inlet manifold.  Ensure Ignition switch and stop switch are in OFF position, Connect wiring harness coupler on the sensor. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 200  Ensure Ignition switch and stop switch are in OFF position.  Connect wiring harness coupler on the sensor. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 201  Ensure Ignition switch and stop switch are in OFF position, Connect wiring harness coupler in the EXAI solenoid.  Assemble Fuel tank as described in section 2 Fuel tank. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 202  Connect TPS and MAP NOTE: wiring couplers. The throttle position sensor (TPS) and Manifold Absolute Pressure Sensor (MAP) are not serviceable and hence should not be removed from the throttle body. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 203  Ensure Ignition switch and stop switch are in OFF position.  Connect the wiring coupler in the TA sensor.  Assemble seat assembly (Refer section 5.4) ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 204 Socket spanner: 8mm fibre washers.  Install fuel tank as described in section 5.3 for Fuel tank assembly.  Assemble Seat assembly as described in section 5.4 for Seat assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 205  Install fuel tank as described in section 5.3 for Fuel tank assembly.  Assemble Seat assembly as described in section 5.4 for Seat assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 206 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions EFI ECU Power & 10.22 Side Stand Relays A. Bullet EFI & Classic EFI Models:  Ensure Ignition switch and stop switch are in OFF position.  Gently push the two...
  • Page 207  Connect the wiring coupler from the sensor.  Ensure Ignition switch and engine stop switch are in OFF position. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 208 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Malfunction 10.23 Indicator Lamp A. Bullet EFI & Classic EFI Models  Gently push the meter downwards from top to locate it on the rubber ring.  Ensure Ignition switch and engine stop switch are in OFF position.

  • Page 209: Ems

    / electrical connection that caused the malfunction. LEVEL 3 GENERIC SCAN TOOL (NACS II DIAGNOSTIC TOOL) A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS, when connected between the motorcycle and a computer.
  • Page 210 Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks at  different intervals, to identify the defective sensor / wiring connection as detailed in the table below, ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 211 It can also be used to capture engine data for future reference for saving data regarding issues of engine  malfunction before in the process of resolving engine malfunction. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 212 The Sensor circuit malfunction P0500 AIR System Switching Valve EXAI Short circuit to ground or open circuit P0412 “A” Circuit (low or open) Crankshaft position sensor The Sensor circuit malfunction P0335 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 213 7) 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. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 214: Nacs Ii Diagnosis

    6. SD memory cable lighter cable Card Reset Button SD memory card Diagnostic connector 7. SD card reader 8. Carrying Box 9. Installation CD 10. User Manual (Included on CD) ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 215  The warranty will become void if NACS II is disassembled or altered.  We recommend you to back up the SD-card data to avoid data loss due to various reasons. ‘ ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 216 First, you need to disable “User Account Control (UAC)” before installing our software. The way to disable UAC is as follows. Click ‘Start button’ and select ‘Control Panel’. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 217 ROYAL ENFIELD NACS II DIAGNOSIS 9. SOFTWARE INSTALLATION 8.2. 9.1. Start the computer. Click ‘User Accounts’ 9.2. Insert installation CD to CD-ROM drive and install following software. a. Main software: NACSII_ROYAL_V0.03_install.exe b. Recording data analyzing software: NACSII- RECORD_ROYAL-V0_01_setup 8.3. Click ‘Changer User’ Account Control Settings”.
  • Page 218 ROYAL ENFIELD NACS II DIAGNOSIS 9.4. 9.7. Click ‘Finish’ to exit installation Click ‘Finish’ to complete the installation 10. SOFTWARE REMOVAL 9.5. 10.1. After installing Firmware program, USB high speed driver will start installation. Click ‘Extract’ to install. Click ‘Star Menu’ - ‘All Programs’ - ‘Control Panel’...
  • Page 219 ROYAL ENFIELD NACS II DIAGNOSIS 10.3. 11. DIAGNOSTIC SOFTWARE FOR Find ‘NACSII_ROYAL’ and click ‘Change / Remove’ . HANDHELD TOOL 11-A. Diagnosis 11-A1. Please connect your NACSII-ROYAL diagnostic tool kit with your motorcycle. NACSII-ROYAL interface- maincable  Diagnostic cable  Motorcycle Orange light indicates whether the system is communicating.
  • Page 220 ROYAL ENFIELD NACS II DIAGNOSIS 11-A3. 11-A6. Select ‘Royal Enfield Press to exit 534 EFI’ . Press ‘Vehicle Info’ page. The page continue. will return to the main menu. 11-A4. 11-A7. NACS II will Using automatically detect move the cursor.
  • Page 221 ROYAL ENFIELD NACS II DIAGNOSIS 11-A9. 11-A11. Press to view Erace DTC. It’s the function to erace ‘History ‘ DTC. Diagnostic Trouble Press to view next Code in both ‘Current’ and page and press ‘History’. to view last page. After viewing all the Press to erace.
  • Page 222 ROYAL ENFIELD NACS II DIAGNOSIS 11-A13. 11-A16. Back to the main Press to view all the content. menu, move the cursor to ‘Special Function’ and Press ‘Special function’ is customized functions provided to specific vehicles. 11-A17. Select “CO 11-A14. Adjustment”, press Record data.
  • Page 223 ROYAL ENFIELD NACS II DIAGNOSIS 11-B2. 11-C. ABS Functions Press to view System Information. 11-C1. Select ‘BOSCH ABS System’ . Press to continue. 11-C2. Select ‘Special Function’ . Then, select ‘Repair Air Bleed’. 11-B3. Press to set Date and Time.
  • Page 224 ROYAL ENFIELD NACS II DIAGNOSIS 11-C3. 11-C6. Read the warning first before start operating air Front Channel bleeding. Activation 11-C7. 11-C4. Follow the instructions on screen to finish the Follow each step on thescreen to finish the activation. procedure. 11-C5.
  • Page 225 ROYAL ENFIELD NACS II DIAGNOSIS 12-3. 12. Diagnostic software for PC base When the first time you use software, 12-1. the software will Before diagnosis, please connect your NACSII- enter register ROYAL diagnostic took kit with your motor cycle. process automatically.
  • Page 226 ROYAL ENFIELD NACS II DIAGNOSIS 12-6. 12-9. There are various Click to show Interface info and green buttons on Contact info of I.C.M. the right. button is for displaying all the vehicle info. 12-7. 12-10. Click to switch Click to read the language.
  • Page 227 ROYAL ENFIELD NACS II DIAGNOSIS 12-15. 12-12. To erase the The window will pop Diagnostic Trouble up for selecting Code, click printer. Note : if you click the erase button, all Diagnostic Trouble Code in ‘Current’ and ‘History’ will be erased! 12-13.
  • Page 228 ROYAL ENFIELD NACS II DIAGNOSIS 12-17-A. 12-17-D. Click to erase ALL selected live data. If you want Click to view selected data values. to erase only one item, please press and hold ‘Shift’ key and select the item that you want to delete.
  • Page 229 ROYAL ENFIELD NACS II DIAGNOSIS 12-20. 13-2. Adjust CO value Select Record Date by clicking and File name, then and click click save adjusted value. 13-3. 13. RECORD ANALYZING SOFTWARE Select the items This software is for reading NACS II handheld which used often.
  • Page 230 ROYAL ENFIELD NACS II DIAGNOSIS 13-8. 13-5. For example, setting Engine speed grater than 3150, To slow down the playing speed of wave chart, enter 3150 in the right block. Click to confirm please drag the slider down. the setting value.
  • Page 231 ROYAL ENFIELD NACS II DIAGNOSIS 13-14. 13-11. Back to Live data selection page, click to view Click to quickly find matched point of setting value. wave chart of the 2 setting values. 13-12. Sometimes, setting only one value still can not find the 13-15.
  • Page 232 ROYAL ENFIELD NACS II DIAGNOSIS 13-17. 13-18. The 3 setting items will be listed in ‘All value match’ block. To analyze conditions and differences of Click to quick find matched conditions. values, it’s necessary to select match items. Select the items and then The selected items will be listed in ‘Any of value match’...

  • Page 233: Electricals

    SECTION 12 - ELECTRICALS ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 234 SECTION 12.1 - BATTERY EXPLODED VIEWS BULLET EFI, BULLET CLASSIC EFI, CONTINENTAL GT Continental GT S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Battery Carrier Assy Washer Battery Carrier Assy Hex. Flanged Bolt M8 X 1.25 X 45 Cover - Battery Black New...

  • Page 235: Battery

    Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.1 Battery - Dismantling Bullet Classic EFI/ Bullet EFI  The battery is located on the left side of the motorcycle.  Ensure the motorcycle is parked on its center stand, in a well ventilated area.
  • Page 236  Pull the battery out NOTE : slightly from the battery Disconnect -VE terminal carrier. FIRST and the +VE terminal NEXT.  Remove the battery from the carrier. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 237 Store the battery carefully and ensure the terminals dok not come into contact with any metal surface which will  result in a short circuit. Do not short the battery terminals as it might result in an explosion of the battery.  ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 238 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.1 Battery - Assembling Bullet Classic EFI/ Bullet EFI  Locate the battery in the carrier with the terminals facing inside.  Connect terminal wire first.  Connect the -VE terminal wire next.
  • Page 239  Position the battery correctly and fully inside the carrier.  Locate the battery cover over the battery and lock it in place. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 240: Bulbs

    Pan Head Screw M5 X 0.8 X 12 Washer Head Lamp Assy. with Bulb Flanged Hex. Bolt M8 X 30 Lens and Reflector Assy Hex. Socket Head Cap Screw M6 X 20 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 241 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Pilot Lamp Bullet EFI/Bullet Classic EFI Dismantling  Loosen 2 pilot lamp rim fixing screw on LH & RH side.  Gently remove the bulb from its holder...
  • Page 242 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Pilot Lamp Bullet EFI/Bullet Classic EFI Assembling  Locate the Pilot lamp bulb in the holder  Install 2 pilot lamp rim fixing screw on LH & RH side.
  • Page 243 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Head Lamp Bullet Classic EFI/ Bullet EFI Dismantling  Loosen rim fixing top with clamp screw mounted on head lamp rim assembly  Loosen 2 pan head screws on LH & RH side mounted on head lamp housing assembly.
  • Page 244 Finger prints  Gently remove the bulb. will etch the glass and decrease bulb life. Always hold the bulb with paper or clean dry cloth during handling. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 245 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Head Lamp Bulb Bullet Classic EFI / Bullet EFI Assembling  Locate the bulb into reflector unit of the headlamp.  Gently press the bulb holding clip and lock the free end in its slot.
  • Page 246 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Head Lamp Bullet Classic EFI/ Bullet EFI Assembling  Locate head lamp assembly. Pan Head Screw M5  Install 2 pan head screws Philips Screw Driver on LH & RH side mounted on head lamp housing assembly.
  • Page 247 LH & RH side and mount on the front Philips Screw Driver headlamp Holder.  Install screw fixing top with clamp on head lamp mounting assembly. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 248 Lens Complete - Tail Lamp Pan Head Tapping Screw - Tail Lamp Cross Recessed Pan Head Screw M6 X 14 Tapping Screw - Tail Lamp Bulb - Tail Lamp 12V, 21/5 W ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 249 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Tail Lamp Bullet Classic EFI/ Bullet EFI Dismantling  Loosen 2 Nyloc nuts Hex Nyloc Nut M6 mounted on LH & RH side on the complete tail lamp Double end spanner 8mm bracket.
  • Page 250 Always hold the bulb with paper or clean dry cloth during handling.  Gently remove the Tail Tapping screws lamp assembly Philips Screw Driver ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 251 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Tail Lamp Bullet Classic EFI/ Bullet EFI Assembling  Locate the bulb in the tail Hex Nyloc Nut M6 lamp Double end spanner 8mm  Locate Tail Lamp...
  • Page 252 Pan head tapping screw tapping screws and mount on tail lamp LH & Philips Screw Driver RH sides.  Refer Section 5.4 for seat Tapping screws assembly Philips Screw Driver ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 253 Trafficator Assy. - With Bulb - Front RH Nut, Nylock M8 X 9.5 Trafficator Assy. - With Bulb - Front LH Trafficator Assy. - With Bulb - Rear LH ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 254 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Trafficator Bullet Classic EFI/ Bullet EFI Dismantling  Loosen 2 Nyloc nuts Nyloc Nut M8 mounted on RH & LH Bracket in the trafficator Double End Spanner 13 mm ...
  • Page 255 Never touch the bulb with housing. your fingers, Finger prints will etch the glass and decrease bulb life. Always hold the bulb with paper or clean dry cloth during handling. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 256 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Trafficator Bullet Classic EFI/ Bullet EFI Assembling  Press bulb gently & Turn clockwise direction to locate the bulb in the holder.  Locate the Trafficator Nyloc Nut M8 assembly on LH &...
  • Page 257 LH & RH side. Socket spanner 10mm  Tighten 2 hex screws on LH & RH side and mount on the rear end of the headlamp holder. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 258 CLUSTER / CONSOLE Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Console Bullet Classic EFI/ Bullet EFI Dismantling  Refer Section 11.2 for Headlamp dismantling  Disconnect the coupler mounted speedometer.  Loosen mounted on bottom side of speedometer in clockwise direction.
  • Page 259 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Console Bullet Classic EFI/ Bullet EFI Assembling  Gently push s p e e d o m e t e r downwards from top end of speedometer unit such that it will get seated speedometer slot.
  • Page 260 CONSOLE BULBS REPLACEMENT Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Console Bulb Bullet Classic EFI / Bullet EFI Dismantling  Disconnect the couplers  Gently pull out the bulb (Speedo meter/Neutral/ High beam& Low beam/ Turn Signal Bulbs) from its holder.
  • Page 261 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.2 Console Bulb Bullet Classic EFI / Bullet EFI Dismantling  Gently fix the bulb Never touch the bulb with (Speedo meter/Neutral/ your fingers, Finger prints High beam& Low beam/...

  • Page 262: Electrical Components

    SECTION 12.3 - ELECTRICAL COMPONENTS ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 263 Starter Motor 0.9 KW Solenoid Switch Magnetic Relay type INSPECTION Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 264 RELAY STARTER WIRING LAYOUT Schematic Diagram - Relay ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 265 Multimeter indicates as open (OL) ,contacts have not closed and hence the Relay starter has to be replaced. Starter motor +ve eyelet terminal Energised the relay Battery +ve terminal using battery ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 266 If the diode is good, then the multimeter will show a voltage drop of 0.4~0.7V. If diode has failed, multimeter will show either open or short with beep sound, then Replace the RR unit. 3 Phase AC Terminals DC Output Positive Terminals ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 267 All the three diodes to be checked by keeping the multimeter negative probe on all the 3 phase terminals one by one. If the RR Unit is not working, replace with good working RR Unit. 3 Phase AC Terminals DC Output Terminals ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 268 Keep the positive(Red) and negative (Black)probes of the multimeter on two ends of the suppressor cap. Resistance shall be 3.75 to 6.25 Kilo Ohms 4. If resistance deviates from the specification or open , Suppressor cap to be replaced. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 269 If insulation failure is observed, failed magneto to be replaced with new magneto.  2. During visual inspection, if stator coil has burnt, magneto shall be replaced with new magneto. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 270 HORN INSPECTION STEP 1 : Set the Multimeter in Continuity check mode. Check for presence of continuity by keeping the horn coupler. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 271  Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing  frequently. BLADE FUSE USAGE LIST – BULLET CLASSIC EFI /BULLET EFI Fuse No. Colour Remarks White Charging Fuse (25A)
  • Page 272 12.3 B. Pulsar Coil coupler  Disconnect Green wired Black coupler from LH side. 12.3 C. Pulsar Coil coupler  Disconnect Green wired Black coupler from LH side. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 273  Disconnect white coupler from LH side. · 12.3 F. ECU Power Relay & Side stand Switch indication relay  Disconnect ECU Power relay and side stand switch relay. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 274 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.3 Switch Module RH Bullet Classic EFI / Bullet EFI / Continental GT  Loosen the 2 Pan head Pan head hex Screw M5 screws mounted on bottom side of Switch...
  • Page 275 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.3 Switch Module RH Bullet Classic EFI / Bullet EFI / Continental GT  Locate the RH switch module  Install 2 pan head screws on RH switch on LH & RH side.
  • Page 276 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.3 Switch Module LH Bullet Classic EFI / Bullet EFI / Continental GT  Loosen the 2 Pan head Pan head hex Screw M5 screws mounted on Philips Screw Driver...
  • Page 277 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions 12.3 Switch Module LH Bullet Classic EFI / Bullet EFI / Continental GT  Locate the LH switch module  Close the LH Switch Pan head hex Screw M5...

  • Page 278: Wiring Diagram

    SECTION 12.4 - WIRING DIAGRAM BULLET EFI / BULLET CLASSIC EFI - WIRING HARNESS CIRCUIT ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 279 BULLET EFI / BULLET CLASSIC EFI - STARTING, CHARGING & IGNITION (EFI) SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 280 BULLET EFI / BULLET CLASSIC EFI - LIGHTING & SIGNALING SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 281 BULLET EFI / BULLET CLASSIC EFI - WIRING HARNESS-ABS SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 282 CONTINENTAL GT - WIRING HARNESS CIRCUIT ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 283 CONTINENTAL GT - STARTING, CHARGING & IGNITION (EFI) SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 284 CONTINENTAL GT - LIGHTING & SIGNALING SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 285 CONTINENTAL GT - WIRING HARNESS-ABS SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...

  • Page 286: Trouble Shooting

    SECTION 13 - TROUBLE SHOOTING ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 287 Repair and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield Authorized Dealer only. Improper repair / maintenance could result in the motorcycle not functioning properly or injury seriously.
  • Page 288 * Check and correct Horn not working Fuse blown Check and correct Loose connections Check and correct Trafficators not working Loose / improper connections Check and correct Bulb fused Replace ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 289 Any EFI Sensor Failure * Check & replace the same XII. ABS (ANTI LOCK BRAKING SYSTEM) ABS lamp continuously ON. Take the vehicle to service center for diagnosis ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 290 Check & replace burnt, excess carbon deposit on seating area, Valve springs broken Piston rings sticky/ worn-out Check & replace Cylinder barrel / Piston excess Check & replace clearance ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 291 Investigate cause of seizure, pin / connecting rod big end check & correct as required Crankshaft bearings in LH/RH Investigate cause of seizure, crankcases seized check & correct as required ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 292 Check & replace bent. Heavy carbon deposit on seating surface) Piston rings worn out/ broken / Check & replace stuck in ring groove Cylinder / piston worn Check & replace ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 293 Clutch plates worn out / warped / Check & correct sticky release / burnt Front / rear brakes jamming Check & correct E. Others Front / rear wheel bearing jammed Check & correct ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 294 Check & Clean chamber Piston ring bad (worn, weak, Check & Replace broken, or sticking) Piston rings clearance excessive Check & Replace Cylinder, piston worn Check & Replace ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 295 C. Bluish / White smoke Excess clearance between valve Check & correct stem & guide Oil scrapper ring worn out Check & correct Cylinder barrel / piston clearance Check & replace high ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 296 Check & clean oil cooler fins Clutch slipping Check & correct Front / Rear brakes jammed Check & correct Engine oil pressure less Check & correct Silencer choked Check & clean ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 297 Drive / counter gears backlash Check & replace Drive / Countershaft bearings worn out Check & replace Gears / bushes seized in drive /counter shaft Check & replace ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 298 F. Gears overshifts Sliding Gear dogs worn out Check & replace Drive shaft/counter shaft splines worn out Check & replace Drive / counter shaft bearings wornout Check & replace ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 299 Check for Pressure Lock in tank, if pressure lock is not there Pump Nipple replace the pump If Pressure Lock is there check for Tank Cap and EVAP Purge valve. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 300 MIL distance not Vehicle Speed Sensor * Check for Connector loose fitment, terminal back out or wire showing in diagnostic cut etc. tool * Check for Supply Voltage ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
  • Page 301 Royal Enfield Support : 1800-2100-007 Email : support@royalenfield.com Twitter : @RoyalEnfieldSupport Web : www.royalenfield.com KS MOTORCYCLES - http://ksmotorcycles.com...

This manual is also suitable for:

Bullet classic efiContinental gt

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