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EURO IV - VEHICLE SERVICE MANUAL Classic Bullet EFI Bullet EFI Continental GT KS MOTORCYCLES - http://ksmotorcycles.com...
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“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.
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EURO IV BIKES – VEHICLE VIEWS ROYAL ENFIELD ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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...
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...
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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"...
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...
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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...
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...
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...
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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.
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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.
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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.
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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.
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...
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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...
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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 ...
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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...
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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.
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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.
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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...
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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...
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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...
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.
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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...
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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...
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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.
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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...
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.
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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...
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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...
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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...
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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.
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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...
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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...
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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.
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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...
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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...
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/ 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...
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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...
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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...
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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...
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...
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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...
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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...
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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) ...
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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...
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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.
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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 ...
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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 ...
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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...
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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...
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...
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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...
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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.
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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...
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...
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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...
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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...
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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.
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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...
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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...
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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.
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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...
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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...
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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...
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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...
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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.
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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.
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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...
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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...
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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 &...
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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.
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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...
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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...
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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...
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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...
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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...
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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...
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...
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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...
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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...
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...
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...
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...
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...
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...
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.
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.
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...
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...
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...
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...
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...
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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...
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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.
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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...
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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...
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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...
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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.
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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.
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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...
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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...
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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...
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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...
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...
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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...
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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 &...
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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...
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.
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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...
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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...
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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 &...
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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...
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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 ...
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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...
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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...
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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...
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.
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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...
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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...
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Gently remove the swing Index mark arm assembly from the frame. ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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...
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...
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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...
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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...
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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...
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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.
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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.
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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...
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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.
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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...
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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...
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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...
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ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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...
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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.
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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.
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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,...
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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).
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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...
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ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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...
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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...
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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.
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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...
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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).
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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.
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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...
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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...
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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...
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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...
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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...
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(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...
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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...
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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...
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“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...
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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.
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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...
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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.
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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 ...
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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...
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‘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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
/ 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.
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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...
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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...
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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...
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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...
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...
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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...
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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...
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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”.
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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’...
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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’...
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.
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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...
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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...
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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.
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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...
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...
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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...
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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.
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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.
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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...
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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.
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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.
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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...
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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...
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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.
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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...
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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...
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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...
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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...
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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 ...
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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...
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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 &...
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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...
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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.
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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.
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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.
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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/...
SECTION 12.3 - ELECTRICAL COMPONENTS ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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...
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RELAY STARTER WIRING LAYOUT Schematic Diagram - Relay ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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...
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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...
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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...
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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...
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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...
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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...
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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)
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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...
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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...
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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...
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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.
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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...
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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...
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...
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BULLET EFI / BULLET CLASSIC EFI - STARTING, CHARGING & IGNITION (EFI) SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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BULLET EFI / BULLET CLASSIC EFI - LIGHTING & SIGNALING SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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BULLET EFI / BULLET CLASSIC EFI - WIRING HARNESS-ABS SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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CONTINENTAL GT - WIRING HARNESS CIRCUIT ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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CONTINENTAL GT - STARTING, CHARGING & IGNITION (EFI) SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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CONTINENTAL GT - LIGHTING & SIGNALING SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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CONTINENTAL GT - WIRING HARNESS-ABS SYSTEM ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
SECTION 13 - TROUBLE SHOOTING ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV KS MOTORCYCLES - http://ksmotorcycles.com...
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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.
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* 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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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Royal Enfield Support : 1800-2100-007 Email : support@royalenfield.com Twitter : @RoyalEnfieldSupport Web : www.royalenfield.com KS MOTORCYCLES - http://ksmotorcycles.com...