Royal Enfield 350 BULLET 1989 Workshop Maintenance Manual
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Royal Enfield 350 BULLET 1989 Workshop Maintenance Manual

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WORKSHOP MANUAL BULLET
WORKSHOP
MAINTENANCE MANUAL
FOR THE
Enfield
India
350 BULLET upto 1989
MAN 15
Page 1

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Summary of Contents for Royal Enfield 350 BULLET 1989

  • Page 1 WORKSHOP MANUAL BULLET WORKSHOP MAINTENANCE MANUAL FOR THE Enfield India 350 BULLET upto 1989 MAN 15 Page 1...
  • Page 2 WORKSHOP MANUAL BULLET INDEX Page Nos. PREFACE, PRECAUTIONS & GENERAL INSTRUCTIONS ROUTINE MAINTENANCE TECHNICAL SPECIFICATIONS DESCRIPTION OF ENGINE PARTS 8-10 DECARBONISING 11-15 SERVICE OPERATION - ENGINE IN FRAME 17-26 SERVICE OPERATION – ENGINE – REMOVED FROM FRAME 27-30 GEAR BOX 31-35 LUBRICATION SYSTEM 37-39...
  • Page 3 Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by Royal Enfield or the publisher for loss, damage or injury caused due to errors or omissions in the information given.
  • Page 4 WORKSHOP MANUAL BULLET ROUTINE MAINTENANCE Introduction Periodic routine maintenance is a continuous process that commences immediately after the machine is used. It must be carried out at specified mileage recordings, or a calendar basis if the machine is not used frequently. Maintenance should be regarded as an insurance policy, to keep the machine in peak condition and to ensure long, trouble free service.
  • Page 5 WORKSHOP MANUAL BULLET Daily A daily check of the Motorcycle is essential both from mechanical and safety aspects. It is a good idea to develop this checking procedure in a specific sequence so that it will ultimately become as instinctive as actually riding the machine. Done properly, this simple checking sequence will give advanced warning of impending mechanical failures and conditions which may jeopardize the safety of the rider.
  • Page 6 WORKSHOP MANUAL BULLET Tri monthly – 3000 miles/5000 kms Clean, and adjust plug gap or replace spark plug. Check and service contact breaker points. Check and adjust ignition timing. Check and adjust valve tappet clearance. Clean airfilter. Clean, tune up carburettor. Clean fuel tap gauze.
  • Page 7 WORKSHOP MANUAL BULLET TECHNICAL SPECIFICATIONS - BULLET - 350 CC Engine Single Cylinder 4 Stroke with Overhead Valves Cubic Capacity - 346 CC Stroke 90 mm. Bore-Nominal - 70 mm Actual 69.875mm or 2.751 in. Compression Ratio 7.25: 1 Compression Pressure - 110 ±...
  • Page 8 WORKSHOP MANUAL BULLET GearBox: 5.32, 7.26, 9.80, & 14.80 Overall gear ratios Small - 6303 Mainshaft ball bearings Large - 6206 16 teeth Final drive sprocket - 5/8" x 94 pitch chain Rear drive chain 38 teeth Brake drum sprocket - Mikcarb-VM-24 Carburettor - Main jet...
  • Page 9 WORKSHOP MANUAL BULLET Page 9...
  • Page 10 WORKSHOP MANUAL BULLET ENGINE PARTS Crankcase D/S Washer Oil filter gauze Washer, below Distributor Crankcase T/S Oil feed & return filters Nut, below Distributor Joint washer Breather pipe Stud -Front engine plates Oil filler cap collar Breather pipe clip Washer, Front Engine plate Cam spindle Piston Nut Front Engine Plate...
  • Page 11 WORKSHOP MANUAL BULLET Push rod inlet 147. Cam bush 116. Nut (short) Rocker Box Push rod, exhaust 148. Timing pinion 20T 117. Nut (long) Rocker Box Push rod end, top 149. 118. Valve Push rod end, bottom 150. Oil pump worm 119.
  • Page 12 WORKSHOP MANUAL BULLET ENGINE Decarbonising: After a few thousands of Kms. of run the carbon build up in the engine will cause general falling off in power, accompanied by increased fuel consumption and starting trouble. Decarbonising will normally be necessary approximately every 8,000 Kms. and this can be carried out without removing the engine from the frame.
  • Page 13 WORKSHOP MANUAL BULLET 3. Removal of Cylinder and Piston REMOVAL OF PISTON Slacken the two clamp nuts on top of the crankcase neck. Remove the 1/4" nut above the tappet chest and lift the barrel Remove the circlip retaining the gudgeon pin on the timing side of piston taking care not to drop the circlip into the crankcase.
  • Page 14 WORKSHOP MANUAL BULLET 5. Decarbonising the Cylinder head - Combustion Chamber CYLINDER HEAD Remove carbon from the valves, ports and combustion chamber by scraping. Take care not to cause any damage to the valve faces or valve seat inserts. Scrape gently to avoid scoring the cylinder head.
  • Page 15 WORKSHOP MANUAL BULLET 8. Valves, Valve Guides and springs VALVE & SPRING ASSEMBLY Wear on the valve stems can be seen on examination and if a definite step has formed, the valves should be renewed. Before replacing the valves, they must be ground on to their seats, if good faces are not formed with a reasonable amount of grinding, the seats must be cut with a cutter (included angle 90°) and the valve refaced in...
  • Page 16 WORKSHOP MANUAL BULLET upwards and pull the cable nipple out of the body, it will now be possible to remove the cable and nipple through the spring, leaving the decompressor body and spring detached from the control cable. The spring and the cap should now be replaced. The valve may be ground in by applying a thin coating of grinding paste on the seat of the valve and twisting it to and fro by means of the cable block at its upper end and occasionally lifting the valve from its seat.
  • Page 18 WORKSHOP MANUAL BULLET SERVICE OPERATION - WITH ENGINE IN FRAME 1. Removal of the Timing cover First place a tray under the engine to hold the oil which will escape when the cover is removed. Remove the exhaust pipe and silencer. Remove ten screws from the timing cover, taking care not to lose the sealing washers, one for each screw.
  • Page 19 WORKSHOP MANUAL BULLET Cleaning/Replacement Filter Arrangement of oil filter Element - Oil Feed and Return Filters The oil filter is located in the timing cover immediately below the oil pumps. The felt element should be taken out and washed in petrol after the first 800 Kms.
  • Page 20 WORKSHOP MANUAL BULLET When matching a plunger in the pump disc, if it is found to be too tight a fit, carefully lap the plunger in the pump disc. Using metal polish until it is just free. If the pump disc is not seating properly in the timing cover or if a new pump disc is fitted, it should be ensured that the pump disc matches properly and has a perfect seating in the timing cover.
  • Page 21 WORKSHOP MANUAL BULLET 5. Removal of Contact breaker housing. Loosen the distributor pinion nut and pull out the distributor pinion off the distributor shaft after removing the idler pinions. Loosen and remove the three screws which secure the spigotted contact breaker housing and seperate from crankcase.
  • Page 22 WORKSHOP MANUAL BULLET Check the push rods. They must rotate thumb free without any up and down play. In case the push rods do not rotate freely or if up and down play is noticed, the push rods need to be adjusted.
  • Page 23 WORKSHOP MANUAL BULLET CLUTCH ASSEMBLY 1. Clutch centre and back plate assembly 2. Clutch sprocket 56 T & drum assembly 12. Clutch intermediate plate (flat) 3. Clutch sprocket drum (N/S) 13. Clutch bonded plate assemb1y 4. Clutch sprocket friction disc 14.
  • Page 24 WORKSHOP MANUAL BULLET 10. Removal of Engine and Clutch sprockets Remove the alternator stator by undoing three nuts. The primary chain is endless hence it is necessary to remove both the engine and clutch sprockets simultaneously. Remove the central hexagon nut securing the alternator rotor, which can then be drawn off, taking care not to lose the key. The engine sprocket is mounted on splines and can be removed along with the clutch sprocket using extractor 2004.
  • Page 25 WORKSHOP MANUAL BULLET The chain should be adjusted so that there is 1/4" up and down movement at the centre of the top run of the chain. Remember to PRIMARY CHAIN ADJUSTMENT check the chain tension at 3 or 4 places and then adjust accordingly.
  • Page 26 WORKSHOP MANUAL BULLET Owing to initial bedding down of the clutch plate inserts, the clutch control may require adjustment after the first few hundred Kms with a new machine. This point should therefore be examined soon after delivery and adjustment made if necessary. Initially, excessive play in the cable can be taken up through midway adjuster and the adjuster at the handle bar end.
  • Page 27 WORKSHOP MANUAL BULLET Fit the rotor first, making sure that it is located concentrically on the end of the drive shaft. Attention must be given to the proper seating of the key. Finally secure the rotor with the appropriate washer and nut. Having fitted the rotor, the stator may then be fitted on to the chaincase inner with the coil connections facing outwards.
  • Page 28 WORKSHOP MANUAL BULLET SERVICE OPERATIONS ENGINE REMOVED FROM FRAME 1. Removal of the Engine from the Frame A. Disconnect alternator leads, B. Disconnect the spark plug cap. Suppressor cap C. Turn off petrol tap and disconnect the fuel pipe, D. Remove carburetter assy. along with throttle cable, E. Remove the air filter assy., F.
  • Page 29 WORKSHOP MANUAL BULLET Inspect the bearings before assembly. The bearing should spin smoothly. Rotated dry, it may appear to be slightly noisy but there should be no signs of corrosion, nor must there be any appreciable radial slackness. The outer race of the roller bearing must be preferably smooth and bright with no evidence of cracks or pitting.
  • Page 30 WORKSHOP MANUAL BULLET 7. Flywheel Assembly The flywheel assembly consists of the crankshaft and the connecting rod. To dismantle the crankshaft remove the set screws securing the crankpin nuts. Holding the crankshaft in a special jig (2037) remove the crankpin nuts. Using 2037, with a pair of steel bars (about 1"...
  • Page 31 WORKSHOP MANUAL BULLET 8. Re-assembly of the Crankcase Replace the bearings, etc., in the crankcase halves after heating the crankcase as described earlier. (Refer page No 29) Fit the inner distance piece in the driving side crankcase. Fit the thrust washer on the drive shaft. Fit the bearing inner race on the drive shaft. Assemble the flywheel into the bearing if necessary using the sprocket nut with a suitable spacer to draw the driving shaft through the inner race of the ball bearing.
  • Page 32 WORKSHOP MANUAL BULLET GEAR BOX NOTE: Before attempting to remove the internal parts, please ensure that the clutch assy has been dismantled along with F.D. sprocket 1. Removal of Gear box from engine This has already been described earlier 2. Dismantling the Gearbox The gear box can be completely dismantled with the engine in the frame except for the removal of the inside operator and the bearings in the gear box case.
  • Page 33 WORKSHOP MANUAL BULLET CHANGE GEAR MECHANISM When fitting parts, if it is found that the gears engage properly; ascertain whether a little more movement is required or whether there is too much movement so that the gear slips right through second or third gear into neutral.
  • Page 34 WORKSHOP MANUAL BULLET Page 34...
  • Page 35 WORKSHOP MANUAL BULLET GEARBOX DESCRIPTIONS Gear box case with bush Plunger spring F/c cover c/w Clutch lever, Gear operator pin Stop plate bolt bearing cap & pins Bush gear operator pin Stop plate Clutch lever Drive sprocket Washer oil level plug Clutch lever grease nipple (16-T) Lock washer (D/sprocket)
  • Page 36 WORKSHOP MANUAL BULLET 5. Re-assembling the Gear box The procedure is the reverse of that given above for dismantling but the following points should be noted. If the main shaft top gear pinion and dog have been removed, make sure that the dog is replaced the right way round or third and top gears can be engaged simultaneously.
  • Page 38 WORKSHOP MANUAL BULLET LUBRICATION SYSTEM Lubrication system is by Dry Sump and effected by an automatic and positive double action oil pumps. The oil tank is integral with the crankcase, for ensuring the full rate of oil circulation immediately when the engine is started and for rapid heating of the oil in cold weather. The capacity of the oil sump is 2.25 Liters.
  • Page 39 WORKSHOP MANUAL BULLET OIL PUMP DIAGRAMS FEED PUMP FEED PUMP PORTS IN THE PORTS IN FEED PUMP DISC TIMING COVER T - Suction port R - Delivery port Y - Suction from Oil tank X -Delivery to big end. W, Z - Through holes Position 1: The plunger A is drawn out of the Position 2: As the pump spindle rotates further feed pump disc C, by the peg B in the spindle D,...
  • Page 40 WORKSHOP MANUAL BULLET RETURN PUMP RETURN PUMP PORTS IN THE RETURN PUMP DISC PORTS IN THE TIMING COVER T' - Suction Port Y' - Suction from Crankcase R' - Delivery Port X -Delivery to Rockers W' Z' - Through holes Position 1: The plunger A' is drawn out of the Position 2: As the pump spindle rotates further return pump disc C' by the peg B on the spindle...
  • Page 41 WORKSHOP MANUAL BULLET Page 41...
  • Page 42 WORKSHOP MANUAL BULLET FRAME REAR SUSPENSION 1. Description of Frame The frame is built of special cold drawn welded steel tubing incorporating reinforcements wherever necessary, for extra strength. The swinging arm unit forms the chainstay and is fitted with rubber bonded 'silent-bloc' bushes. The swinging arm unit is secured to the main frame by a long bolt passing through the pivot lugs.
  • Page 43 WORKSHOP MANUAL BULLET Position of the spring box. SWING ARM ASSEMBLY The special tool for alignment of the swinging arm to be used. (2044). No maintenance is necessary for the swinging arm pivot. 4. Centre Stand To remove the centre stand take out the split pins &...
  • Page 44 WORKSHOP MANUAL BULLET FRONT FORK (Hydraulically damped) 1. Description The telescopic fork consists of two legs each of which comprises a main tube of alloy steel tubing which is screwed into the Casquette fork head at SECTION OF FORK LEG the upper end and securely clamped to the fork crown.
  • Page 45 WORKSHOP MANUAL BULLET The fork is filled with a light oil (S.A.E. 30) to a point above the lower end of the spring so that the damper chamber 'B' is always kept full of oil. Upward movement of the wheel spindle forces oil from the lower chamber 'A' through the annular space between the spring stud and the bore of the main tube valve port into the damper chamber 'B'.
  • Page 46 WORKSHOP MANUAL BULLET After removal of the main tube bush, bottom tube bush and oil seal housing, the main tube can be removed using tool 2036. Before attempting to loosen the main tubes ensure that the 2 pinch bolts on the fork crown bottom has been sufficiently loosened to allow the main tubes to rotate.
  • Page 47 WORKSHOP MANUAL BULLET 8. Steering Head Races The steering head races are the same at the top and bottom of the head lug. They are easily removed by knocking them out with a hammer and drift and new races can be fitted either by a press or by means of a hammer and wooden drift.
  • Page 48 WORKSHOP MANUAL BULLET WHEELS FRONT WHEEL 1. Removal from Fork To remove the front wheel from the fork, place the machine on the centre stand with sufficient packing beneath the stand to lift the front wheel clear off the ground when vehicle is tilted back. Slacken the brake cable adjustment and disconnect the cable from the handlebar lever and from the operation cam lever on the hub.
  • Page 49 WORKSHOP MANUAL BULLET FRONT WHEEL AND HUB ASSEMBLY - SINGLE LEAD 1. Front Wheel rim (WM 2-19) 14. Front brake shoe c/w lining S/L 2. Front Wheel spokes (outer) 15. Front brake shoe spring (7" dia) 3. Front Wheel spoke nipples 16.
  • Page 50 WORKSHOP MANUAL BULLET EARLY HALF WITH HUB If tightening the nuts makes the spindle hard to turn, the bearings are bottoming in the recesses in the hub barrel and the inner races are not resting on the shoulder of the spindle. In this case, the bearing should be removed and a thin packing shim should be fitted between the inner race and the shoulder on the spindle.
  • Page 51 WORKSHOP MANUAL BULLET REAR WHEEL 1. Removal of wheel – quickly-detachable type The rear wheel is quickly detachable without disturbing the sprocket. Place vehicle on centre stand. Remove the split pin and the castle nut securing the long spindle which is located on the sprocket side. Slide out the long spindle from the wheel and remove both the spacers from the RH side fork end.
  • Page 52 WORKSHOP MANUAL BULLET REAR WHEEL AND HUB ASSEMBLY 22. Rear brake cover plate distance collar Rear wheel rim WM 2-19 23. Rear brake cover plate assembly Rear wheel spokes (dust cover side-outer) 24. Rear hub distance collar (drum side) Rear wheel spokes (dust cover side-inner) Rear wheel spoke nipples 25.
  • Page 53 WORKSHOP MANUAL BULLET 4. Dismantling the Rear Brake Shoes. After separating the cover plate from sprocket assy, unscrew the brake shoe pivot pin lock nut and the operating lever nut. The assembly of brake shoes, return springs, pivot pin and operating cam can be removed from the cover plate by unscrewing the pivot pin and applying light blows with a hammer and drift on the end of the operating cam.
  • Page 54 WORKSHOP MANUAL BULLET bearing surface of the operating cam, if this has been removed. Fit the operating lever on its splines in a position to suit the extent of wear on the linings and secure with the nut. The range of adjustment can be extended by moving the lever on to a different spline.
  • Page 55 WORKSHOP MANUAL BULLET It is usual to check the alignment of the wheels at a point about six inches above the ground. If the alignment is checked also towards the top of the wheels, it will be possible to ascertain whether or not the frame is twisted so as to cause one wheel to be leaning while the other is vertical.
  • Page 56 WORKSHOP MANUAL BULLET EARLY HALF WITH HUB WITH REAR SPEEDO DRIVE The key to correct lacing is the inside and outside spokes from the flange must slope down in the opposite direction as in the figure. The spokes are in opposite direction to the inner two spokes. In the group of four spokes laced, the inner spokes of each flange are sloping down in the opposite direction of the outer two spokes of the next grouping of four spokes and so on.
  • Page 57 WORKSHOP MANUAL BULLET TYRES - REMOVAL AND REPLACEMENT 1. At some time or other the need will arise to remove and replace the tyres, either as a result of a puncture or because renewal is required to offset wear. To the inexperienced, tyre changing represents a formidable task, yet if a few simple rules are observed and the technique learned the whole operation is surprisingly simple.
  • Page 58 WORKSHOP MANUAL BULLET Page 58...
  • Page 59 WORKSHOP MANUAL BULLET 12. Make sure that there is no pull on the tyre valve and again commencing with the area furthest from the valve, ease the other beading of the tyre over the edge of the rim. Finish with the area close to the valve, pushing the valve up into the tyre until the locking cap touches the rim.
  • Page 60 WORKSHOP MANUAL BULLET IGNITION AND LIGHTING SYSTEM 1. General The A.C., Lighting and Ignition system comprises of seven main components: Alternator (stator & rotor). (ii) Bridge connected Rectifier (iii) Ignition coil (iv) Contact breaker unit with automatic timing control Lighting switch (vi) Ignition switch (vii)
  • Page 61 WORKSHOP MANUAL BULLET 3. Circuit Detail The alternator stator carries three pairs of series-connected coils, pair being permanently connected across the rectifier bridge network. The purpose of this latter pair is to provide some degree of charging current for the battery whenever the engine is running. Connections to the remaining coils vary according to the position of the lighting and ignition switch controls, as shown schematically...
  • Page 62 WORKSHOP MANUAL BULLET Rectifier The rectifier used for the purpose of converting A.C. into D.C. for battery charging needs no maintenance except to see that the terminal contracts are clean and well secured. The nuts which clamp together the rectifier plates must not under any circumstances be slackened.
  • Page 63 WORKSHOP MANUAL BULLET 8. Contact Breaker Unit/Contact Set The contact breaker setting should be checked after the first 800 Kms. running and subsequently every 5,000 Kms. (3000 miles) Cleaning contact breaker points Remove the contact breaker cover and examine the contacts. If they are dirty or pitted, they must be cleaned by polishing with a fine carborandum stone or very fine emery cloth.
  • Page 64 WORKSHOP MANUAL BULLET CONTACT POINTS Retighten the two screws such that the CB points gap just commenses to open. To check whether the adjustment is correct, insert a thin strip of tissue paper between the points and gently pull out the paper which should not get damaged and should be sliding fit.
  • Page 65 WORKSHOP MANUAL BULLET Page 65...
  • Page 66 WORKSHOP MANUAL BULLET Page 66...
  • Page 67 WORKSHOP MANUAL BULLET 9. Battery The model fitted is a 6 Volt 12 Amp. hour capacity battery. Every week the filler cap of each cell should be unscrewed so that distilled water can be added to bring the acid level above the top of the separator.
  • Page 68 WORKSHOP MANUAL BULLET Replace the bulb and adaptor, The bulb fitted is 6V. 30/24 watt. Locate the bottom of the Light Unit and front rim assembly in the headlamp shell or in the fixing rim attached to the Casquette fork head. Press the front on and tighten the securing screw at the top of the headlamp.
  • Page 69 WORKSHOP MANUAL BULLET Page 69...
  • Page 70 WORKSHOP MANUAL BULLET CARBURETTER (VILLIERS) The carburetter fitted to the engine produced prior to middle of 1982 are Villiers S.25 type incorporating a choke control. The throttle control operates the throttle slide, regulating the amount of mixture entering the engine. The carburetter itself automatically meters and atomises the correct amount of fuel to give the necessary mixture strength.
  • Page 71 WORKSHOP MANUAL BULLET TUNING THE CARBURETTER With the correct specified main jet, throttle and needle setting, the engine can be tuned to a nice tick-over by adjusting the pilot and throttle stop screws. First take off the slackness in the throttle cable by means of the throttle adjuster screw situated on the top ring and lock it by the lock nut.
  • Page 72 WORKSHOP MANUAL BULLET VILLIERS S.25 CARBURETTER 1. Air cable 2. Strangler slide spring 3. Strangler slide 4. Top ring 5. Top disc 6. Top disc washer 7. Needle adjusting screw 8. Needle No. 5 9. Needle collar 10. Needle adjusting spring 11.
  • Page 74 WORKSHOP MANUAL BULLET CARBURETTER (BING) The carburetter fitted to the engine is Bing Type 53/1 (Vehicles produced prior to middle of 1982 are fitted with Villiers carburetters). 1. DISMANTLING In order to remove the carburetter from the engine, the air filter has to be disconnected from carburetter.
  • Page 75 WORKSHOP MANUAL BULLET the second groove (from top) in its lock washer. When assembling make sure that the jet needle can move freely in the slide. The lock washer must be put with its outer fork into the narrow rim inside the throttle slide so that the space in the slide for fixing the cable is not obstructed.
  • Page 76 WORKSHOP MANUAL BULLET Page 76...
  • Page 78 WORKSHOP MANUAL BULLET CARBURETTER 1988 Bullet Motorcycles are fitted with MIKCARB Carburetters VM-24 Type Function The function of the carburetter is to provide combustible Air-fuel mixture by breaking the fuel into tiny particles - in the form of vapour and mixing the fuel vapour with air in a proper ratio and deliver it into the engine combustion chamber.
  • Page 79 WORKSHOP MANUAL BULLET 2. Pilot Jet System The pilot jet system supplies the engine requirements at lower engine speeds only, i.e. during idling rpm. This function is carried out by the pilot jet and pilot air screw. The pilot air screw governs the air fuel mixture ratio.
  • Page 80 WORKSHOP MANUAL BULLET MIKCARB VM – 26 No. Part No. Part Description 141826 Carburetter assy. 141945 Jet needle 141946 '0' ring 141947 Air adjuster spring 141948 Main jet (size 90) 141949 Starter lever washer 141950 Float hinge pin 141951 Air adjuster 141952 Throttle adjuster spring 141977...
  • Page 81 WORKSHOP MANUAL BULLET The taper needle shank has five grooves in it, so that it can be set in relation to the throttle slide. If the needle is set higher on the throttle slide, the quantity of fuel that is being supplied would become much more, than if it would have been set at a lower position.
  • Page 82 WORKSHOP MANUAL BULLET SERVICE LIMITS COMPONENT 350 cc 500cc Inches Inches Small end (gudgeon pin) 19.11 0.752 19.11 0.752 Crankshaft big end-axial play 0.55 0.021 0.55 0.021 Crankshaft runout Connecting rod 0.08 0.003 0.08 0.003 twist 0.075 0.002 0.075 0.002 Crankshaft axial play in crankcase 2.80 0.11...
  • Page 83 WORKSHOP MANUAL BULLET TROUBLE SHOOTING : BULLET MOTOR CYCLES COMPLAINT: ENGINE DIFFICULT/DOES NOT START CHECK OBSERVATION CAUSES REMEDIES Crank the engine Kick starter pedal Clutch slippage: several times. moves freely. No clutch cable free play Adjust clutch cable play How is the cranking pressure? Stuck clutch cable...
  • Page 84 WORKSHOP MANUAL BULLET TROUBLE SHOOTING: ENGINE DIFFICULT/DOES NOT START CHECK OBSERVATION CAUSES REMEDIES 4. Switch ‘on’ ignition and a) No, it doesn’t Kill switch circuit open Check and correct crank engine. Does the amp. Defective ignition switch Replace ignition switch meter needle deflect? Snapped battery connection Check and correct...
  • Page 85 WORKSHOP MANUAL BULLET 6. Clean spark plug No spark Defective spark plug Change the plug electrode tips. Set gap. Connect it to HT lead. Defective plug cap Change the cap Earth its body. Turn ignition switch “on”. Open primary circuit Check and correct Ensure “kill switch”...
  • Page 86 WORKSHOP MANUAL BULLET COMPLAINT: LOW IDLING PROBLEM CHECK OBSERVATION CAUSES REMEDIES 1. Does the engine cut off a) Yes, it cuts off. Throttle stop screw too far out Adjust throttle stop screw suddenly when the throttle Air screw too far in Adjust air screw is closed but remain running Pilot jet blocked...
  • Page 87 WORKSHOP MANUAL BULLET CHECK OBSERVATION CAUSES REMEDIES COMPLAINT LOW IDLING PROBLEM 6. With Ignition on, kick Too far advanced ignition Adjust ignition timing the engine. Is there a timing severe kick back? High compression pressure Check and correct Engine would now low idle smoothly NOTE Find out induction leakage by: METHOD 1...
  • Page 88 WORKSHOP MANUAL BULLET COMPLAINT: LOSS OF POWER CHECK OBSERVATION CAUSES REMEDIES Excessive pay load 1. Is the load on engine a) No, it is over loaded. Reduce pay load O.K? Low tyre pressure Inflate the tyre to right pressure Tight chain - Primary and Adjust chain tension Rear Adjust brake...
  • Page 89 WORKSHOP MANUAL BULLET COMPLAINT: HIGH LUBE OIL CONSUMPTION CHECK OBSERVATION CAUSES REMEDIES Check the parked Yes, External oil Loose drain plugs Tighten the plugs place any oil spot on leaks the ground? Loose joints Tighten fasteners Damaged gaskets Replace the gaskets Damaged sealing surface Face / Replace the parts Start the engine.
  • Page 90 WORKSHOP MANUAL BULLET COMPLAINT: HIGH LUBE OIL CONSUMPTION Method of checking oil circulation: Remove the tappet inspection door. Continuous oil flow through the push rod while the engine is in operation indicates proper oil circulation. Loosen the banjo union at the cylinder head. Engine in idling, oil flow from this joint indicates proper oil circulation up to this point.
  • Page 91 WORKSHOP MANUAL BULLET COMPLAINT: LOW MILEAGE CHECK OBSERVATION CAUSES REMEDIES No, he doesn’t Does the External petrol leakage Check and stop leakage customer report Poor driving techniques: Educate the customer any other Clutch and brake riding performance Racing starts problem? Too many revving Sudden accelerations Over loading...
  • Page 92 WORKSHOP MANUAL BULLET COMPLAINT: LOW MILEAGE CHECK OBSERVATION CAUSES REMEDIES No, it doesn’t Does the road Clutch slippage: speed increase Causes and remedies as given for clutch slippage problem (Page with engine rpm? Yes, it does Is there Causes and remedies as given against white smoke in high oil excessive white consumption (Page 7) smoke?
  • Page 93 WORKSHOP MANUAL BULLET ENGINE OVER HEATING CAUSES REMEDIES Too lean air petrol mixture (characterised by loss Check and correct of power) Too far advance ignition timing (characterised by Adjust the timing kick back while starting and combustion knocks) Excessive carbon deposit in cylinder Decarbonise the engine (Characterised by post ignition) Dirty/ Blocked cooling fins...
  • Page 94 WORKSHOP MANUAL BULLET COMPLAINT: ENGINE NOISY IN OPERATION CHECK OBSERVATION CAUSES REMEDIES 1. Start and accelerate External compression leakage Check and correct the engine. Any high Exhaust gas leakage Check and correct intensity continual, gas leakage sound? 2. Start and run the Cracked / damaged air below Change it engine.
  • Page 95 WORKSHOP MANUAL BULLET COMPLAINT: PREMATURE WEAR OF ENGINE COMPONENTS CHECK OBSERVATION CAUSES REMEDIES 1. Is there any suction Cracked or improperly fitted air Replace the air filter or leakage or air filter filter properly fit it damage? Induction system joint leakages Check and correct 2.
  • Page 96 WORKSHOP MANUAL BULLET COMPLAINT: FLAME AT THE SILENCER (AFTER FIRE) CAUSES REMEDIES Defective spark plug Clean & adjust or replace Too rich air fuel mixture Adjust carburettor Retarded ignition timing Check and adjust ignition timing Leaky exhaust valve Adjust tappet Lap the valve COMPLAINT: CLUTCH SLIPPAGE CHECK...
  • Page 97 WORKSHOP MANUAL BULLET COMPLAINT: CLUTCH DRAGGING CHECK OBSERVATION CAUSES REMEDIES 1. Does the vehicle Excessive clutch lever free Check and adjust tend to move on play engaging gear Distorted steel plates Replace steel plates though clutch lever Dirty/high viscous oil Replace with SAE l0w-30 oil is fully depressed? Broken friction plates...
  • Page 98 WORKSHOP MANUAL BULLET COMPLAINT: PREMATURE WEAR OF DRIVE CHAIN AND SPROCKET CAUSES REMEDIES Too tight chain adjustment Adjust the chain to its normal slackness Too loose chain adjustment Adjust the chain to its normal slackness Over loading of motorcycle Reduce the load Misalignment of F.D sprocket with rear Adjust the chain tension properly wheel sprocket due to faulty chain adjustment...
  • Page 99 WORKSHOP MANUAL BULLET COMPLAINT: BRAKE LESS EFFECTIVE CAUSES REMEDIES Excessive clearance between brake shoe and drum Adjust the brake Oily shoes Replace shoes Glazed shoes and drum Remove the glaze with emery paper Worn out brake shoes Replace brake shoes Worn out drum Replace the drum Bent back plate...
  • Page 100 WORKSHOP MANUAL BULLET COMPLAINT: FRONT FORK HITTING NOISE CAUSES REMEDIES Insufficient oil in the fork (hits at the end of the Top up the oil level compression stroke) Weak coil springs (hits at the end of compression stroke) Replace springs with new ones Worn out spring stud (hits at the end of expansion stroke) Replace it with new Loose main tube fitment...
  • Page 101 WORKSHOP MANUAL BULLET COMPLAINT: MOTORCYCLE PULLING TO ONE SIDE CAUSES REMEDIES Low tyre inflation pressure Inflate it to the right pressure Too tight steering adjustment Adjust the steering to proper play Worn out steering race / balls Replace the worn out parts Bent front fork main tube Replace the main tube Unequal tightening of the main assembly tubes into head...
  • Page 102 WORKSHOP MANUAL BULLET COMPLAINT: DIM HEAD LIGHT CAUSES REMEDIES Loose joints /earth connection Tighten them Poor quality bulb Replace them with genuine bulbs Run down battery Recharge battery Higher voltage bulb Replace with right voltage bulb Lower wattage bulb Use right wattage bulb Faded reflector Change reflector Incorrect focusing...
  • Page 104 WORKSHOP MANUAL BULLET BULLET 350 CC/500 CC - TORQUE VALUES ENGINE ITEM Kg-m LB-inch Rocker Bearing Stud Nut (3/16”) 1.30 112.0 Crank Pin Nut (7/8”) 13.80 1200.0 Timing Shaft Nut (3/4”) 9.20 800.0 Cylinder Head Nut (5/6”) 3.30 285.0 Crankcase Joint Nut (M6 1/4”) 0.90 78.0 Crankcase Joint Nut (M8 5/16”)
  • Page 106 WORKSHOP MANUAL BULLET SPECIAL TOOLS LIST COMMON FOR 350cc and 500cc Page 106...
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  • Page 112 WORKSHOP MANUAL BULLET Metric conversion tables Millimetre. to Inches Inches to Millimetres Inches Decimals Millimetres Inches Inches 1/64 0.0156265 0.3969 0.01 0.00039 0.001 0.0254 1/32 0.03 125 0.7937 0.02 0.00079 0.002 0.0508 3/64 0.046875 1.1906 0.03 0.00118 0.003 0.0762 1/16 0.0625 1.5875 0.04...
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  • Page 114 WORKSHOP MANUAL BULLET SPARES for ROYAL ENFIELD & AMAL HITCHCOCK’S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE: 01564 783 192 FAX: 01564 783 313 E-MAIL: info@hitchcocksmotorcycles.com WEB: hitchcocksmotorcycles.com Page 114...

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