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Manuals
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Royal Enfield Manuals
Motorcycle
Bullet RES 500
Service manual
Royal Enfield Bullet RES 500 Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Index
How this Manual Came to be
Four Stroke Engine Basics
Horsepower and Torque
Performance Boosting
Operation of the Motorcycle
Starting Drill
Breaking the Clutch Free
Actual Starting
Flooded Starting
Learning to Operate the Machine
Moving off and Coming to a Halt
The Stop Reflex
Throttle Control
Upshifting
The Ratchet Shift
Downshifting
Trouble Changing Gears
Coming to a Halt
Stay off that Clutch Lever!
Use of the Brakes
Putting the Machine Away
Troubleshooting - Starting
Push Starting
Ignition
Fuel
Cleaning the Fuel System
Here Are some Possible Problems and Their Cures
Basic Day-To-Day Maintenance: Lubrication, Cleaning, and Adjustments
Cleaning
Lubrication
Wet-Sumping
Preventing Wet-Sumping
Low Oil
Changing Oils
Engine
Checking the Quill-Style Oil Pressure Feed Bush
Oil Change Intervals
Verifying Oil Delivery
Nightmare Time: What about Stripped Drain Plugs?
Gearbox
Primary Case
General Chassis Lubrication
Second-Guessing the Dealer: New Motorcycle Pre-Delivery Preparation
Electrical System
Fuel Delivery Problems
Basic Day-To-Day Maintenance: Checking and Adjustments
Adjusting Pushrod End Play
Clutch Linkage Adjustment
Cable Adjustment
Correcting Slip or Drag - Properly Adjusted Clutch
Simple
The Long Way
Brake Adjustments
Rear Brake Adjustment
Front Brake Adjustment
The Single Leading Shoe Brake
The Twin Leading Shoe Brake
TLS Linkage Adjustment
Brake Improvement
Spoke Tuning
Spokes Can Get too Long!
Chains - Checking and Adjustments
The Rear Chain
Checking Adjustment
Moving the Wheel
Replacing a Chain
The Primary Chain
Chain Adjustment Slipper
Checking Condition of Primary Chain
Carburetor Adjustments
Carburetor Jetting
Checking and Adjusting
The Pilot Jet
Plug Checks
MID-Range Carburetion Check - the Plug Chop
The Midrange-Highrange Circuit
Float Level
Bad Flooding
Chassis Adjustments
Front Forks
Tire Pressure
Wheel Alignment
Controls
Fittings
Checking Your Ignition Timing
The Signs
Checking Point Gap
Chassis Electrics
Changing Light Bulbs
Power Testing
Wiring Considerations
Troubleshooting
Longs
A Typical Checking Strategy
Voltage Drops
Valve Adjustment
Description:the Valve Train
Checking Valve Train Clearance
Hot or Cold?
Checking While Engine Is Running
Checking with Engine Stopped
Checking - Do They Require Adjustment?
Inconsistency
Hot Vs Cold - a Reprise
General Chassis Work
Removing Wheels
Front Wheel
The Rear Wheel
The Regular Wheel
Replacing the Standard Wheel
Removing the QD Wheel
The Cush Drive Rubbers
Checking the Cush Drive Rubbers
Changing Tires
Replacing the QD Rear Wheel
Replacing the Tire
Replacing Control Cables
Inspection
Replacement
Throttle Cable
Clutch Cable
Front Brake
Replacing Brake Shoes
The Rear Brake Shoes
The Whole-Hog Method
The Simple~But-Trickier Method
A Note on Removing the Brake Actuator Shaft Lever
Re-Assembly of Brake Shoes
Checking the Arc
Added Brake Refinements
The Wheel Bearings
Re and Re Wheel Bearings
Examination and Packing
Re-Installation
Ensuring Proper Running Clearance (Bearings)
Checking for Adequate Bearing Clearance
The Front Wheel
Checking/Packing Wheel Bearings
Broken Stud Removal
Removing Screws with Heads Intact
Removing Broken Studs and Screws
Left-Hand Drill Bits
Oversizing
A Final - or First - Option
Disk Brake Maintenance
The Hydraulic System
Maintenance Tasks
Linkage Adjustment
Puck Examination/Replacement
Maintenance of the Hydraulics
Monitoring Fluid Level
Monitoring and Correcting Leaks
Correcting Air Problems
Bleeding the System
Preliminary Caution!
Reverse Bleeding
Forward Bleeding
Down and Dirty
Leaktrouble-Shooting
Repairing/Replacing Cylinders
Fluid Changing
Engine Work
Replacing the Big End Oil Feed Quill Bushing
Removing the Old Cork Bushing
Replacing the Bushing
Removing and Replacing the Timing Cover
Removing the Timing Cover
Inspection of Parts
Removal of the Timing Pinion/Pump Drive Nut
Replacing the Timing Cover
On Startup
Trouble Shooting
Oil Pump Operation
The Timing Chest
Contact Breaker and Drive Gear
The Gears
The Cover
Checking and Setting Ignition Timing
The Objective
Tools and Materials
Setting the Point Gap
Replacing the Point Set
What about the Condenser?
Checking Ignition Timing
Static Timing-In the Shop
The Timing Stick
Finding the Point of Spark Occurrence
Gadgets/Obsessive-Compulsive
Dynamic Timing - Running
Ping Timing
Checking for "Ping"
Top End Overhaul
Checking Compression
"Wet and Dry" Compression Testing
An Explanation of Clearances
Combustion Deposits
Doing the Job
Top End Overhaul - Removing the Cylinder Head
The Cylinder Head
Removing the Cylinder Head
The Valve Assemblies
Valve Spring Compressor
Examining Thevalves, Guides, and Springs
Refacing the Valves and Seats
Choosing a Machine Shop
"Lapping" the Valves
Removal and Replacement of Valve Guides
The Decompression Valve
Valve Spring Length
The Valve Train
Re-Fitting the Cylinder Head
Valves
Torquing Bolts Without a Torque Wrench
Re-Torquing the Head Gasket
Running in Your New Top End
Re-Torquing and Re-Setting
Removing the Cylinder Barrel
Pistonlcylinder Clearances
Connecting Rod Clearances
Examination of Piston and Rings
Checking Cylinder Wear
Interpreting Your Readings
Removing the Piston
Extracting the Piston Pin
Examining Big-End Clearance
Examining Piston-Cylinder Clearances
Visually
The Micrometers Method
Honing, or "De-Glazing" Cylinder Bores
The Cylinder Barrel: Re-Assembly
Replacing Piston Rings
Fitting the Piston
The Cylinder Barrel
Splitting the Crankcase
Timing Chest
Separating the Case Halves
Suggestions for Presses
Drive Side
Timing Side
Examination of Parts
Reassembly
Front Forks
The Front Forks Description and Operation
Damping
The Upper Fork Crown/Casquette/Steering Head
Adjusting Steering Head Bearings
Detecting Bearing Damage
Removal of the Fork Crownlcasquette Assembly
Removal of the Casquette Assembly
Replacing the Bearings and Fork Crown
The Front Stanchion/Main Tube Assemblies
Changing Fork Oil
Re-Centering the Spring Studs
Replacingthe Fork Oil
Dismantling the Fork Leg Assembly
Examination of Components
The Rear Suspension
The Rear Shocklspring Units
The Swingarm Bushes
Removing the Swingarm
De-Bushing the Swingarm
Centering the Bushes
Reinstalling the Swingarm
The Primary Drive
The Clutch
Clutch Servicing
Dismantling the Clutch
Replacing the Clutch
Assumptions
Removing the Alternator and Engine Sprocket
Replacing the Alternator
The es Starter Drive System
Possible Problems
Operation
Gearbox Exploded View
The Gearbox
Adjustment of the Neutral Finder
Removal and Replacement of Countershaft Sprocket
Removing the Outer Cover
The Right Side Shifter
Removing the Inner Cover
Both Shifters
Drawing Anomaly
Breaking the Joint
Mainshaft Bearing
Stripping the Gearbox
Examination of Gearbox Parts
Bushings and Bearings
Enrichment Exercise
Gears, Dogs, and Shafts
Forks and Sliders
Correcting Faulty Gearchanging
Test Riding
Sloppy LH Shift Linkage
Determining Faulty Detent Plunger Action
Excessive Movement against Stops
Overview of the Shifter Mechanism
The Detent Plunger
The Ratchet Shifter Mechanism
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Quick Links
1
Changing Oils
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B U L L E T
by
Pete
Snidal
Table of
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Table of Contents
Troubleshooting
Putting the machine away
15
Wiring considerations
47
Trouble Shooting
78
Troubleshooting
206
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This manual is also suitable for:
Bullet 350 cc
Bullet 500 cc
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