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Royal Enfield Bullet Classic EFI Service Manual

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  Summary of Contents for Royal Enfield Bullet Classic EFI

  • Page 2 SECTION SECTION SECTION SECTION SECTION ONE 01 ONE 01 ONE 01 ONE 01 ONE 01 INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION...
  • Page 3 PREFA A A A A CE PREF PREF We are pleased to release this workshop manual for the new generation of Royal Enfield Motorcycles fitted with unit construction engine, electronically controlled “Engine Management System” and fuel injection technology. We have endeavoured to make this manual user friendly. However, we welcome your valuable suggestions for improvements which you may write to us or e-mail us at vvikram@royalenfield.com.
  • Page 4 Every care is taken to ensure that the information given in this manual is correct at the time of going to print. However, Royal Enfield does not assume responsibility for any damage, loss or injury caused to the vehicle or to the person carrying out repairs, due to errors or omissions in this manual.
  • Page 5: Service Limit

    HOW W W W W T T T T T O USE O USE O USE O USE Y Y Y Y Y OUR O USE Engine breather System SERVICE MANU VICE MANU VICE MANU VICE MANUAL VICE MANU Clutch System Inlet manifold &...
  • Page 6 SECTION EIGHT 08 SECTION EIGHT 08 SECTION EIGHT 08 SECTION EIGHT 08 SECTION EIGHT 08 - Relay starter SUSPENSION AND SUSPENSION AND SUSPENSION AND SUSPENSION AND SUSPENSION AND - Starter motor STEERING STEERING STEERING STEERING STEERING - IC Flasher Front fork working principle - RR Unit Front fork removal &...
  • Page 7 SECTION SECTION SECTION SECTION SECTION TWO 02 TWO 02 TWO 02 TWO 02 TWO 02 GENERAL GENERAL GENERAL GENERAL GENERAL...
  • Page 8 SALIENT FEA SALIENT FEA TURES OF TURES OF THE UNIT CONSTR THE UNIT CONSTR UCTION UCTION SALIENT FEA SALIENT FEA SALIENT FEATURES OF TURES OF TURES OF THE UNIT CONSTR THE UNIT CONSTR THE UNIT CONSTRUCTION UCTION UCTION ENGINE & ENGINE MAN ENGINE &...
  • Page 9 BASIC BASIC BASIC TERMINOL TERMINOL TERMINOLOGY OF TERMINOL OGY OF OGY OF AUT OGY OF AUTOMOBILES OMOBILES OMOBILES OMOBILES BASIC BASIC TERMINOL OGY OF OMOBILES ENGINE : The Engine helps to convert Chemical energy availbale in petrol into heat energy then to Fuel Power mechanical energy for motion.
  • Page 10 TOTAL VOLUME : It is the sum of the swept voume (Displacement volume) and Clearance volume. Total Volume = Swept volume + Clerance volume. COMPRESSION RATIO : It is a ratio between total volume in the engine to the clearance volume available at the end of compression stroke.
  • Page 11 IHP : IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed 1HP (Horse Power Available inside the engine cylinder by combustion process. after explosion) It is utilised to drive the piston. FHP : FHP (Frictional Losses) FHP stands for Frictionl Horse Power.
  • Page 12 IGNITION TIMING : Ignition timing is the timing at which spark commences so that the spark from the spark TDC Position plug can ignite the mixture in the combusion Ignition Timing chamber at the end of TDC during compression Position stroke.
  • Page 13 TECHNICAL SPECIFICA TECHNICAL SPECIFICATIONS TIONS TIONS TIONS TECHNICAL SPECIFICA TECHNICAL SPECIFICA TIONS ENGINE AND ENGINE SYSTEMS BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5) Engine Type 4 Stroke Single Cylinder, Air cooled Bore 84mm Stroke 90mm Displacement...
  • Page 14 CHASSIS BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5) Frame Tubular Front Suspension Telescopic, hydraulic damping, Stroke 130 mm Rear Suspension Swing arm with gas shock absorbers Fr. Fork oil capacity 265 cc + 2.5 cc / each leg...
  • Page 15 BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5) Tail / Brake Lamp 12V 5 / 21W Speedometer lamp 12V, 3.4W Hi beam indicator 12V, 2W Neutral lamp Tell tale 12V, 2W Turn Signal Tell Tale 12V, 2W...
  • Page 16 IDENTIFICA IDENTIFICA TION OF CHASSIS NO TION OF CHASSIS NO., ., ., ., ., ENGINE NO TION OF CHASSIS NO ENGINE NO ENGINE NO ENGINE NO, , , , , IDENTIFICA IDENTIFICA IDENTIFICATION OF CHASSIS NO TION OF CHASSIS NO ENGINE NO ENGINE NO.
  • Page 17 LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL T T T T T OOLS OOLS OOLS AND ITS AND ITS APPLICA APPLICA TION TION LIST OF SPECIAL LIST OF SPECIAL OOLS OOLS AND ITS AND ITS AND ITS APPLICA APPLICA APPLICATION TION...
  • Page 18 LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL T T T T T OOLS OOLS OOLS AND ITS AND ITS APPLICA APPLICA TION TION LIST OF SPECIAL LIST OF SPECIAL OOLS OOLS AND ITS AND ITS AND ITS APPLICA APPLICA APPLICATION TION...
  • Page 19 LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL T T T T T OOLS OOLS OOLS AND ITS AND ITS APPLICA APPLICA TION TION LIST OF SPECIAL LIST OF SPECIAL OOLS OOLS AND ITS AND ITS AND ITS APPLICA APPLICA APPLICATION TION...
  • Page 20 LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL T T T T T OOLS OOLS OOLS AND ITS AND ITS APPLICA APPLICA TION TION LIST OF SPECIAL LIST OF SPECIAL OOLS OOLS AND ITS AND ITS AND ITS APPLICA APPLICA APPLICATION TION...
  • Page 21 LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL T T T T T OOLS OOLS OOLS AND ITS AND ITS APPLICA APPLICA TION TION LIST OF SPECIAL LIST OF SPECIAL OOLS OOLS AND ITS AND ITS AND ITS APPLICA APPLICA APPLICATION TION...
  • Page 22 CONTROL CABLES AND WIRING HARNESS ROUTING CONTROL CABLES AND WIRING HARNESS ROUTING CONTROL CABLES AND WIRING HARNESS ROUTING CONTROL CABLES AND WIRING HARNESS ROUTING CONTROL CABLES AND WIRING HARNESS ROUTING ALL CONTROL CABLES & WIRING HARNESS ROUTING UNDER TANK AND SEAT TOP VIEW UNDER TANK LH VIEW UNDER TANK RH VIEW 02-15...
  • Page 23 GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA TION TION GENERAL GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA VEHICLE INFORMATION TION TION HARNESS ROUTING STEERING RH MAGNETO WIRES ROUTING PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING 02-16...
  • Page 24 GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA TION TION GENERAL GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA VEHICLE INFORMATION TION TION FUSE CARRIERS HORN WIRE ROUTING ARRANGEMENT (E5 & G5) FUSE CARRIERS HANDLE BAR WIRES ROUTING ARRANGEMENT (C5) 02-17...
  • Page 25 GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA TION TION GENERAL GENERAL GENERAL VEHICLE INFORMA VEHICLE INFORMA VEHICLE INFORMATION TION TION TAIL LAMP & TRAFFICATOR ECU MOUNTING BULLET WIRES ROUTING ELECTRA EFI (E5 & G5) THROTTLE BODY MOUNTING ECU MOUNTING BULLET WITH CABLES CLASSIC EFI (C5) 02-18...
  • Page 26 SECTION SECTION SECTION SECTION SECTION THREE 03 THREE 03 THREE 03 THREE 03 THREE 03 SERVICE D SERVICE D SERVICE D A A A A A T T T T T A A A A A SERVICE D SERVICE D...
  • Page 27 SERVICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS (All units in mm unless specified) WEAR LIMITS Wear limits are given as new min, new max and service limits. New components must be within the limits specified.
  • Page 28: Table Of Contents

    Piston ring end gap : compression Piston Pin diameter From top New Min. 19.992 New Min. 0.20 0.35 New Max. 19.997 New Max. 0.35 0.50 Service Limit 0.70 0.85 Service Limit 19.982 Piston ring end gap - Oil Ring Big end axial play New Min.
  • Page 29 Connecting rod bend Valve stem OD (Inlet) New Min. 6.965 New Min. 0.00 New Max. 6.980 New Max. 0.05 Service Limit 6.955 Service Limit 0.08 Cylinder Head warpage Valve to guide (inlet) clearance New Min. 0.00 New Min. 0.02 New Max. 0.05 New Max.
  • Page 30: Table Of Contents

    Valve to guide (Exhaust) Clearance Hydraulic Tappet OD New Min. 0.04 New Min. 21.387 New Max. 0.07 New Max. 21.405 Service Limit 1.00 Service Limit 21.380 Valve Spring : length Hydraulic Tappet guide bore New Min. 42.80 New Min. 21.417 New Max.
  • Page 31: Table Of Contents

    Main shaft Outer diameter Selector fork shaft outer diameter Location New Min. 9.96 New Min. 19.99 23.93 New Max. 9.98 New Max. 20.00 23.95 Service Limit 9.94 Service Limit 19.97 23.90 Lay shaft Outer diameter Selector fork inner diameter Location New Min.
  • Page 32: Table Of Contents

    Lay shaft 1st gear inner diameter Pivot cam plate outside diameter New Min. 18.03 New Min. 12.98 New Max. 18.06 New Max. 13.00 Service Limit 18.09 Service Limit 12.96 Clutch spring Length Lay shaft 2nd gear inner diameter New Min. 24.00 New Min.
  • Page 33: New Min.

    Clutch steel plate : Distortion Throttle cable free play New Min. 0.00 New Min. New Max. 0.05 1 mm New Max. Service Limit 0.10 2 mm Service Limit Duplex Chain - Length across 21 pins Drive chain : slackness 20.00 New Min.
  • Page 34 Brake drum rear : Internal dia. Sprocket REPLACE GOOD New Min. New Min. 152.40 Sharp, bend broken teeth New Max. New Max. 152.50 Service Limit Service Limit 153.50 Drive chain length across 21 pins Wheel rim: Face out / Run out New Min.
  • Page 35: New Max.

    Main tube - run out Caliper Piston Outer Diameter New Min. 0.00 New Min. New Max. New Max. 25.31mm Service Limit 0.04 Service Limit Front fork assembly spring : length Master Cylinder piston OD New Min. New Min. New Max. New Max.
  • Page 36 Tyre tread : Depth New Min. New Max. 1.00 mm Service Limit Spark Plug Gap New Min. New Max. Service Limit 03-10...
  • Page 37 PERIODICAL MAINTENANCE PERIODICAL MAINTENANCE PERIODICAL MAINTENANCE PERIODICAL MAINTENANCE PERIODICAL MAINTENANCE The schedule provided herein is based upon average riding conditions and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carried out. The frequency of the maintenance must be shortened depending upon the severity of the driving condition OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water etc., DESCRIPTION...
  • Page 38 PERIODICAL MAINTENANC PERIODICAL MAINTENANCE E E E E PERIODICAL MAINTENANC PERIODICAL MAINTENANC PERIODICAL MAINTENANC AIR FILTER CLEANING Blow compressed air from outside to inside. BULLET ELECTRA EFI (E5/G5) Check for cracks, holes, clogging etc. Remove the 2 air filter lid mounting screws Replace, if defective and take out air filter lid Assemble in the reverse order of...
  • Page 39 PERIODICAL MAINTENANC PERIODICAL MAINTENANC PERIODICAL MAINTENANCE E E E E PERIODICAL MAINTENANC PERIODICAL MAINTENANC ENGINE OIL OIL LEVEL CHECK Place the motorcycle on the centre stand Before checking the oil level start and warm the engine for few minutes. Switch “OFF” DRAINING PROCEDURE : the ignition, wait for two minutes and then Keep a clean tray under the engine...
  • Page 40 REMOVAL OF OIL FILTER ELEMENT: The oil filter element is located on the Crankcase Cover RH Remove the oil filter cap mounting screws. Remove the oil filter cap along with gasket (Bullet Electra EFI (E5/G5) “O” ring (Bullet Classic EFI (C5) Remove the washer, spring, spring cap, “O”...
  • Page 41 The tightening torque of M10 lock nut is Loosen anchor nut. 2 KG-M. This must be ensured. Over size Cam Spindle (For Spares) 570040 : 0.1 mm Over Size Spindle 570041 : 0.2 mm Over Size Spindle CAUTION : - After the first 800 kms (500 miles) the backlash between the cam gears must be checked.
  • Page 42 REAR SHOCK ABSORBERS ADJUSTMENT The rear shock absorber spring preload can be increased or reduced according to road and load conditions. Rotate the wheel and apply brake and tighten all the nuts and lock the split pin. BRAKE CAM GREASING (EVERY 6,000 KMS) Remove the brake cover plate.
  • Page 43 Fill 265 ml of API SG 10W-30 oil in each CAUTION leg . -Adjust both left and right shock absorbers Bump the fork several times and then to the same notch. assemble bolt cap with “O” ring (to release FRONT FORK air lock if any).
  • Page 44 Pack grease in the top ball race. Assemble the steering stem. If felt, adjust as follows : Loosen crown plate bolts as shown WHEEL ALIGNMENT CHECK picture ‘A’ Hold the vehicle upright off the stand on level ground. Stretch a string about 100 mm above the ground along the wheels.
  • Page 45 Screw in or out the cable adjuster for (B ) ADJUSTMENT AT THROTTLE BODY END setting the required play at lever end (2 to Loosen the lock nuts on both the cables. 3 mm). Adjust both cables unitform and tighten the lock nuts.
  • Page 46 VALVE TIMING CUM ECCENTRIC CAM If required, top up with distilled water SPINDLE Bring piston to TDC so that the key way in the Rotor assembly is at 12 o Clock position Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear.
  • Page 47 Standard : 0.9 - 1.1 mm Remove the piston rings carefully. For Service Limit : 1.5 mm cleaning the groove in the piston, a piece of broken piston ring thrust into a wooden Valve seat width is not within specification, handle and filed to a chisel point can be reface the valve seat.
  • Page 48 VALVE SEAT REFACING Use a 45 degree cutter to remove the roughness or irregularities from the seat. Valve Seat cutters, a grinder or equivalent valve seat refacing equipment are Using 32 degree cutter, remove top 1/4 of recommended to correct worn valve seat. the existing valve seat material.
  • Page 49 After cutting the seat, apply lapping compound to the valve face and lap the valve using light pressure. NOTE : Excessive lapping pressure may deform or damage the seat. Change the angle of lapping tool frequently to prevent uneven seat wear. Lapping compound can cause damage if NOTE : it enters between the valve stem and...
  • Page 50 ENGINE COMPRESSION TEST STEP-A Start and warmup the engine to normal running temperature. Remove the spark plug & connect compression gauge. Remove spark plug & put few drops of engine oil into the combustion chamber. Connect compression gauge & repeat the procedure as explained in the step-A.
  • Page 51 SECTION SECTION SECTION SECTION SECTION FOUR 04 FOUR 04 FOUR 04 FOUR 04 FOUR 04 ENGINE ENGINE ENGINE ENGINE ENGINE...
  • Page 52 LUBRICA LUBRICA LUBRICATION SY TION SY TION SYSTEM TION SY STEM STEM STEM LUBRICA LUBRICA TION SY STEM 04-1...
  • Page 53 LUBRICA LUBRICATION SY LUBRICA TION SY TION SY TION SYSTEM STEM STEM STEM LUBRICA LUBRICA TION SY STEM ROCKER PUSH ROD HYDRAULIC OIL PUMP STRAINER OIL SUMP CRANK LUBRICATION SYSTEM : Oil from the oil tank is circulated to various parts through a powerful oil pump, the capacity of which is 4.5 litres per minute @ 2750 rpm.
  • Page 54 HYDRA HYDRA ULIC ULIC T T T T T APPETS (ROLLER HYDRA ULIC APPETS (ROLLER HYDRA APPETS (ROLLER HYDRA ULIC ULIC V V V V V AL ULIC HYDRA HYDRA HYDRAULIC ULIC APPETS (ROLLER HYDRA APPETS (ROLLER HYDRAULIC ULIC ALVE LIFTER (RHVL) LIFTER (RHVL) LIFTER (RHVL)
  • Page 55 WORKING PRINCIPLE : Oil enters the hydraulic tappets through a feed The metering valve moves sufficiently to keep the hole in the body and flows into the plunger through push rod seat hole free and unclogged. When the the plunger feed hole, filling the “low pressure engine is switched off, the valve seats on the chamber”...
  • Page 56 O DECOMPRESSOR O DECOMPRESSOR AUTO DECOMPRESSOR O DECOMPRESSOR O DECOMPRESSOR BENEFITS OF AUTO DECOMPRESSOR : WORKING PRINCIPLE Eliminates the need to fix a manual system The auto decompressor is assembled in the which will need to be adjusted and serivced exhaust cam and consists of a flyweight, spring periodically.
  • Page 57 ELECTRIC ST ELECTRIC ST TER SY TER SY STEM & SPRA STEM & SPRA G MECHANISM G MECHANISM ELECTRIC ST ELECTRIC STAR ELECTRIC ST ARTER SY TER SY TER SYSTEM & SPRA STEM & SPRA STEM & SPRAG MECHANISM G MECHANISM G MECHANISM 0.2 to 0.5 mm DETAILS B...
  • Page 58 A A A A A UT O CHAIN O CHAIN TENSIONER TENSIONER ASSEMBL ASSEMBLY Y Y Y Y ASSEMBL UTO CHAIN O CHAIN O CHAIN TENSIONER TENSIONER TENSIONER ASSEMBL ASSEMBL WORKING PRINCIPLE The auto chain tensioner has a spring loaded plunger mechanism with a ratchet arrangement. It eliminates need for manual adjustment of the primary chain tension.
  • Page 59 ENGINE BREA ENGINE BREA THER SY THER SY STEM STEM ENGINE BREA ENGINE BREA ENGINE BREATHER SY THER SY THER SYSTEM STEM STEM Breather arrangement inside the RH cover WORKING PRINCIPLE The engine breather system is located on the RH cover of the crankcase. A connecting hole directs the engine breathing into a chamber in the RH cover which has an inbuilt deflector to deflect the oil that may come along with the fumes from the crankcase.
  • Page 60 CH SY CH SY STEM STEM CLUT UTCH SY CH SY CH SYSTEM STEM STEM The clutch system has a seven plate construction to achieve increase effective diameter and improved torque carrying capacity. The clutch is operated through a lever on the cover LH. 04-9...
  • Page 61 INLET MANIFOLD & INLET MANIFOLD & INLET MANIFOLD & THR INLET MANIFOLD & INLET MANIFOLD & THRO O O O O TTLE BOD TTLE BOD TTLE BOD TTLE BOD TTLE BODY Y Y Y Y The inlet manifold has the fuel injector located on top portion and the throttle body attach to it. The throttle body has a butterfly valve attached which is operated buy the throttle cables attached to a drum on the right side.
  • Page 62 Blow Up Charts 04-11...
  • Page 63 CRANK CASE RH - COVER SIDE 04-12...
  • Page 64 CRANK CASE RH - COVER SIDE KEY No. DESCRIPTION KEY No. DESCRIPTION CAM GEAR ASSEMBLY-EXHAUST WITH FD SPROCKET 17 TEETH DECOMPRESSOR ASSY TAB WASHER OIL PUMP ASSEMBLY TAPPET DOOR BUFFED CSK SOCKET HEAD SCREW M6 X 30 CSK SOCKET HEAD SCREW M5 X 12 CIRCLIP ROTOR AND RELUCTOR ASSEMBLY PUMP DRIVE PINION (GEAR)
  • Page 65 CRANK CASE LH INSIDE VIEW 04-14...
  • Page 66 CRANK CASE LH KEY No. DESCRIPTION CRANK CASE-LH CIRCLIP BALL BEARING 6305 (25 X 62 X 17) BEARING SPACER ROLLER BEARING NU305 (25 X 62 X 17) BALL BEARING 6006 RETAINER PLATE, MAINSHAFT BEARING HEX SOCKET HD CAP SCREW , M5 X 16 JACK SHAFT STUD, M8 X 128 FLANGE NUT-M8...
  • Page 67 CRANK CASE RH - INSIDE VIEW 04-16...
  • Page 68 CRANK CASE RH - INSIDE VIEW KEY No. DESCRIPTION KEY No. DESCRIPTION MACHINED WASHER 6.4 CIRCLIP HEX. NYLOCK NUT M6 X 1 DEEP GROOVE BALL BEARING – SLEEVE GEAR HEX FLANGE BOLT M5 X 16 NEEDLE BEARING DRAIN CAP - SUMP SLEEVE GEAR O RING- DRAIN CAP NEEDLE BEARING...
  • Page 69 ENGINE COVER - RH 04-18...
  • Page 70 ENGINE COVER - RH KEY No. DESCRIPTION KEY No. DESCRIPTION UCE, RH COVER SUB ASSEMPLY HEX.SCREW, M5X12 COVER, RH STATOR & PULSOR COIL ASSY - THREE PHASE PLUG PULSOR COIL FIXING SCREW RESTRICTOR (LEE PLUG) ALLEN SCREW M6X30 SEALING WASHER 12X15.5 HEX.SOCKET HEAD CAP SCREW, M6X85 OIL LEVEL WINDOW HEX.SOCKET HEAD CAP SCREW, M6X100...
  • Page 71 CRANK CASE LH - COVER SIDE 04-20...
  • Page 72 CRANK CASE LH - COVER SIDE KEY No. DESCRIPTION KEY No. DESCRIPTION BUSH, C T PAD CRANK CASE-LH CHAIN TENSIONER PAD DOWEL (6MM) PLAIN WASHER COLLAR, MAINSHAFT HEX.NUT,M8 GEAR, - JACK SHAFT AUTO CHAIN TENSIONER ASSEMBLY KEY - JACK SHAFT O RING,CHAIN TENSIONER ASSEMBLY.
  • Page 73 ENGINE COVER - LH 04-22...
  • Page 74 ENGINE COVER - LH KEY No. DESCRIPTION LH COVER SUB ASSEMBLY COVER, LH BUSH OIL SEAL 14 X 20 X 3 GASKET, COVER LH OIL SEAL INA G 12 X 18 X 5 ASSEMBLY, CLUTCH OP CABLE CLEVIS, CLUTCH OPERATING LEVER CLUTCH CABLE ASSEMBLY PIN, CLUTCH OPERATING LEVER LOCK PIN SPRING, CLUTCH OPERATING MECH.
  • Page 75 GEAR TRAIN ASSEMBLY 04-24...
  • Page 76 GEAR TRAIN ASSEMBLY KEY No. DESCRIPTION KEY No. DESCRIPTION BUSH LAY SHAFT SUB ASSEMBLY MAIN SHAFT SUB ASSEMBLY SELECTOR FORK LH SELECTOR FORK CENTRE MAIN SHAFT SELECTOR FORK RH MAIN SHAFT 2ND GEAR SELECTOR FORK SHAFT WASHER, THRUST MAIN SHAFT 4TH GEAR CIRCLIP 10N CAM PLATE ASSEMBLY CIRCLIP...
  • Page 77 GEAR SHIFTING KICK STARTER(E5 & G5) 04-26...
  • Page 78: Gear Shifting

    GEAR SHIFTING KEY No. DESCRIPTION SS ROCKER SHAFT ASSEMBLY, PIN PIVOT STRIKER, GEAR CHANGE SPRING SPRING, GEAR CHANGE STRIKER SPACER PIVOT BEARING, ROCKER SHAFT UPPER HEX. SOCKET HEAD CAP SCREW, M6 X 12 PIVOT BEARING, ROCKER SHAFT BOTTOM ASSEMBLY, GEAR LEVER SHAFT STOP PIN O-RING HEX.
  • Page 79 CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT PISTON ASSY. CRANK SHAFT ASSY. 04-28...
  • Page 80 CYLINDER HEAD, BARREL, PISTON & CRANKSHAFT KEY No. DESCRIPTION KEY No. DESCRIPTION CYLINDER HEAD SUB ASSY ROCKER ARM, EXHAUST (CYLINDER HEAD, VALVE GUIDE, VALVE SEATS) GASKET, ROCKER COVER INLET CYLINDER HEAD - ONLY MACHINED ROCKER COVER - INLET HEAD WASHER-SEAL VALVE GUIDE HEX HEAD SCREW-ROCKER COVER VALVE SEAT INSERT, EXHAUST...
  • Page 81 DAMPER PAD POSITION DETAILS Number of damper pads per engine = 15 570482/b INLET SIDE VIEW 570479/b 570478/b 570482/b 570480/b Quantity per Description Image Part No. engine Damper pad-cylin- 570478/b der head LH Damper pad- 570479/b cylinder head RH EXHAUST SIDE VIEW 570479/b 570479/b 570482/b...
  • Page 82 SECTION SECTION SECTION SECTION SECTION FIVE 05 FIVE 05 FIVE 05 FIVE 05 FIVE 05 T T T T T ORQUE SPECIFICA ORQUE SPECIFICA ORQUE SPECIFICA ORQUE SPECIFICA TIONS TIONS TIONS TIONS ORQUE SPECIFICA TIONS ENGINE DISMANTLING ENGINE DISMANTLING ENGINE DISMANTLING ENGINE DISMANTLING ENGINE DISMANTLING INSPECTION &...
  • Page 83 TORQ Q Q Q Q UE SPECIFICA UE SPECIFICA UE SPECIFICATION - UE SPECIFICA TION - TION - TION - ENGINE ENGINE ENGINE UE SPECIFICA TION - ENGINE ENGINE TORQUE VALUE PART DESCRIPTION LOCATION Kg / M. N / M. 570013 HEX SOCKET HD CAP SCREW, M5 X 16 RETAINER PLATE / SUCTION FILTER MTG...
  • Page 84 TORQ Q Q Q Q UE SPECIFICA UE SPECIFICA UE SPECIFICA UE SPECIFICATION - ENGINE TION - ENGINE TION - ENGINE TION - ENGINE UE SPECIFICA TION - ENGINE TORQUE VALUE PART DESCRIPTION LOCATION Kg/M. N/M. 30 570215 BOLT, PAWL (M6 X 1) GEAR BOX INDEX 1.00 31 570233...
  • Page 85 ENGINE DISMANTLING , ENGINE DISMANTLING , ENGINE DISMANTLING , INSPECTION INSPECTION INSPECTION INSPECTION AND AND ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y ASSEMBL ENGINE DISMANTLING , ENGINE DISMANTLING , INSPECTION ASSEMBL COMPONENTS COMPONENTS COMPONENTS THA THAT CAN BE T CAN BE T CAN BE T CAN BE COMPONENTS...
  • Page 86 SEAT REMO T REMO T REMO T REMO T REMOV V V V V AL B AL B AL B AL B AL BULLET ULLET ULLET ULLET ULLET Remove the 2 screws, at the bottom of the ELECTRA EFI (E5/G5) ELECTRA EFI (E5/G5) ELECTRA EFI (E5/G5) ELECTRA EFI (E5/G5)
  • Page 87 CLUT UTCH CABLE REMO CH CABLE REMO CH CABLE REMO CH CABLE REMOV V V V V AL CH CABLE REMO REMO REMO REMOV V V V V AL OF REMO REMO AL OF AL OF AL OF THR AL OF THRO O O O O TTLE TTLE TTLE...
  • Page 88 Remove the rear mounting at the pillion Remove the flange nut 2 nos. from cylinder foot rest end (C5). head. Remove the rear mounting at the pillion Remove the Silencer Assembly with foot rest end (E5/G5). Exhaust pipe. Remove the Suppressor Cap NOTE : Loosen the rear brake rod adjuster nut B B B B B A A A A A TTER...
  • Page 89 Remove the battery flap cover Remove the fuse carrier plate mounting screws 2 nos. FOR BULLET CLASSIC EFI ( C5) Remove the terminal boot & terminal wires . Remove battery cover on LH side. Remove the battery holding straps pull the Remove the black coupler.
  • Page 90 REMO REMOV V V V V AL OF E-ST REMO AL OF E-ST AL OF E-ST AL OF E-STAR ART MO T MO T MO T MOT T T T T OR REMO REMO AL OF E-ST T MO Remove 4 screws of the starter drive housing and tap gently to free the housing.
  • Page 91 Remove the chain link and the drive chain. Slacken the nyloc nuts & remove the brake REMO REMO REMO REMO REMOV V V V V AL OF SIDE ST AL OF SIDE ST AL OF SIDE ST AL OF SIDE ST AL OF SIDE STAND light switch.
  • Page 92 Engine oil Drain Engine oil Drain Engine oil Drain Engine oil Drain Engine oil Drain CYLINDER HEAD CYLINDER HEAD ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y CYLINDER HEAD CYLINDER HEAD ASSEMBL CYLINDER HEAD ASSEMBL Remove the 4 allen screws along with It is best to drain the engine oil rubber seals from Inlet and exhaust rocker in warm condition.
  • Page 93 Remove inlet and exhaust pushrods Remove the Cylinder head assy. Remove the multi layer steel (MLS) head Remove the Spark plug gasket. REMOVAL OF VALVES Remove the 6 flanged hex nuts, securing Remove the Inlet & Exhaust valves by the cylinder head. using special tool No.
  • Page 94 CYLINDER BARREL SUB ASSEMBLY Remove the Inlet Valve spring retainer, split collar and Spring. Gently tap Cylinder barrel and remove along with 2 dowel pins. Remove Inlet Valve as shown NOTE : Ensure piston is at TDC. Remove gudgeon pin and piston. NOTE: Similarly follow the same process to NOTE :...
  • Page 95 NOTE : Carefully remove the piston rings from Remove oil filter cover bolts. the piston without deforming. Remove Cylinder barrel bottom Gasket. Remove oil filter cap gasket, “O”ring & Spring. Use Special tool No. ST - 25592-4 to hold connecting rod as shown Fig. CAUTION : Care must be taken while removing cover due to spring force.
  • Page 96 Remove the 11 allen screws securing Remove RH cover gasket & 2 dowels. cover RH. Gently tap & pull out the cover evenly Remove Pulser coil by removing 2 screws It may be necessary to tap the cover slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove CAUTION :...
  • Page 97 Remove circlip, oil seal and jet crankshaft Remove Breather bolt and washer NOTE : Oil seal recommended to replace at Remove 6 Nos. allen screws to remove every 20,000 kms interval. breather chamber cover Remove oil filler cap and “O” ring Remove breather chamber gasket Remove Ignition Timing check bolt and washer (if not removed earlier).
  • Page 98 Remove the 2 oil seals from the Kick Shaft Remove the 3 allen screws & 2 dowels hole (Electra EFI - E5/G5 only) from Cam steady plate. INSIDE OIL SEAL OUTSIDE OIL SEAL COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING ON CRANK ON CRANK...
  • Page 99 Remove oil pump plastic gear after Exhaust cam with auto decompressor. removing circlip. Observe short boss of pump drive gear should face outwards. DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR Remove Cam gear inlet. Remove mounting allen screw on flyweight sub assembly. Remove Cam gear Exhaust (Auto Remove flyweight along with return spring decompressor sub assy).
  • Page 100 Remove the Oil pump assembly with Remove the actuating pin in the Exhaust cam. “O” ring. CAUTION : Remove the woodruff key. Ensure "O" ring must be located on the oil pump body outlet. Remove Gear lever from engine LH cover side.
  • Page 101 Remove the rocker shaft assembly by Remove rocker shaft return spring pivot pin gently tilting and twisting out. with “O” ring by using special No. ST 25123-4 Extractor for 5 speed gear box pivot pin as shown in Fig. Straighten lock tab and Unlock the FD sprocket nut.
  • Page 102 Remove FD Sprocket Remove kicker shaft cover with oil seal. NOTE : Remove Kick starter return spring locking Use special tool No. ST 25 while bolt with washer (only for Bulletin Electra removing FD sprocket if necessary. EFI (E5/G5). Pull out Sleeve gear Spacer by using monkey / gas plier as shown in Fig.
  • Page 103 DISMANTLING COVER LH SUB It may be necessary to tap the cover ASSEMBLY : slightly to remove. Remove the 11 allen screws holding the Remove lock pin and spring from clutch cover LH. operating shaft. PULL LOCK PIN Remove inspection plug along with “O” Remove clutch operating shaft assy from ring clutch cover.
  • Page 104 Use Special tool No. ST - 25591-4 Clutch Remove gear lever shaft bush and oil seal. centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch. COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING COMPONENTS DISMANTLING ON CRANK ON CRANK CASE LH...
  • Page 105 Remove Duplex chain along with Sprag DISMANTLING OF CLUTCH ASSEMBLY clutch and Clutch assembly. Remove 2 hex bolts at opposite locations Remove Engine sprocket and sprag clutch gear assembly. Fix Special tool No. ST - 25594-4 Clutch Spring Compressing Tool and tighten the 2 long bolts fully so as to hold the springs down loosen &...
  • Page 106 Remove collar on main shaft (distance Remove Spring retainer plate & 6 Springs. collar from Crankcase LH). Remove clutch drum sprocket with big washer. Remove special distance washer sprag clutch on Crankshaft LH. Remove clutch hub, centre, friction and Remove hex nut and washer to remove steel plates.
  • Page 107 Remove Auto chain tensioner body assy. Remove the rear engine mounting nut by removing the 2 Nos. allen screws. along with the washer. Remove double gear shaft and double gear Remove the front engine mounting nut starter drive. Remove the jack gear after removing the Loosen chain stay bolt circlip.
  • Page 108 Remove centre stand & footrest supports. Loosen the crankcase stud nuts and allen screws as per the following sequence. Remove the front and rear engine studs & slide the engine assembly off the frame. Remove Engine Front Mounting Bracket. Remove Mudguard mounting clip & Rear Engine Mounting Bracket.
  • Page 109 Remove clutch ball bearing from crankcase Remove special thrust washer (lay shaft ) from Crank case LH & 2 Nos. Dowel pins. Pull out the crank shaft from the crankcase Remove needle roller bearing for lay shaft from crankcase LH. Remove roller bearing NU 305 from Remove clutch bearing retainer plate crankcase LH.
  • Page 110 Remove spacer, circlip, crank shaft bearing Remove circlip and sleeve gear ball bearing 6305 from crankcase LH. 6007 from crankcase RH. Remove lay shaft needle bearing from crankcase RH. Remove last circlip from crankcase LH. Remove nyloc nut, machined washer, pawl - camplate, return spring and bolt Remove crank shaft needle roller bearing pawl from crankcase RH.
  • Page 111 Remove Tappet cover by dismantling 4 Remove the exhaust and inlet hydraulic tappets carefully from Crankcase top side. Allen screws. EX. tappet INLET tappet Remove the Tappet cover. NOTE: Remove Inlet tappet first and then the exhaust tappet. CAUTION : Store the tappets carefully &...
  • Page 112 Pull out cam plate pivot pin with “O” ring Remove special thrust washer (Layshaft) by using special tool No. ST 25153-4 from Crank case RH Extractor shown below. Remove LS 1st gear and thrust washer Check that the 4 rollers are in place in the from the Layshaft.
  • Page 113 DISMANTLING OF LAYSHAFT SUB Remove centre selector fork from the ASSEMBLY selector shaft and then LH selector fork. Remove Lay shaft 1st gear and thrust washer. Remove circlip from the selector shaft if required. Remove Double gear (LS 3rd and 4th gear).
  • Page 114 DISMANTLING OF MAINSHAFT SUB Remove 2nd gear and thrust washer. ASSEMBLY Remove main shaft 1st gear. Layshaft Remove the main shaft 2nd gear. MAIN SHAFT SUB ASSEMBLY Remove the main shaft 3rd gear. 05-32...
  • Page 115 REMOVAL OF SLEEVE GEAR SUB Remove circlip & 1st. thrust washer. ASSEMBLY Remove open end needle bearing. Remove 4th gear and 2nd thrust washer. Remove closed end needle bearing. Main shaft REMO REMOV V V V V AL OF KICK REMO AL OF KICK AL OF KICK...
  • Page 116 Pull out kick starter sub assy. as shown in Remove the Kick pinion gear. Fig. Remove the thrust washer from kick REMOVAL OF KICK STARTER SUB spindle. ASSEMBLY Remove circlip & thrust washer. Remove the Kick pawl, plunger and spring from kickstarter shaft.
  • Page 117 VITAL PARTS I. BEARINGS I. BEARINGS I. BEARINGS I. BEARINGS I. BEARINGS Sl.No. USAGE DESCRIPTION NBI 45 × 30 × 20 Crankcase RH - Crankshaft bearing Ball Bearing 6305 C3 (25×62×17) Crankcase LH - Crankshaft bearing Roller Bearing Nu305 C4 (25×62×17) Crankcase LH - Crankshaft bearing Ball bearing 6006, C3 Crankcase LH - Main Shaft bearing...
  • Page 118 UNIDIRECTIONAL FITTINGS LIST Deep groove ball bearing 6007-RSH/C3 in Cam Gear Inlet- Single punch mark must Crankcase RH- Rubber sealed facing FD align with single punch mark of Cam gear sprocket side. exhaust. Gear rocker shaft bottom pivot bearing- Oil pump drive pinion - Short boss facing Smooth machined surface side facing outwards.
  • Page 119 ENGINE ENGINE ASSEMBL ENGINE ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y ENGINE ENGINE ASSEMBL Please ensure all the parts are cleaned and stored in a sequence for inspection and reassembly. Lubricate all moving parts prior to reassembly. While fixing bearings or bushes in the crankcases, it is necessary to heat the crankcase for ease of fixing.
  • Page 120 CRANKCASE RH Assemble 6305 - C3 bearing after 1st circlip. Insert 2nd circlip then bearing Assemble Needle bearing for lay shaft. spacer in Crank case LH as shown in Fig. Assemble sleeve gear ball bearing (6007 R1/C3) and circlip. NOTE : Ensure the rubber sealed face is facing sprocket side,...
  • Page 121 Assemble closed end needle bearing Insert sleeve Gear into Crankcase RH. inside sleeve Gear. NOTE : Do not hammer directly over sleeve Gear. It is recommended to use arbor press. Assemble open end needle bearing. Check Assemble exhaust and inlet hydraulic bearing seating position and for free tappets carefully into Crank case RH rotation.
  • Page 122 Fit bracket lock clip to hold needle roller pin Assemble magnetic drain plug assy. of hydraulic valve lifter and tighten with allen (Torque 2 KG-M) with washer on screw (Torque 1 KG-M). crankcase RH. DRAIN BOLT NOTE : Apply LOCKTITE 542 thread sealant before assembling the drain plug.
  • Page 123 Fix kickstarter sub assy in to Crankcase Assemble the Kick pinion gear over kick RH as shown in Fig. pawl mechanism. TRIP PLATE NOTE : Ensure kick pawl is seated over the Insert the thrust washer above the kick trip plate in the Crank case RH. Rotate spindle.
  • Page 124 Insert spring locking bolt with washer into Assemble striker spring on rocker shaft kick spring eyelet and rotate clockwise to assy. lock Kick starter return spring on the Crank case and tighten (Torque 1 KG-M). NOTE : Ensure striker spring both ends are seated on striker lever rocker shaft.
  • Page 125 Assemble lower pivot bearing 2 allen bolts Assemble High gear. (Torque 0.6 KG-M). Assemble Double gear (LS 3rd and 4th gear). NOTE : It is recommended to tighten the upper pivot bearing first and then the bottom pivot bearing to avoid gear shifting problems.
  • Page 126 ASSEMBLING OF MAINSHAFT SUB Assemble main shaft 3rd gear. ASSEMBLY Smear oil and assemble the 1st thrust washer and then the 4th gear on the main shaft. Assemble main shaft 2nd gear as shown. Assemble 2nd thrust washer and fix circlip to lock the 4th Gear.
  • Page 127 Assemble selector fork sub assembly Assemble circlip on the selector shaft. over main and Layshaft sub assy. as shown in Fig. Assemble LH selector fork on the selector shaft and then insert centre fork so that the cut shoulders of both the forks are matched.
  • Page 128 Insert cam plate piviot pin with “O” ring Assemble the thrust washer, LS2nd gear with special tool No. ST 25123-4 as & High gear with Lay shaft mounted on the shown in Fig. Crank case RH as shown in Fig. NOTE : Apply LOCTITE 577 thread sealant to pivot pin to avoid oil seepage if any.
  • Page 129 Assemble “O” ring, cap pivot, copper washer and tighten bolt (Torque 1 KG-M). NOTE : Ensure the bearing inner races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembling in the crankcase RH. Check Crank shaft big end bearing axial play is within service limit.
  • Page 130 Insert the jack shaft from the crankcase Check connecting rod bend as shown in LH inside & fix the woodruf key. Fig. Assemble the crankcase LH over RH Crank case by tapping gently. Simultaneously holding self motor jack shaft carefully. Assemble Front Engine Mounting Brackets and tighten bolts (Torque 2.5 KG-M).
  • Page 131 Assemble neutral switch with packing. Fit the centre stand and foot rest supports. Locate the crankcase on the frame and fit the front engine mounting stud. Ensure the woodruf key is located correctly on the jack shaft and fix the circlip. NOTE : Ensure step face of jack shaft gear Fit the rear engine mounting stud.
  • Page 132 Fix the dowels in the crankcase and carefully fix the motor with housing starter drive. Apply LOCKTITE 5699 RTV silicon liquid gasket on the joint face. NOTE : Apply LOCKTITE 577 thread sealant to mounting bolts to avoid oil seepage if any.
  • Page 133 Assemble Engine primary sprocket and SPRAG CLUTCH ASSEMBLY sprag clutch gear assembly. 0.2 to 0.5 mm DETAILS B CAUTION : Lubricate the needle bearing well before assembling on the sprag clutch. Assemble the primary chain auto chain tensioner body assy. with “O” ring and tighten with 2 allen screws (Torque1 KG-M).
  • Page 134 CAUTION : Assemble collar on main shaft (distance collar on Crankcase LH). Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk / slippage. Assemble wheel clutch on clutch hub. ASSEMBL ASSEMBL Y OF CL Y OF CL ASSEMBL...
  • Page 135 Use Special tool No. ST - 25594-4 Clutch Assemble Duplex chain over Engine sprag spring compressing tool to compress the clutch sprocket and Clutch assembly. clutch springs over spring holder and Mount on main shaft. tighten with 2 long bolts. Use Special tool No.
  • Page 136 Assemble clutch bearing cup, ball bearing Fix the washer and nyloc hex nut 24 mm (6001) & clutch push pad. over clutch assembly and tighten. Assemble gear lever shaft bush. Use Torque wrench to tighten the nyloc nut on Clutch (Torque 4.2 KG-M). Assemble gear lever oil seal on cover LH .
  • Page 137 Assemble Clutch operating shaft oil seal. Assemble oil filler plug with “O” ring. Assemble clutch operating shaft assembly on cover LH. Assemble the cover LH on Crank case Assemble spring for clutch operating shaft and lock the pin. NOTE : Ensure 2 Nos.
  • Page 138 Assemble lock type washer and nut Assemble clutch cable on Crank case (Torque 7.5 KG-M). cover LH and fix to clevis. Assemble Sleeve gear Spacer over sleeve Lock the tab over the FD sprocket nut. as shown in Fig. Fix Rear Chain master link, plate and lock Assemble FD Sprocket .
  • Page 139 ASSEMBLING PROCEDURE ASSEMBLING PROCEDURE ASSEMBLING PROCEDURE ASSEMBLING PROCEDURE ASSEMBLING PROCEDURE Assemble oil pump on Crank case RH and OF A A A A A UT O DECOMPRESSOR O DECOMPRESSOR UTO DECOMPRESSOR O DECOMPRESSOR O DECOMPRESSOR tighten with 4 allen screws (Torque 0.35 to 0.6 KG-M).
  • Page 140 VALVE TIMING Fix oil pump drive pinion and lock it with the circlip. Bring piston to TDC so that the woodruf key in the timing shaft is at 12’ Clock position. ASSEMBLY PROCEDURE OF CAM GEARS NOTE : Ensure the short boss of the gear is facing outwards.
  • Page 141 Fix Cam steady plate and check for axial Fix oil seal 2 Nos. at Kick Shaft hole on play of Cam Gears to avoid noise problem. Crank case RH cover. INSIDE OIL SEAL OUTSIDE OIL SEAL Assemble the dowels and allen screws on Cam Fix breather chamber gasket.
  • Page 142 Assemble Stator on cover RH and tighten Assemble Breather bolt and washer with 3 mounting screws (Torque 1 KG-M). (Torque 2.0 KG-M). Assemble Pulser coil on cover RH and tighten with 2 screws (Torque 1 KG-M). Assemble Ignition Timing inspection bolt with copper washer (if not assembled earlier) Torque 1.5 KG-M.
  • Page 143 Assemble “O”ring, Spring and gasket oil Assemble cover RH carefully by aligning filter cap. kickshaft and dowels. CAUTION : Fix cover RH and tighten with 11 allen Care must be taken while fixing cover due to spring force and screws (Torque 1 KG-M). gasket.
  • Page 144 Fix Cylinder barrel bottom Gasket. Insert piston rings on its appropriate PIST PIST ON SUB ON SUB ASSEMBL ASSEMBLY Y Y Y Y ASSEMBL PIST PIST PISTON SUB ON SUB ON SUB ASSEMBL ASSEMBL grooves and check side clearance between the ring and grooves. CLEANING Remove piston rings from piston.
  • Page 145 Check the piston pin for wear. Measure Locate the top ring (Index mark “1 IP” facing outside dia of piston pin at 3 points. upwards). NOTE : Top ring has rectangular cross section with black colour (Nitride coating). Stagger piston rings end gap as shown in Fig.
  • Page 146: Cylinder Head

    CYLINDER BARREL CYLINDER BARREL CYLINDER BARREL CYLINDER BARREL CYLINDER BARREL Assemble the multi layer steel (MLS) head gasket on the barrel & 2 Nos. dowels. CLEANING Scrap the carbon deposit from the top edge of the bore. Clean the barrel with cleaning solvent and dry it with compressed air.
  • Page 147 Check the valve stem for run out. Check the Cylinder head face for warpage on surface plate as shown in Fig. Check inlet and exhaust valve stem for Check the valve guide for wear with small wear. bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance.
  • Page 148 In case if the pencil marks are not erased, Make pencil marks on the seating area of grind the valve to the seat as below valve head as shown in Fig. - Apply fine grinding paste on to the valve seating area.
  • Page 149 NOTE : Please ensure cleaning of the cylinder VALVE SEAT INSPECTION : head with solvent and blow thorough Check and ensure proper seating with all oil passages with compressed air. pencil marks as explained above. Lubricate each valve stem with fresh Valve seating on valve seat can also be engine oil and fix the inlet and exhaust valve into the valve guides.
  • Page 150 Similarly follow the same process to Tighten the 6 flanged hex nuts diagonally assemble the exhaust Valve as shown in and evenly. Fig. NOTE: Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring.
  • Page 151 Assemble inlet and exhaust pushrods. Assemble tappet door by applying LOCKTITE 5699 RTV silicon gasket on Assemble the inlet and exhaust rocker Crank case RH then tighten screws bearing with dowel and tighten allen (Torque 0.60 KG-M). screws Assemble the Inlet & Exhaust Rocker covers, dowels &...
  • Page 152 Tighten the front engine mounting stud nuts Assemble throttle body and connect the to the specified torque. throttle cables. Fill recommended the engine oil to the correct level and tighten filler cap with “O” Tighten the rear engine stud nuts to the ring.
  • Page 153 SECTION SECTION SECTION SECTION SECTION SIX 06 SIX 06 SIX 06 SIX 06 SIX 06 ENGINE MANGEMENT ENGINE MANGEMENT ENGINE MANGEMENT ENGINE MANGEMENT ENGINE MANGEMENT SYSTEM SYSTEM SYSTEM SYSTEM SYSTEM...
  • Page 154 GEMENT SYSTEM STEM STEM The Bullet Electra EFI (E5 & G5) and Bullet Classic EFI (C5) are fitted with an intelligent Engine Management System (EMS). It consists of an Electronic Control Unit (ECU) which constantly takes inputs like engine speed,...
  • Page 155 COMPONENTS DESCRIPTION COMPONENTS DESCRIPTION COMPONENTS DESCRIPTION COMPONENTS DESCRIPTION COMPONENTS DESCRIPTION ELECTRONIC CONTROL UNIT (ECU) ALTERNATOR THROTTLE BODY ASSEMBLY TEMPERATURE SENSOR FUEL INJECTOR ASSEMBLY CRANK POSITION SENSOR FUEL PUMP MODULE ROLLOVER SENSOR LAMBDA (O2) SENSOR MALFUNCTION INDICATOR LAMP (MIL) 06-2...
  • Page 156 Located in LH Electrical Box (Bullet Electra EFI - E5 / G5) (Bullet Classic EFI - C5) The ECU consists of a microprocessor. It controls the output devices by giving pulses to the respective devices. It has two memories Flash Memory and E PROM.
  • Page 157 FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUEL INJECTOR Exploded view of fuel injector Assembled between throttle body and cylinder head Specification: Operating Voltage : 10 – 14 V. Operating temperature : –30º C to + 120º C. Fuel Injection pressure : 294 kpa (2.9 bar) Solenoid Operating Resistance : 10.3 ±...
  • Page 158 FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUEL PUMP MODULE Specification: Operating Voltage : 6 – 14.5 V. Operating temperature : –20º C to + 60º C. Controlled Pressure Regulator : 294 KPa. Inbuilt Filter Capability : Upto 10 Microns Assembled on the fuel tank bottom left side The fuel pump creates a positive pressure in the fuel lines and pumps gasoline through the injector.
  • Page 159 FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS THROTTLE BODY MODULE Specification: Operating Voltage : 5 V. Out Put Voltage : 0 – 5V. Throttle Angle : 0 – 80º Throttle Resistance Maximum : 5 K©. Throttle Out Put Voltage at Idling : 0.6 ±...
  • Page 160 Throttle Position Sensor (TPS): TPS is used to monitor the position of the throttle and is located on the butterfly spindle so that it can directly monitor the position of the butterfly throttle valve. The sensor is usually a potentiometer and therefore provides a variable resistance depending upon the position of the butterfly valve and hence throttle position can be sensed by the ECU.
  • Page 161 FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS ENGINE TEMPERATURE SENSOR Specification: Operating temperature : –30º C to +120º C Operating Voltage : 5 ± 0.5 V. Resistance Value w.r.t. Temperature –20º C –– 18.8 Kilo Ohms + 40º...
  • Page 162 FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS FUNCTIONS OF COMPONENTS LAMBDA (HEGO O ) SENSOR Specification: Operating Voltage : Upto16 V (Maximum). Operating temperature : 600º C to 950º C. (TIP) Tightening Torque : 24.5 ± 4.9 N-m (2.5 ± 0.5 Kg f-m) Assembled on the exhaust pipe The Lambda Sensor detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected.
  • Page 163 There are three levels of identifying a malfunction in the ECU or the sensors. Level 1 Visual This is indicated by the lamp in the MIL glowing continuously. Check for any sensor loose connections and plug in properly. If still MIL GLOWS, then check for the the problem by Test Pin or by DOL TOOL. Level 2 Test pin An open single pole connector is provided close to the UCE.
  • Page 164 Level 3 DOL This is done by connecting a DOL tool to the connector near the ECU. This will accurately determine the defective sensor and show the details on the diagnostic screen with the following respective codes as shown below. P Code MAL FUNCTION INDICATION MIL will glow continuous.
  • Page 165 INSTRUCTIONS (DO’S & DON’TS): DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR the engine is running. DO ensure the battery is in good condition & Fully Charged Battery. DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands retracted.
  • Page 166: Trouble Shooting

    TROUBLE SHOOTING S No Symptom Possible Cause Remedy Engine stop switch is in OFF Switch engine stop switch ON position Side stand is ON. Retract side stand completely MIL does not glow when Check battery electrolyte level Battery discharged ignition key switched ON &...
  • Page 167 TROUBLE SHOOTING S No Symptom Possible Cause Remedy Spark plug Fouled Replace spark plug Spark plug cap shorting Replace spark plug cap Ignition coil wire loose connection Check for proper wire connection. or broken. Replace damaged wire connections Ignition related Check power relay resistance / wire Faulty HT coil power relay.
  • Page 168 SECTION SECTION SECTION SECTION SECTION SEVEN 07 SEVEN 07 SEVEN 07 SEVEN 07 SEVEN 07 T T T T T ORQUE SPECIFICA ORQUE SPECIFICA ORQUE SPECIFICA TIONS - ORQUE SPECIFICA TIONS - TIONS - TIONS - ORQUE SPECIFICA TIONS - CHASSIS CHASSIS CHASSIS...
  • Page 169 TORQ Q Q Q Q UE SPECIFICA UE SPECIFICA UE SPECIFICA UE SPECIFICA UE SPECIFICATION - TION - TION - TION - TION - CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS TORQUE VALUE PART DESCRIPTION LOCATION Kg / M. N / M. Handle Bar 146032 Handle Bar Clip Bolts Handle Bar Clip...
  • Page 170 TORQ Q Q Q Q UE SPECIFICA UE SPECIFICA UE SPECIFICA UE SPECIFICA UE SPECIFICATION - TION - TION - TION - TION - CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS TORQUE VALUE PART DESCRIPTION LOCATION Kg / M. N / M. 2 1 580592 FLANGE HEX.
  • Page 171 FRONT ONT WHEEL REMO WHEEL REMO WHEEL REMO WHEEL REMOV V V V V AL WHEEL REMO ✰ Tap the axle gently to remove it out of the fork end and the wheel ✰ Place the vehicle on its center stand. ✰...
  • Page 172 ✰ Locate the bush on the left side of the wheel Whenever the disc brake system is overhauled, ensure that the old fluid is (Disc brake side) drained out completely and then fill with ✰ Remove the wedge between the brake pads fresh brake fluid.
  • Page 173 Loosen the bleeder screw by 1 turn Remove the Master Cylinder top cover, approximately diaphragm plate & diaphragm. Depress brake lever slowly and fully and release. This will force the brake fluid out of the bleeder screw. Repeat this process Remove the protective boot from the till the brake fluid drains out completely bleeder nipple on the calliper assembly.
  • Page 174 Remove the calliper assembly from the fork leg and drain out the brake fluid Fix the diaphragm, plate and top cover. Do not tighten the screws completely since it may be required to top up fluid during the Reassemble the calliper and refit the banjo bleeding process.
  • Page 175 Loosen the bleeder screw by ½ turn to Check the fluid level and top up to “MAX” allow air bubbles in the brake system to level and refit the diaphragm and the top escape out. cover and tighten with the screws. Check for any leaks at the banjo or the bleeding screw area and ensure all mounting bolts are tightened to the correct...
  • Page 176 Remove the Master Cylinder top cover, diaphragm plate & diaphragm. When a slight pressure “build up” is felt on the lever, depress and hold. DO NOT RELEASE THE LEVER. The air in the Place a clean tray or container below the hydraulic system will be expelled upwards calliper assembly to collect the old brake during this operation, allowing the fluid to...
  • Page 177 Remove the Rear view mirror RH. Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar. Disconnect the Front brake switch wire and Remove the boot and the Circlip from the remove the switch from the master master cylinder body.
  • Page 178 CAUTION : INSPECTION Do not clean the hydraulic disc brake parts with Check both the rubber seals on the plunger any other cleaning material, solvents or water. for wear, cracked edges or any other USE NEW BRAKE FLUID ONLY. damage. Replace seals whenever the plunger is removed REASSEMBL REASSEMBL...
  • Page 179 Locate the circlip into the groove of the Assemble the Brake Switch master cylinder. Ensure the circlip is seated correctly inside the groove. Fix the master cylinder assembly on the handle bar with the ’UP’ mark facing upwards. Assemble the rubber Boot. Tighten the master cylinder assy.
  • Page 180 Position the brake hose on the master cylinder such that it is pointing downwards correctly and tighten with the banjo bolt. Replace the banjo bolt sealing washers whenever the bolt is removed. Tighten the banjo bolt firmly Torque 3.5 KG-M. Remove the Grub screws.
  • Page 181 Remove the brake pad tensioner spring plate. Remove pin bolt. Remove the Bellow & Boot. Remove the brake pads from the caliper assembly. Hold the caliper body with the pistons facing downwards. Blow compressed air with a nozzle at a low pressure, into the oil passage hole on the caliper, so that the pistons can be removed...
  • Page 182 CAUTION : Measure the caliper piston O.D. Service limit – 25.31 mm Do not use high pressure air or any pliers or CAUTION : sharp objects to remove the pistons as their working surface can get damaged. Enough care should be taken to avoid damages of the piston O.D.
  • Page 183 Coat the caliper cylinders and Pistons with Install the Pad tension spring plate into clean brake fluid and install the Pistons into the Caliper body. the caliper body with the dished end facing inwards. Assemble Bleed screw with the dust cap on the caliper body.
  • Page 184 First install the brake pad at the piston side Tighten the Pin bolts with a torque of 1.5 and then install the other brake pad 2.0 KG - M after mounting the caliper assembly on the fork assembly. Fix the Grub screws on the pins and tighten to a torque of 0.2 to 0.3 KG-M.
  • Page 185 WHEEL DISC INSPECTION WHEEL DISC INSPECTION WHEEL DISC INSPECTION WHEEL DISC INSPECTION WHEEL DISC INSPECTION Check the wheel disc periodically for any oil or grease stains, slush, grit, scoring marks etc. Keep the disc clean and dry at all times for the brakes to work at peak efficiency. If the Disc is scored heavily, replace the disc.
  • Page 186 BRAKE DR BRAKE DR ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y BRAKE DR BRAKE DR BRAKE DRUM UM ASSEMBL ASSEMBL Remove the cush drives (4 Nos.) from the hub. Remove the drive chain from the sprocket. Disconnect the brake operating rod from the cam lever.
  • Page 187 Clean the brake shoe & cush drive with Remove sprocket drum assy. from the dry cloth / cloth wet with solvent. swing arm along with brake shoes and cover plate carefully. Disconnect chain if INSPECTION not removed earlier. Visually check all parts for breaks, cracks, dents, scoring, glazing or any other damage.
  • Page 188 SECTION SECTION SECTION SECTION SECTION EIGHT 08 EIGHT 08 EIGHT 08 EIGHT 08 EIGHT 08 SUSPENSION & STEERING SUSPENSION & STEERING SUSPENSION & STEERING SUSPENSION & STEERING SUSPENSION & STEERING...
  • Page 189 ONT FORK ONT FORK WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR B ULLET ULLET FRONT FORK ONT FORK ONT FORK WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR BULLET ULLET ULLET ELECTRA EFI (E5 & G5) ELECTRA EFI (E5 &...
  • Page 190 FRONT FORK ONT FORK ONT FORK ONT FORK WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR B WORKING PRINCIPLE - FOR BULLET EFI ULLET EFI ULLET EFI ULLET EFI ONT FORK WORKING PRINCIPLE - FOR B ULLET EFI CLASSIC (C5) CLASSIC (C5)
  • Page 191 FRONT FORK FRONT FORK FRONT FORK FRONT FORK FRONT FORK Gently tap the fork bottom tube downwards DIS ASSEMBL ASSEMBL ASSEMBLY Y Y Y Y ASSEMBL ASSEMBL and remove the bottom tube. Remove the oil control collar from the Place motorcycle on centre stand. spring stud.
  • Page 192 REMO REMO REMOV V V V V AL OF FORK SEALS AL OF FORK SEALS AL OF FORK SEALS REMO REMO AL OF FORK SEALS AL OF FORK SEALS INSPECTION Loosen the pinch bolt on fork crown bottom. Visually inspect all parts for damages, cracks, bends, wear marks or any other damage.
  • Page 193 Remove the handle bar clamp bolts and Take out ball race from steering stem. nuts and take out handle bar. CLEANING Clean all the parts carefully for inspection. Remove the stem lock nut and washer Rub the bearing race balls in a clean cloth. carefully.
  • Page 194 REASSEMBL REASSEMBL Y OF STEERING Y OF STEERING REASSEMBL REASSEMBL REASSEMBLY OF STEERING Y OF STEERING Y OF STEERING Locate 19 balls each on the ball races - steering stem bottom and frame had tube Using a hollow drift, fix the bottom ball race top.
  • Page 195 REMOVAL AND ASSEMBLY OF REAR Assemble front forks, mudguard & front wheel in reverse order of disassembly. SHOCK ABSORBER Assemble the handle bar and other parts. Remove the top and bottom mounting nuts Adjust the steering stem play correctly & and washers.
  • Page 196: Swing Arm

    RECHARGING OF SHOCK Remove the rear wheel sprocket ABSORBERS assembly (1). Remove the shock absorbers (2). Remove the small screw with “O” Ring. 2 2 2 2 2 1 1 1 1 1 Remove the chain guard. Remove the swing arm cap swing pivot. Inject the special purpose needle into the hole provided in the screw (Puncturing the rubber) and start pumping the air into...
  • Page 197 Using a mandrel, drive out the plastic bush Always use reamer to ream the bush after from either sides of the swing arm and pressing into swing arm tube. remove the steel spacer. Apply grease inside the bush and then insert spacer as shown in Fig.
  • Page 198 CENTER ST CENTER STAND CENTER ST CENTER ST CENTER ST Place a washer and tighten nut. DISASSEMBLY Disconnect the stand return spring two nos. (1) Remove the split pins & washers from the both ends of the centre stand spindle (2). Drive out the centre stand spindle.
  • Page 199 SECTION SECTION SECTION SECTION SECTION NINE 09 NINE 09 NINE 09 NINE 09 NINE 09 ELECTRICALS ELECTRICALS ELECTRICALS ELECTRICALS ELECTRICALS...
  • Page 200 ELECTRICAL SYMBOLS ELECTRICAL SYMBOLS BATTER TTER TTER TTERY Y Y Y Y ELECTRICAL SYMBOLS ELECTRICAL SYMBOLS ELECTRICAL SYMBOLS TTER CONSTRUCTION 01. Alternating current (AC) ... Positive Plate Porous mass of lead 02. Direct current (DC) dioxide (Pbo ) (Positive active material) 03.
  • Page 201 PRECA PRECA UTIONS : UTIONS : PRECA PRECA PRECAUTIONS : UTIONS : UTIONS : CAUTION It is important to ensure that the sulphuric Wear rubber gloves while handling a acid is added into the distilled water and not battery. vice versa. Stir and check the specific gravity Use only constant current battery charger of electrolyte and add sulphuric acid till the of correct charging rate, to charge...
  • Page 202 TEMPERATURE OF ELECTROLYTE : CAUTION : Cool the electrolyte to about 30 deg. C Always connect the positive and negative before filling it in the battery, just below the terminals of battery into the positive and maximum level indicated. negative sockets provided in the constant current battery charger.
  • Page 203 MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE Protect battery from direct sunlight, heat, rain and dust. Check the electrolyte level and top up, if Keep exhaust seal cap in place to avoid necessary to the ‘MAX’ mark with distilled deterioration of dry charge properties water every week.
  • Page 204 Carbon deposits on the spark plug Specific Gravity establishes a ‘shunt’ between center and Fully charged Requires Recharging earth electrodes, that prevents good sparking and causes misfiring. Clean the 1 .24 1 .15 deposits off periodically, with a spark plug cleaning tool / machine.
  • Page 205 CHECKING PROCEDURE OF ELECTRICAL COMPONENTS CHECKING PROCEDURE OF ELECTRICAL COMPONENTS CHECKING PROCEDURE OF ELECTRICAL COMPONENTS CHECKING PROCEDURE OF ELECTRICAL COMPONENTS CHECKING PROCEDURE OF ELECTRICAL COMPONENTS PULSAR COIL PULSAR COIL PULSAR COIL PULSAR COIL PULSAR COIL Stator coil Pulsar coil SPECIFICATION Ignition coil Resistance mode - Across the wires Suppressor Cap...
  • Page 206 HORN HORN HORN HORN HORN CAUTION : SPECIFICATION Brown or white/red to core no connectivity. SUPPRESSOR CAP - M14 SUPPRESSOR CAP - M14 SUPPRESSOR CAP - M14 SUPPRESSOR CAP - M14 SUPPRESSOR CAP - M14 Continuity Mode - Beep Sound SPECIFICATION Resistance Mode - 4.5 to 6 K ohms RELA...
  • Page 207 CAUTION : Never try to repair / tamper IC Flasher. RR UNIT RR UNIT RR UNIT RR UNIT RR UNIT E- ST E- ST TER MO TER MO TER MOT T T T T OR E- ST E- ST E- STAR ARTER MO TER MO CHECKING PROCEDURE...
  • Page 208 ELECTRICAL PARTS ELECTRICAL PARTS ELECTRICAL PARTS ELECTRICAL PARTS ELECTRICAL PARTS If the battery is weak (below 10 V), start INSPECTION INSPECTION INSPECTION INSPECTION INSPECTION with the kick starter and do not try to start with self starter. CLUTCH SWITCH Always maintain correct Engine oil level. Check the continuity for the following wires Check for Engine backfire, if it exist &...
  • Page 209 09-10...
  • Page 210 09-11...
  • Page 211 09-12...
  • Page 212 TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING PROBLEMS PROBLEM CAUSES 1. E-start motor not working. 1. Fuse blown. 2. If the battery voltage increases with RPM increase, replace RR Unit. 3. Faulty relay starter. 4. Starter motor cables loose connection. 5.
  • Page 213 SECTION SECTION SECTION SECTION SECTION TEN 10 TEN 10 TEN 10 TEN 10 TEN 10 TROUBLE SHOO TROUBLE SHOO TING TROUBLE SHOO TING TING TING TROUBLE SHOO TROUBLE SHOO TING...
  • Page 214 TROUBLE SHOO OUBLE SHOO OUBLE SHOO OUBLE SHOOTING OUBLE SHOO TING TING TING TING This section discusses trouble shooting on various performance problems. This following check list can be helpful in locating most of the operating troubles. Observation Causes Remedies Complaint : Engine fails to start Ignition switch in ‘OFF’...
  • Page 215 Observation Causes Remedies Loose spark plug Tighten spark plug Loose cylinder head nuts Tighten cylinder head nuts Blown cylinder head gasket Change cylinder head gasket Auto Decompressor mechanism stuck in Ensure flyweight in exhaust cam open position gear assembly in free to operate. Valves Leaking due to poor seating/burnt Check &...
  • Page 216 Observation Causes Remedies Fuel is stale due to vehicle being in storage Clean petrol tank and carburetor for a long period and fill the tank with fresh petrol Fuel adulterated Refill with good fuel Fuel Related No fuel in the tank Fill up the tank Fuel pump pressure low Check and correct...
  • Page 217 Observation Causes Remedies Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Electricals Related Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead.
  • Page 218 Observation Causes Remedies Wrong grade/recycled lube oil Replace it with right grade oil Damaged valve stem seal Replace the seal Worn out / scored valve guide / valve stem Check and Replace Vertically aligned piston ring Properly stagger the piston end gaps rings Smoke through exhaust Excessive piston ring end gap...
  • Page 219 Observation Causes Remedies Burrs in splined position of the shaft Check and Replace Improper position of the return spring. Check and Replace Complaint : Brakes Poor Improperly adjusted brakes Check & Correct Front brake Disc Warped/Scored Check & Correct Brake linings worn / Uneven wear Check &...

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