Royal Enfield ELECTRA Motorcycle Manuals

Manuals and User Guides for Royal Enfield ELECTRA Motorcycle. We have 1 Royal Enfield ELECTRA Motorcycle manual available for free PDF download: Service Manual

Royal Enfield ELECTRA Service Manual (235 pages)

Brand: Royal Enfield | Category: Motorcycle | Size: 55 MB

Preparation for Service
4
Service Bulletins
4
Important Notice
4
Salient Features
13
Easy to Handle and Ride
13
High Performance
13
Stable and Safe Motorcycling
13
Four Stroke Cycle Operation
14
Technical Specification
15
List of Special Tools and Its Application
19
Special Tools and Its Application
20
General Tools
28
Measuring Instruments
30
Lubrication System
35
Oil Flow Chart
35
Preventive Maintenance
37
Running in
39
Recommended Lubricants
39
Specifications
39
Service Data
40
Torque Specification
49
Periodical Maintenance
50
Engine Oil
52
Oil Change
52
Level Check
52
Fitting Procedure
53
Push Rod Adjustment
53
Eccentric Cam Spindle
54
Spark Plug Cleaning
55
Air Filter Cleaning
55
Inspection
55
Throttle Cable Free Play Adjustment
56
CV Carburetor Tuning
56
Float Height Adjustment
56
Decompressor Setting
57
Decarbonising
57
Cylinder Head
57
Exhaust Bend Pipe
57
Primary Chain Tension Adjustment
58
Chemical Method
58
Clutch
58
Oil Level Check
58
Oil Change
58
Gear Box End
59
Clutch Cable Free Play
59
Clutch Operating Mechanism
59
Lever End
59
Gear Box Oil
60
Pedal Play Adjustment
60
Brake Pedal Spindle
60
Rear Brake
60
Battery
61
Rear Shock Absorbers Adjustments
61
Electrolyte Level Checking
61
Terminal Cleaning
61
Rear Chain
62
Specific Gravity Checking
62
Slackness Adjustment
62
Front Fork
63
Disc B Rake Fluid Level Check
63
Steering Play Adjustment
64
Brake Cam Greasing
64
Steering Ball Race Lubrication
65
Wheel Alignment Check
65
Cleaning and Assembly Precautions
66
Engine
69
Removal of Petrol Tank
71
Engine Disassembly
71
Seat Removal
72
De-Compressor Cable Removal
72
Clutch Cable Removal
73
Removal of Throttle Cable
73
Removal of Carburetor
74
Removal of Silencer Along with Exhaust Pipe
74
Removal of E-Start Motor
75
Battery Removal
76
Removal of Chain Case Outer
77
Removal of Rotor Assembly
77
Removal of Chain Adjuster
78
Removal of Clutch Assembly
78
Chain Case Inner Removal
79
Removal of Cylinder Head
80
Barrel Removal
80
Removal of Drive Chain
81
Piston Removal
81
Removal of Side Stand
81
Removal of Rear Brake Switch
82
Gear Box Removal
83
Dismantling Crank Case Assembly
84
Timing Cover
84
Timing Gears
85
Crank Shaft Removal
85
Disassembly
86
Bearings
86
Crank Case Cleaning
86
Tappet Cover
87
Tappet
87
Tappets
88
Cleaning
88
Service Data Chart for Engine
89
Engine Assembly
90
Crank Case Timing Side
90
Crank Shaft
92
Timing Gears
94
Timing Cover
94
Piston Assembly
97
Cylinder Barrel
99
Cylinder Head
99
Crank Shaft Assembly
103
Piston Assembly
105
Cylinder Head Assembly
106
Rocker Cover
107
Valve Timing
108
Tappet Door
109
Rocker Oil Pipe
110
Electric Start
111
Principle of Electric Start
113
Tightening Torque
113
Dismantling Procedure
113
Working Principle
113
Dismantling of Chain Case Front Half
114
Dismantling of Alternator Assembly
115
Dismantling Clutch Assembly
115
Dismantling of Woodruff Key & Tensioner
115
Dismantling Chain Case Back Half
116
Dismantling Clutch Center
116
Dismantling of Chain Case Sub Assembly
116
Assembly Procedure
118
Drive Cover Sub Assembly
118
Sprag Clutch Assembly
118
Sub Assembly of Chain Case Inner
119
Assembly of Chain Case Inner on Engine
120
Assembly of Engine Sprocket & Clutch Drum
121
Assembly of Clutch
121
Assembly of Alternator
122
Assembly of Starter Motor on Vehicle
122
Assembly of Chain Case Front Half
122
Wiring Diagram
123
Starter and Charging Circuit
123
Checking Methods for Electrical Parts
124
Starter Relay
124
Clutch Switch
124
Starter Switch
124
Do's and Don'ts
124
Troubleshooting
125
5 Speed Gearbox
127
Blow up View of 5 Speed Gear Box
129
Gears Operating Positions - 5 Speed
130
Oil Changing Procedure
132
Dismantling of Gear Box Assy. from Engine
132
Level Check
132
Carrier Plate Assy Removal
133
Gear Change Lever Assy Removal
133
Gear Assembly, Removal
134
Lay Shaft Sub Assembly
136
Main Shaft Sub-Assy.
136
Sequence of Assembly
136
Sub Assembly Selector Fork
136
Rocker Shaft Assembly
139
Sub Assembly End Cover
141
Inspection and Service Limits
142
O Rings, Oil Seals, Matting Parts
142
Selector Forks
142
Cam Plates
142
Thrust Washers
143
Circlip
143
Tab Washer
143
Schematic Diagram TCI System
147
TCI System
147
The Advantages of the TCI
148
Contact Circuit
149
Fit and Forget System
149
Safety Features
149
Ignition Circuit Bullet Electra
149
Starter and Charging Circuit - Bullet Electra
150
Complete Circuit
150
Checking Procedure Stator Oil
151
Checking Procedure Pulsar Coil
151
Ignition Coil
151
Relay Starter
152
Starter Motor
152
Specification
152
CV Carburetor
153
Blow up View CV Carburetor
155
Functions of Carburetor
156
Fuel Inlet and Float System
156
Starter System
157
Pilot System
157
Main System
158
Assembling Procedure
159
Tightening Torque Specification
160
Maintenance Tips
160
Service Guidelines
160
Troubleshooting
161
Procedure for Setting Idling Speed and CO%
162
Procedure for Checking CO%
163
PAV on Vehicle Blow up View
163
Working Principle of Secondary Air Valve
164
Front Fork Working Principle
167
Front Fork Disassembly
168
Front Fork Assembly
169
Steering Disassembly
169
Assembly of Steering
171
Gas Filled Shock Absorber
172
Steering Stem Adjustment
172
Removal and Assembly of Rear Shock Absorber
173
Recharging of Shock Absorbers
173
Adjustment of Shock Absorbers
173
Chain Stay
173
Centre Stand
175
Wheels & Brakes
177
Front Wheel Removal
179
Front Wheel Assembly
179
Rear Wheel Removal
180
Brake Drum Assembly
180
Draining the Old Brake Fluid
182
Disc Brake
182
Bleeding Procedure
182
Manual Bleeding
185
Bleeding - Alternate Method
186
Disassembly Master Cylinder
187
Assembly Master Cylinder
190
General Instructions
192
Disc Inspection
192
Service Manual Caliper
193
Dismantling Caliper
193
Caliper Assembly
195
Electricals
199
Electrical Symbols
201
Battery Construction
201
Initial Charge
202
Electrolyte
202
Preparation
202
Temperature of Electrolyte
203
Recharge a Used Battery
203
Soaking Period
203
Charging Procedure
203
Maintenance
204
Indication of Full Charge
204
Specific Gravity
205
Voltage
205
Battery Problems
206
Common Problem Experienced in Field
206
Sulphation
206
Hydration
206
Spark Plug
207
Heat Range
207
Hot Plug
207
Corrective Action
207
Cold Plug
208
Spark Plug Electrode Temperature
208
No Gasket
209
Two Gasket
209
Spark Plug Face Indication
210
Spark Plug Maintenance
211
Checking Procedure
212
Ignition Coil
212
Engine Difficult / Does Not Start
217
Method of Checking Oil Circulation
223
Check for Oil Leakage at Valve Guide
223
White Smoke
223
Low Mileage
224
Engine over Heating
225
Flame at the Carburetor
227
Flame at the Silencer
227
Gear Hand / Not Engaging
228
False Neutral
230

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Royal Enfield ELECTRA Service Manual (235 pages)

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