Royal Enfield Bullet 500CC Dokumentacja

Bullet Classic EFI (C5)Bullet Electra EFI (E5)Bullet EFI (G5)

02-3TOTAL VOLUME :It is the sum of the swept voume (Displacement volume) and Clearance volume.Total Volume = Swept volume + Clerance volume.COMPRESSIO

05-18 Remove the actuating pin in the Exhaustcam. Remove the 4 allen screws to remove Oilpump assy. Remove the woodruff key.CAUTION : Ensur

05-19 Remove rocker shaft return spring pivot pinwith “O” ring by using special No. ST25123-4 Extractor for 5 speed gear boxpivot pin as shown in Fig

05-20 Remove FD Sprocket Pull out Sleeve gear Spacer by usingmonkey / gas plier as shown in Fig. Remove 4 Nos. Kicker Cover screws.(only for Bullet

05-21DISMANTLING COVER LH SUBASSEMBLY : Remove clutch operating shaft assy fromclutch cover. Remove lock pin and spring from clutchoperating shaft.

05-22 Remove gear lever shaft bush and oil seal.COMPONENTS DISMANTLINGCOMPONENTS DISMANTLINGCOMPONENTS DISMANTLINGCOMPONENTS DISMANTLINGCOMPONENTS DI

05-23 Remove Duplex chain along with Spragclutch and Clutch assembly. Remove Engine sprocket and sprag clutchgear assembly. Fix Special tool No. ST

05-24 Remove Spring retainer plate & 6 Springs. Remove clutch drum sprocket with bigwasher. Remove special distance washer spragclutch on Crank

05-25 Remove Auto chain tensioner body assy.by removing the 2 Nos. allen screws. Remove double gear shaft and double gearstarter drive. Remove the

05-26 Remove centre stand & footrest supports. Remove Mudguard mounting clip & RearEngine Mounting Bracket. Remove the front and rear engi

05-27 Pull out the crank shaft from the crankcaseRH. Remove special thrust washer (lay shaft )from Crank case LH & 2 Nos. Dowel pins. Remove cl

02-4IHP :IHP stands for Indicated Horse Power. IndicatedHorse Power is the power actually developedinside the engine cylinder by combustion process.It

05-28 Remove spacer, circlip, crank shaft bearing6305 from crankcase LH. Remove last circlip from crankcase LH. Remove crank shaft needle rolle

05-29 Remove the Tappet cover. Remove the Allen screw, and the bracket -join - hydraulic tappets. Gently pull out the 2 needle roller pinsholding t

05-30 Pull out cam plate pivot pin with “O” ringby using special tool No. ST 25153-4Extractor shown below. Remove LS 1st gear and thrust washerfrom

05-31 Remove circlip from the selector shaft ifrequired. Remove centre selector fork from theselector shaft and then LH selector fork.LALALALALAYYYY

05-32 Layshaft Remove 2nd gear and thrust washer.MAIN SHAFT SUB ASSEMBLYDISMANTLING OF MAINSHAFT SUBASSEMBLY Remove the main shaft 3rd gear. Remov

05-33 Main shaft Remove circlip & 1st. thrust washer. Remove 4th gear and 2nd thrust washer.REMOREMOREMOREMOREMOVVVVVAL OF SLEEVEAL OF SLEEVEAL

05-34 Pull out kick starter sub assy. as shown inFig.REMOVAL OF KICK STARTER SUBASSEMBLY Remove circlip & thrust washer. Remove the thrust wash

05-35I. BEARINGSI. BEARINGSI. BEARINGSI. BEARINGSI. BEARINGSVITAL PARTSII. GEARS / SPROCKETSII. GEARS / SPROCKETSII. GEARS / SPROCKETSII. GEARS / SPRO

05-36UNIDIRECTIONAL FITTINGS LIST Deep groove ball bearing 6007-RSH/C3 inCrankcase RH- Rubber sealed facing FDsprocket side. Gear rocker shaft bot

05-37ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLY OF ENGINEY OF ENGINEY OF ENGINEY OF ENGINEY OF ENGINEBEARINGSBEARINGSBEARINGSBEARINGSBEARINGSCRANKCASE LH A

02-5IGNITION TIMING :Ignition timing is the timing at which sparkcommences so that the spark from the sparkplug can ignite the mixture in the combusio

05-38CRANKCASE RH Assemble Needle bearing for lay shaft. Assemble NU 305 big roller bearing afterbearing spacer in LH Crank case forcrankshaf

05-39 Assemble closed end needle bearinginside sleeve Gear. Assemble open end needle bearing. Checkbearing seating position and for freerotation.

05-40 Fit bracket lock clip to hold needle roller pinof hydraulic valve lifter and tighten with allenscrew (Torque 1 KG-M). Assemble cleaned suctio

05-41 Assemble the Kick pinion gear over kickpawl mechanism. Lock the circlip over kick sub assy.NOTE :Ensure free rotation of kick pinion gearwhile

05-42 Insert spring locking bolt with washer intokick spring eyelet and rotate clockwise tolock Kick starter return spring on the Crankcase and tigh

05-43 Assemble lower pivot bearing 2 allen bolts(Torque 0.6 KG-M).NOTE :It is recommended to tighten the upperpivot bearing first and then the bot

05-44ASSEMBLING OF MAINSHAFT SUBASSEMBLY Smear oil and assemble the 1st thrustwasher and then the 4th gear on the mainshaft. Assemble 2nd thrust wa

05-45 Assemble circlip on the selector shaft. Assemble RH selector fork as shown inFig. Assemble LH selector fork on the selectorshaft and then ins

05-46 Assemble the thrust washer, LS2nd gear& High gear with Lay shaft mounted on theCrank case RH as shown in Fig. Hold the cam plate and gear

05-47 Check Crank shaft big end bearing axialplay is within service limit. Check Crank shaft run out is within servicelimit. Assemble the crank sh

02-6TECHNICAL SPECIFICATECHNICAL SPECIFICATECHNICAL SPECIFICATECHNICAL SPECIFICATECHNICAL SPECIFICATIONSTIONSTIONSTIONSTIONSA. ENGINE AND ENGINE SYSTE

05-48 Insert the jack shaft from the crankcaseLH inside & fix the woodruf key. Assemble the crankcase LH over RHCrank case by tapping gently.Si

05-49 Ensure the woodruf key is located correctlyon the jack shaft and fix the circlip.NOTE :Ensure step face of jack shaft gearshould face inside (T

05-50 Fix the dowels in the crankcase andcarefully fix the motor with housing starterdrive. Apply LOCKTITE 5699 RTV siliconliquid gasket on the joi

05-51 Ensure the distance between sprag clutchgear end face and engine sprocket end faceshould be maintained between 0.2 to 0.5mm as indicated

05-52 Assemble collar on main shaft (distancecollar on Crankcase LH).ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLY OF CLY OF CLY OF CLY OF CLY OF CLUTUTUTUTUT

05-53 Use Special tool No. ST - 25594-4 Clutchspring compressing tool to compress theclutch springs over spring holder andtighten with 2 long bolts.

05-54 Fix the washer and nyloc hex nut 24 mmover clutch assembly and tighten. Use Torque wrench to tighten the nyloc nuton Clutch (Torque 4.2 KG-M).

05-55 Assemble Clutch operating shaft oil seal. Assemble clutch operating shaft assemblyon cover LH. Assemble spring for clutch operating shaftand

05-56 Assemble clutch cable on Crank casecover LH and fix to clevis. Assemble Sleeve gear Spacer over sleeveas shown in Fig. Assemble FD Sprocket

05-57 Assemble oil pump on Crank case RH andtighten with 4 allen screws (Torque 0.35 to0.6 KG-M).CAUTION :Ensure "O" ring is located on th

02-7C. CHASSISBULLET ELECTRA EFI (E5) BULLET CLASSIC EFIBULLET EFI (G5) (C5)1. Frame Tubular2. Front Suspension Telescopic, hydraulic damping, Stroke

05-58 Locate the exhaust cam on the spindle andensure the 2 punch marks on the camaligns with the punch mark on the timingshaft gear. Locate the inl

05-59 Fix Cam steady plate and check for axialplay of Cam Gears to avoid noise problem. Assemble the dowels and allen screws on Camsteady plate and

05-60 Assemble Breather bolt and washer(Torque 2.0 KG-M). Assemble Ignition Timing inspection boltwith copper washer (if not assembledearlier) Torqu

05-61 Fix cover RH and tighten with 11 allenscrews (Torque 1 KG-M). Assemble cover RH carefully by aligningkickshaft and dowels. Assemble the “O” r

05-62 Fix Cylinder barrel bottom Gasket. Remove piston rings from piston.PISTPISTPISTPISTPISTON SUB ON SUB ON SUB ON SUB ON SUB ASSEMBLASSEMBLASSEMB

05-63 Check the piston pin for wear. Measureoutside dia of piston pin at 3 points.ASSEMBLY Locate the oil ring expander into the oil ringgroove. Sl

05-64CYLINDER BARRELCYLINDER BARRELCYLINDER BARRELCYLINDER BARRELCYLINDER BARRELCLEANING Scrap the carbon deposit from the top edgeof the bore. Clea

05-65 Check the Cylinder head face for warpageon surface plate as shown in Fig. Check the valve guide for wear with smallbore gauge and valve stem O

05-66 Make pencil marks on the seating area ofvalve head as shown in Fig. Assemble valves into the valve seat. Using a suction valve grinder rotate

05-67VALVE SEAT INSPECTION : Check and ensure proper seating withpencil marks as explained above. Assemble the valve assembly in position.Keep the C

02-8BULLET ELECTRA EFI (E5) BULLET CLASSIC EFIBULLET EFI (G5) (C5)7. Tail / Brake Lamp 12V 5 / 21W8. Speedometer lamp 12V, 3.4W9. Hi beam indicator 12

05-68 Similarly follow the same process toassemble the exhaust Valve as shown inFig.VALVE LEAKAGE TEST Pour solvent into exhaust port and checkfor

05-69 Assemble inlet and exhaust pushrods. Assemble the inlet and exhaust rockerbearing with dowel and tighten allenscrews Assemble the Inlet &

05-70 Assemble throttle body and connect thethrottle cables. Tighten the front engine mounting stud nutsto the specified torque. Fill recommended t

ENGINE MANGEMENTENGINE MANGEMENTENGINE MANGEMENTENGINE MANGEMENTENGINE MANGEMENTSYSTEMSYSTEMSYSTEMSYSTEMSYSTEMSECTIONSECTIONSECTIONSECTIONSECTIONSIX 0

06-1ENGINE MANENGINE MANENGINE MANENGINE MANENGINE MANAAAAAGEMENT SYGEMENT SYGEMENT SYGEMENT SYGEMENT SYSTEMSTEMSTEMSTEMSTEMThe Bullet Electra EFI (E5

06-2COMPONENTS DESCRIPTIONCOMPONENTS DESCRIPTIONCOMPONENTS DESCRIPTIONCOMPONENTS DESCRIPTIONCOMPONENTS DESCRIPTIONELECTRONIC CONTROL UNIT (ECU)THROTTL

06-3FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSELECTRONIC CONTROL UNIT (ECU)Lo

06-4FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUEL INJECTORSpecification:Oper

06-5FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUEL PUMP MODULEAssembled on th

06-6FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSTHROTTLE BODY MODULEAssembled b

02-9IDENTIFICAIDENTIFICAIDENTIFICAIDENTIFICAIDENTIFICATION OF CHASSIS NOTION OF CHASSIS NOTION OF CHASSIS NOTION OF CHASSIS NOTION OF CHASSIS NO.,.,.,

06-7Throttle Position Sensor (TPS):TPS is used to monitor the position of the throttle and is located on the butterfly spindle so that it candirectly

06-8FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSENGINE TEMPERATURE SENSORAssemb

06-9FUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSFUNCTIONS OF COMPONENTSLAMBDA (HEGO O2) SENSORAssemble

06-10There are three levels of identifying a malfunction in the ECU or the sensors.Level 1 VisualThis is indicated by the lamp in the MIL glowing cont

06-11Level 3 DOLThis is done by connecting a DOL tool to the connector near the ECU. This will accuratelydetermine the defective sensor and show the d

06-12INSTRUCTIONS (DO’S & DON’TS):1) DO NOT remove any of the sensor connections / couplers / Battery connections whenthe Ignition switch is ON OR

06-13TROUBLE SHOOTINGS No Symptom Possible Cause RemedyEngine stop switch is in OFF Switch engine stop switch ONposition Side stand is ON. Retract sid

06-14Spark plug Fouled Replace spark plugSpark plug cap shorting Replace spark plug capIgnition coil wire loose connection Check for proper wire conne

TTTTTORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICATIONS -TIONS -TIONS -TIONS -TIONS -CHASSISCHASSISCHASSISCHASSISCHASSIS

07-1TORTORTORTORTORQQQQQUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICATION - CHASSISTION - CHASSISTION - CHASSISTION - CHASSISTION -

02-10ST 25128-2Magneto Puller for TCIChain case outer puller (TCI)Application : Removal of magneto assemblyApplication : To compress clutch springs wh

07-2TORTORTORTORTORQQQQQUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICATION - CHASSISTION - CHASSISTION - CHASSISTION - CHASSISTION -

07-3FRFRFRFRFRONT ONT ONT ONT ONT WHEEL REMOWHEEL REMOWHEEL REMOWHEEL REMOWHEEL REMOVVVVVALALALALAL✰ Place the vehicle on its center stand.✰ Place a s

07-4✰ Locate the bush on the left side of the wheel(Disc brake side)✰ Remove the wedge between the brake padsand position the wheel between the forkle

07-53 Remove the Master Cylinder top cover,diaphragm plate & diaphragm.3 Remove the protective boot from thebleeder nipple on the calliper assembl

07-63 Reassemble the calliper and refit the banjobolts after draining out the oilBLEEDING PROCEDUREBLEEDING PROCEDUREBLEEDING PROCEDUREBLEEDING PROCE

07-73 Loosen the bleeder screw by ½ turn toallow air bubbles in the brake system toescape out.3 Check the fluid level and top up to “MAX”level and ref

07-83 When a slight pressure “build up” is felt onthe lever, depress and hold. DO NOTRELEASE THE LEVER. The air in thehydraulic system will be expell

07-93 Remove the Rear view mirror RH.3 Disconnect the Front brake switch wire andremove the switch from the mastercylinder.3 Disconnect the Banjo bolt

07-10INSPECTION3 Check both the rubber seals on the plungerfor wear, cracked edges or any otherdamage. Replace seals whenever theplunger is removed3

07-113 Assemble the rubber Boot.CAUTION :Do not use tools with sharp ends.3 Apply Silicon grease on the Lever pivothole and on the Piston surface.3 Fi

02-11LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL TTTTTOOLS OOLS OOLS OOLS OOLS AND ITS AND ITS AND ITS AND ITS AND

07-123 Position the brake hose on the mastercylinder such that it is pointing downwardscorrectly and tighten with the banjo bolt.Replace the banjo bol

07-133 Remove pin bolt.3 Remove the brake pads from the caliperassembly.3 Remove mounting bracket from the Caliperassembly.3 Remove the brake pad tens

07-14CAUTION :Do not use high pressure air or any pliers orsharp objects to remove the pistons as theirworking surface can get damaged.Ensure the pist

07-153 Coat the caliper cylinders and Pistons withclean brake fluid and install the Pistons intothe caliper body with the dished end facinginwards.3 I

07-163 First install the brake pad at the piston sideand then install the other brake pad3 Apply Silicon grease on the Pin OD andthen assemble the Pin

07-17WHEEL DISC INSPECTIONWHEEL DISC INSPECTIONWHEEL DISC INSPECTIONWHEEL DISC INSPECTIONWHEEL DISC INSPECTIONCheck the wheel disc periodically for an

07-183 Remove the cush drives (4 Nos.) from thehub.CAUTION :The cush drives are locked to the hub withrubber lugs. Pull out the cush rubbersgently to

07-193 Remove sprocket drum assy. from theswing arm along with brake shoes andcover plate carefully. Disconnect chain ifnot removed earlier.3 Take out

SUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERINGSECTIONSECTIONSECTIONSECT

08-1FRFRFRFRFRONT FORK ONT FORK ONT FORK ONT FORK ONT FORK WORKING PRINCIPLE - FOR BWORKING PRINCIPLE - FOR BWORKING PRINCIPLE - FOR BWORKING PRINCIPL

02-12LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL TTTTTOOLS OOLS OOLS OOLS OOLS AND ITS AND ITS AND ITS AND ITS AND

08-2FRFRFRFRFRONT FORK ONT FORK ONT FORK ONT FORK ONT FORK WORKING PRINCIPLE - FOR BWORKING PRINCIPLE - FOR BWORKING PRINCIPLE - FOR BWORKING PRINCIPL

08-3FRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKDIS DIS DIS DIS DIS ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLYYYYY Place motorcycle on centre stand.

08-4REMOREMOREMOREMOREMOVVVVVAL OF FORK SEALSAL OF FORK SEALSAL OF FORK SEALSAL OF FORK SEALSAL OF FORK SEALS Loosen the pinch bolt on fork crown bot

08-5 Remove the handle bar clamp bolts andnuts and take out handle bar. Remove the stem lock nut and washercarefully. Tap the steering stem downwar

08-6REASSEMBLREASSEMBLREASSEMBLREASSEMBLREASSEMBLY OF STEERINGY OF STEERINGY OF STEERINGY OF STEERINGY OF STEERING Using a hollow drift, fix the bott

08-7GAS FILLED SHOCKGAS FILLED SHOCKGAS FILLED SHOCKGAS FILLED SHOCKGAS FILLED SHOCKABSORBERABSORBERABSORBERABSORBERABSORBERWORKING PRINCIPLE The pre

08-8RECHARGING OF SHOCKABSORBERS Remove the small screw with “O” Ring. Inject the special purpose needle into thehole provided in the screw (Punctur

08-9 Using a mandrel, drive out the plastic bushfrom either sides of the swing arm andremove the steel spacer.CAUTION :Do not remove plastic bush, un

08-10CENTER STCENTER STCENTER STCENTER STCENTER STANDANDANDANDANDDISASSEMBLY Disconnect the stand return spring twonos. (1) Remove the split pins &a

ELECTRICALSELECTRICALSELECTRICALSELECTRICALSELECTRICALSSECTIONSECTIONSECTIONSECTIONSECTIONNINE 09NINE 09NINE 09NINE 09NINE 09

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTIONSECTIONSECTIONSECTIONSECTIONSECTIONONE 01ONE 01ONE 01ONE 01ONE 01

02-13STFront fork main tube spannerApplication : Loosening and tightening of front fork maintube with fork endLIST OF SPECIAL LIST OF SPECIAL LIST OF

09-1ELECTRICAL SYMBOLSELECTRICAL SYMBOLSELECTRICAL SYMBOLSELECTRICAL SYMBOLSELECTRICAL SYMBOLS01. Alternating current (AC) ...02. Direct current (DC)

09-2PRECAPRECAPRECAPRECAPRECAUTIONS :UTIONS :UTIONS :UTIONS :UTIONS :3 Wear rubber gloves while handling abattery.3 Use only constant current battery

09-3CAUTION :Always connect the positive and negativeterminals of battery into the positive andnegative sockets provided in the constantcurrent batter

09-4MAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE3 Check the electrolyte level and top up, ifnecessary to the ‘MAX’ mark with distilledwater

09-53 Carbon deposits on the spark plugestablishes a ‘shunt’ between center andearth electrodes, that prevents goodsparking and causes misfiring. Clea

09-63 Stator coil3 Pulsar coil3 Ignition coil3 Suppressor Cap3 Battery3 Horn3 Relay Starter3 Starter motor3 IC Flasher3 RR UnitMEASURING INSTRUMENT3

09-7CAUTION : Brown or white/red to core no connectivity.SUPPRESSOR CAP - M14SUPPRESSOR CAP - M14SUPPRESSOR CAP - M14SUPPRESSOR CAP - M14SUPPRESSOR C

09-8E- STE- STE- STE- STE- STARARARARARTER MOTER MOTER MOTER MOTER MOTTTTTOROROROROR3SPECIFICATIONResistance 0.3 to 0.5 ohms.3CHECKING PROCEDURESet th

09-9ELECTRICAL PARTSELECTRICAL PARTSELECTRICAL PARTSELECTRICAL PARTSELECTRICAL PARTSINSPECTIONINSPECTIONINSPECTIONINSPECTIONINSPECTIONSTARTER SWITCHCh

09-10

02-14ST 25113-4Mandrel for oil sealApplication : Fitment of oil seal in front fork bottom tubeLIST OF SPECIAL LIST OF SPECIAL LIST OF SPECIAL LIST OF

09-11

09-12

09-13TROUBLE SHOOTINGTROUBLE SHOOTINGTROUBLE SHOOTINGTROUBLE SHOOTINGTROUBLE SHOOTINGPROBLEMS PROBLEM CAUSES1. E-start motor not working. 1. Fuse blow

TROUBLE SHOOTROUBLE SHOOTROUBLE SHOOTROUBLE SHOOTROUBLE SHOOTINGTINGTINGTINGTINGSECTIONSECTIONSECTIONSECTIONSECTIONTEN 10TEN 10TEN 10TEN 10TEN 10

10-1TRTRTRTRTROUBLE SHOOOUBLE SHOOOUBLE SHOOOUBLE SHOOOUBLE SHOOTINGTINGTINGTINGTINGThis section discusses trouble shooting on various performance pro

10-2Loose spark plug Tighten spark plugLoose cylinder head nuts Tighten cylinder head nutsBlown cylinder head gasket Change cylinder head gasketAuto D

10-3Observation Causes RemediesFuel is stale due to vehicle being in storage Clean petrol tank and carburetorfor a long period and fill the tank with

10-4Observation Causes RemediesIncorrect Electrode gap Adjust the gapSpark plug electrode dirty / fouled Clean park plug & Reset gap.Wrong specifi

10-5Observation Causes RemediesWrong grade/recycled lube oil Replace it with right grade oilDamaged valve stem seal Replace the sealWorn out / scored

10-6Observation Causes RemediesBurrs in splined position of the shaft Check and ReplaceImproper position of the return spring. Check and ReplaceCompla

02-15UNDER TANK AND SEAT TOP VIEWUNDER TANK LH VIEWUNDER TANK RH VIEWALL CONTROL CABLES & WIRING HARNESS ROUTINGCONTROL CABLES AND WIRING HARNESS

2005 Eicher Motors Ltd. (Royal Enfield Motors Unit),Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019, India.Tel : 91 44 4204 3300. Fax : +91-

02-16GENERAL GENERAL GENERAL GENERAL GENERAL VEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMATIONTIONTIONTIONTIONHARNESS RO

02-17GENERAL GENERAL GENERAL GENERAL GENERAL VEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMATIONTIONTIONTIONTIONFUSE CARRI

02-18GENERAL GENERAL GENERAL GENERAL GENERAL VEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMAVEHICLE INFORMATIONTIONTIONTIONTIONTAIL LAMP

SERVICE DSERVICE DSERVICE DSERVICE DSERVICE DAAAAATTTTTAAAAASECTIONSECTIONSECTIONSECTIONSECTIONTHREE 03THREE 03THREE 03THREE 03THREE 03

03-1SERSERSERSERSERVICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS (

03-2New Min.New Max.Service LimitPiston ring end gap : compressionPiston Pin diameter19.99219.99719.982From top 1st 2ndNew Min. 0.20 0.35New Max. 0.35

03-3New Min.New Max.Service LimitConnecting rod bend0.000.050.08New Min.New Max.Service LimitValve stem OD (Inlet)6.9656.9806.955New Min.New Max.Servi

01-1PREFPREFPREFPREFPREFAAAAACECECECECE Part No. 597451 / Qty. 500 / May ‘09We are pleased to release this workshop manual for the new generation

03-4New Min.New Max.Service LimitValve to guide (Exhaust) Clearance0.040.071.00New Min.New Max.Service LimitHydraulic Tappet OD21.38721.40521.380New M

03-5Main shaft Outer diameterLocation A BNew Min. 19.99 23.93New Max. 20.00 23.95Service Limit 19.97 23.90BANew Min.New Max.Service Limit9.969.989.94S

03-6New Min.New Max.Service LimitLay shaft 1st gear inner diameter18.0318.0618.09New Min.New Max.Service LimitPivot cam plate outside diameter12.9813.

03-7New Min.New Max.Service LimitClutch steel plate : Distortion0.000.050.10New Min.New Max.Service LimitThrottle cable free play-1 mm2 mmNew Min.New

03-8New Min.New Max.Service LimitBrake drum rear : Internal dia.152.40152.50153.50New Min.New Max.Service LimitSprocketGOODREPLACESharp, bend broken t

03-9New Min.New Max.Service LimitCaliper Piston Outer Diameter--25.31mmODNew Min.New Max.Service LimitMain tube - run out0.00-0.04New Min.New Max.Ser

03-10New Min.New Max.Service LimitTyre tread : Depth--1.00 mmNew Min.New Max.Service LimitSpark Plug Gap0.70.8-

03-11The schedule provided herein is based upon average riding conditions and indicates the mileage at which regularinspections, adjustments, replacem

03-12AIR FILTER CLEANINGBULLET ELECTRA EFI (E5/G5) Remove the 2 air filter lid mounting screwsand take out air filter lidSPARK PLUG CLEANING Disconn

03-13 After the oil drains out, remove vehicle fromcentre stand and tilt the vehicle to both LHand RH sides 3 to 4 times to drain outmaximum oil. Q

01-2FOREWFOREWFOREWFOREWFOREWORDORDORDORDORDPREPARATION FOR SERVICEGood preparation is very important for carrying out correct service job. The motorc

03-14RE ASSEMBLY Soak the new oil filter in oil for 15 minutes. Refil the oil filter and other parts in the reverseorder of disassembly. Start Engi

03-15 The tightening torque for M10 lock nut is2 KG-M. This must be ensured. Over size Cam Spindle (For Spares)570040 : 0.1 mm Over size Spindle5700

03-16BRAKE CAM GREASING(EVERY 6,000 KMS) Remove the brake cover plate. Clean the brake cam and apply grease. Refit the cover plate. Rotate the whe

03-17CAUTION -Adjust both left and right shock absorbersto the same notch.FRONT FORKA. OIL LEVEL CHECK (EVERY 6000 KMS) Take out front for

03-18 Tighten stem lock nut as shown picture ‘B’ Check play. Steering to be free with out any play. Tighten all the screws in reverse order.STEERI

03-19PRIMARY CHAIN TENSION ADJUSTMENT This vehicle is fitted with Auto chaintensioner. Hence there is no need forperiodic manual adjustment. Screw i

03-20 Specific Gravity - Min 1.22 & Max 1.24 If less, recharge the battery. If required, top up with distilled waterTERMINAL CLEANING : Clean

03-21 Remove the piston rings carefully. Forcleaning the groove in the piston, a pieceof broken piston ring thrust into a woodenhandle and filed to a

03-22VALVE SEAT REFACING Valve Seat cutters, a grinder or equivalentvalve seat refacing equipment arerecommended to correct worn valve seat. If the

03-23NOTE :To avoid damage to the seating face, turnthe valve slowly while inserting. (For further details Ref. page No.05-55) After cutting the seat

01-3HOHOHOHOHOW W W W W TTTTTO USE O USE O USE O USE O USE YYYYYOUROUROUROUROURSERSERSERSERSERVICE MANUVICE MANUVICE MANUVICE MANUVICE MANUALALALALALP

03-24STEP-A Start and warmup the engine to normalrunning temperature. Remove the spark plug & connectcompression gauge.a) Remove spark plug

ENGINEENGINEENGINEENGINEENGINESECTIONSECTIONSECTIONSECTIONSECTIONFOUR 04FOUR 04FOUR 04FOUR 04FOUR 04

04-1LUBRICALUBRICALUBRICALUBRICALUBRICATION SYTION SYTION SYTION SYTION SYSTEMSTEMSTEMSTEMSTEM

04-2LUBRICALUBRICALUBRICALUBRICALUBRICATION SYTION SYTION SYTION SYTION SYSTEMSTEMSTEMSTEMSTEMLUBRICATION SYSTEM :Oil from the oil tank is circulated

04-3HYDRAHYDRAHYDRAHYDRAHYDRAULIC ULIC ULIC ULIC ULIC TTTTTAPPETS (ROLLER HYDRAAPPETS (ROLLER HYDRAAPPETS (ROLLER HYDRAAPPETS (ROLLER HYDRAAPPETS (ROL

04-4WORKING PRINCIPLE :Oil enters the hydraulic tappets through a feedhole in the body and flows into the plunger throughthe plunger feed hole, filli

04-5AUTAUTAUTAUTAUTO DECOMPRESSORO DECOMPRESSORO DECOMPRESSORO DECOMPRESSORO DECOMPRESSORWORKING PRINCIPLEThe auto decompressor is assembled in theexh

04-6ELECTRIC STELECTRIC STELECTRIC STELECTRIC STELECTRIC STARARARARARTER SYTER SYTER SYTER SYTER SYSTEM & SPRASTEM & SPRASTEM & SPRASTEM &

04-7AAAAAUTUTUTUTUTO CHAIN O CHAIN O CHAIN O CHAIN O CHAIN TENSIONER TENSIONER TENSIONER TENSIONER TENSIONER ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLYYYYYW

04-8ENGINE BREAENGINE BREAENGINE BREAENGINE BREAENGINE BREATHER SYTHER SYTHER SYTHER SYTHER SYSTEMSTEMSTEMSTEMSTEMWORKING PRINCIPLEThe engine breather

01-4SECTION EIGHT 08SECTION EIGHT 08SECTION EIGHT 08SECTION EIGHT 08SECTION EIGHT 08SUSPENSION ANDSUSPENSION ANDSUSPENSION ANDSUSPENSION ANDSUSPENSION

04-9CLCLCLCLCLUTUTUTUTUTCH SYCH SYCH SYCH SYCH SYSTEMSTEMSTEMSTEMSTEMThe clutch system has a seven plate construction to achieve increase effective di

04-10INLET MANIFOLD & INLET MANIFOLD & INLET MANIFOLD & INLET MANIFOLD & INLET MANIFOLD & THRTHRTHRTHRTHROOOOOTTLE BODTTLE BODTTLE

04-11Blow Up Charts

04-12CRANK CASE RH - COVER SIDE78791011122122101112 13141516172023181910123456282726252429323334A23536373839404110433130A142Key Nos.A113,14,15,16,17Ke

04-13CRANK CASE RH - COVER SIDEA1 CAM GEAR ASSEMBLY-EXHAUST WITHDECOMPRESSOR ASSYA2 OIL PUMP ASSEMBLY1 TAPPET DOOR BUFFED2 CSK SOCKET HEAD SCREW M5 X

04-14CRANK CASE LH INSIDE VIEW

04-15 KEY No. DESCRIPTION1 CRANK CASE-LH2 CIRCLIP3 BALL BEARING 6305 (25 X 62 X 17)4 BEARING SPACER5 ROLLER BEARING NU305 (25 X 62

04-16CRANK CASE RH - INSIDE VIEW123467859103029272628252423222119181716151411121320

04-17CRANK CASE RH - INSIDE VIEW1 CIRCLIP2 DEEP GROOVE BALL BEARING – SLEEVEGEAR3 NEEDLE BEARING4 SLEEVE GEAR5 NEEDLE BEARING6 HEX. SOCKET HEAD CAP S

04-18ENGINE COVER - RH2749487

GENERALGENERALGENERALGENERALGENERALSECTIONSECTIONSECTIONSECTIONSECTIONTWO 02TWO 02TWO 02TWO 02TWO 02

04-19ENGINE COVER - RHKEY No. DESCRIPTION1 UCE, RH COVER SUB ASSEMPLY2 COVER, RH3PLUG4 RESTRICTOR (LEE PLUG)5 SEALING WASHER 12X15.56 O

04-20CRANK CASE LH - COVER SIDE

04-21CRANK CASE LH - COVER SIDEKEY No. DESCRIPTION1 CRANK CASE-LH2 DOWEL (6MM)3 COLLAR, MAINSHAFT4 GEAR, - JACK SHAFT5 KEY - JACK SHAFT

04-22ENGINE COVER - LH1235467891011121314151617181920

04-23KEY No. DESCRIPTION1 LH COVER SUB ASSEMBLY2 COVER, LH3 BUSH4 OIL SEAL 14 X 20 X 35 GASKET, COVER LH6 OIL SEAL INA G 12 X 18 X 57 A

04-24GEAR TRAIN ASSEMBLY

04-25GEAR TRAIN ASSEMBLYKEY No. DESCRIPTIONA1 LAY SHAFT SUB ASSEMBLYA2 MAIN SHAFT SUB ASSEMBLY1 MAIN SHAFT2 MAIN SHAFT 2ND GEAR3 WASHER

04-26GEAR SHIFTINGKICK STARTER(E5 & G5)5

04-27KEY No. DESCRIPTION1 SS ROCKER SHAFT ASSEMBLY,2 PIN PIVOT3 STRIKER, GEAR CHANGE4 SPRING5 SPRING, GEAR CHANGE STRIKER6 SPACER7 PIVO

04-28CYLINDER HEAD, BARREL, PISTON & CRANKSHAFTCRANK SHAFT ASSY.PISTON ASSY.2524272619211716413125283910111415206736383938373839373837353334323029

02-1SALIENT FEASALIENT FEASALIENT FEASALIENT FEASALIENT FEATURES OF TURES OF TURES OF TURES OF TURES OF THE UNIT CONSTRTHE UNIT CONSTRTHE UNIT CONSTRT

04-29 KEY No. DESCRIPTION1 CYLINDER HEAD SUB ASSY(CYLINDER HEAD, VALVE GUIDE, VALVE SEATS)2 CYLINDER HEAD - ONLY MACHINEDHEAD3 VALVE

04-30DAMPER PAD POSITION DETAILSNumber of damper pads per engine = 15570479/b570479/b570482/b570480/b570482/b570482/b570478/b570480/b570482/b570479/bP

TTTTTORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICAORQUE SPECIFICATIONSTIONSTIONSTIONSTIONSENGINE DISMANTLINGENGINE DISMANTLINGENGINE DI

05-1TORTORTORTORTORQQQQQUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICAUE SPECIFICATION - ENGINETION - ENGINETION - ENGINETION - ENGINETION - EN

05-2S.NoPARTNo.DESCRIPTION LOCATIONTORQUE VALUEKg/M.N/M.30 570215 BOLT, PAWL (M6 X 1) GEAR BOX INDEX 1.00 1031 570233 HEX.SOCKET HD.CAP SCREW, M5 X 40

05-3COMPONENTS COMPONENTS COMPONENTS COMPONENTS COMPONENTS THATHATHATHATHAT CAN BET CAN BET CAN BET CAN BET CAN BEREMOREMOREMOREMOREMOVED VED VED VED

05-4SEASEASEASEASEAT REMOT REMOT REMOT REMOT REMOVVVVVAL BAL BAL BAL BAL BULLETULLETULLETULLETULLETELECTRA EFI (E5/G5)ELECTRA EFI (E5/G5)ELECTRA EFI (

05-5 Remove the clutch cable from the clutchlever at handle bar end.REMOREMOREMOREMOREMOVVVVVAL OF AL OF AL OF AL OF AL OF THRTHRTHRTHRTHROOOOOTTLETT

05-6 Remove the rear mounting at the pillionfoot rest end (C5).NOTE :Loosen the rear brake rod adjuster nutso that the brake pedal can bedepressed t

05-7 Remove the battery flap cover Remove the terminal boot & terminal wires .CAUTION :Always remove earth wire terminal first. Remove the fuse

02-2BASIC BASIC BASIC BASIC BASIC TERMINOLTERMINOLTERMINOLTERMINOLTERMINOLOGY OF OGY OF OGY OF OGY OF OGY OF AUTAUTAUTAUTAUTOMOBILESOMOBILESOMOBILESOM

05-8 Lift the motor upwards and pull out of thehousing in the front.REMOREMOREMOREMOREMOVVVVVAL OF E-STAL OF E-STAL OF E-STAL OF E-STAL OF E-STARARAR

05-9 Remove the chain link and the drive chain.REMOREMOREMOREMOREMOVVVVVAL OF SIDE STAL OF SIDE STAL OF SIDE STAL OF SIDE STAL OF SIDE STANDANDANDAND

05-10CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLYYYYY Remove the 4 allen screws along w

05-11 Remove the 6 flanged hex nuts, securingthe cylinder head. Remove the Spark plug Remove inlet and exhaust pushrods Remove the multi layer st

05-12 Remove the Inlet Valve spring retainer, splitcollar and Spring. Gently tap Cylinder barrel and removealong with 2 dowel pins.CYLINDER BARREL

05-13NOTE :Carefully remove the piston rings fromthe piston without deforming. Remove Cylinder barrel bottom Gasket. Use Special tool No. ST - 25592

05-14CAUTION :Tap only at the places shown to avoiddamage to the RH cover Remove Stator assembly by removing 3mounting screws. Remove Pulser coil by

05-15 Remove Breather bolt and washer Remove 6 Nos. allen screws to removebreather chamber cover Remove circlip, oil seal and jet crankshaft Remov

05-16 Remove the 2 oil seals from the Kick Shafthole (Electra EFI - E5/G5 only)COMPONENTS DISMANTLINGCOMPONENTS DISMANTLINGCOMPONENTS DISMANTLINGCOMP

05-17 Remove oil pump plastic gear afterremoving circlip. Observe short boss ofpump drive gear should face outwards. Remove Cam gear inlet. Remove