Royal Enfield Bullet 350cc Service Manual Download

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Summary of Contents for Bullet 350cc

Page 1: ...B U L L E T by Pete Snidal ...

Page 2: ...this manualmay be reproducedin any form without permission unless the reproductionis for the sole use of the purchaser And Rnally a brief word from our solicitor The author accepts N O responsibility expressed or implied for any andlor all damages to persons or property as a result of following any of the instructions laid out in this manual II The EnfieldBULLET MANUAL by Pete SnidalO 2002 ...

Page 3: ......

Page 4: ...on 10I Chapter 8 The Primary Drive Removingthe Clutch I03 Replacingthe Clutch I05 ExplodedView the 350 Clutch 105 Removingthe Alternator Rotor 106 Replacingthe Alternator Rotor I07 The E S Starter Drive System I07 Chapter 9 GearboxWork Exploded View of Gearbox I08 Adjusting The Neutral Finder I09 Removingand ReplacingCountershaft Sprocket 109 RemovingThe Gearbox Covers I I0 Complete Strip I 1 3 Ex...

Page 5: ...ls Wiring Diagram 145 The UK Models Pre ES Wlrlng Diagram 146 Export Electric Start Models Wiring Diagram 146 Connections Colours and Terminals 153 Chapter 12 Performance Performance Mod f catlons I60 Chapter 13 CleanAir Additions The Pulse Air System 1 65 Crankcase Breather Condenser Tank 1 67 APPENDIX EngineTighteningTorques 170 Chassis TighteningTorque 171 Service Limits and Clearances 172 Inch...

Page 6: ...ancouver ever and him for only part of one year there were a few pre unit Bullets models G and 12 and a half dozen of the post 53 swingarm frame unit models like the Indian made 1956 2003 350 500 bullets of today Although I owned a half dozen Bullets in The Day I never did find a decent service manual Most manufacturers of British Motorcycles in the 50 s seemed to assume a high degree of mechanica...

Page 7: ...void trips of hundreds of miles to have a 15 minute procedure done on your motorcycle seems to me unbeatable Hence this manual It is the product of many hundreds of hours of dedicated work on my part havingtaken a lot of my spare time in the last couple of years My bibliography credits must include many sources beginning with the two books mentioned above many years of Bulletwork of all kinds conv...

Page 8: ...entum carries once again into the intake stroke I Piston 6 ConnectingRod 15 16 Flywheels Rodjournal 8 Plain Big EndBush Floating The essence of motorcycle tuning involves ensuring that these 9 Small End wrist pin Bush 17 23 Crankpins operations occur with the correct timing and that the mechanical 19 Crankshaft primary drive sprocket considerations mechanical thermal and volumetric efficiency are ...

Page 9: ...read at the same throttle opening generallyfull open when an engine is tested on a brake or dynamometer the throttle is opened fully and measured counter torque is applied to hold the engine at given rpms in steps and the readings recorded to make the chart O f course in actual general use the motorcyclist seldom if ever uses full throttle but the shape placement and duration of the curves would b...

Page 10: ...ee If the machine has been sittingfor a time it may be that once you ve got it started you will have trouble engaging first gear without some grinding due to the clutch not breakingentirely free on disengagement This can be made easier by breakingthe clutch free before starting by hauling in the clutch lever and givingthe kickstarter a few strokes before attempting to start Actual Starting If the ...

Page 11: ... 3mm of cable travel In some cases less will be required in some a bit more Experiment and find the best settingfor your machine That s all there usually is to kickstarting a big single Done properly it can be done without taking yourself off the seat often to the amazement of the non cognoscenti Flooded Starting Sometimes in cases of difficult starting the machine will flood induct an excess of f...

Page 12: ...es 75 of your stopping you want to use it from the beginning But if you are turning or on soft or slippery ground locking up the front wheel will almost certainly result in a fall So don t use it unless you re upright going straight and the ground offers good traction However very early in your riding career you want always to be thinking Front Brake Never depend on the rear brake to stop you its ...

Page 13: ...iculty in changinggear in this way your gearbox may need adjustment This is dealt with in detail in a later chapter LESSON 3 DOWNSHIFTING Downshifting is similar to upshifting with the difference beingthat rather than the engine rpm decreasingwith engagement of the next gear it will have to increase since a lower gear is beingengaged This means that as the gear is engaged with an upward movement o...

Page 14: ... once the first auto or truck stops behind you Until then have your escape planned and be ready There are few seasoned motorcyclists who don t know of someonewho s been killedthis way Motorcycles are not only invisible to many motorists they seem to render stop lights and stop signs invisible as well Use of the Brakes Finally a word on braking The motorcycle differs from the auto in that different...

Page 15: ...ilding chained to a support post with a very large chain and the building is bugged to silent alarm to my home And I live in avery quiet part of the country crime wise Summary be as careful a s you can It s a real heart breakerto loseyour motorcycle investment in the space of a few minutes TROUBLE SHOOTING STARTING Generally if no success is attained after havinggone through the flooded starting d...

Page 16: ...ot on the first attempt stop take a rest and try again 6 If it doesn t fire after this begin trouble shooting as described below If it does continue to run alongside the machine applyingjust enough throttle to keep it running and usinga hopping movement step up onto the left footpeg with your left foot Then swing your right leg over the seat the motorcycle will by now be moving fast enough to have...

Page 17: ...es and filters if any in the carburetor fuel circuit are common in the Enfields due to internal tank rusting To verify fuel flow you can remove the float bowl drain screw at the very bottom of the carburetor or if none is present the entire float bowl by removing the four upwards facingfasteners Drain the fuel into a clean container such as a tuna can Turn off the fuel tap before draining the floa...

Page 18: ...cate linkage between float and needle valve If there is still no fuel flow close the fuel tap on the tank disconnect the fuel line at the tap and with your drain container there to catch any flow try opening the tap If you have fuel in the tank but no flow it follows that you ll have to remove the tap You can do this by having a funnel or large mouth container of suitable capacity handy and unscre...

Page 19: ...CHAPTER 3 BASIC DAY TO DAY MAINTENANCE LUBRICATION CLEANING AND ADJUSTMENTS 12 The Enfield BULLET MANUAL by Pete Snidal O 2002 ...

Page 20: ...ax and polish such as Turtle WaxTMare very good for paint chrome and aluminum As you clean the motorcycle develop the habit of lookingcarefullyat the fasteners brackets mounting points for mudguard fenders etc Look for cracks loose nuts and bolts and oil seepage It s agood ideato follow up regularly with spanner wrenches checkingthe tightness of your fasteners You may be surprised at how much bett...

Page 21: ...xiting out the exhaust pipe on startup until the scavenge pump can catch up with the oil balance Rocker PreventingWet Sumping Wet sumpingfrom this majorsource maybe prevented by developing the habit of parkingthe machine in Push Rod Tunnel anticipation of the next starting drill with the piston Flywheels positioned at Top Dead Center as described on page 4 under Starting Drill Thus the Big End is ...

Page 22: ...discussion on the royalenfield yahoogroup a number of members have reported following this procedurewith no trouble with oil leaks and improved shifting gearchanging See Chapter 9 on gearboxwork for more information The last placewhich needs regular level checks is the primary case The primary drive chain and clutch both require a proper supply of clean oil to work and last properly There is unfor...

Page 23: ...p of the cylinder head Passingthrough these rocker blocks it runs down the pushrod tubes to the timing chest the inside of the timing cover where it lubricatesthe timinggears and oil pump s worm drive The gears work it up to the upper ones which funnel it into a hole in the back of the timing case back into the oil tank It will be seen that there are a number of places in which the circulatingoil ...

Page 24: ... are multi gradesof similar viscosity Your second oil change should be in the 4 700 mile range 100 miles 160 Km and you should change the filter at that point as well The third at 1000 and after that every 2000 The third filter at the 2000 change and after that every second change You can track the efficacy of filter changes by carefullywashingyour filter in clean washing solvent and lookingin a s...

Page 25: ...on page 162 Return pump oil delivery may be verified by looseningeither of the rocker oilfeed banjo bolts or the feed fitting at the bottom of the line Be careful not to allow the fitting into which the bolt or bottom fitting screws to rotate in the head or crankcase the line can be twisted off if both fittings are allowed to move as one NightmareTime What About Stripped Drain Plugs I sincerely ho...

Page 26: ... inside of the tank case with a finger and ensure that the cavity is completely clean of shavings just one of these in an oil pump can have dis astrous consequences A disadvantage of this alternative is that your new oilplug will not have a pickup screen attached unless you can somehow solder your old screen onto the new plug Once this fix is effected it would be agood ideato disturb the new tight...

Page 27: ... a s detailed above Pay particularattentionto the interface betweenthe cable end nippleswhere they fit into the control levers Wheel Bearings Each of the wheel hubs contains a ball bearingon each side through which the axle runs Periodically the wheels should be removed and the dust seals and bearings pressed out and the bearings packed An ideal intervalfor this task is duringbrake shoe replacemen...

Page 28: ...etely acquainted with the idiosyncrasiesof this rare bird Let s face it India is basically a third world country and their high tech If that it may be called exports such a s the Enfield Bullet are an entirely different kettle of fish than most other motorcycles For these reasons it is wise for the new Bullet owner on taking delivery to ensure that proper pre delivery preparation has been carried ...

Page 29: ...ppears to be plugged the tank must be drained completely siphon or slow drain through tap and the tap assembly removedfor cleaning Fuel tap showing filter screen D Checkthe jar alsofor any signs of water in the fuel thus drained If some exists the tank should be drained and flushed with afew ounces of methyl alcohol and dried before refilling Removethe tap after drainingto get allthe fuel out If t...

Page 30: ...adjustingscrew accessible through the bottom access plate and loosen off the slotted adjustingscrew This is agood time to lubricate the ball set in the inside end of the screw as it doesn tget much lubrication the grease nipple at the top of the gearbox cover serves only to lubricate the bearing points of the bellcrank Removethe screw completely apply a dab of hi temp grease to the end ball Then r...

Page 31: ...il carefullyfor signs of clutchfriction plate deterioration bits of blackfriction material etc If the chaincase lubricant is clean and free of pollutants it may be saved and re used Then replacethe drain plug and through the filler plug at top of inner chaincase fill the case with about a Litre Quart of clean washing solvent Start the machine and run it for afew minutes usingthe clutch often this ...

Page 32: ... non performance Being careful to arrange your system of keepingthe plates in order and right way around wash each in turn in a clean pan of washing solvent usinga parts brush and let them drip dry a piece of stick in avice will make agood dryingrack and allow you to keep the plates in order While cleaning inspect the friction surfaces for missingpieces and thickness If the lining has becometoo wo...

Page 33: ...he obvious safety considerationstake effect Adjustment is accomplishedbytightening the wing nut at the back of the rear brakeapplication rod where itfits through the clevis at the end of the rear brake cam lever at the rear wheel hub The rear brake linkage will require adjustment as the brake shoes wear and also any time the rear wheel position is changed in adjustingthe rear drive chain N O ADJUS...

Page 34: ...d may result in inadvertent application of the front brake with further possible results involving excessive brake drag The Single LeadingShoe Brake Shown at right is the lower cable adjuster and brake shaft clevis This adjuster may be usedto tighten up the cable when the upper adjuster reaches its limit Setup shown is TLS SLS is similar Loosen the handlebar end adjuster then the locknut on the fo...

Page 35: ...ger untilyou are certain that the second brake shoe is loose not contactingthe drum Now tighten shorten the linkage until definite resistance isfelt againstfurther tightening Bear in mindthat you have a high mechanical advantage and do not over tighten as this will cause the second shoe to contact the drum before the first You have to achieve a balance in which both shoes contact the drum simultan...

Page 36: ...n bicycle shops as well Spokes Can GetToo Long Also remember that when you tighten up a spoke it will be screwed into the nipple and therefore into the inside of the wheel It doesn t have to go very far before becoming dangerous to the inner tube it can result in a tire goingflat quite quickly or at best creating a slow leak Be aware of this possibility and if you find that any spoke is taking mor...

Page 37: ...nning reach down and check the free play of the bottom run of the chain It should move up and down about an inch and a half 37mm It takes a bit of getting used to since there is no black and white to this the chain gets tight fairly gradually at the limits The idea is to have it tight enough so that it won t be tempted to jump off the sprockets but not so tight that when the suspension bottoms und...

Page 38: ...hods In any event the cams help to hold the wheel tight against moving forward from chain tension and will allow you to move the wheel by tapping them around with a hammer and a punch but don t use your socket extension be sure to use your genuine brass drift A time honoured method is to kick the wheel sideways at the rear starting with the chain side to get the chain just about tight enough follo...

Page 39: ...f the springclip pointingagainst the direction of forward rotation of the chain IVow adjust the chain as describedabove and you re away DON T FORGET THE BRAKE RODADJUSTMENT The Primary Chain The primary chain running as it does in an oil bath and dustproof environment rarely requires replacement and seldom even adjustment But it should be checked regularly until you get a feel for how often it can...

Page 40: ...replacing CARBURETORADJUSTMENTS Carburetor Jetting Improperly set carburetion can cause wooly or sputtery running at road speeds spit back from the carburetor and hard starting Most importantly an improperly lean mixture can cause detonation which will make short work of a piston Consequently a regular check of carburetion and timing is very important in a high perform ance air cooled engine such ...

Page 41: ...ot jet is an air bleed tighteningit makes for richness looseningleans it out Plug Checks By a fortunate coincidence the colour of the insulator for the center electrode tip at the business end of the spark plug changes accordingto the mixture At the optimum ratio the tip turns a lovely chocolate brown colour If it s too rich too much fuel not enough air it goes to black and eventually the carbon b...

Page 42: ...throttle So the size of the main jet determines where the fuel flow peaks out at wide open If you don t ever ride wide open you ll never have to worry about this one although too small a mainjet can restrict needlejetflow For full throttle tuning do the plug chop although you may need a slightly steeper hill Run at full throttle for about 30 seconds pulling in the clutch and turning off the igniti...

Page 43: ...s deflected suddenly by such things as speed bumps there is probably nothing amiss with fork oil level To check level remove the cap screw at the top of each tube in the casquette casting and insert a piece of rod about 2 feet 60cm long down the hole to use as a dipstick If you feel around you ll feel an obstruction partway down the tube and the oil level should cover this obstruction the top of t...

Page 44: ...ge on the bottom of the rear sprocket and seeing that it runs parallel to the rear chain But the long straight method above is best Lubrication There are some lubrication points on the general chassis Rear brake lever the control levers the swingarm bushinggrease nipples if any all must be maintained in lubricated condition So also should the chain Chain lubrication is dealt with under chain adjus...

Page 45: ...e front has to chase the piston down the cylinder becausethe spark occurred too late This will result in an excess of unburnt fuel being present when the exhaust valve opens and this fuel will continue to burn in the exhaust system as well as polluting the atmosphere The exhaust note sounds a little flat but other than that the only signs will be overheating of the cylinder head and exhaust pipe t...

Page 46: ...ely hampered by an EPA requirement that the headlamp unit be aimable relative to the rest of the housing and this resulted in a cobbled up adapter which holds a smaller sealed beam unit and the prescribed adjusting screw Original models have a mounting ring into which a second lamp rim fixes The sealed beam unit is mounted in this ring with a series of spring clips Aiming may be accomplished with ...

Page 47: ... be due to breakdownof connections a high resistance developingin a connection or a shortcircuit a connection of very low resistance developing between two parts of a circuit which are not supposed to be connected These may be termed longs or shorts Longs Longs or high resistance paths usually develop due to corrosion There are a number of connectors between wires on the Bullet as well a s many pl...

Page 48: ...ect a temporary hot jumper wire directly from the battery terminal to either terminal 2 or 3 the lamp should light If not the problem will be a long between the switch and the lamp or the lamp bulb or a poor ground the center black wire to the headlamp Let s see where the power comes from for the combinationswitch in the first place If we consult the large diagram page 139 and trace back from term...

Page 49: ...r is at fault Do this also with the battery terminal and the ground terminal on the headlight itself If a voltage drop is found you know you have a bad ground These can best be corrected by directly running aground wire from battery to headlight ground parallelingthe cruder chassis ground These are examples of the logic you need to use to figure out problemswith your electrical system Seepages 138...

Page 50: ...eutral apply kickstarter untilyou feel the piston stop on the compression stroke Pull the compression release and ease the piston up to the top of the stroke listeningfor the wheeze of air out of the exhaust pipe through the decompressor When this wheeze stops you re ready for checking your valve clearances Checking DoThey Require Adjustment Remove the tappet cover at the base of the cylinder on t...

Page 51: ... to be replaced m Another difficulty sometimes experienced is that of one or another of the pressed on ends of a pushrod coming loose This will also result in serious inconsistency of valve adjustment and once again mandates the replacement of the offending pushrod If you have difficulty maintainingvalve adjustment and removing the pushrods has shown no problems you will have to go further and che...

Page 52: ...eel Replace the front wheel in reverse order of the above Be sure to adjust the front brake properly see page 27 2 The RearWheel RemovingThe Rear Wheel Removingthe rear wheel can be a problem since even once it s disconnectedand ready to slide back the rear mudguard will be found to be in the way and the machine will have to be tilted so that the wheel can be twisted out of the space It will be a ...

Page 53: ...an parts tray with the anchor nut brake adjuster nut etc Unscrew the rear brake adjuster nut Loosen off the two main axle nuts working them against one another On some earlier models you will have to unscrew the speedometer cable from the speedometer drive Indian models have this on the front wheel Now you will be able to slide the wheel back twisting it to the right at the rear to dis engage the ...

Page 54: ...er a set of cush drive rubbers so that you can change them the next time you have the wheel apart Replacingthe QD RearWheel This is done in reverse order from the above Be sure to replace the cotter pin through the castellated axle nut and to check the chain and rear brake adjustmentwhile you haveyour tools handy CHANGING TIRES Changingmotorcycle tires can be difficult The sum of my experience ove...

Page 55: ...art you ve pulled over with one tire iron continue around the rim with another This should go easily If not see the previous step Some tires are nastier than others Heavy duty Motocross Knobbies are the worst radial street tires the best Be VERY careful not to pinch the tube between tire iron and inner bead m Once you ve got the top bead off remove the security bolt s if any Removethe tube m If re...

Page 56: ...em in tube reinstallation Tube creep is most common in cases of underinflation and security bolt s are one way to correct this REPLACING CONTROL CABLES Inspection You should inspect the condition of your control cables on a regular and ongoing basis Imaginetrying to ride home if your throttle or clutch cable broke Things to look out for are m Frayed or broken strands on inner cable at or just behi...

Page 57: ...op nipple through the lower 6 body and replacedthe split outer cable adapter it will be helpful to wind the throttle on about 1 4 before reassemblingthe body parts and slidingthem back onto the handlebar slide m Be careful to ensure that the throttle slide opens and closes fully before proceeding to re fit the fuel tank When the throttle is wound off you should be able to hear a distinct Typical c...

Page 58: ...the drum within the first 1 2 12mm of control lever movement at the outer end of the lever REPLACING BRAKE SHOES Removingwheels has already been dealt with earlier in this Chapter See page 45 Obviously to replace brake shoes the wheel in question must first be removed Brake shoes are suppliedfrom the dealers lined re lining is not common So all that is necessary is to remove the old shoes clean up...

Page 59: ...d used for disassembly the actuator shaft should be removed for cleaning and lubrication Reassemblywill then be some combination of the procedure below If the Total Removal method was used re assemble the shoes springs actuator cam shaft and pivot pin as a unit Be sure to lubricate the actuator shaft by applying high temperature grease sparingly Assemble the unit to the cover plate If the shorter ...

Page 60: ... it was Once the shoes have been properly arced assemble in reverseorder Be especially careful of the safety considerations chain adjustment brake adjustment tightening of all bolts adjustment of stop light switch etc FrontWheel First remove the wheel Put the wheel on the bench and unscrewthe cover plate nut For TLSbrake loosenthe lock nuts on the link rodand turn link rodso that both brakeshoes b...

Page 61: ...eways at the rims If more than 1 8 3mm of play is apparent then they should be replaced They should also be replaced or repacked at each brake service which is of course determined by brake wear Personally I use this method to decide on wheel bearing service and it s served me well In particularly dusty wet conditions the bearings will wear faster but then so will the brakes and besides I always r...

Page 62: ...n and shiny if they are dull and or pitted discard the bearing and replace with a new one If in doubt replace anyway They are standard bearings and are available at any bearingsupply house Use double sealed bearings of best quality Recommended SKF from Sweden USA or Britain If the bearings check out re pack them with high temperature grease You can use a grease gun attachment bearing packer or put...

Page 63: ... outside nuts tightened As you do the final tightening turn the stub or axle by hand to check for excessive tightening of the bearings If this occurs you will have to remove a bearing and shim the outside race against the bottom of the bearing pocket in the hub until the tightness no longer occurs Fortunately this is not a common scenario 2 The FrontWheel To remove the front wheel bearings it will...

Page 64: ...somewhere along its length W Corrosion the stud has become a part of the casting or nut into which it has been fitted and tightening loosening attempts have caused it to break off either by twisting or stretching W Bottoming the stud is tightened to the point at which it can go no further into a blind hole and once again breaks off due to being excessively twisted Penetrating Oil In any of these c...

Page 65: ...e completely drilled Oversizing In the most extreme cases you will end up with a hole larger than the root diameter of the original stud or screw In these cases there are three options m Weld up the hole and re drill and re tap m Drill out to the next largest tap size and tap for a larger screw or bolt m Do as above but use a threaded insert a bushing which contains a hole with the original thread...

Page 66: ... to the suspension movement of the wheels relative to the frame or handlebar Thus as well as steel tubing the line system has a neoprene hose section inserted in the run The Caliper The calipers which surrounds the brake disk responds to the supply of master cylinder pressure by providing a squeezing force to the disk This force is generated by the action of a piston in a shallow cylinder of consi...

Page 67: ...y a little creative and gentle application of a slot blade screwdriver or other pry bar will work In extreme cases removal and some dismantlingof the caliper assembly and the application of a simple inexpensive carpenter s C Clamp may be called for Note that when the pistons are retracted fluid will be forced from their cylinders back up the lines into the reservoir and some fluid will likely have...

Page 68: ...g up of ajoint avoid overtightening to a rebuild of a cylinder involving honingand piston rubber replacement See details on leaks below CorrectingAir Problems The first sign of problems with air in the system will be sponginess in the control likely with an improvement to be gained by pumping it up The cure for this is bleedingthe air out of the system concerned although in many cases the reason f...

Page 69: ...ocate and remove the brake bleed screw a hollow screw with a nipple on the end that looks a lot like a grease nipple Remove it completely use some penetrating oil allow to soak and administer a sharp light tap longitudinally to loosen the threads if necessary be careful with this screw it s small and easy to strip Once the screw has been removed clean it thoroughly If it s necessary to use petrole...

Page 70: ...the bleed screw 3 4 turn and apply pressure to the vet syringe plunger Slow but steady This will force clean fresh fluid into the brake cylinder and up the line to the master cylinder 6 Monitor the rising level in the reservoir and draw off the rising excess as necessary to forestall overflowing If the old fluid is more than a year old or dirty cloudy discard it wherever you put your used motor oi...

Page 71: ...leeding Here s how it s done To bleed air from the system you will require a piece of tubing most preferably clear of proper size and preferably clear to fit tightly over the nipple of the wheel cylinder bleed screw a clean jar a clothespin a span ner wrench for the bleed screw and a container of fresh clean brake fluid Begin by placingthe jar on the shop floor beside the wheel cylinder of the sys...

Page 72: ...period investigate the system carefully for leaks DownAnd Dirty This one has been known to work Go as above but with no tube on the bleed screw Pressure the system with the brake lever release the pressure with the bleed screw tightening before the pedal reaches bottom IYaintaininglevel in the reservoir repeat until no air is seen exiting the bleed screw D o a final tighten on the bleed screw and ...

Page 73: ...ire more operating force than can be produced with simple cables and levers and whereas disk brakes are so damn good it looks as if we re stuck with the stuff But we should do everything in our power to mitigate the harmful effects o f it on our babies and that means changing the fluid on a regular basis Yearly is good if you re unlucky enough to live in a climate that requires putting baby up for...

Page 74: ...e intervals are a good time to check the quill bushing NB the factory now supply an alternative quillbushingin neoprene but users report better performance and reliability with the original cork ones _ ____ _ ___ Checking may be accomplished by removing the quill feed bolt in the center of the timing cover above the oil filter housing be sure to have a catch tray to receive the oil which will drai...

Page 75: ...y of the cork to get into the space inside the timing cover slippinga piece of thin sheet metal or cardboard under the timing pinion can be a help here It should not be necessary to remove the timing cover However if it becomes necessary the instructions are outlined below Replacingthe Bushing Before beingfitted a fresh bushing must be soaked in hot water for a half hour or so Some owners keep the...

Page 76: ... loosen it from any gasket sealing and the cover should be pulled off evenly around its periphery If prying with a tool is necessary ensure that it is wide flat and as soft as possible Avoid damagingthe gasket faces of either the cover or the crankcase As the cover is withdrawn 172 the oil pump shaft will be rotated by its movement against the worm gear on the outside of the timing pinion Take spe...

Page 77: ... the above You must be especially careful however to ensure that the pump drive gears are not presented to one another point on turn the engine over slowly using the kick starter and decompressor lever or a spanner on the crankshaft alternator nut as the cover is pushed home onto the crankcase Tighten the fixing screws evenly and securely Wipe any gasket sealant off the outside of the cases and en...

Page 78: ... rear of its cavity in the timing cover As the body is turned by the eccentric on the end of the drive shaft the piston is simultaneously drawn out of the cylinder drawing oil through the port into the cylinder As the end of this intake stroke is reached this port is closed by rotation of the body and the cylinder outlet port is exposed to the cavity outlet port to the filter and quill feed or to ...

Page 79: ...unit and put it and the gear and nut aside Make a noteto order a new oil seal this wear part should be replaced on reassembly Remove each of the timing gears with its spacingwasher on each side and place in a clean parts tray BE SURE TO MARK THEM Do the same with the camwheels and the cam followers Removal of the Timing PinionlPump Drive Nut If it is necessary to remove the timing pinion pump driv...

Page 80: ...as given later in this chapter IT IS IMPORTANT to set the timing more preciselythan this initial setting The Cover With the advance unit and drive pinion properly tightened and the outer spacer washers on all gear spindles the timing cover may now be refitted Instructions are given at the end of the section on Re Re timing cover CHECKING AND SETTING IGNITION TIMING Motorcycle engines being small a...

Page 81: ...e time resulting in some burning of the fuel The exhaust valve openingwill be greeted by a burn that is still well in progress with lots of burning left to do in the exhaust pipe resulting in overheatingof the entire engine and signalled by aflatter exhaust note burning of the chrome on the pipe and generally poor efficiency Retardedtimingwill also burn your exhaust valve necessitatinga valve job ...

Page 82: ...compressor and kick the engine over and neutral as you watch the operation of the points open and close When they close with the ignitionon there is an electromagnetic build up in the primary 12V section of the ignition coil When they open the breaking of the primary circuit brings about a sudden collapse of the magnetic field which induces a high voltage about 15 000V in the secondary circuit fee...

Page 83: ...park plug being careful first to clean the area around the plug hole 2 Preparethe timing stick Take a 6 piece of straight coat hanger welding rod or similar material With the machine in top gear insert the wire through the plug hole as close to straight down a s you can get it Then rotate the rear wheel in a forward direction until the wire is forced upwards When it gets as far up as it gets rotat...

Page 84: ...light still connected and ignition on the light should be off Now rotate the plate counter clockwise against the direction of rotor rotation until the exact moment when the light comes on Lock the TimingAdjuster Screws Do a recheck by rotating the engine through two full turns and ensure that the light comes on exactly as the advance mark on the timing stick coincides with the reference point on t...

Page 85: ...ound in the cylinder head It increaseswith load and spark advance and goes away with decrease in load throttle and spark retard If the machine is test ridden under load and the spark is progressively advanced in small increments until knock can be heard at higher loads higher throttle openings in 3rd or 4th gear then the ideal spot can be found by working backwardsfrom there until the knock can no...

Page 86: ...d of marbles rattling around is that it falls off with throttle opening and appears best at Ic pening and goes away as the throttle is cut back in the cylinder head The unmistakablecharacteristic lwer rpms Pingwill also vary with carburetor mixture or jetting A leaner mixture smaller jets or lower altitude will bring on pre ignition requiring enricheningthe mixture retardingthe spark or both A ric...

Page 87: ...rent one to check your top end if you are not entirely sure that you have a leakage problem There are two other less reliable methods to check however and a conclusive indicationfrom either one of these may also be worthy of consideration Caution be sure your valve clearances aren t too tight First the kickstarter Standing on the kickstarteron compression stroke should support your weight without ...

Page 88: ...efacedwhile you re in there An Explanation of Clearances In order for the piston to slide up and down in the cylinder properly its outer diameter must be smaller than that of the bore of the cylinder The piston by the way is actually oval shaped with the distance across the skirts front to back at the bottom being the greatest If the difference or space called clearance is too great a condition ca...

Page 89: ...ts As mentioned earlier in certain rare in my experience instances combustion deposits alone may be a reason to dismantle and clean the top end An idea of the extent of your deposit problem can be had by removing the exhaust system and looking up the exhaust port with the aid of a good light The exhaust valve will pick up deposits on the stem and the back of the face and these may be seen in this ...

Page 90: ...gthe rubber mounting spigot Examine the spigot these are a common site of failure and you may decide to make a new one of these your first addition to your list of parts to secure You may even choose one of the more common alterna tives such as a piece of radiator hose from an automotive supply house Remove the exhaust system as a single piece by removingthe front engine plate nut which holds the ...

Page 91: ...careful not to damage any fins on head or cylinder barrel they are easy to break off and very difficult to fix First if difficulty is experienced be sure ALL fasteners are out Refer to the diagram and be sure that all head bolts nuts etc are in your parts tray and not still holding the head on Some hammer force may be applied through a block of wood in the exhaust port and below the intake port Wi...

Page 92: ...ty is experienced in getting the retainers to move it may be a help first to place a large socket or similar tool over the valve retainer with the head face down on the bench and give it a smart rap with a hammer This tends to loosen the retainer against the keepers and make subsequent compression easier Do this after removing the caps Remove carbon from the valves ports and combustionchamber by s...

Page 93: ...ve guides will haveto be replaced RefacingtheValves and Seats The fit of the valves and seats may be checked with valve lapping compound and a lappingtool Once the head and valves are cleaned up apply a little fine lapping compound to the valve seat insert the valve and rotate it in the seat with the lappingtool for 30 seconds or so moving it around occasionally as you spin the valve back and fort...

Page 94: ...er head with a solidly braced piece of 7 8 1 23 26mm tube when driving or pressingguides This support must be around the outside of the top of the guide parallelwith the direction of pressing or driving Press or drive it is much better to use the comparativelygentler method of pressingto that of pounding with a drif and hammer Ifat all possible have a competent shop press your guides in and out In...

Page 95: ...Samrat blocks and rockers These are Indian made after market parts and come with good recommendations by many Bullet riders Once the Cylinder Head has been removed and checked the wise owner may elect to remove the cylinder barrel as well to check the condition of the small and big end bushings the rings and piston clearance RE FITTINGTHE CYLINDER HEAD Once the head has been cleaned the valve guid...

Page 96: ...tage in which the threads or the fastener itself let go The recommended torque settingwill be at the stop stage If you use a torque wrench be careful to note these stages they should be a more reliable indicator of what you re doing than simple reliance on the calibration of the tool And the logical conclusion is that if the mechanic uses this knowledge and develops the feel a torque wrench is not...

Page 97: ...w 90 turn relative to the pushrod as you tighten the locknut 89 M Usingfresh gaskets install the rocker box covers 1 15 Do not use gasket sealer as you will be removing them to re torque the head nuts after some running time Fit the spark plug and the decompressor valve and your new top end should be ready for break in M Re fit the fuel tank the fuel line the various cables etc Running inYour NewT...

Page 98: ...t the piston will have galled the cylinder walls and the engine will have to be dismantled and properly put back together It is not a good idea to continue to operate a machine which has seized and come unstuck after cooling down Typical cold piston clearance is in the neighborhood of 004 1 Omm when new and maximum allowable wear would create a clearance in the neighborhood of O ION 25mm Beyond th...

Page 99: ...ow with the machine in Ist gear to prevent the engine from turning during cylinder removal slide the cylinder barrel up until the piston skirt is just visible This is a good time to wrap the connecting rod with a clean rag so as to prevent the entrance of any broken ring material into the crankcase Finally turn the engine over once again until the piston is at Bottom Dead Center and slide the barr...

Page 100: ...en place one of the rings into the cylinder bore ensuringthat it is square to the bore parallel to the cylinder head deck surface This is most easily done by pushinga flat top piston or similar sizedcylinder into the bore to push the ringsquare Start at the bottom of the bore below the wear marks made by the piston This will give you a base line for reading cylinder wear Usinga feeler gauge set me...

Page 101: ...eplacement This will mean complete disassembly of the engine covered elsewhere in this manual and havinga new connecting rod and or big end assembly pressed into your flywheels by a competent shop If excessive clearance is not detected continue with the top end procedure Now with the rag still packed alongside the connecting rod carefully remove the circular clips which retain the piston pin wrist...

Page 102: ...d for perceptible end play in the rod itself radial play in thejournal connection A small amount of side play at the small end is normal 3 16 or 4 5 5mm is acceptable Try also to move the rod up and down along its axis against the rod journal at Top and Bottom Dead Center If any movement is perceptible the big end should be replaced This will require stripping the entire engine separatingthe crank...

Page 103: ...it yourself and compare the readings to those of a new one I fno micrometer is available the clearances may be checked as detailed above with a new piston If the extra size of the new piston will bringyour clearances backwithin tolerance you may decide to try a new piston of the current size and leave reboringthe cylinder to next time If however the bore is worn beyond tolerance a rebore will be n...

Page 104: ...ASSEMBLY I Replacing Piston Rings The first step in fitting new rings before placingthem on the piston is to check their gaps at bottom middle and top of the cylinder as with your old ones Engine Size Nominal Gap Ring Clearance in Lands 350cc O I5 020 400 500mm Top Two OO I 003 025 075mm The gaps should be within spec as supplied but you may have complications If the gap is too small the ring ends...

Page 105: ...e inside of the gasket fact to become squeezed into the engine on assembly this stuff will playhavoc with filter screens and pump parts CopperkoteTM gasket sealer is also very good it allows re use of most gaskets Use of shellac type gasket sealers is not recommended they make subsequent dismantlingdifficult and any re use of gaskets impossible Properly applied CopperkoteTM or PermatexTM silicone ...

Page 106: ...nd attempt to move it up and down at top and bottom dead centers and at the two mid points Check also for side play at these points Any perceptible end play or more than I 4 6mm of side play is causefor dismantlingthe big end for examination and replacement of floating center bush and or crankpin and or steel outer rod bushing The engine of course must be removed from the frame and the gearbox rem...

Page 107: ...e bearings Be certain that whatever system you use applies a perfectly axial force straight down the center of the crankpin A Drive Side For the Drive Side a piece of bar stock drilled at its ends to accept two opposingalternator studs should suffice Drill it also in the center to accept a bolt the nut for which may be held on the crankcase side with a suitable spanner Refinements would be tapping...

Page 108: ...l attention to gasket faces and oilholes Reassembly m Press the timing side bearinginto its recess in the outer side of the case m Press the inner drive side seal and retainer etc into its recess in the inner side of the case refer to your notes and see drawing Follow with circlip and fix it into its slot m Follow these with distance pieces and the inner bearing as shown in drawing m Place the dri...

Page 109: ...CHAPTER 7 FRONT FORKS Oil Control Collar 94 The Enfield BULLET MANUAL by Pere Snidal O 2002 ...

Page 110: ...This valve body spring guide prevents the upper end m of the stud from extending any further down than the lower valve body which is fixed in the end of B the main tube thus limiting the total downward extension of the front fork Damping The fork operation is hydraulicallydampened an oil level above the bottom of the spring is maintained at all times As the forks deflect oil is forced through each...

Page 111: ...ning is accomplished by looseningoff the tension nut clamp or lockingbolt 13 and the stanchiontube clamp bolts 5 It is usually helpful to spread the clamps slightly by driving in slot screwdrivers or steel wedges of appropriate size Then tighten the bearingtension nut checkingas you go until the looseness just stops You must then check to ensure that you haven t over tightened the bearings Put the...

Page 112: ...d a large plastic bag or similar container under the center of the fork crown shaft Bearingballs are about to fall m Lower the crown I until it drops free Do this as slowly as possible collecting the bearing balls as they drop out of the lower bearing races You should have 38 1 4 6mm balls REM part No 140201 m Place all the bearing balls carefully in your parts tray The bearing races and balls may...

Page 113: ...o re align it using a suitable tool such as a pointed scriber your stepped drift or something similar Spring pressure acts to force the stud down through the hole Be sure to replace the copper gasket washer when you replacethe cap nut be careful not to cross thread the nuts ReplacingThe Fork Oil Replace the fork oil after replacingthe by removing the top plugand adding 200 ml of hydraulic oil SAE ...

Page 114: ...g it and the hollow slider stud 19 out This will also free the lower bush 2 U Slide the lower bush 2 off the end of the maintube The nut 16 may now be removedfrom the upperend of the stud I9 thus allowing separationfrom the upper valve body W The spring may now be withdrawn out the bottom of the maintube Examination of Components With the forks apart the various components should be examinedfor we...

Page 115: ...g guide nut l6 securely Slip the lower bushing 2 onto the bottom of the main tube I Fit the Lower valve body assy 3 4 5 over the bottom of the spring stud I9 and slip the spring stud with upper valve See page 95 for larger view body assy attached into the bottom of the main tube and tighten the Valve Port Nut 3 securely Insert the spring 14 into bottom of the maintube I Fit the Oil Control Collar ...

Page 116: ...t should be checked occasionally To check the swingarm bushings put the machine on the center stand and attempt to rock the rear wheel laterally pullingon the top of the wheel with one handwhile pushingon the bottom with the other backand forth If movement is detected about the swingarm mounting the swingarm will have to be removed and the bushings replaced Removing the Swingarm W Park the machine...

Page 117: ... straightnesswhen the bushingis introduced A simple long bolt press to the swingarm Centering the Bushes Once the bushes are pressed in place there is one more consideration in the reinstallation the rubber must be centered in between the positions of maximum and minumum shock absorberdeflection All this means is that before installingthe mountingpin the bolt through the frame and swingarm bushes ...

Page 118: ... pan is too small a trough made of sheet metal or even cardboard may help On R S shift models remove the rear brake pedal by unscrewingthe brake pedal pivot bolt First disconnect the stop light switch linkage and ensure that the delicate switch will not be damaged B Remove the Left Footrest B Unscrew the single outer chaincase center bolt and remove the chaincase cover outer half of the chaincase ...

Page 119: ... intermediate plates you will soon come to understand the reason for the dishes Improper assemblywill of course result in non performance The 350 clutch is discussedhere the 500 clutch differs only in number of plates m Remove the clutch pushrod pad 18 and place it in your parts tray Now remove the nut 21 securing the hub to the gearbox mainshaft placing it and its lockwasher in the parts tray Use...

Page 120: ...gearbox mainshaft to engage the woodruff key in the clutch hub while fitting the assembly you will have to ensure that the alternator key lines up as well the gearbox mainshaft may be rotated slightly between attempts until everything lines up properly Once the clutch hub is in place and then fix it on the taper with a smart rap with a suitable hammer and hollow drift such as a 3 4 deep socket H T...

Page 121: ...e the chaincase m Remove the three alternator stator fixing nuts placing them and their washers in a parts tray Draw the alternator stator away from the engine feeding the connector cable through the inner chaincase as you go be careful with dem wires Note the colour coding of the connectors if the colour changes as a wire goes through a connector write this down somewhere so that you will be able...

Page 122: ...s tapping the stator oppositeto reduce the clearancethere etc When the stator has been remounted satisfactorily connect the wires to the main harness THE ES STARTER DRIVE SYSTEM Operation The starter motor drives the ldler Gear 7 The smaller gear on the ider gear drives the clutch driving gear 12 and thence the sprag clutch inner ring When the inner ring is thus rotated the rollers in the sprag as...

Page 123: ...CHAPTER 9 THE GEARBOX 108 The Enfield BULLET MANUAL by Pete Snidal O 2002 ...

Page 124: ...her direction until it contacts the underside of the neutral finder lever m Tighten the fixing bolt and test Repeat until done REMOVALA N D REPLACEMENT O F COUNTERSHAFT SPROCKET Removal m Remove the outer primary cover and clutch m Remove the engine drive sprocket alternator rotor m Remove all remainingfasteners holding the inner primary case half to the engine Remove the case half When removing t...

Page 125: ...or reconnection m When re fitting the alternator stator ensure with a non magneticfeeler gauge that there is a minimum of 006 15mm at all points Rotate the engine to ensure that this gap exists at all times Damage to pole shoes and the rotor itself will result if this clearance is not maintained Check again after tightening the mounting nuts m When the clutch has been reassembled be sure to tighte...

Page 126: ...outer cover may now be removed This is a s far as you will have to go to service the kickstarter spring or the shifter mechanism For access to the kickstarter pawl assy 32 36 the shifter bellcrank actuator 46 or its bushing 44 or for a cursory examination of gears and bushings the inner cover must be removed Precede this work by drainingthe gearbox oil Place a clean catch pan under the gearbox dra...

Page 127: ...ily to remove the stopplate 67 Remove the two cap nuts holding the plate withdraw the actuator and refit the nuts to hold the inner and outer ratchets in place Both Shifters To remove the inner cover the fixing screws must be removed The mainshaft bearingcover 52 will be seen to be held in place by two screws one of which is used as the anchor for the kickstarter return spring Remove these two scr...

Page 128: ...acing the nut on the end of the shaft to protect the threads and applying pullingforce to the outsides of the case cover while tapping the mainshaft end with a hammer and soft aluminum or brass drift will suffice When the cover is loose carefully pry it away from the gearbox case D O NOT damage the joint surfaces they must maintain oil tightness when this is all over You want to leave the kickstar...

Page 129: ...aft Alternate gears such as Hitchcock Close or Sommers Trials sets do not allow this mixup due to different tooth counts on these two gears impossibleto miss matchthese two With Motorwerks 14 25 Trials gears it is again possible to miss match the set as the tooth count is again identical thanks to Martin EXAMINATION OF GEARBOX PARTS If you re inside your gearbox you were presumably having problems...

Page 130: ...ng 49 should be examined closely as well and replaced if any sign of noisiness or looseness is shown Clean the bearingthoroughly and examine both races and the balls with a magnifyingglass and a strong light All surfaces must be smooth and shiny lf any sign of dullness is present replace the bearing The actuator lever 46 shaft bushing 44 can also result in poor gearchanging performance if worn RHS...

Page 131: ...gis chosen pay particularattentionto the rivets in the parallelogramsetup at the end of the footshift lever Determining Faulty Detent PlungerAction If the detent plungeris faulty but the ratchet mechanismis takingthe bellcrankto the correct position on gear changes you will experienceproper changes from one gear to another once you ve found the one gear but itwon t stay in that gearfor long firing...

Page 132: ...ounting pin or shifter fork has brought about a need for more movement Once the machine has been test ridden and notes made on the exact problems as described above it will be time to take it to your dealer for repair or to proceed yourself as detailed in this Chapter Overview of the Shifter Mechanism Referring to the exploded view Gear selection is accomplished by the movement of the slidinggears...

Page 133: ...ner ratchet for a downshiftto 2nd gear Ratchet ring catching inner ratchet for an upshift from 3rd to top CW Rotation CCW Rotation Right View with the stop plate in place Between gear changes shifter plate centered by spring both sets of teeth equally disengaged stop pins in center of recesses The ratchet return spring 59 has centered the mechanism properly indicating proper setting of the adjuste...

Page 134: ...mentmust endwhen the detent plunger engages inthe appropriateslot for the gear chosen THE CURES I The Detent Plunger Referringto the diagram on page 106 we see that gear changes are accomplished by the slidingof the gearpair marked 13 on the mainshaft 14 This is done by the shifter bellcrank 30 The bellcrank moves between incrementsset by the notcheson one of its arms engagingwith the detent plung...

Page 135: ...ck that the rest of the gearchange mechanism is operating properly Referenceto the following paragraphs will show that each gearchange attempt should bring the bellcrank inside the gearbox to present one its gear position notchesto bear against the tip of the detent plunger Runningthrough the gears should show each change to result in the appearance of a new notch seen through the plunger hole in ...

Page 136: ...a the bellcrank actuator 46 and the bellcrank to the sliding gears to effect gearchanges Each movement of the gearshift lever up or down must be met with engagement of the ratchet teeth in a balanced way ie there must be about the same amount of movementjn either direction by the time the teeth engage If there is too much outer ring movement before engagement in either direction completeness of th...

Page 137: ... 3rd the stops should contact the end of their recesses in the stop plate just as the 3rd gear notch shows in the plunger mounting hole The same for 2nd and for the change from 2nd to Ist the Neutral notch should pass by during the change and the Ist notch should appear as the shift stops Check this operation in both directions Be sure to try all gear changes in each direction when checking In som...

Page 138: ...e pressureof the return springand lay down during operation This will be especially noticablewhen power is applied in the first three gears A glance at the illustrationabovewill show the area in which this problemwill manifest The layshaft just the tip is showingin the dwg turns counterclockwise inside its outboard bushing which is in the end of the kickstartershaft Excessivedrag between these two...

Page 139: ...nic stop This was presumably the thinking of the US EPA in mandatingright foot brakingfor motorcycles imported into the USA Canada and a number of European countries regrettably followed suit The argument is that the overwhelming percentage of your braking is done with the front wheel in any regard and that most riders find with practice that it isn t that difficult to reprogram your reflexesto us...

Page 140: ...be changed since you will no longer require an entry for the crossover shaft and the ratchet assy will mount at a different angle and therefore require different mounting bosses See drawings above The Bellcrank Actuator Lever 46 in the dwg inside the gearcase behind the inner cover will have also have to be restored to original And finally the Shifter Actuator Lever 69 This will then project throu...

Page 141: ...nner case cover are ojten a different size than the old ones It is also a good idea to order a kickstarter pawl since you may well find yours needs replacement once you are inthere Part No is 140333 You will also want to use a sealed outer mainshaft bearing standard part number 6303 ZZ from your automotivejobber or bearing house since this will allow the use of regular SAE9O gear oil in the gearbo...

Page 142: ... m A more period look and feel to the living dinosaur that is your motorcycle m If you have other old Brits an elimination of the need to switch hit between them m A chance to really get in there and do some serious nuts and bolts work on your Living Meccano Set The Procedure First ensure that all the necessary parts are there Check the parts you have against the list on the previous page When you...

Page 143: ...ered ensure that the taper is fitted to the inside ie press it through taper first from the outside A t this time press the new sealed 6303 ZZ sealed main bearing into the case as well Heat the cover to spitting hot before pressingin the bushingand bearing GearboxVent As shipped the Bullet has no venting for the gearbox This is a good time to drill a small hole 13 64 2mm into the outside of the Fi...

Page 144: ...ut no countersink in the new cover Use a regular screw for replacement standard 1 4 20 should fit In a pinch you may use the old countersunk screw Mainshaft End Play Before fitting the Outer Bearing Nut ensure that some endplay is present on the mainshaft the position of the bearing may have changed with the new cover and this could be too far to the left resulting in no endplay at all or too far ...

Page 145: ...g 17 Fit the inner ratchet 67 onto the square shifter shaft 46 18 Now it is time to play with the shifter ratchet adjustment Read the section on the Ratchet Shifter Assembly You may wish to read and review the entire section on shifter adjustment 19 Once the shifter mechanism is performing as properly as you can get it it is time to test it on the road Replace the outer cover You will find that it...

Page 146: ...orcycle I try to remember to do a couple of little practice stops as I start off I don t come back to a full stop just apply a little rear brake and shut of the throttle a bit so as to re programme my brain hopefully for the particular machine I ve just climbed onto This is a good habit to get into EVERY time you start a motorcycle in the world of switch hit shifting 27 If further shifter adjustme...

Page 147: ...ottoms lightly then back off 1 2 turn Make a note of the position of the adjuster slot Tighten up the locknut without movingthe screw After tightening check that the slot hasn t moved Then adjust the cable for about 1 8 3mm slack Clutch Cable Replacement The clutch cable as supplied by the factory has a two stage nipple on the gearbox end It is important that the inner cable be inserted into the e...

Page 148: ... Uses a Lever type detent rather than a spring loaded plunger m Has two moving slider gears to effect changes instead of a single slider gear m Shifter forks actuated by a camplate rather than lever and bellcrank system m Gearchange ratcheting is accomplished by a striker plate and rollers m Needle bearing Kickstarter Shaft support from layshaft This should eliminate some previous difficulties wit...

Page 149: ... rotated by means of the longitudinal movement of the Striker 27 engaging one of the striker pins 1 9 in the Camplate Movement to the right brings about anti clockwise movement of the camplate viewed from the rear toward First gear and movement to the left clockwise toward top This movement is imparted to the Striker via the bellcrank or Rocker Shaft Assembly 22 via the Gearchange Link 24 which is...

Page 150: ...amplate Pawl notches Replace or repair PawllCamplate Soft o r broken Pawl Spr ng 21 9 1 N o t holding Pawl into Camplate Replace if necessary Incomplete Engagement See chart above See chart above See chart abwe DISMANTLING The Entire EngineIGearboxAssembly must be removed in order to access the IndexingPawl 20 All other work except replacingthe case may be done with the gearbox in place on the mac...

Page 151: ...r Releasethe lever while pullingon the clutch cable Work the inner cable out through the slots in the adjuster and locknut This will leave your cable slack enough to Work the gearbox end of the inner cable out of the ball and ramp throwout lever accessible through the hole revealed when you did step 3 Remove the entire cable Remove the kickstarter First loosen off and remove the clamp screw You ma...

Page 152: ... the factory literature of Left Handednesson this shaft 8 Removethe Four Carrier Plate RetainingNuts 5 9 Withdraw the carrier Plate Temporarily replacementof the kickstarter on its shaft will likely help take just a bit of the slack in the mechanism to aid in withdrawing the Pawl assy from the Layshaft Ist gear 10 Removethe 3 Camplate Pivot Plate 3 1 Screws 30 and withdraw the Plate I I The entire...

Page 153: ...gs for stiffness it would be best to compare them with new ones or possibty even just to replace them m All runningparts check all parts against possible faults listed in troubleshooting charts GEARBOX RE ASSEMBLY I Before reassembling ensure that all parts that have failed inspection are on hand as well as fresh gaskets 0 rings and Seals 2 If bearings or bushings have been removed replace them an...

Page 154: ...ayshaft 2 Fit the Layshaft Inner BearingThrustWasher 19 in the Gearbox Case Dwg onto the appropriate end of the Layshaft and insert the Layshaft as assembled thus far into the inner bearing Grease it first and turn the layshaft so that the high gear will mesh with the countershaft gear Check that it turns freely the Countershaft Gear 18 will turn with it You are now ready to do the preliminary ass...

Page 155: ...rollers 19 X 4 are firmly located in their holes in the camplate you might want t o use some grease to ensure they stay in place 12 Arrange the Assembly so that 3rd Gear is selected This will have two camplate detent slots showing below the shifter fork shaft four above it 13 Ensure that the Detent Pawl 20 is facing downward before proceedingwith step 14 14 Locatethe Camplate Pivot Plate 3 l its t...

Page 156: ...r two in the hole with the thumb of your left hand slip the Pawl 10 into its slot in the shaft 6 Holdingthe Pawl down into the kickstarter shaft introduce the shaft onto the end of the Layshaft Ensurethat theThrustWasher 13 is in place on the outside of the Layshaft First Gear Mesh the Ratchet Pawl with the Ratchet Ring in the outside of the gear 7 Present the Carrier Plate to the Gearbox Outer Fa...

Page 157: ... h fresh 0 rings in place into the mounting holes Oil the 0 rings FactoryTool ST 25 156 4 may be used to assist in perfectly square alignment of the Pivot Pins and to avoid damage to the 0 rings If you need to improvise try wrapping the pins with thin sheet stock beverage can Pay special care to maintainingsquareness as you tap the pins into place with a small drift 5 Do the same with the Stop Pin...

Page 158: ...ver fits between the clutch ball and the next little gizmo NOT above the gizmo 5 Usingyour favourite gasket methodology fit the cover to the gearbox case 6 Fit and tighten in stages the 5 case screws leavingthe level screw rear bottom left out for the time being You should have one copper sealing washer for the level screw 7 Ensurethe drain plughas been replaced then fill the gearbox through the f...

Page 159: ... providing an extra rich mixture for cold starting Important Parts I I Screw Top 32 jet Body 17 Pilotjet 33 Floatjet and Needle 25 Return Spring 10 Float Assy 15 Mainjet 36 Float Bowl Retaining 31 Needle Retainer 7 Float Pin 34 Startingjet Plunger Screw 6 Needle Clip 19 0 ring Gasket Return Spring 24 Startingjet Plunger Seal 2 Needle 13 RicheningLever 9 Float Bowl 4 Throttle Slide 5 Pilot Adjustme...

Page 160: ... starting Important Parts 42 Screw Top 40 Needle Jet 32 StartingJet Plunger 10 Float Bowl RetainingScrew 22 Return Spring 39 MainJet 38 StartingJet Plunger 36 Starting Jet Plunger Seal 23 Needle Retainer 5 Float Pin Return Spring 18 Throttle Cable Slack I I Needle Clip 33 RicheningLever 28 0 Ring Adjuster The Starting 2 Needle 17 Pilot Adjustment Screw 43 Float Bowl 19 Throttle Stop Screw 24 Throt...

Page 161: ...iding an extra rich mixture for cold starting Important Parts 3 1 Richening Lever 20 Needle 8 NeedleJet 24 Screw Top 19 Throttle Slide 5 Jet Body 23 Return Spring 16 Pilot Adjustment Screw 33 0 ring Gasket 2 1 MainJet Cap 18 MainJet 3 Float Assy 25 StartingJet Plunger 26 StartingJetPlunger Return Spring I Float Bowl 10 Float Needle 24 StartingJetPlunger Seal 134 The Enfield BULLET MANUAL by Pete S...

Page 162: ... handlebar mountedcable operated lever Important Parts 5 6 Cap and Retainer 4 1 Float Bowl tickler 3 Pilot Adjustment 40 Fuel FilterScreen 33 Float Needle Ring 10 Throttle Slide Screw air 30 Float Assy 46 Float Bowl Cover 14 Air Slide enrichener I I Throttle Return 27 Throttle Stop Screw 33 Float Valve RetainingScrews 15 Air Slide Guide Spring 21 MainJet 31 Float Reservoir 32 Float MountingPin 16 ...

Page 163: ...loat Float Spindle Banjo Banjo Bolt The StartingMixture is enrichened by operation of the float tickler This deviceforces down the float assembly causing the flooding of the carburetor Crude but effective If needed cold runningenrichment may be provided by lowering the air slide not shown with the handlebar mountedcable operatedair lever 136 The Enfield BULLET MANUAL by Pete Snidal Q 2002 ...

Page 164: ...itial ownership period for rust to work its way from the fuel tank through the fuel system to the carburetor and this often gets stuck in the float valve 33 holding it open resulting in fuel running out the overflow tube A temporary fix can sometimes be done by giving the float bowl a sharp rap with a spanner or rock but in most cases this will have to be cleaned by removingthe float bowl the four...

Page 165: ...osition of the clip moves the needle up or down relative to the slide jet To move the clip the top I I must be unscrewed and the slide assembly 4 2 6 3 1 25 12 1 l pulled out Depending on model this may entail removing the air filter and the carburetor from the engine or simply removing the fuel tank Once you have the slide assembly in your left hand wind the throttle on fully and hold the v slide...

Page 166: ...e stop screw for minimum and cleanest runningidle speed and then adjust the pilot screw 5 to reduce the idle speed Work back and forth with the two screws until the best cleanest lowest idle is attained Ensure also that the throttle cable is unobstructed Movethe handlebars back and forth to test for cable complications if the cable routing is bad the idle will rise and fall as you move the bars If...

Page 167: ...lied voltage And don t forget only in a perfect world is there IVO resistance in ANY of the elements other than the load the switches the various connections and the conductors themselves all contribute in some degree to the total resistance and therefore total load Measuring Electrical Quantities The basic three considerations are Voltage or Electrical Pressure the speed of current flow or Ampera...

Page 168: ... your test light or meter to the grounded battery terminal not the chassis of the machine itself as the groundingof the battery terminal should always be the first suspect Touchingthe probe of the light or meter to the ungroundedterminal of the battery should light the test lamp or produce a readingof around 12 5V Then verify the ground connection to the chassis by connecting the test clip to the ...

Page 169: ...Switch Module Ignition Switch Contact Details 1 OFF No Contact 1 2 High Beam 2 ON 1 2 3 4 1 3 Low Beam 8 9 Tmfficabr RH 9 10 Trafficator L H 13 Horn NorthAmerican Export Mid 99 and Earlier ...

Page 170: ...CHAPTER I I ELECTRICAL WORK The Enfield BULLET MANUAL by Pete Snidal O 2002 143 ...

Page 171: ...CHAPTER I I ELECTRICAL WORK 144 The Enfield BULLET MANUAL by Pete SnidalO 2002 ...

Page 172: ...Green 12 4 IOW Home Indian Model ...

Page 173: ...CHAPTER I I ELECTRICAL WORK 146 The Enfield BULLET MANUAL by Pete SnidalO 2002 ...

Page 174: ...CHAPTER I I ELECTRICAL WORK The Enfield BULLET MANUAL by Pete Snidal O 2002 147 ...

Page 175: ... places and the chassis is the element which presumablyconnects them together for a return path t4 the battery Can you trace the headlamp power back to the dip switch Which is high beam Red or White GoingAround the Circuit Test Light Method Once voltage has been verified testing directly at the battery with the test lamp or successfully switching on other devices we proceed through the entire circ...

Page 176: ...n Switch Supply wire if it s good going in and not coming out you know the switch is faulty This would also be indicated if other output devices from the same switch such as the headlight worked but the taillight did not THEJUPIPERIYETHOD TheJumpermethod may be used to verify a bad switch at this point If the connections from switch to taillight and the light itself and its ground are all good jum...

Page 177: ...o the supply voltage This means that in an ideal world the entire voltage of the battery say 12 3V engine off will be present at the headlight high beam So if we connect the voltmeter directly to the high beam wires at the rear of the headlight unit with the headlight on we should get a readingof 12 3V this load voltage balances the supply voltage I I But if one of the elements we have assumed to ...

Page 178: ...not at the terminal points open remember would tell us that the coil is no longer conducting If no power at the coil Brown Wire we would then follow the Brown conductor back to the ignition switch and checkfor power there If there were power there as indicated by our test lamp but not at the coil we would know this wire was bad and clean and replace connections or the entire wire with a permanent ...

Page 179: ...dlight Circuitry many wires eliminatedfor clarity Similarly if the headlight doesn t function on either beam we could jump from the battery terminal directly to the Red or White wire on the rear of the light If the light then works we cantrace backwardsthrough the circuit to the Red or White wired terminal on the combination switch shown above for example 3 or 2 If this gave us light we would know...

Page 180: ...tory has incorporated a change to save power in cases of always on lights mandated in North America In these cases the second output is connected directly to the headlight a shunt type AC regulator is incorporated with no connection through the rectifier If you ever have occasion to disconnect these wires be sure to make a note of the connections into your wiring loom for all four wires and ensure...

Page 181: ...t wiring systems dependingon destination of machines as they are produced These are North American Models UK Models and Home or Standard Models A NORTHAMERICAN MODELS SPECIFICS I STOP RUN SWITCH The North American models have a handlebar mountedstop run switch which is wired between the ammeter and the coil This is not a shorting kill switch but a series wired on off switch It feeds the white wire...

Page 182: ...ht via an AC regulator without the associated power loss of conversionto DC The OldWay A typical Lucas style permanent magnet alternator wiring connection But if coil A were disconnected and wires run separately from it to the light it could feed the light with unrectifiedAC Since some power loss is associated with AC DC conversion and since DC although required to maintain battery charge is not n...

Page 183: ... Beam Term 2 Term 5 Term I Yellow Yellow Red Blue Green Red White Grey Grey Black Pilot X X X X High Beam X X X Low Beam X X Flash X X Turn Signal Switch Position Term 7 White Term LH Term RH Term 6 Violet Ground Left Turn X X Right Turn X X Flash X X Alternator Connections Number Colour Destination I Purple Rectifier Re ulator 2 Purple Rectifier Regulator 3 Amber Headlamp Common AC Regulator Resi...

Page 184: ...minal Colour s Connection Function I IgnitionColl 9 0 Ignition Power 2 Red Black Maln Switch Terminal 5 Power to MalnSwitch 3 Red Fuse Battery in and out i 4 Blue Flasher Turn Signal Power 5 n c n c n c 6 Brown RectifierOutput Connects Rectifierto System 7 Brown Ammeter Power in and out of System 2 Main Switch Connections Terminal Colour s Connection Function I n c n c 1 n c 2 Brown Ammeter Connec...

Page 185: ...ntact Breaker with agrey wire I The ignition Switch Connections Terminal Wire Colour Connection Function 1 2 Brown i Through C I to Rectifier i Rectifier Output Connection to System i I 4 White i Through CI to IgnitionCoil 1 IgnitionPower S 6 Brown Through CI to Ammeter i Connectionto System 16 Red I CI to no further connection n c l 8 Green CI to no further connection 1 n c i l S 12 B l a c k C l...

Page 186: ...n a White Through 4 way Connector to High Beam Indicator High Beam p p p p 3 Red Snap Connectorto Headlamp Low Beam Output 4 Black Green 4 way Connector RightTurn Signal 5 1 Yellow Red Snap Connectorfrom Flasher l PulsingTurn Signal Input 6 1 Black White 4 way Connector 1 LeftTurn Signals 1 7 Yellow Snap Connector to Horn i Horn Ground The Enfield BULLET MANUAL by Pete Snidal O 2002 159 ...

Page 187: ...em first It is a fact that there is great psychological satisfaction in makingyour motorcycle noisier a noisier machinejust feels more powerful However in the case of the stock Indian Made Bullet it is also a fact that the as comes long exhaust system is very restrictive and there is much room for improvement without gettingtoo noisy lmprovementsin the neighborhoodof 20 have been documented on the...

Page 188: ...ally m LARGERCARBURETOR Newbies often flock to larger carburetonas a performanceimprover It must be borne in mind that the only possible effect of such a modificationwill be at throttle openings over full throttle with your present carburetor and then will only provide an effect if the volumetric efficiency of your engine at that time is such that the extra ability of your new carburetor to pass o...

Page 189: ...reet riding with the best pump gas compressionsof higher than 9 1 will not usually be satisfactory Mechanical Efficiency Lastly mechanical efficiency any decrease in relative friction in the engine will of course show itself in greater power output Changes here would involve choice of lubricants flywheel assy balancing important at higher rpms replac ingthe small end bushingwith needle bearings sp...

Page 190: ... neverwill The basic Enfield design is unchanged from days of the famous 500 Fury which produced over 40 bhp and these were not famously unreliable so it is not unrealistic to expect a fairly highly tuned Enfieldto stay together if properly built and maintained Where Do IGet Performance Parts The most important part of the performance parts market from the owner s point of view is getting good adv...

Page 191: ...164 The Enfield BULLET MANUAL by Pete Snrdal O 2002 ...

Page 192: ...a Pulse Air Valve Breatherbox unit which provides a pulsed supply of fresh air to the exhaust system between exhaust pulses to facilitate burning of as yet unburned combustion product gases by the second addition a Catalytic Converter which has been installed at the end of the exhaust header pipe at the muffler connection point The PulseAir Valve Unit Pulse Intake Cover Removed Showingthe Diaphram...

Page 193: ...ier pipe and revert to the Old Ways However the more progressive among us may wish to consider the following m It is most likely illegal most jurisdictions have laws against back modifyinganti pollution equipment effective or not In fact it is likely illegal for your author even to suggest it or offer instructions on how to do it M The Pulse Air Valve is likely havingno adverse effect on engine br...

Page 194: ...is Experiencewill tell you how often this should be done it will vary with conditions of use and condition of your engine Don t Discard It There is no real advantage to removing this condenser It s function is to condense the blow by gasses emitted from the crankcase the hot gasses will when cooled condense to a large degree into liquid consistingmostly of water with some petroleum distillate cont...

Page 195: ... close to its time for top overhaul may create such heavy crankcase emissions that the condenser can t handle them and will pass on thick enough gas that the air cleaner will be getting polluted even if the con denser is in good empty condition In this case it may be necessary to disconnectthe tank s outlet into the air cleaner pluggingthe air cleaner end to admit the gasses directly to the atmosp...

Page 196: ...APPENDIX A P P E N D I X The Enfield BULLET MANUAL by Pete Snidal O 2002 169 ...

Page 197: ...0 7 9 Gearbox Endcover Bolt 1 4 I O 85 0 7 1 CountershaftSprocket Nut 1 3 16 ImpactWrench or Hammer Socket Alternator Rotor Nut 9 16 5 50 475 0 40 Clutch Hub Nut 9 16 5 50 475 0 40 Gearbox MainShaft Nut 5 8 6 50 565 47 RockerBox Stud Nut 145 12 I O Oil Filter Nut 1 40 260 4 10 I Rocker Feed Banjo Nuts I O 8 5 0 7 Rocker Feed Lower Fitting 1 6 138 1 1 Oil Feed Quill Bolt I 1 60 138 11 5 Front Chain...

Page 198: ...a 18 Front MudguardStay Screws 1 4 i 3 Front Engine Plate Stud Nuts M8 U 1 50 130 0 I I Front Mudguard Stay Stud Nuts 5 16 1 20 104 0 8 5 Handlebar Clip Bolts 5 16 3 30 286 0 V 24 Seat Stud Nuts 5 16 2 40 a 208 0 g 17 Main Footrest Nuts 3 8 1 20 104 0 87 IgnitionCoil Bolts M6 l 45 40 0 3 3 Regulator Nut M6 I 45 40 0 3 3 P P Rear Mudguard Carrier Stud Top 3 8 2 00 I 175 0 14 5 Rear Mudguard Carr er...

Page 199: ... 007 Ringto Groove clearance compression Rings Oil Ring Scraper Ring lutchSteel Plate distortion 14 Clutch Friction Plates thickness Bonded with Insets 15 Clutch Plate Lugw dth j 6 00 0 236 i 6 00 0 236 16 Clutch Spr ng free length f 25 5 1 004 i 25 5 1 004 3 17 Wheel Axle shaft run out 0 2 0 008 0 2 0 008 18 Wheel Rim run out 2 0 0 078 j 2 0 0 078 1 19 l Brake Liningthickness i 2 0 0 078 2 0 0 07...

Page 200: ...APPENDIX INCH METRIC CONVERSION TABLE Inches Decimals Millimeters Millimeters to Inches Inches to Millimeters Continued next page The Enfield BULLET MANUAL by Pete Snidal O 2002 173 ...

Page 201: ...APPENDIX INCH METRIC CONVERSION TABLE Inches Decimals Millimeters Millimetersto Inches Inchesto Millimeters 174 The Enfield BULLET MANUAL by Pete Snidal O 2002 ...

Page 202: ... dia 3752 3760 Tappet guide outside dia 7505 7510 Miscellaneous Lubricationsystem Dry Sump tank integralwith crankcase Clutch type Wet multiplate oil immersed EngineSprocket 25 teeth Clutch Sprocket 56 teeth Primary Chain 318 pitch Duplex Wheel Bearings front and rear 17 X 49 X 12mm 6203 or 620322 Wheel Rims front and rear WM2 19 Front SuspensionStroke 155mm Gear Box Overall Ratios 5 01 6 83 9 22 ...

Page 203: ...Tappet guide outside dia 7505 75 10 Miscellaneous Lubricationsystem Dry Sump tank integral with crankcase Clutch type Wet multiplate oil immersed Engine Sprocket 25 teeth Clutch Sprocket 56 teeth Brake Drum Sprocket 38 teeth Prirnary Chain 3 8 pitch Duplex Wheel Bearings front and rear 17X 49 X 12mm 6203 or 620322 Wheel Rims front and rear WM2 19 Front SuspensionStroke 1 55mm Gear Box Overall Rati...

Page 204: ...A P P E N D I X The Enf eld BULLET MANUAL by Pete Snidal O 2002 177 ...

Page 205: ...ber consists of 17 numbers or digits and each one means something MBFFSVB 22Y 2 XXXXXX The first 7 lettersAre always the same They are assigned by The USgovt to Royal Enfield as a Corporate identifier The two numbers following denote the HP 22 for the 500 and 18for the 350 The next number in this case Y is a check digit which is part of a mathematicalformula used by the government to validate the ...

Page 206: ...d Battery Check Clean Battery Chassis Ground Connection Bad Connector Check Charge Battery Specific ElectricalFailure A Light The Horn or Ignition 1 DiagnosingElectricalFaults P 140 Replace Bulb in Light Test Horn by jumping hot wire from battery to hot connector and button connector to ground Poor Battery Staying Power Faulty Component burnt bulb or failed horn Ammeter Never Showing Charging Defe...

Page 207: ... Ist Gear after starting Poor Clutch LinkageAdjustment Cable or Bellcrank Adjust Clutch Linkage Adjusting the Clutch Linkage P 23 oveprevs when pulling hard re synchronies when throttle is rolled back Clutch Slipping engine Dirty or oily plates partially collapsed clutch springs worn friction disks Remove and Inspect Clutch P 103 105 I Poor Clutch Adjustment 1 Poor Gear Changing popping or firing ...

Page 208: ...nt Fork Poor Brake Adjustment ExcessivelyWorn Linings Linings not bedded in to arc of drums Rear brake cam shaft not centered in backing plate CORRECTION Noisy Valve Train Possible Big End Failure Piston Slap due to excessive piston clearance cracked piston Remove and Clean Linings and Drum Remove and Chamfer Lining LeadingEdges Replace Linings Check and Adjust Wheel Alignment and Rear Chain Check...

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Royal Enfield Bullet 350cc, Service Manual

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Summary of Contents for Bullet 350cc

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