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Royal Enfield Bullet Classic EFI Service Manual Download Page 290

ROYAL ENFIELD    VEHICLE SERVICE MANUAL - EURO IV

289

A. Ignition spark weak

Battery voltage low

Recharge/ replace battery

Spark plug cap / high tension wire

Check & correct

loose / shorted / defective
Spark plug incorrect

Replace with correct spark plug

Spark plug sooty / wet

Check &clean spark plug

Spark plug gap incorrect

Correct spark plug gap

Spark plug insulator cracked

Replace spark plug

No spark from Ignition coil

Check & Replace Ignition coil

Pulsar coil defective

Check & Replace

B. No Ignition spark

Battery dead

Recharge/ replace battery

Spark plug cap / high tension wire

Check & correct

shorted / defective / disconnected
Spark plug insulator cracked

Replace spark plug

No spark from Ignition coil

Check & Replace Ignition coil

Pulsar coil defective

Check & Replace

No Fuel in fuel tank

Fill fuel tank.

Stale / adulterated fuel

Clean fuel tank

Fill with fresh fuel

Fuel Tap in Closed Position

Turn fuel knob to On/Reserve

C. Fuel related

Air vent blocked in fuel cap

Clean air vent/s

Fuel filter clogged

Clean fuel filter

Fuel line pinched

Check & correct fuel line

Ambient temperature too low for

Use Choke for starting in cold

engine to start

conditions

Choke Left ON

Shut OFF choke

D. Compression related

Spark plug loose

Tighten spark plug to torque

Tappets adjusted too tight

Check & adjust tappets to specn

Cylinder head gasket blown

Check & replace

Cylinder head nuts loose

Check & tighten to torque

Cylinder head warped

Check & replace

Valve stem bent, seating area

Check & replace

burnt, excess carbon deposit on

seating area, Valve springs broken
Piston rings sticky/ worn-out

Check & replace

Cylinder barrel / Piston excess

Check & replace

clearance

Symptom

     Probable Cause

                   Remedy

1.   ENGINE CRANKS BUT DOES NOT START

KS MOTORCYCLES - http://ksmotorcycles.com

Summary of Contents for Bullet Classic EFI

Page 1: ...EURO IV VEHICLE SERVICE MANUAL Continental GT Bullet EFI Classic Bullet EFI KS MOTORCYCLES http ksmotorcycles com ...

Page 2: ...orized Royal Enfield Service Station Thismanualwillhelpinguideinthebasicservicing periodicalmaintenance systematicdisassembly Partsinspection and assembling procedures of various mechanisms systems of the motorcycle which has to be carried out in Royal Enfield Authorised Dealership or Service Station WhilethismanualisupdatedwithlatestInformationandSpecifications atthetimeofgoingtoprint duetocontin...

Page 3: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 2 EURO IV BIKES VEHICLE VIEWS ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 02 KS MOTORCYCLES http ksmotorcycles com ...

Page 4: ...ank 23 5 4 Seat Assembly 30 5 5 Exahust Pipe Silencer 39 6 Front Suspension 6 1 Front Wheel 46 6 2 Front Mudguard 54 6 3 Handle Bar 60 6 3 Front Fork 70 6 4 Steering Stem 87 7 Rear Suspension 7 1 Rear Wheel 103 7 2 Rer Sprocket Drive Chain Adjustment 111 7 3 Rear Shockers 113 7 4 Rear Mudguard Rear Number Plate 119 7 5 Swing Arm 126 8 ABS 133 9 EVAP 167 10 EMS 174 11 NACS II DIAGNOSIS 213 12 Elect...

Page 5: ...QR8DC Bosch WQR8DC Bosch TRANSMISSION Clutch Wet Multiplate Wet Multiplate 7 Plates Drive Chain links 102 pitch 101 pitch 101 Pitch Primary drive Duplex Chain drive 3 8 pitch Duplex Chain Gear box 5 Speed Constant Mesh Constant Mesh 5 Speed Gear Ratios I 3 063 1 I 3 063 1 II 2 013 1 II 2 013 1 III 1 522 1 III 1 522 1 IV 1 212 1 IV 1 212 1 V 1 000 1 V 1 000 1 Primary Drive Ratio 2 15 1 2 15 1 Secon...

Page 6: ... fork oil Gabriel Fork Oil 2W 35 Gabriel Fork Oil 2W 35 Hydraulic Disc Brakes Front Rear Hydraulic Disc Brakes Front Rear with ABS System with ABS System Brakes Front 300 mm dia disc with twin Front 300 mm dia floating disc piston caliper twin piston floating caliper Rear 240 mm dia disc with single piston Rear 240mm dia disc single piston floating caliper floating caliper Brake oil grade DOT 4 or...

Page 7: ...5 Sparkplug A A A A A R A A A A R 6 HT lead I I I I I I I I I I I 7 Fuelhose I I I I R I I I R I I 8 FuelPump Checkforscrewtightnessinallservices 9 Acceleratorcableplay A A A A A A A A A A A 10 Rubberhose AirfiltertoThrottlebody I I I I R I I I R I I 11 Rubberhose Inletmanifold Adaptor I I I I R I I I R I I 12 Airfilterpaperelement C C C C R C C C R C C 13 Inlet Exhaustvalveseating compression vac...

Page 8: ... C A C A C A C A R 6 HT lead I I I I I I I I I I I 7 Fuelhose I I I I R I I I R I I 8 FuelPump Checkforscrewtightnessinallservices 9 Acceleratorcableplay A A A A A A A A A A A 10 Rubberhose AirfiltertoThrottlebody I I I I R I I I R I I 11 Rubber hose Inlet manifold I I I I R I I I R I I 12 Airfilterelement C C C C R C C C R C C 13 Inlet Exhaustvalveseating I 14 Cylinder head D 15 Exhaust pipe D 16...

Page 9: ... of front fork ST 25110 3 Gauge plate for tightening Alignment of Swing Arm while chain stay mounting tightening into chassis ST 25244 4 Special spanner adjuster To adjust gas filled shockabsorber spring load ST 25833 4 Front Fork Tool 1 2 SD To Loosen and tightening of front fork assembly from the head lamp casing ST 26461 2 Front Fork Assembling To hold pipe seat of front fork while Dismantling ...

Page 10: ...throttle body along with throttle cable Remove the air filter assy Remove the exhaust pipe and silencer Disconnect the engine steady bolt Remove the rear chain Remove the LH Foot rest Support the engine on a suitable box or wooden block Remove the center stand and the stand stop Remove the front engine plates and the small bolt fixing the stand spring bracket Remove the stud securing the rear engi...

Page 11: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 10 SECTION 05 VEHICLE AGGREGATES KS MOTORCYCLES http ksmotorcycles com ...

Page 12: ...EURO IV 11 SECTION 5 1 CABLES 1 2 3 S NO DESCRIPTION QTY 1 Throttle Cable Assembly Twin Cable 1 2 BI Starter Cable 1 3 Clutch Cable Assembly 1 EXPLODEDVIEWS BULLET CLASSIC EFI BULLET EFI CONTINENTAL GT KS MOTORCYCLES http ksmotorcycles com ...

Page 13: ...tle Cable Assembly Twin Cable Bullet Classic EFI Bullet EFI Continental GT Dismantling Slacken the adjusters at thethrottlebodyendfor both cables Gently remove the Throttle cable assembly Slacken the adjuster at the clutch cover end and disconnect the cable from the lever Gently pull out part of theclutchcablefromthe cover Remove the clutch cable from the clutch lever at handle bar end KS MOTORCYC...

Page 14: ...uctions 5 1 Bi Starter Cable Bullet Classic EFI Bullet EFI Continental GT Dismantling Slacken the adjuster at the Bi starter cable end and disconnect the cable from the lever Gently pull out the part of Bi starter cable Remove the Bi starter cable from the clutch lever at handle bar end KS MOTORCYCLES http ksmotorcycles com ...

Page 15: ...embling 5 1 Throttle Cable Assembly Twin Cable Bullet Classic EFI Bullet EFI Continental GT Assembling Locatetheclutchcablein clutchleverathandlebar end Locate part of clutch cable in the cover Slacken the adjuster at the clutch cover end and Connect the cable in the lever Locate the Throttle cable assembly Slacken the adjusters at thethrottlebodyendfor both cables KS MOTORCYCLES http ksmotorcycle...

Page 16: ...mble Instructions 5 1 Bi Starter Cable Bullet Classic EFI Bullet EFI Continental GT Assembling Locate the Bi starter cableintheclutchleverat handle bar end Locate the part of Bi starter cable Slacken the adjuster at the Bi starter cable end and Connect the cable in the lever KS MOTORCYCLES http ksmotorcycles com ...

Page 17: ... 1 3 Cover Filter element 1 4 Hex Nylock Nut M8X9 5 1 5 HexScrewM6 X14 2 6 Lock Washer M6 3 7 Plain Washer M6 1 8 Plain Washer M6 1 9 Hex Nut M6 X 1 X 7 1 10 Hex Bolt M6 X 1 X 12 1 11 Inlet Bellow 1 12 Clip Hose Inlet Bellow 1 13 Hexagon Socket Head Cap screw M5X 8X20 2 14 TA Sensor 1 15 Gasket Air Temp Sensor 1 16 Rubber Tube Air Filter 1 17 Beading Box Cover 1 18 Beading Cover Air Filter 1 19 Co...

Page 18: ...NENTAL GT S NO DESCRIPTION QTY S NO DESCRIPTION QTY 1 Air Filter Box 1 2 Clamp 1 3 Pipe Outlet 1 4 TA Sensor 1 5 Hex Socket Head Cap Screw M5 X 16 2 6 Drain Pipe 1 7 Clip 1 8 Pan Head Screw M5 X 12 4 9 Inlet Cover 1 10 Seal 1 11 Element Air Filter 1 KS MOTORCYCLES http ksmotorcycles com ...

Page 19: ...Photos Aggregate toDismantle Instructions S No Hex Nyloc Nut M8 Loosen hex Nylock nut Gently pull out the cover assembly Remove cover filter element Remove the Air filter Element Unlock and open the Filter box RH CAUTION Ensure the pillion footrest is in extended position to avoiddamagetofilterboxlid KS MOTORCYCLES http ksmotorcycles com ...

Page 20: ...M5X12 Screw Driver NOTE Remove rubber seal from the cover PanHeadScrewM5 X1 Screw Driver CAUTION Ensure Purge valve is placed safely to prevent from damage Removeairfilterelement from the housing Remove the side panel from the frame Remove the 4 pan head screws on the airfilter cover Loosen and remove the pan head screw in side panel RH bottom KS MOTORCYCLES http ksmotorcycles com ...

Page 21: ...ed CLEANING Gently Tap filter element with minimum force to dislodge heavy embedded dust particles Using low pressure compressed air blow air from INSIDE to OUTSIDE for Bullet EFI Bullet Classic EFI Models blow air from OUTSIDE to INSIDE for Continental GT Models to remove the fine dust particles DO NOT WASH THE ELEMENT IN WATER GASOLINE OR ANY SOLVENTS Clean Airfilter element every 3 000 Kms OR m...

Page 22: ...n filter box RH Position washer on the mounting stud Locate nyloc nut on stud and tighten sufficiently tillitiscompletelyresting on the washer and resistance to tighten further is felt Ensure beading is correctly located on the filter box lid Close filter box lid and lock in place Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No Hex Nyloc Nut M8 CAUTION Ensure the ...

Page 23: ...tthe mounting peg in the housing Install the 4 pan head screws on the cover and tighten evenly Ensure the rubber grommets are in place in the side panel RH Locate side panel RH in the frame ensuing the pegs in the frame are seated in the grommets Tighten the RH side panel at the bottom using pan head screw Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions PanHeadScrewM5X...

Page 24: ...uel Tank With Sticker Black 1 2 Cap Fuel Tank 1 3 Thigh Pad R H 1 4 Flanged Hex Bolt M6X1X27 2 5 Washer Tank 2 6 Sleeve Tank Mtg Rear 2 7 Rear Damper Tank 2 8 Thigh Pad L H 1 9 PA Tube Assembly 1 10 Hex Socket Button Head Cap Screw M6X12 5 11 Washer 5 12 Washer 5 13 Clamp Plate Fuel Pump 1 14 Fuel Pump 1 15 ORing 1 16 Low Fuel Sensor 1 17 Front Damper Tank 2 18 Quick Connector 1 19 Fuel Hose Pa Tu...

Page 25: ...icker Red 1 3 Front Damper Tank 2 4 Flanged Hex Bolt M6 X 1 X 27 2 5 Bush Fuel Tank 2 6 Rear Damper Tank 2 7 ORing 1 8 Fuel Pump 1 9 Clamp Plate Fuel Pump 1 10 Washer 5 11 Washer 5 12 Fuel Hose Assembly 1 13 Hex Socket Head Cap Screw M6 X 16 5 14 HexScrewM6X12 4 15 Punched Washer Fuel Gauge Mtg 4 16 Fuel Gauge Unit 1 17 O Ring Fuel Gauge 1 18 Quick Connector 1 19 Fuel Hose PA Tube 1 20 Cap Injecto...

Page 26: ...ose from the Fuel tank Slide fuel tank towards rear to release front locking clamp from the rubber supports in frame Remove fuel tank from frame carefully Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions CAUTION Drain the fuel completely from the fuel tank S No Hex Flange Bolt M6 Socket Spanner 10 mm CAUTION Do not lift tank too high to Prevent accidental damage to th...

Page 27: ...upler Disconnect EVAP hose from the Fuel tank Slide fuel tank onwards rear to release front locking clamp from the rubber supports in frame Remove tank from frame carefully Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions CAUTION Drain the fuel completely from the fuel tank S No Hex Flange Bolt M6 Socket Spanner 10 mm CAUTION Do not lift tank too high to Prevent accid...

Page 28: ...essary WARNING Gasoline is extremely flammable and highly explosive which could result in serious injury Do not smoke or allow open flame or sparks in the vicinity Store the fuel carefully to avoid spillage Aggregate Component Fastener Torque Range NM Kg M Fuel Tank Fuel tank Mounting Flanged hex bolt M6 30 5 0 5 TORQUE CHART KS MOTORCYCLES http ksmotorcycles com ...

Page 29: ...k Connect fuel hose to the fuel tank Ensure the two dampers and mounting sleeves are properly located in the mounting slots Ensure the mounting are aligned and assemble 2 hex bolts with large washers Tighten the two bolts evenly Assemble Seat Fill fuel in the tank Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions Placeapieceofclothonthe top front portion of the fuel tank...

Page 30: ...Gently lift up fuel tank at the end and Connect low fuel sensor coupler wire Connect EVAP hose into the Fuel tank Connect fuel hose into the Fuel tank Install 2 Hex bolts at the rear end of fuel tank alongwithwashers seals and rear dampers Assemble Seat Fill fuel sufficiently Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No Hex Flange Bolt M6 Socket Spanner 10 mm H...

Page 31: ...O DESCRIPTION QTY S NO DESCRIPTION QTY 1 Complete Seat Assy 1 2 Flanged Hex Bolt M 6 X 20 4 3 Pillion Handle 1 4 Hex Nut With Nylon Insert M6 4 5 Flanged Hex Bolt M8 X 20 2 6 Hex Nut With Nylon Insert M8 2 7 Flanged Hex Nut M8 X 7 7 X 8 2 8 Stud M8 2 9 Plain Washer M8 4 10 Rubber Support Seat Front 1 KS MOTORCYCLES http ksmotorcycles com ...

Page 32: ... Special 4 7 Flanged Hex Bolt M8 X 60 1 8 Stud Seat Mounting 1 9 Hexagonal Bolt M8 X 45 2 Domed Cap Bolt M8 X 45 chrome 2 10 Washer Classic Models 2 Plain Washer Chrome 2 11 Spring Bush 2 12 Bush Seat Spring 4 13 Spring 2 14 Split Seat Assy Pillion 1 15 Sub Frame Black 1 16 Flanged Hex Bolt M6 X 1 X 35 2 17 Flanged Hex Bolt M6 X 1 X 27 2 18 Flanged Hex Bolt M8 X 170 1 19 Hex Nut With Nylon Insert ...

Page 33: ...ESCRIPTION QTY S NO DESCRIPTION QTY 1 Single Seat Assembly with Cowl Red 1 2 Plain Washer 3 3 Cross Recessed Pan Head Screw M6X14 3 4 Rubber Support Rear 2 5 Rubber Support Middle 2 6 Rubber Support Front 2 1 2 3 3 3 2 2 4 4 6 6 5 5 KS MOTORCYCLES http ksmotorcycles com ...

Page 34: ...S No Hex Nut with Nyloc InsertM8 Socket Spanner13 mm Hex Flange Bolt M8 Socket Spanner 13 mm Flange Hex Bolt M8 Socket Spanner 13 mm Hold nut and remove long mounting bolt from the sub frame Rear Seat Removal Gently remove the rider seat from the frame Remove the seat spring mounting bolts on LH RH side Loosen hex bolt at the front end of the seat KS MOTORCYCLES http ksmotorcycles com ...

Page 35: ...r hex bolt on LH RHsideoftheseats Gently lift the seat from the rear end Domed Hex Nut M8 Double end ring spanner 17mm Flange hex Bolt M8 Socket Spanner 13 mm Remove Rear shockers mounting Domed hex nut from LH RH side and loosen the bolt Hex Flange Bolt M8 Socket Spanner 13 mm Loosen the 2 hex bolt under the rear seat to remove seat from Sub frame 5 4 Seat Dismantling Bullet Classic EFI Rider Sea...

Page 36: ...eat Dismantling Continental GT Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions S No Remove the seat assembly Gently pull seat latch to release seat SEAT LATCH Unlock Remove Side panel LH KS MOTORCYCLES http ksmotorcycles com ...

Page 37: ...et Spanner13 mm Hex Flange Bolt M8 Socket Spanner 13 mm Flange Hex Bolt M8 Socket Spanner 13 mm Rear Seat Assembly Tighten the 2 hex bolt under the rear seat to assemble seat into Sub frame Tighten the seat spring mounting bolts on LH RH side Tighten hex bolt at the front end of the seat Positiontheriderseaton the frame CAUTION Please take care not to damage the fuel tank while assy KS MOTORCYCLES...

Page 38: ...ts Flange Hex Nut M8 Double end ring spanner 17mm Hex Flange Bolt M8 Socket Spanner 13 mm Locate nut and tighten long mounting bolt into the sub frame Flange hex Bolt M8 Socket Spanner13 mm Locate the seat in to front end tighten rear hex bolt on LH RH side of the seats Tighten Rear shockers mounting Domed hex nut Bolt from LH RH side 5 4 Seat Assembling Bullet Classic EFI Rider Seat Assembly KS M...

Page 39: ...at tab in the bracket in the frame Ensure the lock pin is position on the center of the seat latch Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No Locate the Side panel LH and lock in the seat Gently press the seat rear end tolock the seat KS MOTORCYCLES http ksmotorcycles com ...

Page 40: ... Exhaust Pipe Guard 1 3 Philips Pan HeadScrew M6 X 6 5 4 Flanged Hex Bolt M8 X 20 4 Flanged Hex Bolt M8 X 20 2 Flanged Hex Bolt M8 X 20 3 5 Flanged Hex Bolt M6 X 35 1 6 Combined Heat Shield Silencer Guard 1 7 Silencer CAT Assy 1 8 Bracket front silencer 1 9 Bracket Silencer Mounting Bracket Silencer 1 10 Gasket Exhaust pipe Silencer 1 11 Hex Nut M6 1 12 Clamp Silencer 1 13 Exhaust Pipe Assy 1 14 E...

Page 41: ...autions Photos Aggregate toDismantle Instructions Hex Flange Bolt M8 Socket Spanner 10 mm S No Hex Flange Bolt M8 Socket Spanner 10 mm Flange Hex Nut M8 Socket Spanner 10 mm Remove the center silencer bracket mount ing screw with plain washer Remove the rear mount ing nut at the pillion foot rest end mounted on silencer Remove the flange hex nuts from cylinder head KS MOTORCYCLES http ksmotorcycle...

Page 42: ...emovethe2Hexflange nuts holding exhaust pipe to cylinder head Gently remove the silencer assembly with Exhaust pipe Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions S No Hex Flange Bolt M8 Socket Spanner 10 mm Flange Hex Nut M8 Socket Spanner 10 mm NOTE Ensurethecoppergasketis removed from the cylinder head exhaust pipe KS MOTORCYCLES http ksmotorcycles com ...

Page 43: ...as leakage CAUTION Do not clean the silencer and exhaust internals with any solvents gasoline etc as it will damage the catalytic converters REPLACE Gasket between the silencer and exhaust pipe joint whenever the silencer exhaust pipe are dismantled Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder head Copper gasket in HEGO sensor whenever exha...

Page 44: ...ghten the rear Mount ing nut at the pillion foot rest end Tighten the center silencer bracket mount ing screw with plain washer Connect HEGO sensor connector to the exhaust pipe Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm Hex Flange Bolt M8 Socket Spanner ...

Page 45: ... flange hex nuts on exhaust pipe into cylinder head Tighten the rear Mounting nut at the pillion foot rest end Connect HEGO sensor connector from the exhaust pipe Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm KS MOTORCYCLES http ksmotorcycles com ...

Page 46: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 45 SECTION 06 FRONT SUSPENSION KS MOTORCYCLES http ksmotorcycles com ...

Page 47: ...ket Button Head Cap Screw 6 5 Disc Front 1 6 Spacer Disc Side 1 7 Grease Seal 25 X 40 X 7 2 8 Wheel Bearing 6203 17 X 40 X 12 2 9 Spacer Assy 1 10 Front Hub 1 11 Brass Nipples 40 12 Spokes Front 40 13 90 90 19 52 V Front Tyre Import 1 14 Tube Tyre 3 25X19 1 15 Wheel Rim 1 85 X 19 1 5 Thk 1 16 Rim Tape 1 17 Spacer Speedodrive 1 18 Speedo DrIve Assy Disc Brake 1 19 Plain Washer M16 1 20 Hex U Nut M1...

Page 48: ...Side 1 4 Hex Flange Bolt M8X 25 6 5 Toner Front Wheel 1 6 Front Disc 1 7 Grease Seal 25 X 40 X 7 1 8 DeepGrooveBallBearing 6203 17X40X12 2 9 Bearing Spacer Assy 1 10 Hub Front 1 11 Spokes Front 36 12 Nipple3 6mm 36 13 Tyre Front 100 90 18 1 14 Tube Front 100 90 18 1 15 Rim Front Aluminium 2 5X18 1 16 Rim Tape 1 17 Spindle Front Wheel 1 18 Wheel Speed Sensor Assy 1 KS MOTORCYCLES http ksmotorcycles...

Page 49: ...t surface Provide a suitable support below the front end of the engine such that the front wheel is about 4 inches 10 cms above the ground Disconnect speedo cable at speedo drive Disconnect wheel speed sensor coupler near head lamp housing Hex Bolt M8 Hex Nut M8 Ring Spanner13 mm Double end Ring Spanner 13mm Loosen the pinch bolt on the right side fork end Holdtheaxleontheright side and loosen the...

Page 50: ...ide and removecompletelyfrom the right side Slide out the wheel from the fork legs Remove the speedo drive after removing wheelfromtheforklegs Remove the wheel speed sensor and spacer after removing wheel from the fork legs CAUTION Do not depress the front brake lever when wheel is removedasthiswillresultin the brake pads coming too far out of the brake caliper NOTE Place a 4 mm thick wooden piece...

Page 51: ...per seating in rim Tyres button to be above the tyre wear indicator mark on the side walls Inspect spokes for any loosening breakage Inspect hub or any damage Inspect Toner ring for any damage Axle nut for thread damage Inspect wheel rim for run out jump it should not exceed 2 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 52: ... wooden piece card board sheet placed between the brake pads Locate spacer speedo drive on the right side in the hub Locate stepped spacer in the left side disc side of the hub with its larger face outside Locate front wheel between the fork ends duly ensuring the spacers and the speedo drive do not fall off and the brake disc is correctly positioned between the brake pads KS MOTORCYCLES http ksmo...

Page 53: ...structions 6 1 Front Wheel Assembling Bullet Classic EFI Bullet EFI Ensure the peg in the Speedo drive is correctly positioned in the slot in the right side fork end Continental GT Position wheel speed sensor such that the wire coupler can be connected and the wire is not stretched KS MOTORCYCLES http ksmotorcycles com ...

Page 54: ...m the right side and tighten nut on left side Hold the pinch bolt and tighten the nylock nut on the right side fork end Only Bullet Classic EFI Bullet EFI Tighten hex socket screw on fork end RH Only for Continental GT Rotate the wheel and check for smooth rotation Connect the speedo cable to speedo drive and check for proper working of speedo meter Depress brake lever 2 or 3 times to check front ...

Page 55: ...guard Stay Front Black Mod 4 3 Mudguard Stay Center LH Black New 1 5 Hex Flanged Bolt M8 X 1 25 X 38 2 6 Phillips RoundHeadMachined Screw M6X13 6 7 Lock Washer M6 6 8 Hex Nut M6 X 1 6 9 Flanged Hex Bolt M8 X 20 6 10 Spring Washer 6 11 Cable Guide 1 12 Clamp Front Caliper Brake Hose 1 13 Cross Recessed Pan Head Screw M6 X 14 1 14 Plain Washer M6 1 15 Hex Nut M6 X 1 X 5 1 EXPLODEDVIEWS BULLET EFI BU...

Page 56: ...SCRIPTION QTY A1 Front Mudguard Mud Flap Extension Kit 1 1 Front Mudguard 1 2 Mud Flap Front 1 3 Fork Brace 1 4 Hex Socket Button Head Screw M6X1 4 5 Lock Washer Internal Teeth 3 6 Pan Head Screw M5 X 0 8 X 12 3 7 Hex Nut M8 3 8 Hex Socket HD Cap Screw M6X20 Stainless Steel 4 A1 Key Nos 2 5 6 7 KS MOTORCYCLES http ksmotorcycles com ...

Page 57: ...nd RH Loosen and remove 2 flanged hex bolts along with spring washers holding front mudguard centre stay frontbrakecaliperto fork end LH 2 flanged hex bolts along with spring washers holding front mudguard front and rear stays to fork end LH Loosen wheel speed sensor screw and remove sensor along with screw Gently rotate the mudguard stays into the mudguard and slide out of the fork legs Flanged H...

Page 58: ...nstructions 6 2 Front Mudguard Continental GT Remove Front wheel as described in Front Wheel section Loosen and remove the 4 socket head cap screws on the fork brace betweentheforklegsRH LH Gently lift up and remove mudguard from the fork legs Socket head cap Screw M6 Allen Key 5 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 59: ...k end LH 2 flanged hex bolts along with spring washers holding front mudguard front and rear stays to fork end LH Install and locate the 4 flanged hex bolts along with spring washers holding front mudguard front centre rearstays to fork end RH Locate Brake hose grommet in the holding clip in front mudguard Assemble Front wheel as described in Front Wheel section CAUTION Ensure mudguard does not ge...

Page 60: ...structions 6 2 Front Mudguard Continental GT Gently lift down and locate mudguard on the fork legs Socket head cap Screw M6 Allen Key 5 mm Install and locate the 4 socket head cap screws on the fork brace betweentheforklegsRH LH Locate Front wheel as described in Front Wheel section KS MOTORCYCLES http ksmotorcycles com ...

Page 61: ...LH 1 4 Cable Strap 6 2 Cable Strap 8 3 5 Handle Bar Complete 1 6 Rear View Mirror LH 1 7 Rear View Mirror RH 1 8 Grip Complete Throttle RH 1 9 Lever Holder Assy LH 1 10 Clutch Lever 1 11 Switch Module LH 1 12 Switch Module RH 1 13 Rotor Plate 1 14 Pan Head Screw M5 X 10 1 15 Front Brake Lever kit 1 16 Add On Lead Front Brake Switch 1 17 Add On Lead Clutch Switch 1 18 Clutch Switch 1 EXPLODEDVIEWS ...

Page 62: ...w M8 X 35 6 4 Grommet ClipON 2 5 Hex Socket Head Cap Screw M6 X 20 4 6 Top Yoke 1 7 Handle Bar Assy LH 1 8 Handle Bar Assy RH 1 9 Counter Weight Assy 2 10 Mirror Dummy Ring 2 11 Handle Grip LH 1 12 Switch Module LH 1 13 Lever Holder Assy LH 1 14 Handle Bar Complete LH 1 15 Hex Socket Head Bolt M8 X 40 2 16 Rubber Sleeve Handle Bar 2 17 Handle Bar Complete RH 1 18 Master Cylinder Front 1 19 Switch ...

Page 63: ... Bar Bullet Classic EFI Bullet EFI Remove Headlamp from the headlamp casing and disconnect wire terminals Philips head screw driver Double end spanner 15mm Disconnect wire couplers from handle bar inside the head lamp casing Remove Rear view mirrors LH RH Disconnect all control cables from the handle bar KS MOTORCYCLES http ksmotorcycles com ...

Page 64: ...emoving from handle bar Hex SS Bolt M12 Socket spanner 14 mm Hex bolts M6 Socketspanner 10mm Hex Nut M8 Socketspanner 12mm Remove master cylinder assembly from the handle bar and support suitably to prevent hydraulic oil leak from master cylinder Loosen and remove 2 Hex bolts along with washers from the handle bar clip top Loosen and remove 2 hex nuts along with washers from the handle bar clip bo...

Page 65: ...rom the headlamp housing and disconnect wire terminals Philips head screw driver Double end spanner 15mm Disconnect handle bar LH RH wire couplers inside the head lamp housing Remove Rear view mirrors LH RH Disconnect all control cables from the handle bar Remove the 2 hex bolts on the clamp holding Front brake master cylinder to handle bar KS MOTORCYCLES http ksmotorcycles com ...

Page 66: ...prevent hydraulic oil leak from master cylinder Hex bolts M6 Socketspanner 10mm Hex Socket Head Screw M8 Allen Key 6 mm Hex Socket Head Screw M6 Allen Key 5 mm Loosen the hex socket screw clamping the handle bar assemblies LH RH to the fork main tubes Remove the 2 rubber grommets on top of the handle bar LH RH and remove the 2 hex socket head cap screws Removehandle barLH RH form the fork main tub...

Page 67: ...hwashers on the handle bar clip top Locate master cylinder assembly on the handle bar and support suitably to prevent hydraulic oil leak from master cylinder while locating Install the 2 hex bolts on the clamp holding Front brake master cylinder to handle bar 6 3 Handle Bar Bullet Classic EFI Bullet EFI Hex SS Bolt M12 Socket spanner 14 mm Hex Nut M8 Socketspanner 12mm CAUTION Ensure the brake lev...

Page 68: ...Connect all control cablesonthehandlebar LocateRearviewmirrors LH RH Connect wire couplers on handle bar inside the head lamp casing Locate Headlamp in the headlamp casing and connect wire terminals 6 3 Handle Bar Bullet Classic EFI Bullet EFI Double end spanner 15mm Philips head screw driver KS MOTORCYCLES http ksmotorcycles com ...

Page 69: ...and Install the 2 hex socket head cap screws Install the hex socket screw clamping the handle bar assemblies LH RH to the fork main tubes Locate master cylinder assembly on the handle bar and support suitably to prevent hydraulic oil leak from master cylinder 6 3 Handle Bar Continental GT Hex bolts M6 Socketspanner 10mm Hex Socket Head Screw M8 Allen Key 6 mm Hex Socket Head Screw M6 Allen Key 5 m...

Page 70: ...ng Front brake master cylinder to handle bar Connect all control cables from the handle bar LocateRearviewmirrors LH RH ConnecthandlebarLH RH wire couplers inside the head lamp housing Locate Headlamp on the headlamp housing and Connect wire terminals 6 3 Handle Bar Continental GT Philips head screw driver Double end spanner 15mm KS MOTORCYCLES http ksmotorcycles com ...

Page 71: ...g Washer 2 3 Outer Tube M C RH Fork End 1 4 Outer Tube M C LH Fork End 1 5 Guide Bush 2 6 Plain Washer Big 2 7 Oil Seal LH RHFront Fork 2 8 OilSeal Stopper LH RH 2 9 DustSeal LH RH 2 10 Slide Bush 1 11 Fork Pipe Spining Inline Fork 2 12 Cap Oil Lock Spindle Tapper 2 13 Rebound Spring 2 14 Seat Pipe 2 15 Piston Ring Front Fork 2 16 Main Spring 2 17 Washer Fork Main Spring 2 18 Spacer Tube Front For...

Page 72: ...ng PistonRing Kit 1 A5 Main Spring Fork Major Kit 1 1 Outer Tube RH 1 2 Outer Tube LH 1 3 Inner Tube Assy 2 4 Piston Front Fork 2 5 Bush Outer Tube 2 6 Bush Washer 2 7 OilSeal 2 8 Circlip Snap Ring 2 9 Dust Seal 2 10 Spindle Taper 2 11 Gasket 2 12 Bolt M10X1 2 13 Spring 1 2 14 Washer Spring Top 2 15 Spacer 2 16 Bolt Cap 2 17 O Ring 2 18 Washer 2 2 19 Bolt M8 X 1 25 X 45 2 20 Piston Ring 2 21 Sprin...

Page 73: ...ure wheel speed sensor is removed from the fork end LH Disconnect Trafficator couplers LH RH inside headlamp casing Loosen Hex Nylock nuts on steering stem pinch bolt LH RH remove trafficator assembly with bracket on LH RH side Hold the pinch bolts LH RH and loosen hex nut Loosen nut by holding forkpinchboltinbottom yoke steering stem on RH LH side Hex Nylock Nut M8 Ring spanner 12mm Hex bolt M8 H...

Page 74: ...Instructions 6 4 Front Fork LH RH Bullet EFI Bullet Classic EFI Loosen and remove 2 Hex socket screws from the topof the front forks ontheheadlampcasing Gently rotate and remove the fork assembly LH RH from the head lamp casing and the steering stem HexHdCapscrew M10 Allen Key 8 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 75: ...rd as detailed above in Section 6 2 Ensure front brake caliper is dismantled from the fork LH Ensure wheel speed sensor is removed from the fork end LH Remove Headlamp from the headlamp housing and disconnect all electrical connections inside headlamp housing Loosen and remove the 2 hex bolts holding head lamp housing to the holder RH LH Loosen the 2 hex socket screws inside the head lamp holder R...

Page 76: ...ket head cap bolts 2 each on LH RH sides from the steering stem Loosen the 4 hex socket head cap bolts 2 each on LH RH sides from the top yoke Gently rotate and remove the forks LH RH from the steering stem and top yoke NOTE Support the head lamp holders with the trafficators whileremovingthe forksLH RHfromthesteeringstem Hex Screw M6 Allen key 5 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 77: ...e top of the front forks on the head lamp casing Hex Screw M10 Allen Key 8 mm Hex Nylock Nut M8 Ring spanner 12mm Hex bolt M8 Hex Nylock Nut M8 Double end spanner 12mm Ring spanner 12mm Hold the pinch bolts LH RH and Install hex nut Loosen nut by holding forkpinchboltinbottom yoke steering stem on RH LH side Install Hex Nylock nuts on steering stem pinch bolt LH RH and locate trafficator assembly ...

Page 78: ...ns Photos AggregatetoAssemble Instructions 6 4 Front Fork LH RH Bullet EFI Bullet Classic EFI Ensure wheel speed sensor is located in the fork end LH Locate front mudguard as detailed above Assemble Front wheel as described in Front Wheel section 6 1 KS MOTORCYCLES http ksmotorcycles com ...

Page 79: ...upport the head lamp holders with the trafficators whileremovingthe forksLH RHfromthesteeringstem Hex Socket Screw M6 Allen key 5 mm Hex Socket Screw M8 Allen key 6 mm Install the 4 hex socket head cap bolts 2 each onLH RHsides onthe steering stem Install the 2 hex socket screws inside the head lamp holder RH LH Ensure the head lamp holders are fixed on the front fork main tube Install and locate ...

Page 80: ...nstructions 6 4 Front Fork LH RH Continental GT Ensure wheel speed sensor is located in the fork end LH Ensure front brake caliper is located in the fork LH Locate front mudguard as detailed above Assemble Front wheel as described in Front Wheel section 6 1 Hex bolt M8 Tspanner12mm KS MOTORCYCLES http ksmotorcycles com ...

Page 81: ... 6 inches from the top and loosen top nut Remove fork assembly from the bench vise Hold upright and gently removeforktopnutwith washer allowing spring to expand slowly Hex nut M16 Double end spanner 24 mm Remove washer spacer and washer spring top from the inner tube NOTE Replace all Rubber parts plastic bushes O rings washers whenever they are removed Remove long spring from inner tube KS MOTORCY...

Page 82: ...gregate to Dismantle Instructions 6 4 Front Fork Oil Draining Invert the fork assembly to drain out the oil from the fork Gently pump main tube into the bottom tube to drain out the oil completely Repeat the above process to drain oil from the other fork assembly KS MOTORCYCLES http ksmotorcycles com ...

Page 83: ...ork Oil Filling Fill Fork oil 195 ml leg For Bullet Classic Models and 430 ml leg For Conti GT Model with 2W 35 Grade Locate long spring into the inner tube NOTE Replace all Rubber parts plastic bushes O rings washers whenever they are removed Locate washer spacer and washer spring top in the inner tube KS MOTORCYCLES http ksmotorcycles com ...

Page 84: ...ions Photos AggregatetoAssemble Instructions 6 4 Front Fork Oil Filling Locate fork top nut with washer allowing spring to compress slowly Repeat the above process to fill oil and assemble the other fork assembly Hex nut M16 Double end spanner 24 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 85: ...he nut on the seat pipe inside Loosen and remove the hex socket head nut inside the outer tube Hex bolt nut M6 Ringspanners 10mm Special Tool ST 25834 2 Allen Key 10mm Remove the special tool from the inner tube Remove the dust seal retainer clip and fork sealfromtheoutertube Pull out the inner tube from the outer tube sharply to remove the innertubealongwiththe guide bush seat pipe assembly rebou...

Page 86: ...eatpipeassembly rebound spring and cap oil lock Locate the dust seal retainer clip and fork seal in the outer tube Locatethe specialtool in the inner tube Locate and install the hex socket head nut inside the outer tube Locate special tool inside inner tube such that it engages with the nutontheseatpipeinside Locate the pinch bolt and nut on Fork RH Special Tool ST 25834 2 Allen Key 10mm Hex bolt ...

Page 87: ...es and bends Inspect front fork outer tube for any damages cracks at oil seal seating area WEAR LIMIT Main tube straightness Fork spring long Long Pitch Short Pitch SpringLength mm Fork spring short ServiceLimit 0 15mm Guide Bush Length NewSpring mm ServiceLimit mm KS MOTORCYCLES http ksmotorcycles com ...

Page 88: ... 7 Flanged Hex Nut M8 x 7 7 X 8 2 8 Hex Nut with Nylock insert M8 X 9 5 2 9 Flange Bolt M8 75 2 10 Stem Lock Nut 1 11 Steering Stem Lock Nut Washer 1 12 Washer 2 13 HexSS Bolt M8x48 2 14 Stud M8 32 2 15 Washer 2 16 Nut 2 17 Clip Handle Bar 1 18 Sleeve Threaded 1 19 Sleeve Plain 1 20 Hex Socket head Cap Screw M10 x 1 5 x 35 1 21 Adaptor AHO 1 22 Rubber Spacer 2 23 Bush 2 24 Cover Tube 2 25 Head Lam...

Page 89: ...ESCRIPTION QTY 1 Lock Nut 1 2 Top Yoke 1 3 Hex Socket Head Bolt M8 X 35 8 4 Ring Nut 2 5 Dust Cap Top Yoke 1 6 Ball Race Top Yoke 1 7 Steering stem Ball Cage 2 8 Ball Race Frame Head Tube 2 9 Dust Cap Frame 1 10 Steering Stem Assembly 1 11 Ball Race Bottom Yoke 1 12 Dust Seal Bottom Yoke 1 KS MOTORCYCLES http ksmotorcycles com ...

Page 90: ...djustment should be done and on Every 12 000 Km Lubrication is recommended LockNutM20 Socket Spanner 30 mm Dome Lock Nut M24 Socket Spanner 30 mm Torque 50 Nm Finally tighten all the nuts and bolts in reverse order If felt adjust as follows Loosen steering bottom bridge pinch bolt and nuts of Right Left side Loosenthestemlocknut and then tight steering stem tapper nut to adjust excess play Again r...

Page 91: ... Socket Screw M5 Allen Key 6mm Steering Dome Nut X Don t CAUTION Do not Use Sockets Directly Dome Lock Nut M24 Socket Spanner 30 mm If felt adjust as follows Loosen the steering dome nut with long extension rod Loosenthepinchboltsin bottom yoke on LH and then RH side Holdthe Forkpipe Main Tube pull and push simultaneously lift the front wheel upwards and check for Steering play Rock the front whee...

Page 92: ...o tighten dome nut Dome Lock Nut M24 Socket Spanner 30 mm Torque 50 Nm Loosen the lock ring nut before adjusting Steering play Again check andconfirm the steering free play After adjusting the play then tighten Dome nut to Torque After adjusting the play then tighten lock nut against ring nut In case of excessive steering play tighten the steering ring nut by using special tool C spanner KS MOTORC...

Page 93: ...inental GT Hex Socket Screw M5 Allen Key 6mm Torque 25 NM NOTE Take a small test ride to ensure that Steering free movement No dragging No sound from steering stem mounting area Now check the handle bar free movement by turning extreme Left to Right side Tighten the pinch bolts in bottom yoke LH and then RH by using Allen key KS MOTORCYCLES http ksmotorcycles com ...

Page 94: ... throttle and bi starter cables from the hole in the headlamp casing Loosen remove the hex Nylock nut and bolt holding RR cover and cover tube to the steering stem Hex Soc Hd Cap screw M10 Allen key 12 mm Loosen and remove the steering stem lock nut from the headlamp casing along with the washer Remove the fork cover tubesLH RHalongwith the rubber spacers and plastic bushes Loosen socket head scre...

Page 95: ...he steering stem and remove from the frame Remove the Headlamp casing from the frame Usingalongchisel gently tapanddriveout the top and bottom races from the frame head tube along with the dust cap Remove the top and bottom ball cage from the ball races Usingashortchisel drive out the ball race along with dust cap from the headlampcasingandthe ball race from steering stem KS MOTORCYCLES http ksmot...

Page 96: ...e in steering stem Loosen and remove the steering stem lock nut from the headlamp casing along with the washer Remove the fork cover tubesLH RHalongwith the rubber spacers and plastic bushes Locate steering stem and assemble on the frame Usingalongchisel gently tap and drive in at the top and bottom races on the frame head tube along with the dust cap Locate the top and bottom ball cage from the b...

Page 97: ... Install the hex Nylock nut and bolt holding RR cover and cover tube to the steering stem Locate the fork cover tubesLH RHalongwith the rubber spacers and plastic bushes Locate and install the steering stem lock nut in the headlamp casing along with the washer Hex Soc Hd Cap screw M10 Allen key 12 mm Locate the clutch throttle and bi starter cables on the hole in the headlamp casing Connect wiring...

Page 98: ... all wiring couplers of the instrument cluster to main wiring harness Remove speed sensor wire coupler from wiring harness Remove the top lock nut on the top yoke Remove the top yoke along with the instrument cluster and ignition switch Support steering stem and the bottom and loosen and remove the top ring nut first and the second ring nut next KS MOTORCYCLES http ksmotorcycles com ...

Page 99: ...ntly lower the steering stem and remove from the frame Remove the top and bottom ball cage from the ball races Usingalongchisel gently tapanddriveout the top and bottom races from the frame head tube along with the dust cap Usingashortchisel drive out the ball race along with dust cap from the top yoke and the ball race from steering stem KS MOTORCYCLES http ksmotorcycles com ...

Page 100: ...longwith dust cap in the top yoke and the ball race on steering stem Usingalongchisel gently tap and drive in at the top and bottom races from the frame head tube along with the dust cap Locate the top and bottom ball cage in the ball races Locate steering stem and assemble on the frame NOTE Replace all Rubber parts plastic bushes O rings washers whenever they are removed KS MOTORCYCLES http ksmot...

Page 101: ...Continental GT Locate and install the second ring nut first and top ring nut next Locate the top yoke alongwiththeinstrument cluster and ignition switch Locate the top lock nut on the top yoke Locate speed sensor wire coupler from wiring harness Connect all wiring couplers of the instrument cluster to main wiring harness KS MOTORCYCLES http ksmotorcycles com ...

Page 102: ...CTION Inspect the steering ball cages and ball races for any rusting pitting and damaged balls races Inspect steering stem for any damages run out as these will affect the stability and steer ability for the motorcycle KS MOTORCYCLES http ksmotorcycles com ...

Page 103: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 102 SECTION 07 REAR SUSPENSION KS MOTORCYCLES http ksmotorcycles com ...

Page 104: ... 2 8 Rear Hub Spacer Assy 1 9 Rear Hub 1 10 Spokes Outer Rear 20 11 Spokes Inner Rear 20 12 Brass Nipples 40 13 Tyre Rear 110 80 18 1 14 Tube Rear 110 80 18 1 15 RimRear 1 15 WheelRimAmryOg 1 16 Rim Tape 1 17 Cush Rubber 4 18 Adaptor Rd Sprocket 1 19 Sprocket Rear Drive 1 20 Low Head Socket Cap Screw M10 X 1 5 X 16 6 21 Bearing 1 22 Dust Seal Rd Spracket 1 23 Spindle Short 1 24 Spacer Sprocket Sid...

Page 105: ... 18 10 Bearing Spacer Assy 1 11 Rear Hub Assembly 1 12 Spokes Outer Rear 18 13 Brass Nipples 36 14 Cushion Rubber 4 15 Tyre Rear 130 70 18 1 16 Tube Rear 130 80 18 1 17 RimRear 1 18 Rim Tape 1 19 Adaptor RD Sprocket Metalic Silver 1 20 Sprocket Rear Drive 1 21 Low Head Socket Cap Screw M10 X 1 5 X 16 6 22 Bearing 6005 25 X 47 X12 1 23 Dust Seal Rd Spracket 1 24 Spindle Short 1 25 Spacer Sprocket S...

Page 106: ...scenterstand onafirm and flat surface such that the rear wheel is about 4 inches 10 cms above the ground Hex Nut M16 Double end spanner 24mm Gently release the brake hose from the holding clips in the swing arm Hold the axle from the left side Loosen and remove the hexnutontherightside Remove wheel spindle from left side Observe and mark the alignmentindexmarksin the both sides of swing arm KS MOT...

Page 107: ... of the brake caliper Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the eventif therear brakepedal is accidently pressed Remove the caliper assembly by gently pulling out from the swing arm slot and support the caliper suitably Ensure the spacer is removed and stored carefully Gently pull rear wheel towards the left so that the hub becomes fr...

Page 108: ...ove the tyre wear indicator mark on the side walls Inspect spokes for any loosening breakage Inspect hub or any damage Inspect Toner ring for any damage Axle nut for thread damage Inspect wheel rim for run out jump it should not exceed 2 mm Inspec cush rubbers for wear or deterioration and replace only as set if required KS MOTORCYCLES http ksmotorcycles com ...

Page 109: ...kness marked on disc Front Disc Rear Disc Rear wheel disc flatness run out UCE 535 A B New Min Flatness 0 00mm 0 00mm New Max Flatness 0 10mm ServiceLimit Run out disc A B Rear Disc Thickness BBI New Min New Max ServiceLimit 5 00 only GT 4 5 mm CON GT KS MOTORCYCLES http ksmotorcycles com ...

Page 110: ...heet placed between the brake pads Ensure the four Cushion rubbersareinpositionin the rear wheel hub Locaterearwheelonthe sprocket ensuring the cushion rubbers are seated on the lugs correctly Locate the caliper assembly on the lug in the swing arm Position rear wheel swing arm such that he brake disc is on the left side NOTE Ensure the brake disc is located in between the brake pads KS MOTORCYCLE...

Page 111: ...swing arm Position the spacer correctly between the hub and the caliper assembly Alignthecaliperbracket spacer hub and chain tensioner holes Insert the wheel spindle from left side fully Hold the axle from the left side and tighten the axlenutontherightside Gently locate the brake hose into the holding clips in the swing arm Hex nut M16 Double end spanner 24mm Torque 70 Nm NOTE Ensure the caliper ...

Page 112: ...ay adjustment Remove the split pin from the castle nut Loosen the Castle spindle nut Loosen the locknut of each end of the swing arm To reduce the free play turn the drive chain slack adjusting nut at each end of the swing arm in Clockwise direction 20 to25 mm Split Pin Index Mark Drive Chain slack adj nut Swing Arm Reference Mark Lock nut Castle spindle Nut KS MOTORCYCLES http ksmotorcycles com ...

Page 113: ...sh the rear wheel forward Check the front and rear wheelscorrectlyaligned Check and ensure the alignmentmarksoneach side of the swing arm Finallytorquethecastle spindle nut Tighten the lock nut for the chain slack adjusting nut CAUTION Improper drive chain slack will overload the engine and It leads to chain slippage or breakage It is recommended to maintain drive chain slack within the specified ...

Page 114: ...7 6 5 5 4 1 5 3 5 6 7 S NO DESCRIPTION QTY S NO DESCRIPTION QTY 1 Shockabsorber Chrome Plated 2 2 Shock Absorber 2 3 Hex Bolt 3 8 X45 For RH Side Only 1 4 Hex Bolt 3 8 BSF x 2 For LHSide Only 1 5 Plain Washer M10 6 Plain Washer M10 2 6 Single Coil Spring Lock Washer 4 7 Domed Nut 4 8 Flanged Hex Bolt M10 x 44 2 9 Spring Shock Absorber 2 KS MOTORCYCLES http ksmotorcycles com ...

Page 115: ...i clockwise to reduce spring tension Ensure the spring tension is the same in both the left and right side shockabsorbers After adjustment ensure the adjuster notches are seated correctlyagainstthepeg in the shockabsorber CAUTION Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident Regularly inspect shock absorbers and front f...

Page 116: ...rs on bothLH RHsidesalong with single coil spring lock washer and plain washer Remove 2 Hex bolts mounted on the inner side of Rear shock absorbers top end on bothLH RHsidesalong with plain washer Loosen 2 Domed nuts mounted on bottom end of rear shock absorbers on both LH RHsidealongwithsingle coil spring washers and plaint washers Gently remove the Rear Shockabsorbers Chrome plated from LH RH si...

Page 117: ... hex bolts mounted on top end of Rear shock absorbers on both LH RH sides along with single coil spring lock washers and plain washers Loosen 2 domed nuts mounted on bottom end of rear shock absorbers on both LH RH sides along plain washer Gently remove the Rear Shock Absorbers from LH RH side Flanged Hex Bolt M 10 Socket Spanner 17 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 118: ...ar shock absorbers on both LH RH side along with single coil spring washers and plain washers Install 2 Hex bolts on the inner side of Rear shock absorbers top end on bothLH RHsidesalong with plain washer Domed Nut M10 Hex Bolt M6 Socket Spanner 10mm Torque 4 Kg M Install 2 domed nuts on top end of Rear shock absorbers on both LH RH sides along with single coil spring lock washerandplainwasher Ref...

Page 119: ...orbers on LH RH sides Install 2 Domed nuts on bottom end of rear shock absorbers on both LH RH side along with single coil spring washers and plain washers Install 2 hex bolts on top end of Rear shock absorbers on both LH RH sides along with single coil spring lock washers and plain washers Flanged Hex Bolt M 10 Socket Spanner 17 mm Torque 4 Kg M KS MOTORCYCLES http ksmotorcycles com ...

Page 120: ...asher M6 10 7 Hex Nyloc Nut M6 9 8 Plug Carrier End 2 9 Grommet 1 10 Beading Rear Number Plate 1 11 Hex Bolt M8X 30 1 12 Number Plate Holder Complete 1 13 Tail Lamp Bracket Complete 1 14 Beading 1 15 Reflector 1 16 Hex Nut M6X1 2 17 Lock Washer Internal Teeth M6 8 18 Piece Mudguard 1 19 Washer Plain M6 2 20 Hex Bolt M6 X 35 2 21 Mudguard Carrier LH Mod Black 1 22 Faced Hex Nut 1 2 CEI 2 23 Rear Mu...

Page 121: ... 2 Dome Cap Bolt M8 X 45 Special 2 9 Plug Carrier End 2 10 Grommet 1 11 Beading 1 12 Number Plate Holder Comp Black 1 13 Tail Lamp Bkt Comp Black Mod 1 14 Beading 1 15 Reflector Assembly 1 16 Hexagonal Nut M6 X 1 X 7 4 17 Flanged Hex Bolt M8 X 30 1 18 Piece Mudguard 1 19 Lock Washer Internal Teeth 2 20 HexBolt M6X35 2 21 Washer Plain 2 22 Hex Nut M6 2 S NO DESCRIPTION QTY S NO DESCRIPTION QTY 6 2 ...

Page 122: ...e Export 1 6 Number Plate Rear Export 1 7 Tail Lamp 1 8 Trafficator Assy With Bulb Rear LH 1 9 Trafficator Assy With Bulb Rear RH 1 10 Reflector 1 11 Flanged Hex Bolt M8 X 1 X 20 4 12 Hex Nut With Nylon Insert M8 2 13 Lock Washer M6 2 14 Washer 2 15 Hex Nut M6 2 16 Hex Socket Button Head Screrw M6 X 16 2 17 Hex Nut With Nylon Insert M6 2 18 Cross Recessed Pan Head Screw M6X 4 2 19 Punched Washer M...

Page 123: ...llet EFI Loosen 2 hex bolts mounted on top end of Mudguard Carrier on both LH RH side along with washer Remove 2 Hex screws mounted on bottom end of Mudguard carrier on both LH RH side Gently remove the Rear Mudguard assembly along with Mudguard carriers Flanged Hex Bolt M8 Socketspanner13mm Hex Socket head cap Screw M8 Allen Key 5 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 124: ...r Section 5 4 removal of Seat dismantling Loosen 2 hex bolts mounted on top end of Rear mudguard along with Hex nuts Loosen 2 hex screws mounted on rear end of Rear mudguard along with punched washers Gently remove the Rear mudguard from its position Flanged Hex Bolt M8 Socket Spanner13 mm Crossrecessedpanhead screwM6 Allen Key 5 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 125: ...let EFI Gently locate the Rear Mudguard assembly along with Mudguard carriers Install 2 Hex screws on bottom end of Mudguard carrier on both LH RH side Install 2 hex bolts on top end of Mudguard Carrier on both LH RH side along with washer Hex Socket head cap Screw M8 Allen Key 5 mm Flanged Hex Bolt M8 Socketspanner13mm Torque 3 Kg M KS MOTORCYCLES http ksmotorcycles com ...

Page 126: ... GT Locate the Rear mudguard on its position Install 2 hex screws on rear end of Rear mudguard along with punched washers Install 2 hex bolts on top end of Rear mudguard along with Hex nuts Refer Section 5 4 for assembling Seat dis mantling Crossrecessedpanhead screwM6 Allen Key 5 mm Flanged Hex Bolt M8 Socket Spanner13 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 127: ...240 T30 1 6 Washer Shake Proof M12 1 7 Hex Nylock Nut 1 8 Chain Pad 1 9 CSK Screw M6X20 2 10 Bracket Complete Chain Guard Black Powder Coated 1 11 Flange Bolt with Collar M6 X 1 2 12 Chain Guard 1 13 Chain Tensioner RH 1 14 Chain Tensioner LH 1 15 Plate Chain Adjuster 2 16 Flanged Hex Nut M8 X 1 25 4 7 6 3 2 8 9 2 4 3 5 9 12 11 11 13 10 14 15 16 1 15 16 16 16 A1 EXPLODEDVIEWS BULLET EFI BULLET CLA...

Page 128: ...6 2 6 OilSeal SwingArm 2 7 Spacer OilSeal SwingArm 2 8 End Cap RH Swing Arm 2 9 Rear Chain Pad 1 10 Washer 2 11 HexScewM6X16 2 12 Clip Rear Disc Hose 3 13 Philips Pan Head Screw M6X6 3 14 Chain Tensioner Comp LH 1 15 Chain Tensioner Comp RH 1 16 Plate Chain Adjuster 2 17 Flanged Hex Nut M8X1 25 4 18 Flanged Hex Bolt 1 19 Spacer Swing Arm 1 20 Hex Nut with Nylock M12 1 21 Domed Bolt 3 8 X40 1 22 Sp...

Page 129: ...e such that the rear wheel is about 4 inches 10 cms above the ground Hex Nut M16 Double End Spanner 24 mm Hold the Axle from the left side Loosen and remove hex nut on right side of the swing arm Remove wheel spindle from left side Gently release the brake hose from the holding clip in the swing arm Remove the caliper assembly by gently pulling out from the swing arm slot and support the caliper s...

Page 130: ...r is removed and stored carefully Gently pull rear wheel towards the left so that the hub becomes free fromlugsinthesprocket Slide out the Rear wheel assemblyfromtheswing arm Remove the Hex bolt on the other end of the swingarmalongwithend cups spacer celconbushes washer hex nut Gentlyremovetheswing arm assembly from the frame Hex Bolt M 8 Socket Spanner13 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 131: ...egatetoAssemble Instructions 7 5 Rear Swing Arm Bullet Classic EFI Bullet EFI Locate the swing arm assembly from the frame Install the Hex bolt on the other end of the swingarmalongwithend cups spacer celcon bushes washer hex nut Hex Nut M16 Double End Spanner 24 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 132: ...Aggregate toDismantle Instructions 7 5 Rear Swing Arm Continental GT Loosen the Hex bolt on the other end of the swing arm along with needle bearings oil seals spacers end cups spacer swing arm hex nut Gentlyremovetheswing arm assembly from the frame Index mark KS MOTORCYCLES http ksmotorcycles com ...

Page 133: ...s Photos AggregatetoAssemble Instructions 7 5 Rear Swing Arm Continental GT Locate the swing arm assembly to the frame Install the Hex bolt on the other end of the swing arm along with needle bearings oil seals spacers end cups spacer swing arm hex nut KS MOTORCYCLES http ksmotorcycles com ...

Page 134: ...Brake Hose Assy ABS To Front Caliper 1 4 Brake Hose Assy ABS To Front Master Cylinder 1 5 Banjo Bolt Rear Disc Black 7 6 Master Cylinder Front 1 7 Brake Hose Assy ABS To Rear Master Cylinder 1 8 Master Cylinder Assy Comp Rear 1 9 Rear Brake Switch 1 10 Brake Hose Assy ABS To Rear Caliper 1 11 Caliper Assy Rear 1 12 ABS Modulator 1 EXPLODEDVIEWS BULLET EFI BULLET CLASSIC EFI ANTILOCK BRAKE SYSTEM K...

Page 135: ...rake Hose 1 2 Clamp Front Caliper Hose 1 3 Hex Bolt M6 X 1 X 10 1 4 Wire Strap 1 5 Sleeve 2 6 Rubber Grommet 2 7 Flanged Hex Bolt M6 X 1 X 20 1 8 Bracket Assy ABS Cover 1 9 Wheel Speed Sensor 1 10 Hex Button Head Screw M6 X 1 X 16 1 11 Engine Mounting Plate Rear LH Black 1 12 Engine Mtg Plate Rear RH Black 1 13 Hex Button Head Screw M6 X 1 X 16 1 14 ABS Modulator 1 KS MOTORCYCLES http ksmotorcycle...

Page 136: ... Cyl 1 5 Banjo Bolt 7 6 Master Cylinder Front 1 7 Brake Hose Assy Abs To Rear Master Cyl 1 8 Master Cylinder Assy Comp Rear 1 9 Rear Brake Switch 1 10 Brake Hose Assy Abs To Rear Caliper 1 11 Caliper Assy Rear 1 12 Abs Modulator 1 13 Brake Pad RH Front Caliper 1 14 Brake Pad LH Front Caliper 1 15 Reservoir Threaded Rear 1 16 Diaphragm 1 17 Reservoir Cap 1 18 Clip Reservoir 1 19 Reservoir Hose Rubb...

Page 137: ...CRIPTION QTY A1 ABS System 1 1 Flanged Hexoganal Bolt M6X1X10 3 2 ClampRH Brake Hose 1 3 Clamp LH Brake Hose 1 4 Clamp Front Brake Hose 1 5 Flanged Hexoganal Bolt M6X1X20 2 6 Sleeve 2 7 Grommet 2 8 Bracket ABS Modulator 1 9 Flanged Hex Bolt M8X20 2 10 Hex Socket Button Head Screw M6X1x16 1 11 Wheel Speed Sensor ABS 1 KS MOTORCYCLES http ksmotorcycles com ...

Page 138: ...cause the motorcycle to skid during emergency brake applications CAUTION While ABS assists in improved vehicle control during braking decreased stopping distances on dry and graveled surfaces it maynot bevery effectiveinwet snowcovered offroad conditions loosegravel surfaces hilly roadsetc since the traction of the wheel itself will be very minimal in these conditions Asfaraspossible allbraking in...

Page 139: ...r in the head lamp casing alongside the EMS MIL and low fuel warning lamp CONTINENTAL GT LocatedintheRPMmeterin instrument cluster Bullet EFI and Classic EFI Located inside the cover near throttle body on the right side CONTINENTAL GT Located above the centre stand on the frame 1 ABS INDICATOR 2 MODULATOR KS MOTORCYCLES http ksmotorcycles com ...

Page 140: ...THE ABS SYSTEM PARTS 3 ECU Located adjacent to Modulator 4 FRONT BRAKE MASTER CYLINDER Located on Handle bar RH side 5 FRONT WHEEL CALIPER Located on the fork end LH side 6 WHEEL SPEED SENSOR FRONT Located on the fork end LH side KS MOTORCYCLES http ksmotorcycles com ...

Page 141: ...AKE MASTER CYLINDER Bullet EFI and Classic EFI CONTINENTAL GT Located on the frame right side near brake pedal 9 REAR HYDRAULIC FLUID RESERVOIR Located on the rear engine mounting brackets of Frame 8 1 LOCATION OF THE ABS SYSTEM PARTS Located on the frame bottom on RH side underneath engine KS MOTORCYCLES http ksmotorcycles com ...

Page 142: ...PER Located on swing arm LH side 11 WHEEL SPEED SENSOR REAR Located on the rear caliper assembly mounting bracket 12 TONER RING REAR WHEEL Located on the rear hub left side below the brake disc 8 1 LOCATION OF THE ABS SYSTEM PARTS KS MOTORCYCLES http ksmotorcycles com ...

Page 143: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 142 8 1 LOCATION OF THE ABS SYSTEM PARTS CONTINENTAL GT BULLET EFI BULLET CLASSIC EFI KS MOTORCYCLES http ksmotorcycles com ...

Page 144: ...Y SEVERELY BUT WILL ALSO DEACTIVATE THE MODULATOR AND THE ECU DO NOT ATTEMPT TO REMOVE THE ECU OR THE ELECTRICAL CONNECTIONS FROM THE MODULATOR AS IT WILL ERASE THE MEMORY AND THE PROGRAMME IF FOR ANY REASON THE BRAKE HOSES OR THE MODULATOR HAS TO BE SERVICED THEN THE ENTIRE HYDRAULIC FLUID SYSTEM BLEEDING HAS TO BE CARRIED OUT AND THE ECU HAS TO BE REPROGRAMMED KS MOTORCYCLES http ksmotorcycles c...

Page 145: ...S Modulator ECU Drain out hydraulic brake fluid from the front and rear reservoirs and brake calipers by loosening the bleeding screws in the front and rear calipers and gently pumping the brakes Remove the ABS cover from the RH side Bullet Classic Models Only by loosening 2 Hex bolts on the sides CAUTION Brake fluid is extremely corrosiveandhenceplease takecarenottospillonany part of the motorcyc...

Page 146: ...antle Instructions 8 2 ABS Modulator ECU Remove wiring coupler to the ABS ECU and gently pull out ECU Remove 2 hex bolts on the sides and 1 hex bolt at the bottom holding modulator to the mount ing bracket Remove ABS assembly from the bracket Hex Bolt M6 Double end spanner 10mm KS MOTORCYCLES http ksmotorcycles com ...

Page 147: ...cket Install 2 hex bolts on the sides and 1 hex bolt at the bottom holding modulator to the mount ing bracket Connect wiring coupler to the ABS ECU and gently locate out ECU Hex Bolt M6 Double end spanner 10mm Ensure Ignition switch andenginestopswitchis in OFF position Locate and install the 4 banjo bolts holding 4 brake hoses to the modulator KS MOTORCYCLES http ksmotorcycles com ...

Page 148: ...Size Tool Usage Precautions Photos AggregatetoAssemble Instructions 8 3 ABS Modulator ECU Locate the ABS cover on the RH side Bullet Classic Models Only by installing 2 Hex bolts on the sides Hex Bolt M6 Double end spanner 10mm KS MOTORCYCLES http ksmotorcycles com ...

Page 149: ...he wooden piece card board sheet in between the brake pads Remove the clip hanger from the caliper assembly by using combination plier Remove the pad pin from the caliper assembly by using combination plier Remove the worn out brake pad from the caliper assembly Clean the caliper assembly by dry clean cloth Pad Service Limit3 8mm KS MOTORCYCLES http ksmotorcycles com ...

Page 150: ...semble Instructions 8 4 Brake Pad Assembling Place the new brake pad into caliper assembly as shown Insert the pad pin in caliper assembly by using combination plier Insert the clip hanger in caliper assembly Place the wooden piece card board sheet in between the brake pads KS MOTORCYCLES http ksmotorcycles com ...

Page 151: ...push rod anti clockwise to reduce the rearbrake pedal free play Rotate the master cylinder push rod clockwisetoincreasethe rear brake pedal free play After adjustment tighten the lock nut in master cylinder push rod assembly NOTE PleaseDetachbrakereturns spring from Master Cylinder b e f o r e p r o c e e d i n g Applicable for only Classic 500 Bullet 500 Models LockNut Push Rod Master Cylinder Ad...

Page 152: ...clean brake fluid Ensure that the plastic tube is below the fluid surface throughout the operation This will prevent atmospheric air from getting sucked into caliper unit Open thebleedscrew to a turn Fill the Master cylinder with Fresh brake fluid from a sealed container till MAX level NOTE As these Euro IV Bikes are fitted with ABS the Bleeding process consumes more time since thebleedingprocessh...

Page 153: ...ghten the bleed screw Now release the brake lever Then gently stroke the lever until the pressure is felt at lever to a satisfactory limit and then tighten the bleed screw WARNING Wipe out Brake fluid which is spilled on the parts thoroughly otherwise colour parts may get fade CAUTION Don t Mix DOT 4 Above Brake Fluid together Repeat the above steps in a sequential manner untilthefluidpressureis f...

Page 154: ... a lengthy tube to the Caliper bleed screw and the another end to a container Unscrewthebleedscrew by 1 2 full turns and slowly pump the system by actuating the Lever until all the fluid is expelled then tighten the screw Remove the rear view mirror Disconnect the Brake Switch coupler Hex nut M7 Ring Spanner11 mm Hex nut M8 Double end spanner 14 mm KS MOTORCYCLES http ksmotorcycles com ...

Page 155: ...njo bolt and Washers Remove the Nut lever Bolt lever and then brake Lever RemovetheClampbolts Clamp and the Master cylinder from the handlebar Remove the wire from the coupler by pressing the projection in terminal CAUTION Clean the Cover thoroughly before opening the Master cylinder reservoir Hex Bolt M6 Ring Spanner 8mm Hex Bolt M7 Spanner12mm Hex Bolt M5 Ring Spanner 8mm KS MOTORCYCLES http ksm...

Page 156: ...iaphragm plate and Diaphragm and empty out any remaining brake fluid by using syringe Remove the Boot and the Circlip from the Master cylinder body Remove the Conical spring piston compression spring CAUTION Clean Master cylinder bore reservoir portion andPiston with seals with clean new Brake fluid Do not clean the rubber parts with petrol or any other gasoline product or water USEBRAKEFLUID ONLY...

Page 157: ...eals and cylinder bore with clean brake fluid Then assemble the piston sub assembly by gently pressing into the bore Assemble the circlip into thegrooveof themaster cylinder Ensure that circlip is seated inside the groove properly Assemble the rubber Boot Apply Silicon grease on the Lever pivot hole and on the Piston surface CAUTION Do not use tools with sharp ends Special Tool Circlip removal too...

Page 158: ...ats in the slot provided Assemble the Coupler Terminal and ensure proper locking of wires Assemble the master cylinderassemblyonthe handle bar by using the clamp with UP mark facing upwards Tighten the master cylinder assy clamp top Bolt Clamp first and then tighten the bottom Bolt AssembletheLever Bolt leverandNut leverand tighten Torque values Bolt lever 6 Nm Nut lever 6 Nm Hex Bolt M5 Ring Span...

Page 159: ...jo bolt with new Washers and then tighten the Banjo bolt Torque 3 5 KG M Connect the Switch connectors properly Fill the brake fluid to the Upper level mark and bleed the system Then assemble the Diaphragm diaphragm plate and Cover Tighten screws gently Assemble the rear view mirror Hex Bolt M8 Ring Spanner13 mm Torque35 Nm Hex nut M8 Double end spanner 14 mm Torque 15 Nm KS MOTORCYCLES http ksmot...

Page 160: ...n the rubber parts with petrol or any other gasoline product or water Use clean brake fluid only In case of water contamination of Brake fluid drain the fluid completely refill the system and bleed Do not top up brake fluid above Max level to avoid front wheel binding problem CheckperiodicallywhethertheDischasbeencontaminatedwithoil brakefluidorgreaseandcleancontaminated Disc with a high quality b...

Page 161: ...er till the hydraulic oil is fully flushed out of the master cylinder and the hose Loosen both the Caliper mounting bolts on the fork endandremove the caliper 8 10 Brake Pads Loosen both the Caliper mounting bolts on the fork endandremove the caliper Remove the Grub screw on the brake caliper Hex Bolt 13 mm GT Hex Bolt 12 mm C5 B5 Socket Spanner 13mm 12mm Hex bolt 12mm Hex Bolt 13 mm GT Hex Bolt 1...

Page 162: ... Aggregate toDismantle Instructions 8 10 Brake Pads Loosen and remove 2 hex socket head screws from the caliper body Remove the brake pad from Caliper Assembly Remove the Pad tensioner spring plate Hex Bolt 13 mm GT Hex Bolt 12 mm C5 B5 Socket Spanner 13mm 12mm KS MOTORCYCLES http ksmotorcycles com ...

Page 163: ...lace a shop towel over the pistons to prevent the pistons from becoming projectiles Push the Dust seals and Piston seals in and lift them out using a blunt tool Care should be taken to avoid any damage on the bore of the sliding surface CAUTION Enough care should be taken to avoid damages of the piston O D while servicing handling Remove the Bleed Screw Positionthecaliperbody with the Pistons down...

Page 164: ...8 11 Pistons seals in caliper Coat clean brake fluidon new Dust seals and Piston seals and install them in the sealgrooves of the caliper body Coatthecalipercylinders and Pistons withSilicon grease or clean brake fluid and Install the pistons into thecaliperbodywiththe dished end facing inwards KS MOTORCYCLES http ksmotorcycles com ...

Page 165: ...ggregatetoAssemble Instructions 8 12 Brake pads Install the Pad tension spring plate into the Caliper body Assemble Bleed screw into caliper body Assemble the Mounting Bracket with caliper Body First install the pad near to the piston and then assemble other pad KS MOTORCYCLES http ksmotorcycles com ...

Page 166: ...in bolt by pressingbrake pads into caliper body Mount the Caliper assembly into Fork andtighten the Mounting bolts Tighten the Pin bolts Install the Grub screw and tighten Connect the brake hose to the caliper with New sealing copper washer and then Tighten the Banjo bolt Fill the brake fluid and bleed the hydraulic brake system Torque 17 Nm Torque 25 Nm Torque35 Nm KS MOTORCYCLES http ksmotorcycl...

Page 167: ... WSS_GENERIC 6 5017 H Front Inlet Valve malfunction EV 7 5018 H Front Outlet Valve malfunction AV 8 5013 H Rear Inlet Valve malfunction EV 9 5014 H Rear Outlet Valve malfunction AV 10 5035 H Pump Motor Malfunction 11 5019 H Valve Relay malfunction Failsafe relay 12 5055 H ECU malfunction 13 5052 H Power Supply Malfunction Low Voltage 14 5053 H Power Supply Malfunction High Voltage 15 5122H Varcode...

Page 168: ... Valve To Tank 1 2 Hose T Connector To Throttle Body 1 3 T Connector 1 4 Hose T Connector To Canister 1 5 Hose Purge To Canister 1 6 Cable Clip Evap 2 7 Adaptor Purge Valve LH 2 8 Purge Valve 1 9 Adaptor Purge Valve RH 1 10 Canister 1 11 Hose Canister Vent 1 12 Bush Pav 2 13 Hex Socket Hd Cap Screw M6 X 20 2 14 Grommet 2 15 Bracket Assy Canister Mtg 1 16 Wire Clip 11 17 Hose T Connector To Purge V...

Page 169: ... Hose Purge Valve To Tank GT 1 5 Clip Evap Hoses 10 6 Hose T Connector To Throttle GT 1 7 Adaptor Purge Valve LH 2 8 Canister Assy 1 9 Grommet 2 10 Sleeve 2 11 Hex Socket Hd Cap Screw M6 X 20 2 12 Hose Canister Vent 1 13 Canister Cover 1 14 Hose Purge Valve To Canister GT 1 15 Hose T Connector To Canister GT 1 16 T Connector 1 17 Hose Purge Valve To T Connector GT 1 18 Adaptor Purge Valve RH 1 19 ...

Page 170: ...or parked under the sun the hot radiation from the engine sunlight causes the fuel in the tank to warm up and releases fuel vapors The EVAP system prevents these fuel vapors from escaping into the atmosphere and stored in a charcoal canister As soon as the engine is started these vapours are purged from the canister into the combustion chamber The system consists of a canister purge valve rubber h...

Page 171: ...s off the purge valve is closed When the engine is started the vacuum created in the suction port is used to open this one way valve and allow the vapors to go into the inlet port The canister is connected to the fuel tank to trap all the fuel vapours that build up in the fuel tank LOCATION OF EVAP Located behind swing arm in Bullet Classic EFI models KS MOTORCYCLES http ksmotorcycles com ...

Page 172: ...nspect rubber hoses and joints periodically for any cuts cracks or fractures Replace if damaged Inspect Canister periodically for any damage to its body cuts or cracks Replace all rubber hoses and connectors every 12 000 Kms KS MOTORCYCLES http ksmotorcycles com ...

Page 173: ...tle Instructions Canister Bullet Classic EFI Bullet EFI Remove2boltsmounted on the Piece mudguard Remove the canister alongwith thetubes and connectors Canister Continental GT Remove2boltsmounted on the Frame additional bracket Remove the canister alongwith thetubes and connectors KS MOTORCYCLES http ksmotorcycles com ...

Page 174: ...er Bullet Classic EFI Bullet EFI Locate Cannister in the piece mudguard bracket such that it can be tightened with 2 hex bolts Tighten the 2 bolts Canister Continental GT Locate Cannister in the bracket in the frame below throttle body such that it can be tightened with 2 hex bolts Tighten the 2 bolts KS MOTORCYCLES http ksmotorcycles com ...

Page 175: ...URO IV regulation related to exhaust emissions Optimum fuel efficiency and power output Excellent cold start ability and sustained high speed drive ability FUNCTIONAL DIAGRAM OF THE EMS In addition to optimizing engine performance the ECU also has an inbuilt memory by which any EMS related malfunctions will get stored and help diagnose the fault accurately Thereisalsoaninbuiltsafetysystem which in...

Page 176: ...d Only Memory This memory records informationrelatedtoperformanceofthevarioussensorsintheEMS onarealtimebasisANDalsorecordsanysensor failures if it occurs during operation of the motorcycle The main advantage of E2PROM is it records data even when the motorcycle s electrical system is switched OFF This will help in diagnosing the motorcycle performance and also to view the history and defect codes...

Page 177: ...ower Ground2 11 IG Ignition Coil 12 CRK P Crank Pulse Sensor 13 14 TA Air Temperature 15 TEST Test Switch 16 INJ Injector 17 VSP Vehicle Speed Sensor 18 19 20 21 22 MIL Multi Indicator Lamp 23 CRK M Crank Pulse Sensor GND 24 TW Engine Temp Sensor 25 SSTAND Side Stand Switch 26 ROLL Roll Sensor 27 PM Manifold Pressure Sensor 28 EXAJ Exhaust Air Injection 29 NLSW Neutral Switch 30 K LINE Diagnostic ...

Page 178: ...pen with gears in neutral leading to crankshaft speed above 5500 RPM the high frequency electrical pulses from the crank position sensor will prompt the ECU to restrict fuel supply so that the crank speed reduces below 5000 RPM This is a safety aspect to prevent damage to moving engine parts 3 ENGINE TEMPERATURE SENSOR The engine temperature sensor EOT is located on the cylinder head below the inl...

Page 179: ... the ECU based on which the fuel injection is metered continuously to control exhaust emissions and for optimum performance of the motorcycle 5 EXHAUST AIR INJECTION UNIT SOLENOID The exhaust air injection unit EXAI is located underneath the fuel tank In addition to the Hego sensor the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the cylinder head primarily during i...

Page 180: ...e cold conditions The throttle body also has a throttle position sensor TPS and manifold absolute pressure sensor MAP 7 THROTTLE POSITION SENSOR TPS Throttle Position Sensor TPS is located on the throttle body at the end of the butterfly valve spindle to monitor the position of the butterfly valve The sensor consists of a potentiometer and provides a variable resistance depending upon the position...

Page 181: ...uired amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle 9 AMBIENT AIR TA SENSOR The TA sensor is located on the rear side of the filter box assembly in Bullet EFI Classic EFI models and on the outlet pipe of the air filter housing in Continental GT models The ambient temperature input is provided to the ECU on a real time basis based on which the ECU de...

Page 182: ...ntdamagetothefuelinjector fuelhose Anyexcesspressureisbypassed back into the fuel tank 11 FUEL INJECTOR Thefuelinjectorislocatedatanangleontheintakesideofthecylinderheadsoastomaximizefuelsprayandminimize wall wetting for optimum performance of the motorcycle The Fuel Injector is a solenoid operated electromagnetic valve which enables the pressurized fuel delivered by the fuel pump to be atomized a...

Page 183: ...ngine from starting 13 ROLLOVER SENSOR The rollover sensor is located on the frame under the seat The rollover sensor also known as a banking sensor is a safety feature If the banking angle of the motorcycle goes below 60o OR in the event of an accident causing the motorcycle to fall over on either of its sides with the engine running the rollover sensor will command the ECU to cut off both the fu...

Page 184: ...hicleisstarted MILwillglowforfewsecondsandswitch OFF this indicates that all the functions of EMS are functioning correctly In the event of any malfunction the MIL will glow continuously The EMS should be checked using either the test pin methodOR the Royal EnfieldNACS II diagnostic tool connectedtothe socket in the wiring harness of the motorcycle SPECIFICATION Operating Voltage KS MOTORCYCLES ht...

Page 185: ... the Fuel tank Ensure Ignition switch and stop switch are in OFF position UnlocksidepanelLHand remove the panel LH Gently pull seat latch cable torelease seat and remove seat Gently pull out the ECU from the rubber housing located in the frame Gently release lock and disconnect the wiring coupler from the ECU Remove ECU CAUTION Ensure both Ignition and Engine kill switch are in OFF position before...

Page 186: ...d remove 1 Hex Flange Bolt M6 X 1 X 45 from cover RH rear It may be necessary to gently tap and remove coverRHasthemagnetic forcesintherotorcanbe acting on the stator and making it difficult to remove Remove gasket Remove 2 Hex Flange Bolt M5 X 0 8 X 16 holding Pulsar coil to cover RH inside Remove 3 Hex Socket HeadCapScrewM5X30 holding stator coil to cover RH inside Fastener Size Tool Usage Preca...

Page 187: ...rature Sensor The Engine temperature sensor is located on the cylinder head right side belowtheinletmanifold Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor Gently Loosen engine temperature sensor and remove along with O ring Deep Groove Socket bit 17mm KS MOTORCYCLES http ksmotorcycles com ...

Page 188: ...2 Sensor The Hego sensor is assembled on the inner side of the exhaust down pipe near the cylinder head Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor Loosen Hego sensor and remove along with copper washer from the exhaust down pipe Deep Groove Socket 21mm KS MOTORCYCLES http ksmotorcycles com ...

Page 189: ... the EXAI solenoid Releasethe2clipsonthe Inlet and outlet pipes connected to the EXAI solenoid and dis connect the pipes Gland Nut Double end spanner 16mm SocHdCapScrew M5X20 Allen Key 4mm Hex Screw M6 X 16 Socket spanner 8mm NOTE Ensure spacer between the EXAI solenoid bracket is removed Loosen Gland nut at cylinder head end and disconnect braided hose connecting reed valve to cylinder head Remov...

Page 190: ...moved from the throttle body Slacken the locknuts on the adjusters and remove throttle cables from the throttle body Disconnect rubber hose connecting throttle body to the EVAP canister Disconnect manual Bi Starter cable from throttle body by loosening and removing the plastic nut on LH side Loosen hose clip on air inlet rubber hose Loosen hose clip on Adaptor between throttle body and cylinder he...

Page 191: ... sensor Loosen and remove 2 Hex Soc Hd cap screws holding TA sensor to Filter Box Assembly Remove TA sensor with gasket Philips head screws Philips Screw driver Hex Soc Hd Cap Screws M5X20 Allen Key 4mm B Continental GT Model TheTAsensorisassembled on the pipe outlet bet ween air filter housing and Throttle body Ensure Ignition switch and stop switch are in OFF position Remove seat assembly Refer ...

Page 192: ...in section 5 3 for Fuel tank dismantling Loosen remove 5 Hex Socket Button Head Cap Screws along with the copper fibre washers Remove clamp plate Pull out fuel pump from the fuel tank Take care to remove the Oringfromthefueltank CAUTION Store fuel in a tight sealed container in a well ventilated cool and dry place Do not smoke or allow open flame or sparks in the vicinity NOTE Ensure Ignition swit...

Page 193: ...sembly as described in section 5 4 for Seat dismantling Remove fuel tank as described in section 5 3 for Fuel tank dismantling Disconnect the wiring coupler from the fuel injector Loosen worm clip on the inlet fuel hose and remove fuel hose from cap injector assembly Remove hex nut from top of injector cap assembly and remove injector cap along with O ring Remove the spacer from the stud Gently pu...

Page 194: ...he electricals box LH Ensure Ignition switch and stop switch are in OFF position Gentlypullouttherelays from their sockets to remove B Continental GT Two identical relays are locatednear the battery Located in a rubber holder on the side of the battery carrier Ensure Ignition switch and stop switch are in OFF position Remove side panel LH Gently pull out relay from the rubber holder and electrical...

Page 195: ... 10 11 Roll Over Sensor Located below the seat on the frame Ensure Ignition switch and engine stop switch are in OFF position Disconnect the wiring coupler from the sensor Loosen and remove the hexsocketscrewholding the sensor to the frame and remove the sensor Hex Soc Hd Screw M6 Allen Key 5mm KS MOTORCYCLES http ksmotorcycles com ...

Page 196: ...S indication Ensure Ignition switch and engine stop switch are in OFF position Disconnect the wiring couplersfromthemeter Gently push the meter upwards from below to release it from the rubber ring There are no serviceable parts in the meter B Continental GT Located in the RPM meter in the instrument cluster Ensure Ignition switch and engine stop switch are in OFF position The instrument cluster d...

Page 197: ...h Ignition andEnginekillswitchare in OFF position before Connecting ECU into the wiring harness DO NOT disconnect BatterywiththeIgnition switch KillswitchinON position and the ECU is connected Ensure ECU is not stored near any Magnetic substances wet surfaces direct sunlight and hot areas asitwilldamagetheECU B Continental GT Locate ECU under the Fuel tank Connect the wiring coupler on the ECU and...

Page 198: ...lt M6 X 1 X 45 on cover RH rear Install and tighten 7 Hex Flange Bolt M6 X 1 X 70 on cover RH top centre and bottom Install and tighten 2 Hex Flange Bolt M6 X 1 X 85 on cover RH front ConnectMagnetowiring coupler in the electrical harness Fill engine oil CAUTION Ensure stator coupler is disconnected before removing cover RH Gently tap on the tabs provided in the front andrearof CoverRHto release t...

Page 199: ...e Instructions 10 15 Engine Temperature Sensor Locate engine temperature sensor alongwith O ringonthe cylinder head right side belowtheinletmanifold Ensure Ignition switch and stop switch are in OFF position Connect wiring harness coupler on the sensor Deep Groove Socket bit 17mm KS MOTORCYCLES http ksmotorcycles com ...

Page 200: ...Assemble Instructions 10 16 Hego Lambda or O2 Sensor Deep Groove Socket 21mm Locate Hego sensor along with copper washer on the exhaust down pipe near the cylinder head Ensure Ignition switch and stop switch are in OFF position Connect wiring harness coupler on the sensor KS MOTORCYCLES http ksmotorcycles com ...

Page 201: ...x Screws on the reed valve mounting bracket to frame Locate EXAI Solenoid on the frame under the fuel tank along with the reed valve Install Gland nut at cylinder head end and connect braided hose connectingreedvalveto cylinder head Connect 2 clips on the Inlet and outlet pipes connected to the EXAI solenoid Ensure Ignition switch and stop switch are in OFF position Connect wiring harness coupler ...

Page 202: ...tween the cylinder head inlet and air filter outlet house Gently slide throttle body on the inlet bellow and adaptor Locate hose clip on Adaptor between throttlebodyandcylinder head Locate hose clip on air inlet rubber hose Connect manual Bi Starter cable on throttle body by tightening and locating the plastic nut on LH side Connect rubber hose from throttle body to the EVAP canister Locate the lo...

Page 203: ...filter box assembly Install 2 Hex Soc Hd cap screws on TA sensor to Filter Box Assembly Ensure Ignition switch and stop switch are in OFF position Connect the wiring coupler on theTA sensor Locate TA sensor along with gasket on pipe outlet between air filter housing and throttle body UsingalongreachPhilips headscrewdriver Install 2 screws holding TA sensor to pipe outlet Ensure Ignition switch and...

Page 204: ...ion Hex Soc Button Hd Cap Screws M6X12 Socket spanner 8mm Locate the O ring in the fuel tank Locate fuel pump assembly inside the fuel tank at left side Install clamp plate Install 5 Hex Socket Button HeadCapScrews along with the copper fibre washers Install fuel tank as described in section 5 3 for Fuel tank assembly AssembleSeat assembly as described in section 5 4 for Seat assembly KS MOTORCYCL...

Page 205: ... spacer in the stud Locate hex nut from top of injector cap assembly and place injector cap along with O ring Locate worm clip on the inletfuelhoseandlocate fuel hose on cap injector assembly Ensure Ignition switch and stop switch are in OFF position Connect the wiring coupler from the fuel injector Install fuel tank as described in section 5 3 for Fuel tank assembly AssembleSeat assembly as descr...

Page 206: ...ntinental GT Ensure Ignition switch and stop switch are in OFF position Gently push the two identical relays in their sockets inside the electrical box LH Ensure Ignition switch and stop switch are in OFF position Gently push the two identical relays in the rubber holder and electrical socket Locateinarubberholder onthe sideofthe battery carrier Locate side panel LH KS MOTORCYCLES http ksmotorcycl...

Page 207: ...ns 10 22 Roll Over Sensor Hex Soc Hd Screw M6 Allen Key 5mm Locate the hex socket screw on the sensor to the frame and install the sensor which is located below the seat on the frame Connect the wiring coupler from the sensor Ensure Ignition switch and engine stop switch are in OFF position KS MOTORCYCLES http ksmotorcycles com ...

Page 208: ...e meter downwards from top to locate it on the rubber ring Ensure Ignition switch and engine stop switch are in OFF position Connect the wiring couplersfromthemeter There are no serviceable parts in the meter Ensure Ignition switch and engine stop switch are in OFF position Locate theRPM meter in the instrument cluster The instrument cluster does not have any individual serviceable parts KS MOTORC...

Page 209: ...ill help narrow down to the sensor electrical connection that caused the malfunction LEVEL 3 GENERIC SCAN TOOL NACS II DIAGNOSTIC TOOL A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS when connected between the motorcycle and a computer The tool will take inputs from the ECU and provide to the computer to display the defect code that wi...

Page 210: ...vel 2 test pin method to resolve the defect LEVEL2TESTPINMETHOD An open single pole connector is provided close to the UCE Connect a piece of wire to this connector and suitably ground it to the motorcycle body Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks at different intervals to identify the defective sensor wiring connection as detai...

Page 211: ...rt 5 Roll over sensor Malfunction Long 3 Short 3 Fuel Injector Circuit Malfunction Long 3 Short 7 Ignition Coil Circuit Malfunction Long 4 Short 1 Fuel pump relay circuit Malfunction Long 7 short 0 Vehicle Wheel speed sensor Malfunction only for Continental GT Model LEVEL3 GENERICSCAN TOOLMETHOD When the fault is detected the GST raises a flag to conform readiness Permanent Confirmed Pending DTC I...

Page 212: ...sor HG Short circuit to ground or open circuit low or open P0130 Fuel Injector IJ1 Short circuit to ground or open circuit P0201 Short circuit to Battery Ignition Coil IG1 Short circuit to ground or open circuit P0351 Short circuit to Battery Fuel Pump Relay FLR Short circuit to ground or open circuit P0230 Short circuit to Battery O2 sensor Heater HR Short circuit to ground or open circuit P0030 ...

Page 213: ...F if side stand is extended 4 DO NOT rev the engine fully immediately after starting OR just before shutting off the engine 5 DO NOTremove thefuel hose high pressure fromthefuel pumptofuel injector when engineis runningOR with the ignition switch ON Fuel flows at a very high pressure during these times 6 DONOTuseaboosterorhighvoltage chargingunitinsteadofabattery Useonlyagood correctlychargedbatte...

Page 214: ...NACS II ROYAL Interface USB Hi speed cable connector Reset Button SD memory card Diagnostic connector 4 USB Hi speed cable 5 Cigarette lighter cable 6 SD memory Card 7 SD card reader 8 Carrying Box 9 Installation CD 10 User Manual Included on CD 2 NACS II ROYAL DIAGNOSTIC TOOL KIT SECTION 06 NACS II DIAGNOSIS KS MOTORCYCLES http ksmotorcycles com ...

Page 215: ...rating Temperature 00 C 700 C Dust and water resistance IP55 Standard 5 WARNING When NACS II is already connected to the motorcycle do NOT plug in AC Adaptor Do not remove SD card when you are using NACS II The failure caused by the use of unapproved cables accessories is out of warranty The warranty will become void if NACS II is disassembled or altered We recommend you to back up the SD card dat...

Page 216: ...software successfully First you need to disable User Account Control UAC before installing our software The way to disable UAC is as follows Click Start button andselect Control Panel s Why there is a pop up window displaying cannot find COM port A Check whether the driver of USB Hi speed cable is installed If USB port is not recognized please install USB driver 8 1 6 TROUBLE SHOOTING s Why I can ...

Page 217: ...tings Click User Accounts 8 4 Click Finish to complete the installation ROYAL ENFIELD NACS II DIAGNOSIS 9 SOFTWARE INSTALLATION 9 1 Start the computer 9 2 Insert installation CD to CD ROM drive andinstall following software a Main software NACSII_ROYAL_V0 03_install exe b Recording data analyzing software NACSII RECORD_ROYAL V0_01_setup KS MOTORCYCLES http ksmotorcycles com ...

Page 218: ...exit installation After installing Firmware program USB high speed driver will start installation Click Extract to install Click Next to continue Click Finish to complete the installation 10 SOFTWARE REMOVAL Click Star Menu All Programs Control Panel Click Uninstall a program 10 2 KS MOTORCYCLES http ksmotorcycles com ...

Page 219: ...le NACSII ROYAL interface maincable Diagnostic cable Motorcycle Orange light indicates whether the system is communicating 11 A1 When the IG of the motorcycle is ON the system starts to run entering welcome page ROYAL ENFIELD Press Diagnosis 11 A2 F1 Find NACSII_ROYAL and click Change Remove When Unistalling NACSII_ROYAL window pops up please click Next Click Finish to exit uninstall KS MOTORCYCLE...

Page 220: ...Using and to move the cursor Move the cursor to select Diagnostic Trouble Code Press tosee the content OK 11 A8 Diagnostic trouble code page includes F1 Current F2 History and F4 Erase Current is for the DTC occurred at the time and History is for DTC occurred in the past Erase is for erasing current DTC and History DTC Press to view Current DTC OK OK Select Royal Enfield 534EFI Press to continue ...

Page 221: ...atafor further analysis 11 A10 When displays on the screen press toview freeze data Press andto view next page and last page After viewing all content press to exit The screen will return to the previous page Erace DTC It s the function to erace Diagnostic Trouble Code in both Current and History 11 A11 Press toerace To confirm erasing DTC Press Yes When showing on the screen it means the DTC has ...

Page 222: ...al Function and Press 11 A16 Special function is customized functions provided to specific vehicles 11 A17 OK C F1 Select CO Adjustment press and toadjust the CO value is for increasing fuel injection value is for decreasing fuel injection value After finish adjustment press tosave Press to exi t If you want to OK go back tothe main page press unti l the page return to the top of the page 11 B 11 ...

Page 223: ...o select the item Change figure using or and press to confirm the item At this time the pink block will return to white Press to apply the setting 11 B4 ABS Functions 11 C Select BOSCH ABS System Press to continue 11 C1 Select Special Function Then select Repair Air Bleed 11 C2 Read the warning first before start operating air bleeding 11 C3 OK OK OK KS MOTORCYCLES http ksmotorcycles com ...

Page 224: ...g 11 C3 Follow each step on thescreen to finish the procedure 11 C4 SILA Lamp Blinking Test Follow the screen guide to finish the test 11 C5 Front Channel Activation 11 C6 Follow the instructions on screen to finish the activation 11 C7 Follow the instructions on screen to finish the activation 11 C8 KS MOTORCYCLES http ksmotorcycles com ...

Page 225: ...c Cable Motorcycle IG ON 12 1 Double click NACSII_ROYAL onthe desktop to open diagnostic software 12 2 When the first time you use software the software will enter register process automatically Please make sure your PC is connected to the internet When the window displays Product key click NEXT Software will get the password by itself 12 3 Registration is completed Click EXIT 12 4 This is the pag...

Page 226: ...necting to engine system Please wait 12 8 There are various green buttons on the right button is for displaying all the vehicle info 12 9 ROYAL ENFIELD NACS II DIAGNOSIS Click to read the Diagnostic Trouble code Click Current toread current DTC Click History to read history DTC 12 10 If you want to print trouble code click to print DTC data It will take a moment 12 11 KS MOTORCYCLES http ksmotorcy...

Page 227: ...one Diagnostic Trouble Code freeze data it s for saving the engine dynamic data for further analysis Click to return to Diagnostic Trouble Code page 12 14 To erase the Diagnostic Trouble Code click Note if you click the erase button all Diagnostic Trouble Code in Current and History will be erased 12 15 Click tosee specification of live data 12 16 Click toseethe live data You can select All Data t...

Page 228: ...ALL selected live data If you want to erase only one item please press and hold Shift key and select the item that you want to delete Then click button The selecteditemwill be erased 12 17 D This button is for special function Functions depend on ECU type Take CO adjustment as an example Select the item and click 12 18 The page will display What to do for next step Click to continue 12 19 KS MOTOR...

Page 229: ...ert SD card to PC 13 RECORD ANALYZINGSOFTWARE Open the software of NACSII_Record_Royal Select Analyze Record Data 13 1 Select Record Date and File name then click 13 2 Select the items which used often Selecteditemswillbe listed in the block of Live Data Item Click toview wave chart of selected items 13 3 13 4 Wave chart starts running until press Stop button Drag Yellow line forward and back to v...

Page 230: ...toselect page number Click the2nd togo back to last page Select items to set breakdown point for analysis After selecting items click For example setting Engine speed grater than 3150 enter 3150 in the right block Click toconfirm the setting value 13 9 When window pops up Setting OK the setting is completed 13 10 The setting value will display in the blockunder Break Click toview wavechart KS MOTO...

Page 231: ...ease select Live data item Take throttle position as an example Enter throttle position grater than 9 8 in the right block and click tofinish setting 13 12 After Setting 2 values of the 2 items the 2 items will be listedin the block of All value match Click to go back to Live data selection page BacktoLivedata selectionpage click toview wave chart of the 2 setting values Click to quickly find the ...

Page 232: ...ch block Continue to set match conditions AND OR AND All conditions of setting items must be satisfied OR One of or any of selected items must be satisfied Setting items listed in All value match and Any of value match must be satisfied If there isno matched condition the window will pop up showing condition can t match 13 17 Click towave chart 13 18 Click to quick findmatched conditions 13 18 Aft...

Page 233: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 232 SECTION 12 ELECTRICALS KS MOTORCYCLES http ksmotorcycles com ...

Page 234: ...T S NO DESCRIPTION QTY S NO DESCRIPTION QTY 1 Battery Carrier Assy 1 2 Battery Carrier Assy 1 3 Cover Battery Black New 1 4 Battery 12V 14AH 1 5 Strap Battery 2 6 Hex Bolt M8 X 1 25 X 16 1 7 Washer 1 8 Hex Flanged Bolt M8 X 1 25 X 45 1 9 Cap Battery Carrier Rubber Rectangle 1 10 Clip Lock 1 11 Phillips RoundHeadMachinedScrew M6X13 2 KS MOTORCYCLES http ksmotorcycles com ...

Page 235: ...sure the ignition switch and engine stop switch are in OFF position Unlock and remove the battery cover Remove the two straps holding the battery to the battery carrier Pull the battery out slightly from the battery carrier Remove the battery from the carrier Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No NOTE Disconnect VE terminal FIRST and the VE terminal NEXT...

Page 236: ...on switch and engine stop switch are in OFF position Unlock and remove the battery cover Remove the battery carrier bracket by loosening the two screws Pull the battery out slightly from the battery carrier Remove the battery from the carrier Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions S No TERMINAL TERMINAL NOTE Disconnect VE terminal FIRST and the VE terminal NEX...

Page 237: ...d replace the battery immediately CAUTION If necessary top up ONLY with pure and clean distilled water till the level is between the MAX and MIN lines DO NOT OVERFILL as it will overflow through the vent hole of the battery and cause irreparable damage to the motorcycle parts WARNING Motorcycle batteries contain lead and lead components acids and chemicals known to cause cancer birth defects or ot...

Page 238: ...y terminal protector to prevent oxidation of the terminals Ensure the protective covers are properly located over the terminals toprevent any metal coming in contact with the terminals and causing a short circuit Position the battery correctly and fully inside the carrier and strap the battery securely using the two rubber straps Locate the battery cover over the battery and lock it in place Faste...

Page 239: ...lly or battery terminal protector to prevent oxidation of the terminals Ensure the protective covers are properly located over the terminals toprevent any metal coming in contact with the terminals and causing a short circuit Position the battery correctly and fully inside the carrier Locate the battery cover over the battery and lock it in place Fastener Size Tool Usage Precautions Photos Aggrega...

Page 240: ...b 12V 2W Ba 7S Cap 2 5 Head Lamp Assy with Halogen Bulb LHT 1 6 Head lamp Bulb 12V 60 55W Halogen 1 7 Bulb 12V 4W BA 7S Cap 1 8 Screw Rim Fixing Top with Clamp 1 9 Pan Head Screw M5 X 0 8 X 12 2 10 Head Lamp Assy with Bulb 1 11 Lens and Reflector Assy 1 12 Rim Assy 1 13 Housing Assy 1 14 Bulb Holding Spring 1 15 Bulb 12V T4W 1 16 Housing Locating Bracket 1 17 Pan Head Screw 1 18 Head Lamp Holder R...

Page 241: ...ener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions 12 2 Pilot Lamp Bullet EFI Bullet Classic EFI Dismantling Loosen 2 pilot lamp rim fixing screw on LH RH side Gently remove the bulb from its holder KS MOTORCYCLES http ksmotorcycles com ...

Page 242: ...ener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions 12 2 Pilot Lamp Bullet EFI Bullet Classic EFI Assembling Locate the Pilot lamp bulb in the holder Install 2 pilot lamp rim fixing screw on LH RH side KS MOTORCYCLES http ksmotorcycles com ...

Page 243: ...ing top with clamp screw mounted on head lamp rim assembly Loosen 2 pan head screws on LH RH side mounted on head lamp housing assembly CAUTION Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling Gently Press the clip by thumbtoreleasethefree end from bulb holder Gently pull out the bulb ...

Page 244: ... holder on LH RH side Gently remove the headlamp assy S No Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions Philips Screw Driver Flanged Hex Bolt M8 Socketspanner13mm Hex Socket head cap screwsM6 Philips Screw Driver CAUTION Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry clot...

Page 245: ...structions 12 2 HeadLampBulb Bullet Classic EFI Bullet EFI Assembling Locate the bulb into reflector unit of the headlamp Connect the electrical connections carefully assemble the headlamp Locate the rubber grommet Gently press the bulb holding clip and lock the free end in its slot KS MOTORCYCLES http ksmotorcycles com ...

Page 246: ...e Instructions 12 2 HeadLamp Bullet Classic EFI Bullet EFI Assembling Locateheadlampassembly Install2panheadscrews onLH RHsidemounted on head lamp housing assembly Install Screw on rim fixing top with clamp mounted on head lamp rim assembly Pan Head Screw M5 Philips Screw Driver KS MOTORCYCLES http ksmotorcycles com ...

Page 247: ...ections Locate the headlamp assembly Install 2 hex socket head cap screws on the inner side of head lamp holder on LH RH side Install 2 hex bolt along with washer on LH RH side and mount on the front end of the headlamp Holder Install screw fixing top withclamponheadlamp mounting assembly Hex socket headcap screwM6 Philips Screw Driver Flanged Hex Bolt M8 Socketspanner13mm Philips Screw Driver KS ...

Page 248: ...TY S NO DESCRIPTION QTY 1 Tail Lamp 1 2 Lens Base Sealed Classic 1 Lens Complete Tail Lamp 1 3 Cross Recessed Pan Head Screw M6 X 14 3 4 Bulb Tail Lamp 12V 21 5 W 1 5 Bulb 12V 21 5W Tail Lamp 1 6 Plain Washer M6 6 7 Pan Head Tapping Screw Tail Lamp 2 8 Tapping Screw Tail Lamp 2 EXPLODEDVIEWS TAILLAMP KS MOTORCYCLES http ksmotorcycles com ...

Page 249: ... EFI Dismantling Loosen 2 Nyloc nuts mountedonLH RHside onthecompletetaillamp bracket Disconnect the tail lamp coupler Gently pullout Tail Lamp assembly along with tail lamp bracket Gently rotate the bulb holder in anticlockwise to remove the bulb from its holder assembly Gently pull out the bulb Hex Nyloc Nut M6 Double end spanner 8mm KS MOTORCYCLES http ksmotorcycles com ...

Page 250: ...ews mounted ontaillampLH RHsides Remove 2 tapping screws mounted on inner side of tail lamp on both LH RH sides Pan headtapping screw Philips Screw Driver Tapping screws Philips Screw Driver Gently remove the Tail lamp assembly CAUTION Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling K...

Page 251: ...nthetail lamp Locate Tail Lamp assemblyonthetaillamp bracket Connect the tail lamp coupler Install 2 Nyloc nuts mountedonLH RHside onthecompletetaillamp bracket Hex Nyloc Nut M6 Double end spanner 8mm S No Fastener Size Tool Usage Precautions Photos AggregatetoAssemble Instructions KS MOTORCYCLES http ksmotorcycles com ...

Page 252: ...ion5 4forseat assembly S No Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions Pan headtapping screw Philips Screw Driver Tapping screws Philips Screw Driver CAUTION Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling Gently hold the bulb push inside rotate clo...

Page 253: ...Assy LH Front 1 3 Trafficator Assy RH Rear 1 4 Trafficator Assy LH Rear 1 5 Trafficator Assy With Bulb Front RH 1 6 Trafficator Assy With Bulb Front LH 1 7 Trafficator Assy With Bulb Rear LH 1 8 Trafficator Assy With Bulb Rear RH 1 9 Bulb 12V 10W 4 10 Bracket LH Front Black 1 11 Bracket RH Front Black 1 12 Nut Nylock M8 X 9 5 2 EXPLODEDVIEWS TRAFFICATOR LIGHTS KS MOTORCYCLES http ksmotorcycles com...

Page 254: ...2 Nyloc nuts mounted on RH LH Bracket in the trafficator Gently remove the Trafficator assembly on LH RHside Nyloc Nut M8 Double End Spanner 13mm Press bulb gently Turn anticlockwisetotakeout the bulb Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling KS MOTORCYCLES http ksmotorcycles co...

Page 255: ... side mounted on the rear end of the headlamp holder Gently remove the Trafficator assembly on LH Rh side from the headlamp holder Hex socket headcap screwM6 Socketspanner10mm Pull out the Indicator housing Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling KS MOTORCYCLES http ksmotorcyc...

Page 256: ...le Instructions 12 2 Trafficator Bullet Classic EFI Bullet EFI Assembling Nyloc Nut M8 Double End Spanner 13mm Locate the Trafficator assembly on LH RH side Install2NylocnutsonRH LH side of the brackets Press bulb gently Turn clockwise direction to locate the bulb in the holder KS MOTORCYCLES http ksmotorcycles com ...

Page 257: ... screwM6 Socketspanner10mm Locate Trafficator assembly into the headlamp holder on LH RH side Tighten 2 hex screws on LH RH side and mount on the rear end of the headlamp holder Locate the bulb Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling KS MOTORCYCLES http ksmotorcycles com ...

Page 258: ...smantling Disconnect the coupler Loosen 4 hex screws on both LH RH side mounted on the Instrument cluster bracket assembly Refer Section 11 2 for Headlamp dismantling Disconnect the coupler mounted on speedometer Loosen the nut mounted on bottom side of speedometer in clockwise direction Gently push the speedometer upwards from bottom end of speedometer unit such thatitwillcomeoutfrom the speedome...

Page 259: ...ing Gently push the s p e e d o m e t e r downwards from top end of speedometer unit such that it will get seated in the speedometer slot Installthenutonbottom side of speedometer in Anti clockwise direction Connect the coupler mounted on speedometer Refer Section 11 2 for Headlamp Assembling Install 4 hex screws on both LH RH side on the Instrument cluster bracket assembly Connect the Couplers KS...

Page 260: ...l GT Dismantling Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling Disconnect the couplers Gently pull out the out the bulb Disconnect the couplers Gently pull out the bulb Speedo meter Neutral High beam Low beam Turn Signal Bulbs from its holder CONSOLE BULBS REPLACEMENT KS MOTORCYCLES...

Page 261: ...ulb life Always hold the bulb with paper or clean dry cloth during handling 12 2 Cluster Bulb Continental GT Dismantling Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling Gently fix the bulb Speedo meter Neutral High beam Low beam TurnSignalBulbs onthe holder Connect the couplers Gently...

Page 262: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 261 SECTION 12 3 ELECTRICAL COMPONENTS KS MOTORCYCLES http ksmotorcycles com ...

Page 263: ...oth bolts WIRING LAYOUT SCHEMATIC DIAGRAM OF E START MECHANISM UCEMODELS TECHNICAL SPECIFICATIONS System Battery 12V DC 12V 14 Ah Starter Motor 0 9KW Solenoid Switch Magnetic Relay type STARTER MOTOR Crank Shaft Jack Shaft Sprag Clutch Gear Sprag Clutch Bearing Jack Gear Engien Sprocket Double Gear Big Small Self Motor Pinion KS MOTORCYCLES http ksmotorcycles com ...

Page 264: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 263 RELAY STARTER WIRING LAYOUT Schematic Diagram Relay KS MOTORCYCLES http ksmotorcycles com ...

Page 265: ...oltage of 12V across the relay coil 2 pole female terminal Battery positive on coil positive and Battery negative on coil negative 2 After energizing the coil check the continuity between Battery ve terminal and Starter ve terminal Ring terminal usingMultimeter IftheMultimeterindicates0Ùwithabeepsound thecontactshavegotclosed Ifthe Multimeter indicates as open OL contacts have not closed and hence...

Page 266: ...capacitor STEP 2 To check the condition of 3 positive diodes of RR unit keep the positive probe Red of the multimeter in any one of the 3phase terminals yellow wire inserted in black red connector and the negative probe Black of multimeter on the positive terminal of DC output red wire inserted in two pole connector and check for the condition of diode as shown in the below image If the diode is g...

Page 267: ...with eyelet single pole connector and negative probe Black colour of the multimeter shall be kept on anyone of the 3 phase terminals yellow wire If the diode is good then the multimeter will show a voltage drop of 0 4 0 7V If diode has failed multimeter will show either open or short with beep sound then Replace the RR unit STEP5 All the threediodes tobe checkedby keeping the multimeternegative pr...

Page 268: ...nce check mode 2 Keep the positive Red and negative Black probes of the multimeter on two ends of the suppressor cap 3 Resistance shall be 3 75 to 6 25 Kilo Ohms 4 If resistance deviates from the specification or open Suppressor cap to be replaced SUPRESSOR CAP KS MOTORCYCLES http ksmotorcycles com ...

Page 269: ...ws open during resistance check the coil has got cut or short with the core and magneto has to be replaced B INSULATION TEST 1 For checking the insulation strength keep the multimeter in continuity mode and check continuity between any3phaseterminalsandenginebody Ifthereisabodyshort insulationfailure multimeterwillindicate0ohms or resistance value 50 ohms with a beep sound If insulation failure is...

Page 270: ...FIELD VEHICLE SERVICE MANUAL EURO IV 269 INSPECTION STEP 1 1 Set the Multimeter in Continuity check mode 2 Check for presence of continuity by keeping the horn coupler HORN KS MOTORCYCLES http ksmotorcycles com ...

Page 271: ...Fuse 25A 3 Blue Ignition EFI Fuse 15A 4 Red Signalling Horn Fuse 10A 5 Brown Spare Fuse 5A 6 Blue Lighting Fuse 15A 7 White ABS Main Fuse 1 25A 8 Red ABS Main Fuse 2 10A 9 Brown ABS ECU 5A 10 White Spare Fuse 25A 11 Blue Spare Fuse 15A 12 Red Spare Fuse 10A BLADEFUSEUSAGELIST CONTINENTAL GT Fuse No Colour Remarks 1 White Charging Fuse 25A 2 White Main Fuse 25A 3 Blue Ignition EFI Fuse 15A 4 Red Si...

Page 272: ...te toDismantle Instructions 12 3 Electrical connections A Magneto coupler 12 3 B Pulsar Coil coupler 12 3 C Pulsar Coil coupler Disconnect yellow wired Black coupler from LH side Disconnect Green wired Black coupler from LH side Disconnect Green wired Black coupler from LH side KS MOTORCYCLES http ksmotorcycles com ...

Page 273: ...2 3 Electrical connections D Relay Starter Coupler 12 3 E Ignition Coil Coupler 12 3 F ECU Power Relay Side stand Switch indication relay Disconnect ECU Power relay and side stand switch relay Disconnect white coupler from LH side Disconnect Relay starter WHITE and Battery Coupler RED from LH Side KS MOTORCYCLES http ksmotorcycles com ...

Page 274: ...ic EFI Bullet EFI Continental GT Loosen the 2 Pan head screws mounted on bottom side of Switch Module RH Pan head hex Screw M5 Philips Screw Driver SWITCHES Gently open the RH switch module top and bottom portion to access the RH Switch Remove 2 pan head screws mounted on RH switch on LH RH side Gently remove the switch module RH KS MOTORCYCLES http ksmotorcycles com ...

Page 275: ...tch Module RH Bullet Classic EFI Bullet EFI Continental GT Locate the RH switch module Install2panheadscrews onRH switchon LH RH side Pan head hex Screw M5 Philips Screw Driver Close the RH Switch module cover top and bottom portion Install the Pan head screw mounted on bottom side of Switch Module RH KS MOTORCYCLES http ksmotorcycles com ...

Page 276: ...12 3 Switch Module LH Bullet Classic EFI Bullet EFI Continental GT Loosen the 2 Pan head screws mounted on bottom side of Switch Module LH Pan head hex Screw M5 Philips Screw Driver Gently open the LH switch module top and bottom portion to access the LH Switch Gently remove the switch module LH KS MOTORCYCLES http ksmotorcycles com ...

Page 277: ...mble Instructions 12 3 Switch Module LH Bullet Classic EFI Bullet EFI Continental GT Locate the LH switch module Pan head hex Screw M5 Philips Screw Driver Close the LH Switch module cover top and bottom portion Install2PanheadscrewS mounted on bottom side of Switch Module LH KS MOTORCYCLES http ksmotorcycles com ...

Page 278: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 277 BULLET EFI BULLET CLASSIC EFI WIRING HARNESS CIRCUIT SECTION 12 4 WIRING DIAGRAM KS MOTORCYCLES http ksmotorcycles com ...

Page 279: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 278 BULLET EFI BULLET CLASSIC EFI STARTING CHARGING IGNITION EFI SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 280: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 279 BULLET EFI BULLET CLASSIC EFI LIGHTING SIGNALING SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 281: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 280 BULLET EFI BULLET CLASSIC EFI WIRING HARNESS ABS SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 282: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 281 CONTINENTAL GT WIRING HARNESS CIRCUIT KS MOTORCYCLES http ksmotorcycles com ...

Page 283: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 282 CONTINENTAL GT STARTING CHARGING IGNITION EFI SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 284: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 283 CONTINENTAL GT LIGHTING SIGNALING SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 285: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 284 CONTINENTAL GT WIRING HARNESS ABS SYSTEM KS MOTORCYCLES http ksmotorcycles com ...

Page 286: ...ROYAL ENFIELD VEHICLE SERVICE MANUAL EURO IV 285 SECTION 13 TROUBLE SHOOTING KS MOTORCYCLES http ksmotorcycles com ...

Page 287: ...F Position Push stop switch to ON position 2 Side stand not retrieved Retrieve side stand 3 Vent hole clogged in fuel tank cap Clean vent hole 4 Spark plug cap lead not connected Fix cap lead firmly 5 Spark plug electrode dirty fouled Clean spark plug 6 Spark plug insulation cracked Replace spark plug 7 Clutch slipping Adjust clutch cable free play 8 Main or EFI Fuse failed Replace with new fuse I...

Page 288: ...II BRAKES POOR 1 Brake pad worn Uneven wear Replace Brake pads 2 Oil grease on disc Clean and refit 3 spongy brake fill brake fluid remove air from the system VIII MOTORCYCLE WOBBLES 1 Under inflated tyres Inflate to correct pressure 2 Loose Broken spokes Tighten Replace spokes 3 Wheels misaligned Ensure proper alignment 4 Wheel rim runout Rectify 5 Tyres not fitted correctly Refit tyres correctly...

Page 289: ...nd correct 2 Bulb fused Replace Brake light remains on 1 Switch not adjusted properly Adjust connecting links properly 2 Switch sticky Replace switch X ELECTRONIC FUEL INJECTION EFI Malfunctioning Indicator Lamp MIL glowing continuously 1 Sensor Coupler Loose Connection Check for any EFI sensor coupler loose connection and correct them 2 Any EFI Sensor Failure Check replace the same XII ABS ANTI L...

Page 290: ...fuel tank Fill fuel tank Stale adulterated fuel Clean fuel tank Fill with fresh fuel Fuel Tap in Closed Position Turn fuel knob to On Reserve C Fuelrelated Air vent blocked in fuel cap Clean air vent s Fuel filter clogged Clean fuel filter Fuel line pinched Check correct fuel line Ambient temperature too low for Use Choke for starting in cold engine to start conditions Choke Left ON Shut OFF choke...

Page 291: ...tartermotorrotates battery worn out starter motor starter motor BUTenginedoes brush notcrank Magneto rotor woodruff key broken Check replace woodruff key Starter clutch assembly slipping Check replace starter clutch assy Inlet Exhaust rocker arm seized in Investigate cause of seizure rocker shaft check correct as required Cam shaft seized in cylinder Investigate cause of seizure head cover check c...

Page 292: ...blocked Fuel flow partially blocked Check clean fuel tap filter Air filter dirty clogged Check clean replace Pulse air valve pipe connections Check correct loose cracked C Compressionrelated Spark plug loose Check tighten to torque Inlet Exhaust tappets adjusted Check correct wrongly Cylinder head gasket blown Check correct Cylinder head studs loose Check tighten to torque Cylinder head seating ar...

Page 293: ...ly Check correct Cylinder head gasket blown Check correct Cylinder head studs loose Check tighten to torque Cylinder head seating area warped Check replace Cam shaft sticky rotation seized Check correct in cylinder head Valve spring broken or weak Check replace Valve not seating properly stem Check replace bent Heavy carbon deposit on seating surface Piston rings worn out broken Check replace stuc...

Page 294: ...r B Fuel Inductionrelated Inlet manifold loose cracked Check tighten replace inlet manifold C CompressionRelated Spark plug loose Tighten spark plug to torque Tappets adjusted too tight Check adjust tappets correctly Cylinder head bolts loose Check tighten to torque Cylinder head gasket damaged Check Replace Cylinder head warped Check Replace Valve spring broken or weak Check Replace Valve not sea...

Page 295: ...cked Ignition coil defective Check replace B Brownsmoke Adulterated Bad fuel Clean fuel tank Fill with fresh fuel Air filter box poorly sealed Check correct element partially clogged C Bluish Whitesmoke Engine oil level too high Check Maintain Oil level as Recommended Valve stem seal damaged Check correct Excess clearance between valve Check correct stem guide Oil scrapper ring worn out Check corr...

Page 296: ...g insulator cracked Check replace Suppressor cap H T lead loose Check correct as required Suppressor cap H T lead defective Check correct as required Ignition coil defective Check Replace Pulsar coil Magneto defective Check replace C Fuel Inductionrelated Adulterated Bad fuel Clean fuel tank Fill with fresh fuel Air filter dirty clogged Check clean replace D CompressionRelated Spark plug loose Tig...

Page 297: ...aky noise Replace stem seals Valve stem to guide clearance high Check replace D Cylinderbarrel central Piston rings broken Check replace portionnoise Cylinder Piston scored Check replace Check air filter housing also for damages Excess clearance between piston barrel Check replace Piston slap Cam chain pads worn out Check replace Auto chain tensioner jammed Check replace Excessive clearance betwee...

Page 298: ...ft forks pins worn out Check replace Selector drum grooves worn out Check replace Clutch pad sticky worn out Check replace Clutch plates movement sticky Check correct D Clutchassemblyrelated Springs weak broken Check replace Friction plates worn out burnt Check replace Steel plates warped Check replace No end float of clutch assembly in shaft Check correct E Gearsdoesnotengage Shift forks sticky i...

Page 299: ...tion sensor resistance FlywheelMagnetoAssy Check for stator short circuit Check for connector loose fitment DTC History not ECU Clear DTC using only scan tool do not re set ECU by test pin able to clear method Fuel pump ECU ECU internal short replace ECU Continuous ON Fuel Pump Fuel Pump Check for Connector loose fitment terminal back out or wire Not working cut etc Check for supply voltage batter...

Page 300: ... cut etc Sensor Circuit Failure HEGO Sensor Check for Connector loose fitment terminal back out or wire cut etc Engine Oil Check Connectors for loose pin Temperature TE If the issue still persists Replace Sensor Sensor TA Sensor Check for Connector loose fitment terminal back out or wire cut etc Sensor Circuit MAP Sensor Check for Connector loose fitment terminal back out or wire Malfunction cut e...

Page 301: ...Royal Enfield Support 1800 2100 007 Email support royalenfield com Twitter RoyalEnfieldSupport Web www royalenfield com KS MOTORCYCLES http ksmotorcycles com ...

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