Royal Enfield Continental GT Owner'S Manual Download Page 5

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Contents

Manual Bi Starter (choke) ...................

PRE OPERATIONAL CHECKS ....................

RUNNING IN PERIOD..................................

ELECTRONIC FUEL INJECTION (EFI) .........

EFI ....................................................

The Advantages of EFI .......................

Malfunction Indicator Lamp (MIL) .........

ROLL OVER SENSOR ...............................

STARTING ................................................

GEAR SHIFTING .......................................

PARKING ..................................................

Center Stand ......................................

Side Stand .........................................

TOOLS & FIRST AID KIT...............................

RECOMMENDED LUBRICANTS ...................

PERIODICAL MAINTENANCE .....................

MINOR MAINTENANCE TIPS ......................

Control Cables, Hand lever,
Center / Side Stand Pivots ..................

Oil Level Inspection ............................

Engine oil change ...............................

Spark Plug .........................................

Brake fluid (Front & Rear) ...................

Inspection of tyres and wheels ..........

Tyre pressure .....................................

Front W heel removal ..........................

Front W heel reassembly .....................

Rear wheel removal ...........................

Rear wheel reassembly......................

Adjustments-Clutch lever free play ....

Rear brake light switch adjustment......

Drive Chain free play ..........................

Chain lock fitment ...............................

Adj. of gas filled shockabsorber .........

Removal of Battery from the Vehicle.....

Summary of Contents for Continental GT

Page 1: ......

Page 2: ...ition Pirelli Sports Demon tyres and a remapped ECU the new Continental GT is part homage part engineering tour de force This manual will help you to operate your motorcycle and guide you to wholly maintain it We have also provided tips on safe riding and on minor adjustments for the care of your motorcycle Please avail the four free services at the nearest Authorised Service Point at the appropri...

Page 3: ... to explain and need not to be exactly the same on the model you own Technical specifications are subject to change without prior notice Copyright 2014 Royal Enfield A unit of Eicher Motors Ltd All Rights Reserved No part of this manual shall be copied distributed or otherwise dealt without the express permission in writing from Royal Enfield Notice Part No 585441 A Revision 1 0 Qty 500 Apr 2014 D...

Page 4: ...LES OF THE ROAD 19 VEHICLE IDENTI NUMBER DETAILS 21 KEY PARTS LOCATION 22 Right Side View 22 Left Side View 23 Top View 24 OPERATION OF CONTROLS 25 Ignition Switch 25 Steering Lock 26 Steering Unlock 26 Fuel Tank Cap 27 Side Panel LH Battery Cover 27 Utility Box 27 Side PANEL RH 27 Alpha Numeric display unit 28 Head Lamp Switch 30 Head Lamp Day Flash 30 Dip Switch 30 Engine Start Switch 31 Engine ...

Page 5: ...DICAL MAINTENANCE 44 MINOR MAINTENANCE TIPS 48 Control Cables Hand lever Center Side Stand Pivots 48 Oil Level Inspection 48 Engine oil change 49 Spark Plug 50 Brake fluid Front Rear 51 Inspection of tyres and wheels 51 Tyre pressure 52 Front Wheel removal 52 Front Wheel reassembly 53 Rear wheel removal 54 Rear wheel reassembly 55 Adjustments Clutch lever free play 57 Rear brake light switch adjus...

Page 6: ...hing 68 STORAGE PRECAUTION 70 Preparing the motorcycle for re use 71 LONG TRIP PRECAUTIONS 72 COMPLETE WIRING DIAGRAM Domestic 73 TROUBLE SHOOTING 74 Engine fails to start 74 Engine misfiring 75 Poor pickup 75 White Blue smoke 76 Engine overheating 76 Excessive fuel consumption 76 Brakes Poor 77 Vehicle wobbles 77 Electricals 77 Electronic Fuel Injection EFI 78 WARRANTY 79 EMISSION WARRANTY 81 FRE...

Page 7: ...e Pin Contact Nos Res Off Mobile Email Engine No Battery No Frame No Battery make Reg No Licence No Date of Sale Valid till dt Model Key No Tyre make Colour Sold by Dealer Code Vehicle Installation Form VIF No Personal Vehicle Information ...

Page 8: ...n and signed to the service outlet Availing the free services in the specified time is a prerequisite for warranty consideration The cost of fuel oil grease etc used for all free services are chargeable to the customer NOTE Please ensure that the free service details are recorded in this sheet immediately after the service is carried out Date of Service Kms Covered ServicingASP Dealer s Name Addre...

Page 9: ...s and damages to the motorcycle Statement in this manual preceded by the following words are with special significance Warning Indicates a potentially hazardous situation which if not avoided could result in serious injury or damage CAUTION Indicates a potentially hazardous situation if not avoided may result in minor or moderate injury or damage NOTE Indicates important and useful messages for cl...

Page 10: ...ssion ratio 8 5 1 Max Power RPM 29 1 BHP 21 4 kw 5100 rpm Max Torque RPM 44 Nm 4000 rpm Air Filter Element Paper Element Filter Engine Oil Capacity dry fill 2 75 Litres Lubrication Forced Lubrication Wet Sump Engine Oil Grade Royal Enfield 15 W 50 API SL Grade Engine Oil JASO MA Fuel System Electronic Fuel Injection Programmed PGM EFI ...

Page 11: ... Bosch Super TRANSMISSION Clutch Wet Multiplate 7 Plates Primary drive Duplex Chain Primary Drive Ratio 2 15 1 Gear box Constant Mesh 5 Speed Gear shift pattern 1 N 2 3 4 5 Gear Ratios 1st 3 063 1 2nd 2 013 1 3rd 1 522 1 4th 1 212 1 5th 1 000 1 Secondary Drive F D Sprocket 18 Teeth Final Drive Ratio 2 00 1 Drive Chain Links 100 Links ...

Page 12: ...r 12V 0 2W L E D Neutral Telltale Bulb 12V 1 12W Horn Dual 12V 2 5A dual tone LT HT Starter Motor 12V 0 9 KW WARNING Using bulbs other electrical gadgets other than specified rating may lead to over loading erratic behaviour premature failure of electrical system Modifications on the bike which are not approved by Royal Enfield may not only disqualify for warranty but also affects performance of t...

Page 13: ...0 Litres Suspension Front Telescopic Stroke 110mm Rear Gas Charged Stroke 80 mm Front fork oil capacity 430 ml per leg Front fork oil Gabriel Fork Oil 2W 35 Hydraulic Brakes Front 300 mm dia floating disc twin piston floating caliper Rear 240 mm dia disc single piston floating caliper Brake oil grade DOT 3 or DOT 4 Brake oil capacity Front 50 ml Rear 100 ml Technical Specification Note Fuel tank c...

Page 14: ...rb Weight with 90 Fuel 185 Kg Gross vehicle weight 365 Kg NOTE 1 Values Dimensions given above are for your guidance only 2 In view of continuous improvements being done on our products the specifications are subject to change without notice Technical Specification NOTE BS III This vehicle meets Emission Norms Bharat Trem Stage III ...

Page 15: ...Royal Enfield dealer for details Whenever refuelling your motorcycle please exercise utmost caution and carefully observe the following rules DO NOT smoke and please ensure that there are no open flames or sparks near the motorcycle when refuelling OR servicing the fuel system Switch OFF mobile phones and other hand held electronic devices Open the fuel filler cap slowly Refuel in a well ventilate...

Page 16: ...torcycle riding techniques and become thoroughly familiar with the operation of your particular motorcycle New riders should gain experience under various conditions while driving at moderate speeds Pay strict attention to road surfaces and wind conditions Any two wheeled vehicle may be subject to the following upsetting forces Wind blasts from passing trucks Rough uneven road surfaces Slippery ro...

Page 17: ... absorbers and front forks and look for leaks Replace worn out parts Worn out parts can adversely affect stability and handling Warning For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle Warning Avoid any contact with the exhaust system Wear clot...

Page 18: ...avate an initial problem cause costly repairs jeopardize your personal safety Warning DO NOT tow a disabled motorcycle The steering and handling of the disabled motorcycle will be impaired due to the force of the towline If a disabled motorcycle must be transported use a truck or a trailer Towing a motorcycle may cause loss of control of the motorcycle in the front leading to an accident Warning D...

Page 19: ...osture is a pre requisite for stable and safe riding Sit in lean forwarded position Keep your elbows close to your body Hold the handle bar grips close to its inner end Look extensively ahead including rear view mirrors without turning the head BRAKING Apply front and rear brakes gently and simultaneously for maximum braking efficiency WARNING Applying any one of the brakes suddenly may cause the ...

Page 20: ...ng stability and increases the possibility of loss of control Keep to the correct side of the road center line when meeting oncoming vehicle Actuate your turn signals and exercise caution when passing other vehicles going in the same direction Never try to pass another vehicle going in the same direction at street intersections on curves or when going up or down a hill At street intersection give ...

Page 21: ...event it from falling over Protect your motorcycle against theft After parking your motorcycle ensure that steering head is locked and then remove the Ignition key Rules of the Road NOTE To help you to establish the relative distance of vehicles behind your motorcycle adjust each mirror in such a way that a small portion of your shoulder is visible and a large portion behind your motorcycle is see...

Page 22: ...21 Vehicle Identification Number Details CHASSIS NUMBER Punched on the steering head tube RH side ENGINENUMBER Punched on top of the Engine LH side ...

Page 23: ...22 1 RH Trafficator front 2 Brake Pedal 3 Kick Start Lever 4 Starter Motor 5 Horn 6 RH Side Panel 7 RH Trafficator Rear 1 2 6 7 RIGHT SIDE VIEW 4 3 Key Parts Location 5 ...

Page 24: ...23 Key Parts Location 7 1 2 3 6 5 4 LEFT SIDE VIEW 1 Trafficator front LH 2 Spark plug 3 Gear Change Pedal 4 Centre stand 5 Side Stand 6 SidePanel LH Battery Cover 7 Trafficator rear LH ...

Page 25: ...4 Day flash switch 5 Head lamp dip switch TOP VIEW 6 Manual Bistarter Choke 7 Speedometer 8 Ignition switch 9 Malfunction Indicator Lamp 10 Tacho Meter 11 Engine Kill switch 12 Park head light switch 13 Electric Start Switch 14 Fuel tank cap 1 2 3 4 8 11 12 13 14 9 7 5 6 10 ...

Page 26: ...gnition key all the indicating lights in instrument cluster starts glowing on for few seconds and the engine will get ready to start The key cannot be removed from ON possition Turn the ignition key in anticlockwise direction to OFF Once you turn off all the electrical systems goes off Now the key can be removed OFF ON ...

Page 27: ...NLOCK CAUTION Do not lubricate barrel locks with petroleum based lubricants or graphite Inoperative locks may result in damage to your vehicle Push the key in steering lock Position and turn clockwise direction to unlock the steering The key can be removed from the lock in this position Operation of Controls CAUTION Protect your motorcycle against theft After parking your Motorcycle and lock the s...

Page 28: ...SIDE PANEL RH Utility box is provided at the bottom area of battery carrier It is covered with side panel LH SIDE PANEL LH BATTERY COVER Turn key clockwise to unlock the side panel Pull the side panel outside for opening the same Key cannot be removed in this position Unscrew the indicated screw and then pull the side panel for opening the same UTILITY BOX ...

Page 29: ...eading by default NOTE Once you turn ON the ignition key whatever was the last selection mode will get displayed TRIP METER MODE A light push for less than one second on the PUSH button switch will change the display from odometer to Trip meter TRIP A NOTE For resetting the Trip Meter 1 Set the display as TRIP A or B as a current mode 2 Press the PUSH button for more than 3 Seconds 3 Automatically...

Page 30: ...ealer and check the same FUEL LEVEL INDICATOR The fuel level indicator indicates the level of fuel in the fuel tank If the battery voltage is less than 12 volts the low voltage indicator will start glowing continuously While the ignition is ON low voltage indicator symbol will glow until engine reaches 700 RPM In running condition if the battery voltage is below 12 Volts for more than 3 seconds co...

Page 31: ...30 DIP SWITCH HEAD LAMP DAY FLASH PRESS FOR HEAD LIGHT FLASH LOW BEAM HIGH BEAM Operation of Controls HEAD LAMP SWITCH HEAD LAMP ON POSITION LAMP HEAD LAMP OFF ...

Page 32: ...31 Operation of Controls ENGINE STOP SWITCH ENGINE ON ENGINE OFF TURN SIGNAL SWITCH LEFT RIGHT OFF PUSH TO OFF ENGINE START SWITCH PRESS ...

Page 33: ...32 MANUAL BI STARTER CHOKE Operation of Controls HORN PRESS Apply choke in cold start condition while starting the Bike ...

Page 34: ... and sufficient lubrication 4 Brakes steering and throttle for proper responsiveness 5 Cable for fraying or crimping and free operation Warning For your personal welfare and safety all the points mentioned above should be performed periodically Failure to do so may affect safe operation damage your motorcycle and could result in an accident causing serious injury 6 Engine oil level 7 W heel spokes...

Page 35: ...ter every hour of running Vary the speed of the motorcycle regularly during running but avoid using the motorcycle above 1 2 throttle opening position 2 501 2000 Kms The recommended speed is below 80 90 kmph Avoid driving the motorcycle with full throttle opening Vary the speed of the motorcycle regularly but avoid using the motorcycle above 3 4th throttle opening position 3 2001 Kms and above Avo...

Page 36: ... free MALFUNCTION INDICATOR LAMP MIL A Malfunctioning Indicator Lamp MIL is provided in the RPM meter which is located on the right side of the Cluster unit 1 EFI Mal Function Indicator When both the Ignition Engine kill switch is 0N the MIL will glow for few seconds and will go OFF This indicates that all the functions of Electronic Control Unit ECU and other sensors are working perfectly and the...

Page 37: ...the engine running condition The Roll Over Sensor will switch off Ignition and cut off fuel supply to prevent the motorcycle from moving suddenly while it is in gear To re activate the system after the motorcycle has been made upright please switch off both the Ignition Engine kill switch wait for a few seconds and switch ON again This will help to RESET the Roll Over Sensor and the engine can be ...

Page 38: ...ease the starter button wait for 30 seconds before pressing the starter button again Press starter button and release starter switch once the engine starts A clutch switch is provided in the system for the safety of the rider This is to prevent the vehicle from starting when the vehicle is in gear To start the engine when it is in gear pull clutch lever press the starter button and release slowly ...

Page 39: ...d to run slowly for 15 30 seconds This will allow the engine to warm up and let oil reach all surfaces needing lubrication Failure to adhere may result in damage to the Engine Manual bi Starter choke NOTE It may be necessary to operate and hold the manual bi starter when starting the engine for the first time in cold mornings temperatures below 10 C or at high altitudes to prevent the stalling and...

Page 40: ...l But will also cause serious damage to the fuel pump Please ensure fuel is filled up as soon as the low fuel last bar start blinking CAUTION Air cooled engine requires air movement over the cylinder head and exhaust pipe to maintain proper operating temperature Never accelerate the engine abnormally in stand still condition of the motorcycle Failure to adhere this may result in damage to exhaust ...

Page 41: ...ith toe towards down to engage 1st gear Gently open throttle and release clutch simultaneously If clutch is released suddenly the engine may stall and cause a jerky start NOTE Always start motorcycle with gear in neutral position Always move the motorcycle in first gear position only When engine speed decreases or while climbing a gradient or running at a reduced speed shift to the appropriate low...

Page 42: ...m lever on the center stand and pull vehicle upwards gently PARKING VEHICLE ON SIDE STAND Select a firm flat surface Lower Side Stand and gently tilt motorcycle to the left till it rests firmly on the side stand Warning Always park the motor cycle on a firm and flat surface Parking in a soft ground may cause stand to sink and the motorcycle to fall causing injury to you or to others and damage to ...

Page 43: ...ouble End Spanner 10 X 13 2 7 Double End Spanner 8 X 10 1 8 Allen Key 5 MM 1 9 Allen Key 3 MM 1 10 Tyre Removal Lever 2 1 4 5 6 7 3 S No Description Qty 1 Antiseptic cream 5 gms 1 2 Gauze bandage 5 cm x 2 cm 1 3 Elastic Gauze bandage 8 cm x 1 mtr 1 4 Wash proof plaster 1 9 cm x 7 2 cm 2 5 Sterilized Gauze Swab 5 cm x 5 cm 2 6 Sterilized elastic plaster 7 cm x 6 cm 1 7 First aid kit pouch 1 2 1 2 3...

Page 44: ...tioned in above point No 1 Engine Oil Grade Royal Enfield 15 W 50 API SL Grade Engine Oil JASO MA Front Fork Oil Grade Royal Enfield Front Fork Oil or Gabriel Fork Oil 2W 35 Capacity 430 ml leg Brake Fluid Grade DOT 3 or DOT 4 Capacity 2 75 Ltrs for dry fill 2 50 Ltrs during oil filter element replacement Warning DO NOT switch oil brands indiscriminately because some oil interact chemically when m...

Page 45: ...a nearest Royal Enfield Authorised Dealer Service Point for expert advice and to carry out the periodical maintenance Warning For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the motorcycle to malfunction and stall abruptly resulting in...

Page 46: ...C C C 4 Magnetic drain plug under gear box and secondary C C C C C C C drain plug under cranksharft in crankcase RH 5 Spark plug C A C A C A C A C A R C A C A C A C A R 6 HT lead for crack I I I I I I I I I I I 7 Fuel hose clip Injector O Ring Seal Ring I I I I R I I I R I I 8 FuelPump Check for screw tightness in all services 9 Accelerator Throttle pully cable free play A A A A A A A A A A A 10 R...

Page 47: ...h lever free play Adjust every 1000 Kms or earlier as required 17 Rear brake pedal pivot L L L L L L L L L L L 18 Battery terminals apply petroleum jelly C C C C C C C C C C C 19 Battery Electrolyte level I I I I I I I I I I I 20 Earth wire eyelet contact below ECU Mounting I I 21 Rear WheelDrive Chain Adjust every 1000 Kms or earlier as required Lubricate every 3000 Kms or earlier as required 22 ...

Page 48: ...k starter pivot Lubricate every 1000 Kms or earlier as required 28 Brake Oil level check Replacement I I I I I I I I R I I 29 Pivot Side Stand Center Stand pivot L L L L L L L L L L L 30 Rider Pillion Foot rest pivot L L L L L L L L L L L 31 Swing arm needle bearings and spindle L L 32 Vent Pipe under air filter box I C I C I C I C I C I C I C I C I C I C 33 Throttle body cleaning spray C C C C C ...

Page 49: ...uthorised Dealer Service Point CONTROL CABLES HANDLE BAR LEVER PIVOTS CENTER SIDE STAND PIVOTS Lubricate after using the motorcycle in rain after waterwash or if used in dusty conditions Wipe the area free of dirt grease Apply a few drops of oil on the pivots Place motorcycle on its center stand on a firm surface Warm up engine for a few minutes switch off The level is correct if the oil level is ...

Page 50: ...on the crankcase after all the oil is drained out Refer Periodical Maintenance Chart for frequency Remove primary drain cap to drain oil clean suction filter magnet Then remove secondary drain plug to drain oil clean the magnet Finally remove primary drain bolt to drain the complete oil Primary Drain Plug Secondary Drain Plug TILT VEHICLE RH LH Place motorcycle on its centre stand on a firm flat s...

Page 51: ... cleaner Set the gap between 0 80 to 0 90 mm Refit the spark plug on the cylinder head and connect H T Lead NOTE Replace oil filter paper element whenever oil is being replaced CAUTION Do not fill oil over MAX mark It may cause the engine to smoke and result in loss of power Do NOT use the motorcycle if the oil is below the MIN mark Doing so will cause serious damage to the moving parts inside the...

Page 52: ... INSPECTIONOFTYRESANDWHEELS Inspect the tyre periodically for tread wear cracks and cuts FRONT BRAKE REAR BRAKE MIN Check and remove stone splinters nails or other particles embedded in the tyre treads Bald spots swelling may be caused by internal damage Replace the tyres if defective Replace tyres when the tread depth has reached the minimum as specified Periodically inspect wheels for spokes bre...

Page 53: ...y matched to wheel rims See your Royal Enfield Dealer Mismatching tyre tubes rims and air valves may result in damage to the tyre bead during mounting allow tyre slippage on the rim and cause tyre failure Place the vehicle on center stand Place a wooden block the front end of engine to support the vehicle Loosen the pinch bolt on the RH fork guide by 6 mm allen key Hold the axle head by double end...

Page 54: ... not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper Place the wheel speed sensor in position Ensure slot on hub and speedo sensor is matched correctly Insert the wheel along with wheel speed sensor and LH spacer between the front fork ends ensuring the brake disc is located between the brake pads Insert and tap the fr...

Page 55: ...nected to cluster unit and then check for proper working of speedo meter Press brake lever 2 or 3 times to check front brake efficiency Place the vehicle on center stand on a firm and flat surface Observe and mark the alignment index marks in the both sides of swing arm Remove axle nut on the RH side Remove wheel spindle from LH side along with wheel collar and LH side spacer Index mark ...

Page 56: ...he rear brake pedal is accidently pressed Minor Maintenance Tips Remove the distance collar Tilt the motorcycle towards RH side and take out the rear wheel assembly conveniently REARWHEELREASSEMBLY Tilt vehicle to right and insert wheel assembly between the swing arms Position the rear wheel with cush rubber on the rear driven flange adaptor Fix the LH side spacer in rear wheel hub Remove the wood...

Page 57: ... swing arm Ensure the brake disc is located in between the brake pads Ensure that swing arm end plate is seated properly and the chain adjuster nuts are correctly tight ened and Locked Insert and tap the rear wheel axle gently Index mark CAUTION Do not force the spindle into the wheel as the threads may get damaged Tap it through the wheel gently Ensure the index marks alignments on both sides of ...

Page 58: ...ment nut while holding the rear brake light switch body in position 2 If the brake light do not glows after pressing the pedal for approximately 25mm turn the adjusting nut in clockwise direction by 2 to 3 threads and check for brake light function 3 If the brake light continuously glows turn the adjusting nut in anti clockwise direction by 2 to 3 threads so as to get the positions in which the li...

Page 59: ...ng nut Swing Arm reference mark Index mark Adju ster Lock nut 1 If the drive chain free play is incorrect adjust as follows a Loosen the axle nut of the rear wheel axle b Loosen the QD sprocket spindle nut c Loosen the locknut at both end of the swing arm d To reduce the free play turn the drive chain slack adjusting nut in clockwise direction e To increase the free play turn the drive chain slack...

Page 60: ...ve f Later adjust the nut on LH side by matching the index mark with respect to RH side index g Ensure that both the sides are in same index marks h Finally torque the spindle and axle nuts to 7 kgm i Tighten the adjuster locknut by 13mm spanner against chain slack adjusting nut Warning Chain slackness beyond 30mm will lead to chain slippage Maintain drive chain slackness within the specified limi...

Page 61: ...in oposite direction Adjust both the rear shock absorbers to the same thread possitions Recommended 10 mm height adjustment only from factory setting Warning Riding the motorcycle with the shock absorbers adjusted in different positions can cause loss of control Regularly inspect shock absorbers and front forks for any leaks NOTE Ensure accessories fitted if any do not foul with rear shock absorbe...

Page 62: ...rrier bracket by loosening the two screws Take out the battery BATTERY MAINTENANCE The Motorcycle is provided with 12V 14 AH battery The battery must be periodically checked for Cleanliness and corrosion free terminals Electrolyte level If electrolyte level is low top up with distilled water only NOTE The poor contact or loose fitment of Battery terminals may cause ECU failure Battery Carrier brac...

Page 63: ...overfill the battery electrolyte level as it will spill out through the overflow pipe and cause corrosion to vehicle parts Use only distilled water meant for use in batteries to avoid damage to battery Smear the terminals with petroleum jelly Do not use grease in the battery terminals Place the terminal boot cap properly Refit the carrier bracket Refit LH side panel lock it Ensure ignition switch ...

Page 64: ...sconnect electri cal connections Thumb push and remove the bulb holding clamp gently Remove the bulb Position new bulb inside the reflector such that the three projections on the bulb align with the slot on the reflector Refix the bulb holding clamp Connect the Electrical connections Position head lamp doom onto the head lamp shell and tighten the mounting screw on top Always hold the bulb with pa...

Page 65: ...bly by pulling seat lock cable Remove the tail light glass by unscrewing its mounting screw Replace the bulb 12V 21 5W A s s e m b le back the tail light in the r e v e r s e order of dismantling process Hold the bulb press inside and rotate anticlockwise to remove the tail light bulb from its holder ...

Page 66: ...g back side Open the Indicator housing Take out the bulb holder with help of is screw driver Take out the bulb and replace the same Refit the holder fitting its lock in proper position Minor Maintenance Tips Fix the rubber gasket cover Assemble back the indicator housing cover ...

Page 67: ... is very important to keep all the Electrical connections intact Warning While doing Arc welding any where in motorcycle the battery terminals and the Electronic Control Unit ECU coupler are to be completely disconnected Failure to do so many cause damage to the Electrical system of the Motorcycle Warning Please get the electrical system of your Motorcycle checked thoroughly and get the faults cor...

Page 68: ...n in fig and fix it back NOTE It is adviceable to replace air filter paper element once in 10 000 KMS In case of vehicle running in dusty mud road condition it may be replaced as earlier as required Usage of high pressure compressed air is not recommended to clean air filter paper element Fitment of air filter paper element is reverse order of removal process Remove the air filter cover screws and...

Page 69: ...parts if required Follow the directions in the label carefully before using the degreaser Use low pressure jet of water to clean the entire vehicle Never spray water with great force on head lamp Meter cluster unit trafficator lights front and rear wheel hubs electrical connections and wires control cables EFI components sparkplug battery air fillter cover etc Use Luke warm water and mild detergen...

Page 70: ...and or in highways at high speeds AFTERWASHING Ensure the vehicle is thoroughly dry by wiping with a clean soft water absorbent cloth or chamois leather Remove all plastic bags and adhesive tapes Lubricate control cables pivots for footrest side stand centre stand brake and gear shifter linkages rear chain etc with lube oil Polish the painted and plated surfaces using polishing wax Start the bike ...

Page 71: ...chain thoroughly and apply lubrication oil on it Remove battery from the bike Clean its terminals and apply petroleum jelly on the terminals to avoid corrosion Maintain electrolyte level between max and min marks by adding distilled water and wipe the battery dry Store the battery in a cool dry and well ventilated place Do not place the battery in direct sun light near open flame or where temperat...

Page 72: ... line for any cracks or cuts Clean the air filter Remove plastic covering from the silencer Remove spark plug on cylinder head and pour in a few drops of engine oil Crank engine a few times to lubricate cylinder walls and piston Clean spark plug and refit Switch ON the ignition switch Start vehicle and warm up engine for a few minutes before riding the vehicle NOTE Do not raise the engine rpm the ...

Page 73: ... level Proper drive chain tension and correctly adjusted rear brakes Check for proper functioning of all lights horn etc CHECKS AFTER EVERY 1500 KMS OF RUN Tightness of all fasteners Tyre treads condition and wear pattern of tyres Battery condition and electrolyte level Correct oil level in engine Working of all lights and horn Proper drive chain tension ITEMS TOBECARRIED Tool kit First aid kit Bu...

Page 74: ...73 Complete Wiring Diagram NOTE Complete Wiring Diagram is attached on this page ...

Page 75: ......

Page 76: ...ion Push stop switch to ON position 2 Vent hole clogged in fuel tank cap Clean vent hole 3 Spark plug cap lead not connected Fix cap lead firmly 4 Spark plug electrode dirty fouled Clean spark plug 5 Spark plug insulation cracked Replace spark plug 6 Clutch slipping Adjust clutch cable free play 7 Main or EFI Fuse failed Replace with new fuse CAUSES REMEDIES Contact Authorised Dealer Service Point...

Page 77: ... Fill tank with fresh petrol III POOR PICKUP 1 Brake pedal adjusted too tight Re adjust properly 2 Choked air filter Clean Replace air filter 3 Rear chain adjusted too tight Re adjust properly 4 Under inflated tyres Inflate to correct pressure 5 Accelerator cable free play excessive Adjust cable free play 6 Clutch Slipping Adjust clutch cable free play 7 Faulty fuel supply Remove fuel pump clean F...

Page 78: ...top up if necessary 2 Clutch slipping Check and correct 3 Cylinder fins not clean Clean the cylinder fins at regular intervals VI EXCESSIVE FUEL CONSUMPTION 1 Under inflated tyres Inflate to correct pressure 2 Choked air filter Clean Replace 3 Fuel leakage Check and rectify tank float unit drain pipe breather pipe fuel line pump CAUSES REMEDIES Contact Authorised Dealer Service Point ...

Page 79: ...om the system VIII VEHICLE 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 IX ELECTRICALS Bulbs do not glow 1 Bulb fused Replace bulb CAUSES REMEDIES Contact Authorised Dealer Service Point ...

Page 80: ...IC 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 Trouble Shooting CAUSES REMEDIES Contact Authorised Dealer Service Point Warning Please get the electrical system of your Motorcycle checked thoroughly and get the faults cor...

Page 81: ...e schedule given in the owner s manual from RE Authorised Dealer Service Point 4 During the warranty period RE s obligations shall be limited to repairing replacing free of charge such part or parts of the vehicle which on examination to have manufacturing defect Such defective part parts which have been replaced becomes property of RE 5 Cost of oil oil filter fuel and other consumables are charge...

Page 82: ...on of the vehicle such as slight vibration oil leakage discoloration of exhaust bent pipe silencer soft or hard shock absorber etc i Defects arising from fitment of unauthorised additional Electrical loads j Vehicle serviced repaired at unauthorised service points k Vehicle used for competition racing l Electrical component like bulbs fuses etc Electronic components failure due to repairs by arc w...

Page 83: ...standards then the Authorised Dealer Service Point shall take necessary corrective measures and shall at its sole discretion repair or replace free of charge such components of the emission control system to meet the required emission standards The method s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfiel...

Page 84: ...field will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised Dealer Service Point OR for any loss due to non availability of the motorcycle during the period of examination and repairs by Royal Enfield and or their Authorised Dealer Service Point Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on acco...

Page 85: ...rol certificate valid for the period immediately preceding the test during which the failure is discovered the test having been carried out either for obtaining a new certificate or pursuant upon being directed by an officer as referred to in sub rule 2 of rule 116 of the Central Motor Vehicles Rules CMVR Produce the Owner s Manual and Log book for verification details Produce receipts covering ma...

Page 86: ...or its Authorised Dealer Service Point if the motorcycle shows that any of the conditions stipulated in the Owner s manual with regard to use and maintenance have been violated The motorcycle has been run on adulterated leaded fuel or lubricant other than those specified by Royal Enfield in the Owner s manual or any other document given to the customer at the time of sale of the motorcycle The emi...

Page 87: ... POLLUTION 1 Ensure that the periodical maintenance is carried out as stipulated in the owner s manual through a Royal Enfield Authorised Dealer Service Point 2 Use only Unleaded petrol 91 octane from reputed fuel pumps 3 Ensure the fuel used is not adulterated 4 Use correct spark plug as recommended in the owner s manual 5 Use lubricants as per recommendations given on grade brand in the owner s ...

Page 88: ...t the specified time in any of the Royal Enfield Authorised Dealer Service Point nearest to you and as a token of satisfactory service kindly return the free service coupon duly filled in and signed to the service outlet Availing the free services in the specified time is a prerequisite to warranty consideration The cost of fuel oil oil filter element grease etc used for free service is chargeable...

Page 89: ...e Record Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer s Name Address 1ST FREE SERVICE Cost of oil oil filter element and other consumables used are chargeable to ...

Page 90: ...ront fork oil Inspect for leakage 9 Air filter element Clean 10 Spark plug M14 Check clean adjust gap 11 H T Lead Inspect for cracks 12 Fuel pump Check mounting screws 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Accelerator cable Adjust play 16 Clutch cable Adjust play 17 Engine oil sump strainer Clean 18 Engine oil Replace 19 Engine oil filter ...

Page 91: ...ails in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer ...

Page 92: ...spect for leakage 9 Air filter element Clean 10 Spark plug M14 Check clean adjust gap 11 H T Lead Inspect for cracks 12 Fuel pump Check mounting screws 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Accelerator cable Adjust play 16 Clutch cable Adjust play 17 Engine oil Check level top up 18 Hand levers kick starter pivot Lubricate 19 Steering free...

Page 93: ...tails in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer...

Page 94: ...pth 9 Air filter element Clean 10 Spark plug M14 Check clean adjust gap 11 H T Lead Inspect for cracks 12 Fuel pump Check 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Accelerator cable Check adjust play 16 Clutch cable Adjust play 17 Engine oil sump strainer Clean 18 Engine oil Replace 19 Engine oil filter paper element Replace 20 Hand levers kic...

Page 95: ...tails in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer...

Page 96: ...htness 8 Front fork oil Replace oil 9 Air filter element Clean 10 Spark plug M14 Check clean adjust gap 11 H T Lead Inspect for cracks 12 Fuel pump Check 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Accelerator cable Check adjust play 16 Clutch cable Adjust play 17 Engine oil Check top up 18 Hand levers kick starter pivot Lubricate 19 Steering fr...

Page 97: ...ALER ASP COPY 12 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 15 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 15 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature ...

Page 98: ...ignature CUSTOMER COPY 12 000 250 Kms Service Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 15 000 250 Kms Service Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 15 000 250 Kms Service Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 99: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 21 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature 21 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY Paid Service Maintenance Record ...

Page 100: ...ignature CUSTOMER COPY 18 000 250 Kms Service Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 21 000 250 Kms Service Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 21 000 250 Kms Service Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 101: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 27 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 27 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 102: ...ignature CUSTOMER COPY 24 000 250 Kms Service Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 27 000 250 Kms Service Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 27 000 250 Kms Service Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 103: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 33 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 33 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 104: ...ignature CUSTOMER COPY 30 000 250 Kms Service Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 33 000 250 Kms Service Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 33 000 250 Kms Service Brief Work Done Dealer s Stamp Signature Paid Service Maintenance Record ...

Page 105: ...103 All India Road Signs MANDATORYSIGNS INFORMATIONSIGNS CAUTIONARYSIGNS ...

Page 106: ...104 Sl No Date Kms Details Idling CO Authorised Dealer Service Point Job Card No Stamp Signature Log Book ...

Page 107: ...105 Sl No Date Kms Details Idling CO Authorised Dealer Service Point Job Card No Stamp Signature Log Book ...

Page 108: ...106 Sl No Date Kms Details Idling CO Authorised Dealer Service Point Job Card No Stamp Signature Log Book ...

Page 109: ...107 Sl No Date Kms Details Idling CO Authorised Dealer Service Point Job Card No Stamp Signature Log Book ...

Page 110: ...108 Notes ...

Page 111: ...109 Notes ...

Page 112: ...110 Notes ...

Page 113: ...111 Notes ...

Page 114: ...112 Notes ...

Page 115: ...Telephone Residence Invoice No Delivery Note Advice No Have you visited Royal Enfield website Yes No Bike Regn No Telephone Office E Sales Representative or ...

Page 116: ......

Page 117: ...LESS 22PSI 16 Front Brake Light NW F 17 Speedo sensor cable coupler connection function WF NW 18 Clutch Operation H N Smooth 19 Clutch Lever Free Play EP V T 2 3 mm 20 Accelerator Operation T SY Smooth 21 Lever Brackets Tightness LF Tight 22 Switch Modules Tightness LF Tight 23 Steering Movement T Free 24 Clip on Handle Bar fasteners LF 25 DOME Lock Nut T Stem LF 4 5 to 5 5 Kgm 26 Brake Tail Light...

Page 118: ...e LESS 32PSI 54 Rear Tyre Condition Check Tyre Line Seating WF Good 55 RR Shock Absorber Operation Adjustment H N AD Smooth 56 Swing Arm Bolts Fitment LF 57 Rider Foot Rest Foldable Function LH RH H NW 58 Presence of Foot Rest Peg circlip Missing 59 Mudguards Paint Related SC PD R DN No Defects 60 Fuel Tank Paint Related SC PD R DN No Defects 61 side panel Paint Related SC PD R DN No Defects 62 Po...

Page 119: ...al received 3 Recommended Lubricants explained 4 Maintenance Schedule sheet in Owner s Manual shown and explained 5 Next Free Service due explained 6 All Free Paid Services explained 7 Warranty Guidelines explained 8 Running in period details shown in the manual explained 9 Service Station Address given and Location explained 10 Service Incharge Name Mobile No given 11 Bike delivered in neat and c...

Page 120: ...for you KEEP RIDINGP 13 Control Switches Disc Brake System usage explained 14 Fuse Box location shown and explained 15 Recommended Tyre Pressure explained 16 Bike starting Gear shifting procedure explained 17 Quantity of Fuel in Fuel Tank informed 18 Bike orientation short distance drive provided 19 Date and Time of Installation 20 Name of Person who did Installation NO YES ...

Page 121: ...ies with the provisions of the Motor Vehicles Act 1988 and the rules made there under including the following mass emission norms Brand name of the vehicle Chassis number Engine number motor number in case of battery operated vehicles Sub rule No of rule 115 2 i 115 14 F Emission norms Bharat Stage III Bharat Stage I II III Bharat Trem Stage III etc Date Continental GT For ROYAL ENFIELD Quality As...

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