Royal Enfield ELECTRA Service Manual Download

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Summary of Contents for ELECTRA

Page 1: ...e Ltd 70 Northwick Business Centre Blackley Glos GL56 9RF Telephone 01386 700907 Fax 01386 700738 E mail sales watsonian squire com Web site www royal enfield com w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 2: ... _ w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 3: ...n procedures of various parts of the motorcycle It also aims at introducing the latest field tested practices and major factory approved repairs to the Royal Enfield technician Due to continuous improvements there may be variation in the product We have endeavored to make this manual user friendly However we welcome your valuable suggestions for improvements Wishing you all the best and Happy Ridi...

Page 4: ...ine Royal Enfield parts Failure to do so may result in product malfunction and possible injury to the driver and or passenger SERVICE BULLETINS In addition to the information presented in this Service Manual Royal Enfield will periodically issue Technical Service Bulletins These Bulletins cover interim engineering changes and supplementary information IMPORTANT NOTICE All images shown are for refe...

Page 5: ...NERAL 5 SPEED GEAR BOX Salient features Four stroke cycle operation SECTION SEVEN 07 Technical specifications TCI TRANSISTORIZED COIL C Bearings used IGNITION SYSTEM Tools and equipments Lubrication system SECTION EIGHT 08 SECTION THREE 03 CV CARBURETOR PREVENTIVE MAINTENANCE SECTION NINE 09 Running in STEERING SUSPENSION Recommended lubricants Front Fork _ Service data Gas Shock absorbers Torque ...

Page 6: ...ry Spark Plug c_ Checking methods SECTION TWELVE 12 TROUBLE SHOOTING NOTE To avoid needless disassembly carefully read all related service information before repair work is started In w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 7: ... r __ l _ SECTION ONE 01 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 8: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 9: ... that are important for the success of the work Non adherance may result in functional failures of the assembly TOOLS AND EQUIPMENTS General section contain special tool usage and general tools lists Note Proper service and repair is improtant for the safe and reliable operation of all mechanical products The service procedures recommended and described in this Service Manual are effective methods...

Page 10: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 11: ... C l C _ l _ L L SECTION TWO 02 i sJI 1 ti J ij r r _ It1il i1 llif w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 12: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 13: ...shocks from pot holes and road irregularities 1370 mm wheel base for rides free from tail wagging and overturning Front brake Hydraulic 280mm ventilated disk for instant stop Rear brake foot operated 152mm single lead internal expanding Powerful head light 12V 60 55W Halogen for safe night riding Horns 12V 2 5Amps Max 4 EASY TO HANDLE AND RIDE E Start 5 Speed gear box toe left side gear shifting S...

Page 14: ... to BDC BDC to TDC TDC to BOC BDC to TDC Gas Flow Air Petrol Air Petrol Air petrol burns Exhaust gas mixture is mixture gets gas expands flow out drawn into compressed Piston is Towards stroke cylinder Few degrees pushed down end fresh BTDC spark plug flows in charge produces spark t t I j V 1st stroke 2nd stroke Jrd stroke 4th stroke w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 15: ...gle Cylinder Fuel used Unleaded Petrol Catalic converter Hot tube type Bore 84mm Stroke 90mm Swept volume 499cc Compression ratio 8 5 1 Max power RPM 17 Kw 5000 rpm Max toruqe RPM 40Nm 3000 rpm Low idle rpm 900 1000 Starting Electric Start Air filter Paper Element Carburettor Ucal CV B829 Main Jet 110 Pilot Jet 15 Needle P 2M Needle lock groove from top 2ndf Air screw turns out Initial 0 5 to 3 Fl...

Page 16: ... 1 21 1 5th 1 1 7 Over all ratios 1st 14 477 1 2nd 9 514 1 3rd 7 193 1 4th 5 728 1 5th 4 726 1 8 Secondary drive Chain Sprocket 5 8 pitch 9 Wheel F D sprocket teeth 38 18 10 Secondary ratio 2 11 1 11 Drive chain link 95 12 Over all ratio Max 14 477 1 13 Over all ratio Min 4 726 1 E CHASSIS 1 Frame Tubular Welded 2 Front suspension Telescopic Hydraulic damper 3 Rear suspension Swing arm with Gas fi...

Page 17: ... gap Rotor to stator gap Battery Head lamp Pilot lamp Pilot lamp inside Head light Tail lamp Brake lamp Turn lamp Speedometer lamp Ammeter light Turn signal indicator RH Side 6203 RS1 C3 6203 RS2 CN 90 90 100 90 26PSI 26PSI 28PSI 32PSI Inbuilt Handle Bar Twist Grip on right hand side of handle bar Hand lever on LH Side Toe lever LH Hand lever on RH Side Foot lever RH Thumb lever on LH side of hand...

Page 18: ...t4 14 Performance rating FMVSS 116 15 Capacity 60ml 16 Fuel tank capacity 14 5 1 Litres 17 Reserve 1 25 Litres I BEARINGS SL NO DESCRIPTION USAGE QTY 1 Crank case drive side BALL BEARING NU 6305 C3 1 2 Crank case drive side ROLLER BEARING NU305 C4 1 3 Crank case timing side ROLLER BEARING NU 205 R 1 4 Driven gear ES NEEDLE BEARING K 16 x 20x17A 1 5 Main shaft sleeve GB Casing BALL BEARING 6008 1 6...

Page 19: ...al Fitment of oil seal in front fork bottom tube ST25114 4 Extractor for fork oil seal Removal of oil seal in front fork bottom tube ST25115 2 Cam spindle extractor Removal of cam spindle ST25116 4 Tappet circlip assy tool Fitment of tappet circlip ST 25117 4 Extractor for rocker spindle Removal of rocker spindle ST 25118 4 Cylinder head nut tightening tool To removal and tightening of cylinder he...

Page 20: ...98 2 Extractor for Engine Sprocket Application Removal of Engine Sprocket ST 25099 3 Extractor for Clutch Centre ST 25101 2 Extractor for Timing Pinion Application Removal of Timing pinion w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 21: ...actor for Piston Pin ST 25104 2 Clutch Brake Bar ST 25105 2 Special spanner for Front Fork Valve Port Application Removal of Piston Pin Application Holdi ng the center and back plate assembly w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 22: ...2 4 Expander for front fork oil seal Application Loosen and tightening of front fork main tube Application Alignment of chain stay while tightening Application Expander for oil seal while inserting main tube into bottom tube of front fork w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 23: ...seal in front fork bottom tube C C C ST 25114 4 Extractor for rocker spindle Application Removal of oil seal in front fork bottom tube _ _ l ST 25115 2 L Cam Spindle extractor Application Removal of cam spindle L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 24: ...on Fitment of tappet circlip ST 25117 4 Extractor for rocker spindle Application Removal of rocker spindle Cylinder head nut tightening tool Application Removal and tightening of cylinder head nut w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 25: ...4 Adaptor for dial guage ST 25123 1 Valve Spring compressor Application Removal of tappet guide Application To fit dial guage on cylinder head Application To compress the valve spring for removal and fitting of valve w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 26: ... TCI ST 25151 4 Chain case outer puller TCI ST 25153 4 Extractor for 5 Speed Gear box rocker pipe Application Removal of magneto assembly Application Removal of chain case outer w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 27: ...apping tool oil pump return ST 25244 4 Adjuster Special Spanner Application To prevent damage of rocker pivot pin O ring Application To ensure fitment of pivot pin groove Application To adjust gas filled shock absorber w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 28: ... Socket spanner set 10 to 32mm along with rachet handle speed brace extensions and universal joint 0 0 0 0 0 0 Tubular spanner set 6mm to 20 mm __ __ __ _ _I _ l Screw driver common 10cm 15cm 24 cm 30cm t Screw driver philips 6cm 15cm 24cm w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 29: ... _ Allen key 5mm 8mm Hammer ball pein 500gm Piler side cutting 24cm Hammer Plastic 500gm Circlip plier inside 15cm outside 15cm Hack saw frame Hack saw baldes w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 30: ...NSTRUMENTS Cold chisel Centre punch Steel rule 30mm 60mm Number and letter punches 5mm Feeler gauge long strips Cutting files Round flat Vernier Caliper 150mm w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 31: ...auge To measure bores to 0 01 mm accuracy Small Bore gauge To measure small bore like small end valve guide etc Torque wrench 5Nm to 30Nm 25 to 75 Nm To tighten fasteners to specified torques V Blocks To support jobs for measurement w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 32: ...watts Compression guage To measure engine compression pressure Tyre pressure guage To check tyre inflation pressure Hydrometer To check electrolyte specific gravity GARAGE EQUIPMENTS Arbor press 1 2 ton To press out in silent block valve guides cam spindles etc w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 33: ...res clean parts to operate spark plug tester etc Water washing Machine To water wash the motor cycle Plastic Trays To keep removed parts neatly Grease gun To grease through grease nipples at clutch lever bearing brake pedal pivot and speedo drive w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 34: ...ent Battery Charger To charge the batteries Work benches Ramps To keep the aggregates and vehicles for working Spark Plug cleaner cum tester To clean and test spark plug w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 35: ...is stored in a tank A feed pump draws the oil from the tank and supplies it to the crank shaft and cam spindles Cylinder wall gets lubricated by oil splash from the rotating crank pin From the lubricated points the oil flows down to the crank case sump The return pump pumps oil from the crankcase sump and lubricates rockers rocker spindles valves and valve guide Oil flows down due to gravity throu...

Page 36: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 37: ...r r C C C C _ L L SECTION THREE 03 L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 38: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 39: ...Ominutes after every hour of operation Vary the speed of the Motorcycle from time to time Do not operate it at one set throttle position The recommended speed limit is 40 50 kmph 2 150 500 KM Avoid prolonged operation above throttle The recommended speed limit is 50 60 kmph 3 500 1 000 KM Avoid cruising speeds in excess of throttle The recommended speed limit is 70 80 kmph After 500km of operation...

Page 40: ...r bore Point of measurement Ring to groove clearance comp rings Middle New Min New Min 0 03 New Max Three Points as Shown New Max 0 07 Service Limit Service Limit 0 15 Piston to bore clearance Ring to groove clearance oil ring i New Min 0 08 New Min 0 01 New Max 0 10 New Max 0 50 Service Limit 0 30 Service Limit 0 18 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 41: ...mit 19 982 Piston ring end gap Oil Ring Big end axial play C C G New Min 0 20 New Min 0 25 NewMax 0 70 New Max 0 50 Service Limit 0 90 Service Limit 0 60 _ Small end bore Crank shaft Run out _ _ New Min 20 01 New Min 0 00 New Max 20 02 New Max 0 04 Service Limit 20 05 Service Limit 0 08 L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 42: ...ead warpage Valve to guide inlet clearance New Min 0 00 New Min 0 02 NewMax 0 02 New Max 0 05 Service Limit 0 05 Service Limit 0 08 Valve guide bore Valve stem OD Exhaust d New Min 7 000 New Min 6 945 New Max 7 015 New Max 6 960 Service Limit 7 025 Service Limit 6 935 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 43: ... Valve Spring length Tappet guide bore C C New Min 42 80 NewMin 7 000 New Max 44 80 New Max 7 015 Service Limit 41 50 Service Limit 7 025 Push rod run out Tappet guide clearance _ _ New Min 0 00 New Min 0 013 _ New Max 0 02 New Max 0 043 Service Limit 0 05 Service Limit l L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 44: ...gear to body clearance Duplex Chain Length across 21 pins 18 1920 21 NewMin 0 05 New Min 190 New Max 0 10 NewMax 191 Service Limit 0 15 Service Limit 195 Spark Plug Gap Accelerator cable free play l J I L S New Min 0 6 New Min 1 New Max 0 7 New Max 2 Service Limit Service Limit w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 45: ... Max 3 3 Service Limit 2 88 Clutch steel plate Distortion New Min 0 00 New Max 0 05 Service Limit 0 20 Clutch spring Length New Min 17 9 New Max 18 9 Service Limit Rear Sprocket chain pull off New Min New Max Service Limit 5 00 Drive chain slackness New Min 50 00 New Max 60 00 Service Limit w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 46: ...00 Sprocket Axle shaft run out GOOD REPLACE J Ll 4 New Min New Min 0 00 New Max Sharp bend broken teeth NewMax 0 01 Service Limit Service Limit 0 02 Brake drum rear Internal dia Wheel Face out l Run out New Min 152 40 New Min 0 New Max 152 50 NewMax 1 Service Limit 153 50 Service Limit 2 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 47: ...rvice Limit 0 05 Fronl fork a5 s mbly pring length _ New Min 538 New Max 544 Service Limit 527 Clutch cable Free play New Min 2 New Max 4 Service Limit 1 Tyre tread Depth New Min New Max Service Limit 1 00 Caliper Bore Inner Diameter New Min New Max Service Limit 25 46 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 48: ...n Outer Diameter New Min New Max Service Limit 25 31 Master piston OD New Min NewMax Service Limit 12 64 Master Cylinder Bore New Min NewMax Service Limit 12 76 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 49: ...in plug 30 7 Crank case flange nuts M6 10 8 Crank case flange nuts MB 25 9 Came Spindle Sleeve lock nut 20 10 Cylinder base stud 5 11 Cylinder base stud nut 10 12 Cylinder head mounting Studs 12 13 Cylinder head nut 33 14 Exhaust pipe mounting nuts 12 15 Exhaust pipe mounting Studs 6 16 Oil filter cover nut 17 17 Oil filter stud 8 18 Oil pipe banjo bolts 29 19 Rocker cover screws 12 20 Spark plug ...

Page 50: ...e oil strainer C C C C C C C C C C C 4 Push Rods Tappets A A A A A A A A A A A 5 Eccentric Spindle Adjust when required 6 Spark plug A A A A A R A A A A R 7 HT lead for crack I I I I I I I I I I I 8 Air filter element C C C C R C C C R C C 9 Carburettor Clean Inspect and Tune 10 Fuel hose I I I I R I I I R I I 11 Acceleratorcable play A A A A A A A A A A A 12 Rubber hose Airfilterto Carburetor I I...

Page 51: ...ed 33 Forkoil I I I R I I I R I 1 Checklevel every 1000Kms orear1ieras required 34 Front disc brake Checkoil level in MasterCylinderEvery 1000kms 35 Rear brake play Adjust every 1000 Kms or earlier as required 36 Rear brake cams L L L L L 37 Steering ball races L L L 38 Spokes tightness 39 Wheel rim run out 40 Tyre wear I 41 Hand levers kick starter pivot Lubricate every 1000 Kms or earlier as req...

Page 52: ...inspect for oil If oil is between the high and low marks refit the dip stick If oil is only present on the lower end of the dip stick Top up as specified above Run the engine tor ONE minute leave to stand for TWO minutes and re check the level Top up oil if required OIL CHANGE EVERY 6000 KMS Keep vehicle on level ground Start the engine and warm up before draining Drain the oil from oil tank and s...

Page 53: ...ut the adjuster screw to give zero clearance between rocker and valve stem Just able to rotate Bring piston to TDC in compression stroke Tighten lock nut and refit tappet door and both the rocker covers VAL VE TIMING Bring piston to TDC so that the key way in the timing pinion is at 12 Clock position Position and fit the exhaust cam aligning its two punch marks with the two punch marks on the timi...

Page 54: ...the rotation of the sleeve during tightening the lock nut The backlash is first adjusted between pinion to exhaust gear and then exhaust to inlet gear to get effective backlash adjustment The tightening torque for M1Olock nut is 2 kg m This must be ensured Over size Cam Spindle For Spares 500443 a 0 1 mm Oversize spindle 500449 a 0 2mm Over Size Spindle During first service the backlash between th...

Page 55: ... lead INSPECTION Adjust Electrode Gap as specified Check up the spark plug for serviceability on spark plug tester NOTE A serviceable spark plug produces thick light blue spark across the electrode If spark plug produces yellow red side sparks replace it with new AIR FILTER CLEANING Remove the 5 air filter lid mounting screws and take out air filter lid Remove the 3 cover mounting screws take out ...

Page 56: ...arm up the engine for 2 minutes 4 Checkforthe smooth running ofthe Engine 5 If erratic turn pilot screw in or out upto one turn 6 Adjust the idling screw until the engine is smoothly ticking over 7 Refit the boot to the pilot screw THROTTLE CABLE FREE PLAY ADJUSTMENT FREE PLAY 1 TO 2 MM Loosen the lock nut screw in the cable adjuster to increase the play Screw out the cable adjusterto reduce the p...

Page 57: ...ble adjuster lock nut and turn adjuster screw till the exhaust valve clearance just begins to close Tighten lock nut and refit exhaust rocker cover DECARBONISING EVERY 15 000 KMS CYLINDER HEAD Remove carbon from the valves ports and combustion chamber by scrapping Take care not to cause any damage to the valve faces or valve seat inserts Scrape gently to avoid scoring the cylinder head Remove the ...

Page 58: ...olution Keep for 45 to 60 minutes Remove the solution Clean the pipe thoroughly in running water ADJUSTMENT EVERY 3000 KMS Check the slackness at the centre of the top run If more adjust as follows Loosen adjuster lock nut Screw out the adjuster till a play of 5 to 6mm is achieved at the centre Tighten the lock nut CLUTCH OIL LEVEL CHECK EVERY 1000 KMS Loosen I remove the level plug The clutch oil...

Page 59: ...re cable adjusters are fully IN at Refit front foot rest and gear shift lever handle bar and gear box end C CLUTCH CABLE FREE PLAY 2 4mm LEVER END Loosen lock nut at lever end Screw in or out the adjuster for setting the required play If adjuster is fully out adjust at gear box _ end Remove the inspection cover screw 2 nos _ Remove the filler plug to check the actuating free play l Loosen the clut...

Page 60: ...rain plug Fill EP 90 oil through filler plug oil oozes out of level hole Refit filler and level screws REAR BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut Turn in out the pedal stop pin till the pedal and footrest are in the same level Tighten the lock nut PEDAL PLAY ADJUSTMENT PEDAL PLAY 20TO 30 MM Tum in outthe adjuster nutfor correct pedal play BRAKE PEDAL SPINDLE GREASING EVERY 3 000 KMS Gr...

Page 61: ...ows Using special tool place it on the slot provided on the adjuster Twn the adjuster such that the adjuster m6ves up to increase the spring tension and vice versa to reduce the spring tension Adjust both leftand right shock absorbers so that the same notch rests on the support in both sides BATTERY ELECTROLYTE LEVEL CHECK MG Electrolyte level can be seen through the casing Level to be between max...

Page 62: ...less recharge the battery REAR CHAIN SLACKNESS ADJUSTMENT Check slackness Slackness to be 25 to 30mm If more or less adjust as follows Remove split pin and castle nut on the RH side Loosen spindle nut Loosen anchor nut Loosen the brake rod nut w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 63: ... 12 000 KMS Place a clean tray below front fork Remove spring stud nut and drain oil Tighten the spring nut Remove filler screws and fill 200ml of API SG 10W 30 oil in each leg Fit and tighten the plug screws Bump the fork several times Recheck level and top up if required DISC BRAKE FLUID LEVEL CHECK Check brake fluid is above the Min level in master cylinder l l l Check oil level with a 5 mm dia...

Page 64: ...ly if the e is any spill over in other parts using a soft cloth preferably a wet cloth BRAKE CAM GREASING EVERY 6 000 KMS Remove the brake cover plate Clean the brake cam and apply grease Refit the cover plate STEERING PLAY ADJUSTMENT EVERY 3 000 KMS Keep a wooden plank unde rthe stand Rock the front end and feel the play at stem top end If felt adjust as follows Loosen head lamp casing allen scre...

Page 65: ...12 000 KMS Remove steering stem assembly Clean and check the balls and races throughly for damages pittings discolouration Change ifdefective Pack grease on the bottom ball race Pack grese in the top ball race Assemble the steering stem WHEEL ALIGNMENT CHECK Hold the vehicle upright off the stand on level ground w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 66: ...rvice you contemplate by proper investigation and analysis 2 Keep the vehicle on a ramp so as to stand and work People work faster this way WORKING WITH MOTOR CYCLE ON RAMP o 3 Neatly arrange parts removed in trays 4 Inspect all parts decide the parts you need for servicing and procure it Only then start assembly 5 Clean all components except rubber and electrical parts in kerosene oil mixed with ...

Page 67: ...ormal direction of chain rotation The number of notches from the punch marks of the chian adjuster cams to the notch resting on the pin are to be equal at LH RH sides 17 Check for correctness of assembly after each stage 18 Tighten all nut and bolts to correct torques 19 Always smear oil or grease on the oil seal lips before installing 20 Apply specfic on outer surface of seals to achieve better s...

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Page 69: ...r c r C C C C C C _ L L L L SECTION FOUR 04 L L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 70: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 71: ...assembly Timing gears Oil pumps Gearbox foot control mechanism Remove the 2 nos flange bolts with plain Gears gear shafts washer from front side of tank mounting Exhaust pipe Airfilter Carburetor ENGINE NEED TO BE REMOVED FROM THE FRAME FOR THE FOLLOWING WORKS Crank case repair change Crank case centre gasket ch9rige Lift the tank from the seat side remove Crank shaft main bearings change Gear box...

Page 72: ...nge bolts from both sides of the seats Hold the seat from pillion side gently pull towards tail light side DE COMPRESSOR CABLE REMOVAL Remove the De Compressor Cable distance piece stopper Remove 2 nos screws from the LH switch module Remove one end of the cable from lever w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 73: ...Remove the oil filler plug Remove the clutch cable other end from clutch operating mechanism lever take out the cable REMOVAL OF THROTTLE CABLE Remove the stopper from the cable Remove the 2 nos Screws and take out the cable Loosen the lock nut at carburetor end and remove the cable other end w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 74: ...r Filter box REMOVAL OF SILENCER ALONG WITH EXHAUST PIPE Remove the silencer bracket mounting screw with plain washer Remove RH Pillion footrest Remove the flange nut 2 nos from cylinder head Note Remove the rear brake adjuster nut down the brake pedal Remove the Silencer Assembly with Exhaust pipe w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 75: ...ve the Banjo Bolt 2 nos from Cylinder Head with 4 nos Aluminium washer Remove the Banjo Bolt with 2 nos with Copper washer from crank case remove the rocker pipe Remove the motor terminal rubber boot Remove the terminal nut take out the motor lead Remove the motormounting allen screw 2 nos Remove the motor assembly from the vehicle w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 76: ...ttery flap cover Remove the terminal boot terminal red wire coupler Remove the black coupler Remove the battery terminal Always remove earth wire terminal first Remove the fuse earner plate mounting Allen bolt 2 nos remove w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 77: ... oil Remove 10 nos Allen bolt Remove feed plug with O ring Allow to drain the oil after draining oil pull out the chain case outer with special tool no ST25151 4 Note Before removing the chain case inner remove the stator coupler from wiring harness REMOVAL OF ROTOR ASSEMBLY Remove lock nut with spring washer Use special tool ST 25128 2 remove the rotor assembly Remove the woodruff key w w w h i t...

Page 78: ... OF CLUTCH ASSEMBLY Remove spring plate screw 3 nos with 3 nos star washer Remove the spring plate with 6 nos spring Remove the thrust pad Remove the clu ch plate 1 no Front plate 2 nos dish plate 3 nos plain plate 5 nos friction plate Remove Clutch drum lock ring from clutch centre Use special tool ST 25098 2 to pull out the engine sprocket w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 79: ...y Hold clutch center with special tool ST 25104 2 and open clutch center holding nyloc nut Pull out clutch center using special tool ST 25099 3 CHAIN CASE INNER REMOVAL Remove chain case align stud nyloc nut with copper washer Remove 3 nos counter sunk Allen screw Remove the breather pipe Pull out the chain case inner w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 80: ...ial tool ST25117 4 pull out the Rocker spindle inlet side Take out both push rod assembly At the time of pulling out rocker spindle ensure spring washer should not fall inside Remove the 6 nos flange nut 4 Nos from the outside 2 nos from inside Remove the deflector plate Remove the cylinder Head assembly by taping with Mallet BARREL REMOVAL Loosen the cylinder block lock flange nut w w w h i t c h...

Page 81: ...he piston pin by special tool ST 25102 1and take out piston assembly REMOVAL OF DRIVE CHAIN Rotate the rear wheel to bring the chain lock to a convenient position and remove the chain lock Remove the drive chain pulling by hand REMOVAL OF SIDE STAND Remove the coupler of side stand Engine cut off switch from harness Remove the side stand w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 82: ...om the harness Remove the piece mudguard bracket bolt with 2 nos plain washer 1 no star washer Remove RH footrest rider Ensure rear brake switch mounting bracket is free by loo ening the nyloc nut After removing nyloc nut tap and remove the engine mounting flange bolt Loosen the gear box mounting flange bolt nut w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 83: ...after removing the nut Hold the crank case assembly with gear box formally and down load Keep a wooden block below the engine before removing mounting bolts KEEP THE CRANK CASE ON A CLEAN WORK TABLE GEAR BOX REMOVAL Note Ensure gear box oil is drained before __ opening the gear box end cover L L Remove the kick starter lever w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 84: ...t assembly Remove the 4 nos gear box mounting stud nut 4 nos plain washer and slide out gear box assembly DISMANTLING CRANK CASE ASSEMBLY TIMING COVER Remove the Timing Cover Screws 10 nos Note Loosen timing cover screws in 3 stages as per the following sequences 1 8 5 2 9 4 6 10 3 7 3 Tap remove the timing cover Remove the gasket w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 85: ...LH threaded Turn it clockwise to loosen Using Special tool ST 25101 2 extract the timing pinion from the crankshaft Remove the woodruff key CRANK SHAFT REMOVAL Loosen the crank case stud nuts as per the following sequence 1 9 14 3 13 10 2 11 12 8 7 4 6 5 Remove 1 13 14 studs along with engine mounting brackets LH RH Remove dowel studs 2 11 by taping w w w h i t c h c o c k s m o t o r c y c l e s ...

Page 86: ...CASE CLEANING Remove the strainers and oil drain plugs Clean both drive and timing crank case halves with kerosene and brush in a cleaning trough Dry both halves with dry compressed air DISASSEMBLY BEARINGS Heat the bearing bore of the crank case timing side on a hot plate to approx 1so0 c Tap the crank case on wooden block and remove the roller bearing Remove the distance piece from crank case dr...

Page 87: ...g TAPPET COVER Remove the circlip from the decompressor shaft Slide decompressor lever Pull out decompressor shaft with O ring TAPPET Heat the crank case around the cam spindle with a blow lamp Use special tool ST 25115 2 forremoving the cam spindles out from crank case Remove a circlip from exhaust tappet Remove the decompressor lifter sleeve Remove tappet guides using Special tool ST 25119 2 Now...

Page 88: ... would result in crankshaft misalignment BEARINGS Rotate on the inner race to check for freeness and unusual noise Check radial clearance as shown in the picture for ball baring Check axial clearance as shown in the picture for Ball Bearing Replace the bearing if found to be noisy or having excessive radial axial play TAPPETS Insert the tappet into the tappet guide and check for the radial clearan...

Page 89: ... 00 0 05 0 08 C 14 Cylinder Head Warpage 0 00 0 02 0 05 15 Valve guide bore 7 000 7 015 7 025 C 16 Valve stem OD Inlet 6 965 6 980 6 955 17 Valve to guide Inlet clearance 0 02 0 05 0 08 18 Valve stem OD Exhaust 6 945 6 960 6 935 19 Valve to guide Exhaust clearance 0 04 0 07 1 00 20 Valve Spring Outer Length 42 80 44 80 41 50 C 21 Push Rod Run out 0 00 0 02 0 05 22 Tappet OD 6 972 6 987 6 962 _ 23 ...

Page 90: ... bottom Press the tappet guide after inserting tappets Press the cam spindles After removing cam spindle fit only next oversize Place the decompresser liftersleeve with its flange upwards on exhaust tappet Lockthe sleeve with circlip using the special tool ST 25116 4 TAPPET COVER Replace O ring on the shaft Insertthe decompresser shaft through the cover w w w h i t c h c o c k s m o t o r c y c l ...

Page 91: ...the shaft splines as shown in the figure Lock the lever with a new circlip CRANK CASE DRIVE SIDE Assemble circlip on outer circlip groove on drive side half Heat the bearing bore on a hot plate to 150 c Place the ball bearing 6305 into position Locate the circlip on the inner groove w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 92: ...ean crankshaft in clean kerosene Dry the crankshaft with compressed air Lubricate the big end bearing with fresh engine oil INSPECTION Visually check for the cracks breaks scratches overheating bends seizure etc Replace the crankshaft if any damage is noticed Pump engine oil into the crankshaft lubricating passages The oil will ooze out from the big end bearing when the passage is free and clear w...

Page 93: ...out as shown as shown in the picture Checkthe big end radial play by measuring Check up the web to web width as shown the deflection at the small end as shown Check up the big end axial play as shown Check up the small end for its wear w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 94: ...reaks shear scoring etc Check up the timing gear bush for wear scratches and seizure mark Replace parts found defective TIMING COVER Remove cap oil filter along with O rings spring washer spring cap with O ring Pull out oil element and bottom O ring Remove allen screws four numbers from DISASSEMBLY cover feed pump and take out cover along Remove the oil seal with O ring Remove flange dome nut from...

Page 95: ... shaft has a collar which would seat in the recess in the return pump side CLEANING Clean all the components thoroughly in cleaning solvent and dry them with compressed air INSPECTION Visually inspect all components for cracks breaks scoring scratches bent or any other damage Check up the oil spindle for run out Check up the clearance between the gear and the body w w w h i t c h c o c k s m o t o...

Page 96: ... Fit the drive gear onto the drive shaft t Fit the driven gear spindle and driven gear into position Fit cover return pump with O ring and tighten it in position with four alien screws Similarly fit the feed pump assembly also Place the new O ring into the oil filter housing Place the new oil filter element into the housing Before fitting oil filter element soak with engine oil w w w h i t c h c o...

Page 97: ...BLY DISASSEMBLY Remove the piston rings CLEANING Scrub the carbon deposits from the piston groove with the help of scrapper Scrap the carbon deposits from the skirt area and groove area of piston without causing any scratches or scoring Clean piston piston ring and piston pin with cleaning solvent and dry it with compressed air INSPECTION Visually inspect for cracks breaks scratches scoring seizur...

Page 98: ...der Check the outside dia of piston pin at 3 points ASSEMBLY Insert the oil ring expander into the oil ring groove Slide the bottom rail to the bottom of the expander Slide top rail to the top of the expander Place the second ring in position Note Second ring has grooved outer edge t Fit the top ring Note Top ring has rectangular cross section w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 99: ...eizure mark etc of the bore Check for the cylinder wear at 6 points as shown in picture Scored Scuffed or excessive worn out bore to be replaced with new set CYLINDER HEAD DISASSEMBLY Using ST 25123 1 compress the inlet valve spring Remove the valve collets Release the special tool Take out valve spring retainer valve spring washer and valve stem seal Remove the valve Similarly remove the exhaust ...

Page 100: ... dry them with compressed air INSPECTION Visually check for any cracks breaks scoring bend or any other damage Check the cylinder head face for warpage Check the valve guide for wear with small boreguage Replace valve if the valve head is knife edged X Check the valve stem for run out w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 101: ...it on the valve seat Using a Suction valve grinder rotate the valve back and forth several times Remove the valve and check for pencil marks Proper seating erases all the pencil marks In case if the pencil marks are not erased grind the valve to the seat as below Apply fine grinding paste onto the valve seating area Do notallow the grinding paste to seep into the valve stem and valve guide w w w h...

Page 102: ...he valve and valve seat thoroughly Check and ensure proper seating with pencil marks as explained above Valve seating on valve seat can also be checkedas follows Assemble the valve assembly in position Keep the cylinder head on a table Fill petrol on top of the valves Seepage of petrol past the valve seat indicates improper valve seating Check the spring for its height Check run out of push rods j...

Page 103: ...shaft is seated properly u Apply grease on the sealing face of the crankcase Position the centre gasket Insertthe inner distance piece on the crank shaft Place the drive side half of crank case on the crank shaft and slowly move it down to its position _ l Ai v Rotate the crankshaft and ensure its freeness Position the engine mounting plates LH and RH Position all crank case studs except 2 and 11 ...

Page 104: ...bly Assemble the 4 nos gear box mounting stud nut 4 nos plain washer and slide out gear box assembly Assemble the gear lever shaft assembly Assemble the pivot pin screw in the rocker assembly Assemble the gear box end cover Fit6 nos gearbox end cover mounting allen screws Assemble the kick starter lever ASSEMBLE THE CRANK CASE ALONG WITH GEAR BOX ON FRAME Hold the crank case assembly along with ge...

Page 105: ...n pin with circlips Stagger the piston rings as shown Oil Scrapper Oil Scrapper Bottom Ring End Top Ring End ___ ___ 3 Top Ring End Second Ring End Remove the cloth CYLINDER BARREL Apply grease on the seating surface of the crankcase and place cylinderbase gasket Lubricate piston rings with sufficient supply of the fresh engine oil Supportthe piston on crankcase as shown in the picture Thoroughly ...

Page 106: ...e washer on barrel side stud and engage the nut CYLINDER HEAD ASSEMBLY Place the cylinder head gasket on cylinder block Position the cylinder head with push rod holes facing timing side Position the deflector plate on driving side Engage all the cylinder head nuts 6 nos Tighten them in 3 stages 1 F _ __ _ ___ Tightening Torque 24 Nm PUSH RODS Place the longer push rod in exhaust push rod tunnel an...

Page 107: ...aust rocker and spindle ROCKER COVER Place the rocker gaskets Place the rocker covers and tighten the alien screws Bnos NOTE The inlet rocker has provision for the breather pipe TIMING GEARS Fit the wood ruff key on the timing end of the crank shaft Place the timing pinion with its larger bore facing crank case on to the timing shaft aligning its key way with the key on the shaft w w w h i t c h c...

Page 108: ...lettappet push the inlet cam gear onto the spindle ensuring that the single punch mark on it aligns with the single punch mark on the exhaust cam wheel I For adjustment of the backlash between pinion cam gears refer page no 03 16 NOTE Valve timing is correct when all the timing marks align as shown in the picture Adjust the backlash between Inlet exhaust cam gear by rotating cam gear sleeve tighte...

Page 109: ...ith the pump drive shaft gear Place the timing cover screws with washers and tighten them in 3 stages as per the following sequence 1 8 5 2 9 4 6 10 3 7 3 NOTE Screws 1 2 5 and 10 are longer Tightening Torque 10Nm TAPPET DOOR Apply grease on the tappet door gasket face of the crank case Position the tappet door gasket Locate the tappet door on its stud Push the tappet door in Ensure the flat of th...

Page 110: ...ds to the cylinder head with banjo bolts Use aluminium washers on both sides of the oil pipe eyelet Tighten the oil pipe nut and Banjo units Tighten Torque 17 Nm NOTE Forotherassemblyfollow the reverse order of lowering w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 111: ... C C C _ SECTION FIVE 05 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 113: ... switch Battery is connected to the starter motor through the relay starter switch A conventional switch will not be in position to withstand very high current and hence relay starter switch is used WORKING PRINCIPLE When the ignition switch is switched ON electric supply from the relay starter is made available at the engine starting switch on the RH side of Handle bar When this is pressed relay ...

Page 114: ...CHAIN CASE FRONT HALF Remove the oil level screw and drain the oil Remove the 1Onos allen bolt and pull out chain case by special tool St 25151 4 Note Before dismantling disconnect the stator coupler from the harness Remove LH sidefoot rest by taking out M1O nut Note Remove gear lever by loosening removing cross lock bolt for 5 speed GB w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 115: ...chain tensioner pad nut and slide out the tensioner along with washers DISMANTLING CLUTCH ASSEMBLY Take out the clutch cap clutch springs front plate after removing the clutch cap screws along with washers by loosening them alternatively Pull out the clutch pad and take out the clutch plates DISMANTLING OF CLUTCH DRUM ENGINE SPROCKET Remove the clutch center retaining spring w w w h i t c h c o c ...

Page 116: ...c nut Pull out clutch center using special tool ST 25099 3 DISMANTLING CHAIN CASE BACK HALF Remove the 3 socket head screws and remove chain case back half assembly with drive cover DISMANTLING OF CHAIN CASE SUB ASSEMBLY Keep the chain case back half assembly on a worktable and remove the 5 nos drive cover fixing screws Remove the drive cover assembly w w w h i t c h c o c k s m o t o r c y c l e ...

Page 117: ...ifting Sprag clutch assembly away from idler gear for ease of dismantling Take out sprag clutch assembly by holding both drive driven gear Hold the clutch driven gear and remove clutch driving gear assembly by rotating it in anti clockwise direction Remove circlip using internal circlip plier from driven gear groove Take out the sprag clutch from the driven gear w w w h i t c h c o c k s m o t o r...

Page 118: ... spindle is inline with the rib in drive cover as shown in picture Check for any blockage of oil hole before assembling the spindle Apply anabond 112 a very thin layer otherwise excess anabond will block the oil hole inside the bore SPRAG CLUTCH ASSEMBLY Assemble the sprag clutch in the driven gear by hand pressing evenly all around Note Ensure wide flanges of sprag clutch facing upwards w w w h i...

Page 119: ...ternal circlip plier in driven gear groove Assemble the driving gear in to sprag clutch by rotating driving gear anti clock wise direction Note Check the free rotation of driving gear in anti clockwise for engagement in clock wise direction Fix the Gasket Assemble the Sprag clutch assembly by ensuring driven gear facing upwards Assemble Idler gear by shifting Sprag clutch assembly away from idler ...

Page 120: ...flow from spindle cross hole drive cover boss hole at the bottom Assemble drive cover assembly by ensuring dowel spindle alignment Tighten drive cover with 5 nos allen screw and ensure free rotation of idler gear with finger ASSEMBLY OF CHAIN CASE INNER ON ENGINE Apply grease on crank case drive side joint face Assemble gasket on crank case drive side joint face w w w h i t c h c o c k s m o t o r...

Page 121: ...t ASSEMBLY OF ENGINE SPROCKET CLUTCH DRUM Assemble clutch center Assemble chain tensioner pad by continuously adjusting screw in minimum position Assemble engine sprocket clutch drum with duplex chain Note Ensure alignment of engine sprocket teeth with driving driven gears teeth ASSEMBLY OF CLUTCH Assemble clutch plates in reverse order of disassembly w w w h i t c h c o c k s m o t o r c y c l e ...

Page 122: ... chain case outer pour the recommended oil 420ml Assemble Toe lever Assemble LH footrest ASSEMBLY OF STARTER MOTOR ON VEHICLE Assemble starter motor tighten with 2 nos allen screw with washers Note Crank the engine gently for ease of assembly Do not rotate the starter motor while assembling as it will damage the O ring w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 123: ...RING DIAGRAM STARTER AND CHARGING CIRCUIT SWITCH MODULE RH BLUE WHITE It jR iiEffiD W HIT E l TO IGNITION COIL RED BLUE 2x6 3 COUPLER IGNITl l BJ a m ffilIE __ _j SWITCH IJ RED FU E15A c w Y X afl 4 l 12V 14Ah BATTERY NEUTRAL SWITCH l f _ z D w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 124: ...ve to the motor terminal and veto the body of the motor Direction of rotation Clockwise DO S AND DON TS DO S Check battery for electrolyte level periodically and top up with distilled water only For longer battery life de clutch before starting If the battery is weak start through the kick starter and do not try to start with self starter Always maintain correct oil level in chain case inner Check...

Page 125: ...ng Malfunctioning of clutch switch Malfunctioning of starter switch Battery discharge Motor not working If Motor rotating Go to check 2 2 Cranking Cranking RPM less Battery Not fully charged of Engine Engine not cranking Failure of sprag clutch Note Remedies Bring the vehicle in neutral Press the clutch lever start switch together Retract side stand fully Check Replace Check correct Check Replace ...

Page 126: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 127: ...isassembly a ndAS efQt Jyp r9ceq_ 1 1 re i I _ _ _ TOrtjue Specification _ ln pectiori and Service Limits C C C C s 11 l C JjJ 2 I C _ l L SECTION SIX 06 i li1 4 i ifftz e i t i L t J J r t L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 128: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 129: ...eeve gear 52 Spring 86 Rocker shaft assy 20 2nd gear main shaft 53 Bolt 87 Hex screw M6 21 Main shaft 54 Kick starter crank 88 Washer plain 22 Washer Thrust 55 Hex screw 89 Spring kick starter _ 23 4th gear main shaft 56 Allen screw M6 90 Kick starter shaft 24 Circlip 57 Gasket 91 Needle bearing 25 3rd gear main shaft 58 Cover inspection 92 Spring plunger 26 main shaft 59 Socket head screw MS x 15...

Page 130: ...TIONS 5 SPEED KICK START SHAFT 550015 M S M S 3RD GEA a 550012 Gears in neutral Drive through 1st gear Drive through 2nd gear L S HIGH GEAR 550007 lr A INSHAFT rs50004 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 131: ...r r C C C C _ _ C _ GEARS OPERATING POSITIONS 5 SPEED Drive through 3rd gear Drive through 4th gear Drive through top gear w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 132: ...Refit feed plug and level screw DISMANTLING PROCEDURE For repair replacement of gear box casing and indexing pawl the engine as a unit is to be dismounted from the chassis All other gear box related repairs can be carried out on the vehicle itself only rear wheel is to be removed FOR DISMANTLING AS A GEAR BOX UNIT REMOVE Drain the Oil gear box clutch Gear lever LH and RH rider foot rest Clutch cab...

Page 133: ... CHANGE LEVER ASSY REMOVAL Use special tool ST 25153 4 and remove the pivot pins from both sides of the end cover Remove the cylindrical pin Remove the stop pin Disengage the striker plate from cam plate roller by pressing the strik r plate down with thumb and pull out rocker shaft assembly CARRIER PLATE ASSY REMOVAL Remove the carrier plate nuts along with washers Remove main shaft nut and washer...

Page 134: ... the main shaft from clutch side and remove the gear assy along with the cam plate Tap and remove main shaft sleeve along with gear ASSEMBLY PROCEDURE NOTE Heat the gear box casing up to 120 C to assemble Sleeve gear bail bearing and Lay Shaft needle roller bearing Fit the ball bearing sleeve gear circlip Fit lay shaft needle bearing circlip Fit gear levershaft open bush in the casing w w w h i t ...

Page 135: ...e casing Apply Fit FD sprocket lock plate and after anabond 112 on indexing pawl bolt tightening lock the nut threads Locate sleeve gear into the ball bearing Fit thrust washer on lay shaft bearing face press with arbor press keeping profile towards sleeve gear w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 136: ...ee rotation of the lay shaft MAIN SHAFT SUB ASSY SEQUENCE OF ASSEMBLY Thrust Washer Main shaft 4th gear 26T Thrust washer Circlip in 2nd groove from carrier plate end Main shaft 3rd gear 23T Main shaft 1st gear 16T From other end of main shaft fit 2nd gear 20T SUB ASSEMBLY SELECTOR FORK Fit circlip on selectorshaft selector forks as shown in pie w w w h i t c h c o c k s m o t o r c y c l e s c o ...

Page 137: ...configuration ensure 4 nos roller are without any damages Hold the complete gear assembly with fork cam plate and gently push inside the gear box NOTE Ensure alignment of main shaft with sleeve gear hole fork shaft with fork hole inside the gear box and sliding gear with lay shaft Before assembly ensure indexing pawl is in downward position Fit cam plate pivot pin with O ring by aligning cam plate...

Page 138: ... Fit the dowel pin 2 nos Fit kick starter shaft assy in carrier plate Fit carrier plate sub assy in casing keeping kick starter shaft pawl in closed position NOTE Ensure alignments of dowel pins in the gear box casing and kick starter shaft hole with lay shaft Tighten the carrier plate with 4 nyloc nuts plain washers w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 139: ...KS shaft hole Fit eyelet end of kick starter return spring on carrier plate with screw tighten ROCKER SHAFT ASSEMBLY Fit spacer and rocker shaft return spring Fit stricker lever return spring Fit the rocker shaft assy in casing Keeping stricker lever down by left hand thumb w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 140: ...ot use special tool ST 25156 4 to prevent tearing of O ring ensure alignment of pivot pin groove with the dowel hole Fit 3mm stop pin Fit spacer on gear lever shaft assembly Fit gear lever shaft assembly in gear box and connect gear lever shaft and rocker shaft link with pivot pin screw tighten nyloc nut plain washer Fit neutral switch with packing w w w h i t c h c o c k s m o t o r c y c l e s c...

Page 141: ...d clutch operating lever hole in one line Fit 2 dowel pin on end cover Apply grease on joint face and fit packing Fit end cover assembly on gear box aligning the dowel and kick starter shaft Tighten end cover with 6 allen screws NOTE Fit oil level allen screw with copper washer Fit inspection cover with packing and tighten with 2 nos countersunk alien screw w w w h i t c h c o c k s m o t o r c y ...

Page 142: ...ipped Damaged splines of sliding gears FINAL DRIVE SPROCKET Replace if Teeth or bent chipped or broken O RINGS OIL SEALS MATTING PARTS GASKETS Always replace O rings and Oil seal before reassembly Always replace gasket packing etc before reassembly Always clean the joint surfaces apply sealing compound If wear rings are found on the mating surfaces of the shaft and sleeve gear distance piece repla...

Page 143: ...or scuffing on surfaces observed CIRCLIP To be free from distortion and a snug fit in grooves Circlip should not rotate freely in groove after fitting TAB WASHER Always replace tab sealing washer before reassembly w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 144: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 145: ...tie matic bia g ram ii _ W b klri6Jfii9 di I 1 i O 0 1 i HOH Adviintages i i _ I a C Wiring qifoqit Values and Ch ckingmethod t tl iI ti C C _ _ i 1 _ C C _ __ r _ L SECTION SEVEN 07 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 147: ... Volt minimum DC supply from battery to start the engine The principle of transistorized coil ignition is Inductive type The TCI system has a strong spark intensity long arc duration to ensure total combustion FUSE 10A RECTIFIER 1 11111 lL J IREGULATOR A UNIT SINGLE 1PHASE CHAIN CASE OUTER PULSER COIL OUTPUT FIG 1 TCI UNIT B IGNITION UNIT C IGNITION COIL THE TC CONSTITUTES THE FOLLOWING COMPONENTS...

Page 148: ...age in the secondary winding which distributed to the spark plug The energy supplied to the primary coil is from the Battery THE ADVANTAGES OF THE TCI The major advantage is the spark duration 0 7 0 8 milliseconds This ensures complete combustion of the air fuel mixture under all operating condition Improved ignition of lean mixture because of high intensity of spark t Good startability Lesser ele...

Page 149: ...If vehicle is in Gear condition we will not be able to start the vehicle without depressing clutch Fuse for Electrical System Main TCI CONTACT CIRCUIT BULLET ELECTRA SWITCH MODULE RH SWITCH MODULE LH POSITION RED BROWN RED BLUE YELLOW YELLOW REO GREY WHITE BLUE WHITE RED WHITE POSITION YELLOW BLUE GREEN YELLOW WHITE BLACK BLACK BLACK BLACK RED WHITE WHITE GREEN RED A 8 C D E F G H 2 3 1 4 6 5 7 B ...

Page 150: ...SWITCH MODULE RH BLUE WHITE jR E D W HRIT E if TO IGNITION COIL RED BLUE 2x6 3 COUPLER IGNITJ U EIEl iWBIIE _____ _J SWITCH RED FU E15A COMPLETE CIRCUIT BULLET ELECTRA NEUTRAL SWITCH t_ l z 0 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 151: ... mode Check the Resistance between wires a Yellow 1 to yellow 2 b Yellow 2 to yellow 3 c Yellow 3 to yellow 1 CHECKING PROCEDURE PULSAR COIL SPECIFICATION Resistance 190 to 220 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green white to white wire CHECKING PROCEDURE IGNITION COIL SPECIFICATION Resistance a Between Brown to Red white 4to 5 ohm b Betwee...

Page 152: ...Y STARTER SPECIF CATION Resistance 4 to 5 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green white to white wire CHECKING PROCEDURE E STARTER MOTOR SPECIFICATION Resistance 0 3 to 0 5 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between motor terminal aluminium body w w w h i t c h c o c k s m o t o r c y c l e s c...

Page 153: ...i BloWl JpChart I 0 i Qrkl g F fri 9tiot1s I i 1 i 1_ 1 li ght i ngJorq ue __ __ _ 1 Maintenance Tips 1 1 i_ _ I j l SeKtice Guidelines _ TtoubleShooting _ ldling RRMSettinQ P o dure r Working Sys tern ofPAV SECTION EIGHT 08 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 154: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 155: ...t jet 6 Jet needle retainer spring 19 Needle valve assy 33 Pilot air jet 7 Jet needle washer 20 Clip needle 34 Clip Hose drain 8 Jet needle E ring 21 Float pin 35 Plunger assy 9 Jet needle ring 22 Screw 36 O ring 10 Jet needle 23 O ring 37 Washer 11 Piston valve assy 24 Float body 38 Spring 12 Diaphragm piston valve 25 Float chamber body assy 39 Pilot Screw 13 Diaphragm retainer ring 26 Screw assy...

Page 156: ...l through the float system from where it is metered for the engine requirement The fuel level in the bowl is maintained by the float system The float system is a very important part of the main pilot and starter circuits The fuel level in the bowl must be high enough to reach them But even more significantly the fuel level actually effects how rich or leaner the engine run through its entire range...

Page 157: ...assage and the outlet tothe manifold The outletto the venture is on the engine side of the throttle valve With the throttle valve closed as it should be for starting almost all the airthat goes to the engine must pass through the starter passage This creates enough suction to draw fuel up from the bowl into the chamber below the plunger Here the fuel is mixed with the air and the mixture is drawn ...

Page 158: ...stant velocity carburetor uses a butterflythrottle valve located closerto the engine in the carburetor body to regulate engine speed The slide in a CV carburetor moves in direct proportion to the engine demand This assures the correct venture size and air velocity throughout the midrange operation of the engine The constant velocity carburetor uses venture vacuum to control slide movement This is ...

Page 159: ...ooves will have the effect of richening the mixture DISASSEMBLY Unscrew the top cover fixing screw and remove the diaphragm top cover piston valve spring and piston valve assembly from the carburetor Remove the ri ng and diaphragm from the piston valve Generally it is not advisable to remove the jet needle if it is necessary un screw the jet needle fixing plate screws and remove the jet needle alo...

Page 160: ...ged air filter will have an adverse effect on both the carburetor as well as the engine performance 8 kgf cm 18 kgf cm 18 kgf cm 35 kgf cm 7 kgf cm 7 kgf cm 20 kgf cm 10 kgf cm 20 kgf cm 35 kgf cm 20 kgf crn 25 kgf cm SERVICE GUIDELINES Spray carburetor cleaner in all passages to ensure that there is no blockage due to dust dirt gum or carbon deposit especially in the main air passage pilot air pa...

Page 161: ...spec Flooding Check float tor damage or float height IDLING NOT Pilot jet clogging Clean jet with spray replace STABLE Incorrect pilot screw setting Adjust pilot screw as per specification High Low fuel level Adjust float height to spec Piston valve sticky Clean piston valve mixing body and ensure no damage in piston valve and diaphragm FLOODING High fuel level Adjust float height tor spec Imprope...

Page 162: ...se position Now adjust the idle screw to bring down the engine revolution to the specified idle rpm After adjusting the idling rpm check the CO and readjust the pilot screw if necessary CARRY OUT THE CO EMISSION CHECK AS FOLLOWS Warmup the engine by riding the vehicle for about 4 kms Warmup the measuring instrument as per the equipment manufacturer s recommendations before carrying out the measure...

Page 163: ...r C C C C C _ _ l PROCEDURE OF CHECKING CO PAV ON VEHICLE BLOW UP VIEW VACUUM AIR CLEANER CARBURETTOR SECONDARY J AIR EXHAUST w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 164: ...ressure pulses Utilising these negative pressure pulses air is drawn from the air cleaner and admitted in to the exhaustthrough a reed valve When there is a positive pressure reed closes and prevents exhaust from entering the system The air suction valve is provided with air cut valve system to cut off the air supply during acceleration to prevent after burn TROUBLE SHOOTING The only method of ver...

Page 165: ...i _ I Disassembly ahd Assembly I t Gas Shock absorber ii W9rkin d r i dipl R n ioval and S embly How tcnechar i _ Chain S tc1y Disassembly and Assembly Centre tand Disassembly an dAssembly I SECTION NINE 09 fa 1 i _ 1 ti _ 1 x i 1 l l 1 d 1 r1 _ 1 t 1 5_ t 2 _ w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 167: ...MBER TO CHAMBER B H EN C _ E LI G HT E R DAMPING AT EXTREME END OF COMPRESSION STROKE OIL COLLAR ENTERS INTO VALVE PORT THIS REDUCES THE PASSAGE AREA AND CREATES HYDRAULIC CUSHION THRU ANNULAR SPACE BETWEEN SPRING STUD VALVE PORT t THRU SPRING STUD HOLES OIL FLOW DURINC REBOUND STROKI OIL IN CHAMBER B PRESSURISED CLOSING BOTH VALVES FLOWS INTO A ONLY THRU ANNULAR SPACE LESS OIL PASSAGE AREA H E N ...

Page 168: ...tom tube and drain the oil if Pull out the bottom tubes Take out oil control collar Remove ring clamp and dust cover Remove the cirdip from the bottom tube and take out the spacer and dust seal Place special tool ST 25114 4 on bottom tube and lever out the oil seal along with spacer Using special tool ST25105 2 remove the valve port Take out spring stud and front fork spring w w w h i t c h c o c ...

Page 169: ...damage Measure the main tube for bent Measure the spring length Inspectthe valve port spring guide valve for proper operation FRONT FORK ASSEMBLY Assemble the front fork in the reverse order of dis assembly Replace the oil seals and the O rings with new STEERING DISASSEMBLY Remove the front fork assembly Disconnect all wires and remove headlamp unit and trafficators Take out cover tube bush and wa...

Page 170: ...from head tube Take out ball race from steering stem CLEANING Clean all parts in solvent and dry with compressed air Rub the bearing race balls in a clean cloth i t INSPECTION Inspect the balls for marks of wear corrosion pitting and damage Replace if necessary Inspect the races for Grooves Excessive uneven wear Replace if found defective Check all parts for cracks breaks or any other damage w w w...

Page 171: ...ce on head tube top Fit ball race along with cover on head tube Bottom Fit ball race along with cover on head lamp casing Apply grease on steering stem bottom ball race and keep 19 balls on it Apply grease on top balls race head tube and place 19 balls in it w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 172: ...serves several important functions to improve the ride control characteristics of the shock absorbers The main function is to increase the resistance offluid flow intothe reserve tube This improves valving performance during the beginning of rebound stroke Another function is to minimize aeration of the shock absorber s hydraulic fluid The pressure of the nitrogen gas air prevents air bubbles or f...

Page 173: ...K ABSORBERS Remove the small screw with O Ring Inject the special purpose needle into the hole provided in the screw Puncturing the rubber and start pumping the air into the chamber till the pressure reached to 100 PSI 7 BAR Tolerance for filling pressure can be 6 7 BAR to 7 BAR Fit the small screw with O Ring NOTE The shock absorber needs recharging when the system pressure is less than 5 BAR CHA...

Page 174: ...p and pull out the chain stay stud Using a mandrel drive out the silent block bush from the swing arm tube Do not remove silent block unless defective Remove old silent block bushes with new ASSEMBLY Press in new silent blocks to the chain stay head tube Position special tool ST 25110 3 on shock abosorber mounting pins I w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 175: ...ers Fit chain guard Assemble the rear wheel C CENTRE STAND C DISASSEMBLY Disconnect the stand return spring 2nos C Remove the split pins washers from the C ends of the centre stand spindle C C C _ Drive out the centre stand spindle _ __ L ASSEMBLY Assemble the centre stand in the reverse order of disassembly L L L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 177: ...Rear Wheel ahd brake Removal Ai n blY DiscBrake BleedingProcedure Oisas embly ancJ Asseml ly Master Cylinder Discfn P dti6n Disassembly and As senibly C l iper_ SECTION TEN 10 J _ 1 f r f r E l J Jj tl J J _ _ t itft i t _ ti l s w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 179: ... mm thick wooden piece or cardboard sheet between the brake shoes to avoid locking of shoes Remove the oil seal from both sides of the wheel Drive out bearings and take the spacer ea iuut Do not depress the front brake lever when wheel is removed as this will result in brake shoes getting interlocked Fix a wooden piece between the brake shoes FRONT WHEEL ASSEMBLY Assemble the front wheel in revers...

Page 180: ...LH side Tilt the vehicle on its stand to the left Pull the wheel from the sprocket lug and slide it out Remove the cush drives 4 Nos from the hub The cush drives are locked to the hub with rubber lugs Lever the cush drives slowly out Else the lug may break Remove the oil seal Drive out the bearings 2 Nos and take out the spacer BRAKE DRUM ASSEMBLY Remove the drive chain from the sprocket w w w h i...

Page 181: ...bsprocket assy along with brake shoes and cover plate Take out hub sprocket brake shoes and oil seal spacer Remove oil seal Drive outthe bearing from the hub sprocket CLEANING Clean all parts except brake shoes cush drive and tyre with solvent and dry with compressed air Clean the brake shoe cush drive with dry cloth cloth wet with petrol w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 182: ...f brake fluid as they may not be compatible Use brake fluid to clean rubber parts Do not use petrol petroleum products or water Cover painted plastic and rubber parts while bleeding Replace brake pads as a set Replace banjo copper washers with new ones Replace caliper dust seals and piston seals with new ones Replace damaged parts Do not repair them BLEEDING PROCEDURE DRAINING THE OLD BRAKE FLUID ...

Page 183: ...t on the plate Diaphragm are to be removed bleed screw which is inserted in a Glass Plastic beaker Brake lever to be actuated C to remove the brake fluid completely C C C Cap from the Caliper assembly to be removed B The Banjo bolt copper washers are C to be removed from the Caliper assembly C _ __ L C L L w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 184: ... 75 kgf m Caliper mounting bolts according to the recommended specification The location of Master Cylinder should be changed in the handle bar such that cylinder portion is parallel to ground This ensures thorough bleeding is required for the slanted master cylinder assembly alone Dust cap bleed screw are removed from the Caliper assembly Connect the transparent plastic tube with Bleed screw and ...

Page 185: ...lever Then tighten the bleed screw Release the brake lever Repeat the steps 7 8 9 1Oin a sequential man efuntil the fluid pressure is felt in the brake lever Then gently stroke the lever until the pressure is felt at lever to a satisfactory limit Ensure tightening torque in the bleed screw Specification 0 4 0 7 kgf m w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 186: ... screws Caliper mounting bolts Wipe out Brake fluid spilled on the parts thoroughly BLEEDING ALTERNATE METHOD USING AN HAND PUMP The above procedure of brake fluid draining precautions should be followed here also Fill the Master cylinder with Fresh brake fluid from a sealed container Connect the longer end of the Hand pump to the Bleed screw of Caliper assembly Release the air in the Hand pump by...

Page 187: ...a lengthy tube to the Caliper bleed screw and the another end C to a container If the air bubbles stops coming out of the plastic tube the close the bleed screw Then gently stroke the lever until the pressure is felt at the lever to a satisfactory limit Tighten the Bleed screw to the specified torque 0 4 0 7 kgf m Unscrew the bleed screw by 1 2 full turns and slowly pump the system by actuating th...

Page 188: ...er Bolt lever and the Lever Remove the Clamp bolts Clamp and the Master cylinder from the handlebar Remove the wire from the coupler by pressing the projection in terminal Remove the Brake Switch Clean the Cover thoroughly before opening the Master cylinder reservoir w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 189: ...nder body Remove the Conical spring compression INSPECTION Check the seal hose side and Seal lever side for wear deterioration or other damage while servicing Check the Master cylinder and Piston for scoring or otherdamages Check the Master cylinder bore Inner Diameter Service limit 12 76 mm Check the Piston Outer Diameter Service Limit 12 64 mm w w w h i t c h c o c k s m o t o r c y c l e s c o ...

Page 190: ...YLINDER Assemble the conical spring compression with the piston Smear the piston seals and cylinder bore with clean brake fluid Then assemble the piston sub assembly by gently pressing into the bore Assemble the circlip into the groove in the master cylinder Ensure that circlip is seated inside the groove properly Assemble the Boot Do not use tools with sharp ends w w w h i t c h c o c k s m o t o...

Page 191: ...d tighten the Banjo bolt C C _ C Assemble the master cylinder assembly on the handle bar using the clamp with mark facing master cylinder assy Tighten the Torque value 3 5 kgf m master cylinder assy side Bolt Clamp first and then tighten the other side Bolt Clamp Then connect the Switch connectors Torque value 0 90 kgf m Fill the brake fluid up to the Upper level mark l approx 5mm from the top and...

Page 192: ... or water Use clean brake fluid only In case of water contamination of Brake fluid drain the fluid completely refill the system and bleed DISC INSPECTION Check periodically whether the Disc has been contaminated with oil brake fluid or grease and clean contaminated Disc with a high quality brake degreasing agent Check the Disc thickness and the Run Out of Disc 11 SI No Parameter Service Limit Insp...

Page 193: ...based liquids C While seivicing the brake care should be taken to avoid the Disc Friction pad surface C getting contact with oil or grease as it may deteriorate brake system performance to great extent Contaminated pads worn C out pads should be replaced as a pair and disc surface shall be cleaned by good _ f_ degreasing agent r C Repairing of damaged parts are not Dismantle the Mounting boltto Re...

Page 194: ...Position the caliper body with the Pistons down and apply small squirts of air pressure to the fluid inlet hole to remove the Pistons WARNING Do not use high pressure air or bring the nozzle too close to the inlet Place a shop towel over the pistons to prevent the pistons from becoming projectiles w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 195: ...iper piston O D Service limit 25 31 mm Enough care should be taken to avoid damages on the piston OD while servicing handling i tt tt _ Remove the Bleed screw CALIPER ASSEMBLY Coat clean brake fluid on new Dust seals and Piston seals and install them in the seal grooves of the caliper body Piston seal on the inner most groove and Dust seal at the outer groove Coat the caliper cylinders and Pistons...

Page 196: ...Bellow Inner diameter Assemble them as shown Install the Pad spring in the Caliper Assemble Bleed screw with caliper body Apply Silicon grease on the Pin OD Assemble the Mounting Bracket with caliper Body First install the pad near to the piston and then assemble other pad w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 197: ...unting bolts New sealing washer C Tighten the Banjo bolt Torque 350 to 380 kg cm Fill and bleed the hydraulic brake system Procedure given separately C _ Recommended tightening Torque 270 to 300 kg cm Tighten the Pin bolts with a torque of 150 200 kgf cm after mounting the caliper assy with the fork assembly _ r l J _1z i A 7 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 199: ... C C C C _ _ t tJi l ri l 1 il1 l I J i f t l _i s i _ _ 1 lia triqR Syrpqg s_ 1 tt r a aM Lnt 3ha e SpcJ rk F hjg SECTION ELEVEN 11 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 201: ...oles ExhaustTube Porous Mass of Lead Dioxide Pbo as Positive Active material Porous Mass of Spongy Lead Pb as Negative Active material Dilute Sulphuric Acid H2 S04 Micro Porous Acid Resistant Electrical insulator between Pos Neg Plates Polypropylene Casing to house the Plate group electrolyte To seal the battery container To facilitate filling of electrolyte and water topping up To facilitate fill...

Page 202: ...harging Keep fire and spark away from battery charging area Be sure to connect the long vent tube to the battery While fixing it to the motorcyle route it correctly Avoid the running the mqtorcycle without connecting the battery CHARGING INT AL CHARGE ELECTROLYTE Dilute sulphuric acid with distilled water to a specific gravity of 1 240 PREPARATION Take required distilled water in a glass plastic c...

Page 203: ...on charge Battery 12V14AH Duration 10Hrs RECHARGING Charging Current 1 4Amps RECHARGE A USED BATTERY when the specific gravity of electrolyte is less than 1 220 when a charged battery remains unused for more than 3 weeks Never add sulphuric acid to battery electrolyte for topping up or increasing specific gravity It would lead to sulphation CHARGING PROCEDURE Top up the electrolyte level with dist...

Page 204: ...rvals of 30 minutes each to read constantly 1 240 or more of specific gravity Voltage 13 2V MAINTENANCE Check the electrolyte level and top up if necessary to the max mark with distilled water every week For topping use only distilled water Keep the battery surface clean and dry Neverovercharge the battery it damages the battery Remove the battery from the motorcycle and store it separately when t...

Page 205: ... boost charged once in 3 to 4 weeks It is always a good practice to boost charge the batteries before fitment to ensure full state of charge Recharge stored batteries once a month Check the terminals and cables for corrosion Apply petroleum jelly on terminals to prevent corrosion Check specific gravity of electrolyte The float graduation in level with the electrolyte in it is the specific gravity ...

Page 206: ...cal reaction This battery capacity SHEDDING The active materials of the plates falling off is shedding qver charging and rough handling are the main cause buckling plates rendering the battery unserviceable Over charging means charging of the battery with excessive current COMMON PROBLEM EXPERIENCED IN FIELD A CORROSION OF POSITIVE GRIDS CAUSES Improper Impurities in water acid like Cl Mn Fe INDIC...

Page 207: ...ater OM water tor topping up Periodic topping up to prevent exposure of plates If the battery is idle for longer duration to boost charge before reuse to compensate for self discharge SPARK PLUG Spark Plug is a vital part of ignition system They are subjected to high combustion pressure arounf 40 times the atmospheric pressure intense heat more than 2000 deg C temperature and severe vibration Use ...

Page 208: ... C Rapid spark plug fouling leading to misfiring Cause 450 deg C Use of spark plug colder than required Self cleaning temperature 450 to 850 deg C Normal Burns combustion 850deg C residues that come in contact with electrodes Remian clean for long periods Auto ignition temperature Above 850 deg C Cause pre ignition electrodes melting and blisters on insulators surface Cause Use of spark plug hotte...

Page 209: ... filled with combustion residue LONG REACH SPARK PLUG IN A CYLINDER HEAD DESIGNED FOR SHORT REACH PLUG Over heating Pre ignition Damage to piston spark plug removal difficult SHORT REACH SPARK PLUG IN A CYLINDER HEAD DESIGNED FOR LONG REACH PLUG Starting problem Mis firing Difficult in fitmet of new spark plug due to residue on cylinder head threads w w w h i t c h c o c k s m o t o r c y c l e s ...

Page 210: ... comustion chamber in 4 Stroke Engines Engine is running in slightly over heated condition Incomplete combustion of fuel due to Too rich air petrol mixture Retarded ignition timing Continuous low speed operation Excessive electrode gap Colder spark plug Low H T Voltage Over heated engine and over heated spark plug due to Too lean air petrol mixture Use of hot spark plug Use of longer reach spark p...

Page 211: ...ning tool I machine Check spark plug for worn out the earth and center electrodes Ifthe earth electrode has worn off to a knife edge and center electrode hc1s reduced in height replace it with new Check spark plug for worn out earth and center electrodes If the earth electrode has worn off to a knife edge and center electrode has receded in height replace it with new INSPECTION Clean the electrode...

Page 212: ...the Resistance between wires a Yellow 1 to y_ ellow 2 b Yellow 2 to yellow 3 c Yellow 3 to yellow 1 CHECKING PROCEDURE PULSAR COIL SPECIFICATION Resistance 190 to 220 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green white to white wire CHECKING PROCEDURE IGNITION COIL SPECIFICATION Resistance a Between Brown to Red white 4 to 5 ohm b Between Brown t...

Page 213: ...PROCEDURE RELAY STARTER SPECIFICATION Resistance 4 to 5 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green white to white wire CHECKING PROCEDURE E STARTER MOTOR SPECIFICATION Resistance 0 3 to 0 5 ohm CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between motor terminal aluminium body w w w h i t c h c o c k s m o t o r...

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Page 215: ... r C C C C SECTION TWELVE 12 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 217: ...rings Change the clutch springs pressure Worn out clutch plates Replace the clutch plates Glazed steel plate clutch Replace the glazed plates plate Distorted steel plates Replace the distorted steel plates Stuck clutch rod Clean and lubricate 2 Compression weak Loose spark plug Tighten the spark plug Tight push rod adjustment Adjust correctly Blown cylinder head gasket Change the gasket Leaky valv...

Page 218: ...hole with inlet thumb Crank Stuck closed float needle Clean and free float needle engine several valve times How is Float height too high Adjust float height the petrol Blocked pilot jet pilot Clean the jet discharge smell Is there discharge orifice orifice petrol strain on Loose carburetor to engine Tighten hose b Heavy petrol smell Too rich air petrol mixture from Petrol stains on Carburettor th...

Page 219: ...of Side Stand Cut off Switch TCI Fuse Blown Then the engine would start easily Complaint Low Idling Problem 1 Does the a Yes it cuts off on Throttle stop screw too far out engine cut off closing throttle Pilot screw too far in suddenly when Pilot jet blocked the throttle is closed but Pilot discharge orifice blocked remain Weak compression running as long as throttle remains partly open b No it do...

Page 220: ...stuck open slide valve Clean and free the slide valve b No it is not go to check 4 4 Doesthe a Yes it does Pilot screw too far in Adjust the mixture screw engine low idle Suction leakage Check and correct erratically Worn out slide valve Replace slide valve b No it is not go to check 5 5 Doesthe a Yes it does Excessive spork plug gap Adjust gap to 0 7 engine mis fire Fouled spark plug Clean and ad...

Page 221: ...ck open choke plunger Check and correct Choked air filter Clean air filter Weak spark Check and correct Choked air jet Clean the air jet Poor compression Causes remedies for poor compression as given for compression weak in check 1 in engine difficult to start b Excessive white smoke Forcauses and remedies check high lub oil consumption complaint c No smoke Blocked petrol jets Clean them Float hei...

Page 222: ... less free end Replace the piston rings the engine gap Keep a clean tray below the Bend connecting rod Replace the crankshaft pipe Now start Excessive piston to cylinder Replace the defective part and check for clearance the smoke Glazed cylinder walls Replace Defective return pump Check and correct Oil leakage from oil tank to Check and correct crank case b No white smoke Oil leakage combustion c...

Page 223: ... cylinder head The bottom between cylinder bore and piston rings Check to find out whether the oil enters the combustion chamber from the top or bottom Remove the rocker oil pipe banjos two nos and bend the pipe away from the _engine Keep a clean tray below the pipe Start and run the engine If white smoke stops the oil enters the combustion chamber from the top If white smoke continues the oil ent...

Page 224: ...res Replace tyres b Yes he does go to check 2 2 Is the engine a Yes it is over loaded Excessive pay load Carry correct pay load Tight primary secondary Adjust chain tension Chain Too much oil in clutch or gear Drain and maintain level box Sticky wheel bearing Clean and lubricate Under inflated tyres Inflate to right pressure Binding brakes Adjust the brakes Wheels misaligned Align the wheels b No ...

Page 225: ...Yes Needle fitted on lower Fix the needle on the right excessive black groove groove smoke during Chokedair jet Clean the air jet high speed Loose worn out main jet Tighten change main jet operation Choked air filter Clean the air filter b No Now the vehicle mileage will be good Complaint engine over heating Causes Remedies Too lean air petrol mixture characterised by loss of power Check and corre...

Page 226: ...es Worn out bearing Replace them continuous grinding like noise b No go to check 6 6 Does the a Yes Excessive clearance between Change the worn out part knock reduce piston and cylinder with increase in engine temperature b No go to check 7 7 Does the noise a Yes Low octane petrol Use correct octane petrol increase with Engine over heating Check and correct temperature Excessive compression ratio ...

Page 227: ...justments duce unusual Worn out bearing Check and correct sounds components knocks Low octane petrol Check and correct Too hiqh compression ratio Check and correct b No Caution Use of non genuine parts cause premature wear of the components Complaint Flame at the carburettor back Fire Causes Remedies Too lean air petrol mixture Characterised by loss of power Check and correct Over heated engine Ch...

Page 228: ...ker shaft bore undersize Change rocker shaft rocker shaft Burrs in hole Clear burrs pivot pins slide freely in the rocker shaft Yes go to check 4 4 Does the cam No it is tight Oversize pivot pin Change to correct size pin plate rotate Cam plate ratchet face Replace pivot pin camplate freely on the rubbing against the face of pivot pin the pivot pin Selector fork face rubbing Change selector fork a...

Page 229: ...s go to check 7 No it is tight while Burrs in splined position of Replace the shaft sliding the shaft Wrong size shaft Replace the shaft Yes go to check 8 No it is tight Circlip position to be just Position the circlip properly after thrust washer and not and ensure no excessive play to be on oil groove Yes go to check 9 No it is tight Pawl touching the gear box File t he gear box casing casing En...

Page 230: ...ight Causes and remedies as given in check 3 in Gear Hard rocker shaft pivot pins slide freely in the rocker shaft Yes go to check 2 2 Operate the No it ls tight Mis aligned gear shift shaft Check correct I replace toe lever up Chain case outer bush too Check correct I replace and down tight on gear shift shaft ls the lever free Improper fit oil seal Check correct replace Misaligned clutch case in...

Page 231: ...pin Change to correct size pin Cam plate ratchet face Replace pivot pin camplate rubbing against the face of the pivot pin Selector fork face rubbing Change selector fork against the cam plate face camplate Burr in the cam plate track Remove burr in the cam plate outer side of the rom plate inner track and outer side Ratchet rivet protruding from File fit it cam plate Selector fork peg edges File ...

Page 232: ... fit in the Camplate notches correctly Yes go to check 1 2 12 How is the Excessive play Under size main shaft Change to correct size play in 4th washer gear position after the fitment of washer and circlip Correct play Then there will not be false neutral w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 233: ... r C C c c C C C C _ __ L L __ L l_ w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 234: ...I j r i l J l l w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Royal Enfield ELECTRA, Service Manual

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