Royal Enfield Bullet Instruction manual

Page Nos.
PREFACE,
PRECAUTIONS GENERAL INSTRUCTIONS -
l
ROLJTINE MAINTENANCE
-
TECHNICALSPECIFICATIONS 350cc & 500cc
6-9
DESCRIPTlON OFENGINE PARTS - 10-13
DECARBONISING
SERVICE OPERATION
- ENGINE ON FWE
SERVICE OPERATION - ENGINE - REMOVED FROM FRAME
GM BOX
FRAME REAR SUSPENSION
FRONT FORK [HYDRAULIC)
WHEELS
ADJUSTMENT OFBRAKES
TYRES - REMOVAL AND REPLACEMENT
IGNITION
AND LIGHTING SYSTEM
WIRING DLAGWS
ELECIIUCAL CONNECTION DETAILS
CARBURETTOR
SERVICE LIMITS
TROUBLE SHOOTING
TORQUE VALUE CHART
SPECIALTOOLS
101-106
METRlC CONVERSION TABLE
107

PREFACE -
We take pleasure in releasing this Maintenance Manual as a guide t
-
senice. Most of the servicing can well done by the average owner. N
diagrammatic Sketches and photo illustrattons have been introduced for better
understanding. However for anowner who feels uncertain of his ability to, undertake
-
any stripping and re-building for a major overhaul, we strongly reco
work be done by an authorised 'ENFIELD DEALER/DISTRIBUTOR
that the use of proper servicemaintenance tools andgenuine Enfield
best results.
-
Whilsteverycare is taken to ensurethat the information in this manu
no liability can be accepted by Royal Enfield or the publisher for
10s
or injury caused due to errors or omissions in the informations given.
PRECAUTIONS AND GENERAt INSTRUCTIONS
Observe the following points without fail, when dismantling and
reassembhg Motor-cycle parts.
-
Be sure to replace packings, gaskets, circlips. '0' rings and cotter pins
with new ones, for 'safe riding'.
.
-
Tightenbolts & nuts startingfrom the larger diameterones to thesmaller
diameter and from inside to outside diagonally, with specffied tightening
torque.
-
Use always genuine spares and recommended grade of oils only.
When using a torque wrench for checking, always loosen the bolt or nut
by half turn and then tighten to the specified torque. Never use torque
wrench for loosening
a bolt or nut.
L
B~.G SPARE PARTS n
When ordering spareparts foryourMotorcycleit is advisable to dealdirectwith
the Enfield official dealer/distributor, who should be able to supply most of the
parts ex-stock.
\
AlwaysquotetheEngineNumber and FrameNumber and descriptionof partrequired.
It is advisableto indicatethecolour schemeespeciallywhile orderingpartsforframe.
side panels,tank, mudguards, etc.,
/

ROUTINE MAINTENANCE
Introduction
Periodic routine maintenance is a continuous processthatcommences immediately after
the machine is used. It must
be carried out at specifiedmileage recordings, or an a calendar
basis
if the machine is not used frequently.
- -
Maintenance should be regarded as an insurance policy, to keep the machine in peak
conditionand to ensure long, trouble free service.
The various maintenance tasks are described under their respective mileage and
period.
The intervals between thevarious maintenance tasks serves only asa guide. As the machine
gets older or used under particularly adverse conditions, it would be advisable to reduce the
period between each check.
For
ease of referenceeach serviceoperation isdescribed in detailundertherelevantheading.
In orderto cuttheroutine maintenancetasks,a good selectionof generalworkshop tools
is ab~olutel~essential.
Included in the kit must be a range of m
phillips head screw drivers and pair if circlip
No specialtools arerequired forthenormalroufine maintenancetasks. Thetools contained
in thetool Mt supplied with every new machine will prove adequatefor each task, or if they are
not available,the tools found
in theaveragehousehold will usually suffice.

Adaily check of the Motorcycle is essential both from mechanical and safetyaspects. It is a
good idea to develop this checkingprocedure in a specific sequence so that It wtll ultimately
become as instinctive as actually riding the machine. Done properly,
this simple checking
sequence
will give advancedwarning of impendingmechanical failures and conditions which
may jeopardize the safetyof the rider.
- Clean the motorcycle with a clean cloth.
- Check engine oil leve1,usingthe dipstick provided in the oil tank cap. Maintain oil level
upto 'H' mark. If necessary top up ofl to the required level.
- Check proper operations of all controls viz. clutch, accelerator, brakes, aI1 lights and
horns.
- Check tyre pressure, with a pressure gauge. Cneck tyre pressure when the tyres are
cold. It is worth purchasing
a smallpocket pressure gaugewhich can be relied upon, to
give consistentreadings than garage forecourtgaugeswhich tend to be less dependable.
;; <G?i'air-.r.-*,6z7-.---.. as> G.
x*2~;<p:p:>.;:.;:2?<:2:*-.-+<q2=s3@~*.: -P---- ;~~+X*?:~T+;.E%*~~~*- ,,,; -pT3-. ?!.. -:<-n-.&$.&zg
- -. .
-;$$,~g~@;gss~~:~gon@:3@Psr*~Rear G~~+z.2~a.42.G..-c ~~~~~~~e2~z2~2~~-~~~v:L+g.~~~~~E5~+zs2~:~~~~:~~ ,136:: PSI:
o , -.-
.--
-
Check tyres forforeign materials and remove them to prevent possible punctures.
- Check for adequate fuel in the petrol tank, for thejourney planned.
- Check for proper chargingof the battery after startlng the machine.
- Check ofl levels - engine & clutch
- Check contact breaker gap and adjust if necessary
- Check and adjusttappet clearance if necessary
- Check clutch, throttle and kontbrake cables and adjust if excessive play noticed
- Lubricaterear chain
d.
*. ,*
- Adjust kont &rearbrakes
-
Check wheel rims, for excessiverunout,breakage of spokes and tyres tor cracksor cuts.
- Check condition ofbatteryand electrolyte level, and top up with distilledwater upto the
level provided.

-
- Clean,'and adjust plug gap or replace spark plug.
- Check and service contact breaker points.
-
- Check and adjust Ignition timhg.
- Check and adjust valve tappet clearance.
- - Clean airfilter.
- Clean, tune up carburettor.
- Clean fuel tap gauze.
- Clean fuel tank and fuel lines.
- Check andadjust clutch. ,
-
- Adjust front & rear brakes.
- Check front fork oil level.
- Check all elecmcalconnectionsand functionsofhead Light. trafficator,horn, speedameter.
etc.
Carry out alI the operatiommentionedfor hf monthly suvfce and check the
following:
- Changeofl-engine & clutch.
- Clean or replace ofl fflter
- Changefrontfork ofl
- Check front & rearbrake linings and replace lf necessary
- Check for play in steeringhead bearings and adjust
- Check operation of steering lock and lubricate if necessary
- Check operation of side stand and condition of sprlx.

TECHNICAL SPECIFICATIONS - BULLET - 350 CC
Engine
Single Cylinder 4 Stroke with Overhead Valve
Cubic Capacity : 346cc
Stroke : 9Omrn.
Bore-Nominal : :70rnm
Actual : 69.875 mm/2.751 in.
CompressionRatio : 7.25 : 1
compression Pressure
: 110 + 5 PSI (recommended)
Engine outpl l t : 18 BHP / 5625RPM
Torque
: 2.74kgm/2875RPM
Piston and piston rfngs:
Ring dearan ce in grooves : Dimensions for new components]
Plaln (2) : .001/.003"
Scraper : .002/.004"
Ring end gap in bore : .015/.020
Maximum rir-ggap permissible : 0.030"
Gudgeon
pin diameter : .7498/.7500'!
Crank pln diameter : 1.24875/ 1.249"
Connecthg rod small end diameter : .7505/.7507"
crankshaft:
Driving side Ball bearLng :
25 X 62 X 17 mm (63051
Roller bearing
: 25x62~17 mm (NU 305orN 305)
Timing side Roller bearing : 25x52~15mm(NU205orN205R)
CamW : .3125 in.
Valve lift : .3125in.
Valve tizuing with -012" clearance
Exhaust opens : 75" BTL)C
Exhaust closes : 35"ATDC
Inlet opens : 30" BTDC
Inlet closes : 60"ATDC
Rocker bearing inside diameter
: .625/.626" (J3irnensions for new Components]
Rocker spindle diameter
: .6235/.624"
Inlet valve stem diameter : .3425/.3430
Exhaust valve stem diameter : .3405/.3410
Vdve guide internd diameter : .3437/.3447'
Valve guide external diameter : .6270/.6275
Tappet.guide internal diameter : .3752/.3760n
Tappet guide external diameter : .7505/.7510n
~rication : Dry sump, OU: tank integral with crank case
Clutch : Wet multiplate,OiI immersed
Engine sprocket
: 25teeth
Clutch Sprocket : 56 teeth
Primary drive chain : 3/8" pitch Duplex chain.

Gear Box:
Overall gear ratios
Mainshaft ball bearings
Final drive sprocket
Rear drive chain
Brake
dnun sprocket
Carburettor
Main jet
Pilotjet
Contact Breaker [Coil igdtion):
Points gap
Timhgbefore T.D.C.
Spark plug
Spark plug gap
Condenser (Capacitor)
Suspension:
Front
Stroke
Rear
Wheel Rim Type
we Size
Wheel Bearings :
Font&Rear) .
Brakes
Front
Rear
Fuel tank
Full Tank Capacity
Reserve Capacity
Oil Capacity h Grade:
Oil Tank
Fork
Clutch
Gear box
Dimensions:
Weight Dry)
Pay load (Max)
Ground clearance
Overall length
Overall width
Saddle Height
Wheel base
Electxicals:
System
5.32, 7.26, 9.80,
& 14.80
Small
- 6303
Large
- 6206
16teeth
5/8" pitch chain
38 teeth
Mikd-W-24
90
25
:
0.14/0.16" (0.35 to 0.4 mm)
: 1/32" (0.8 mm)
:
14 mm. diameter B7HS (NGKI or equivalent
: 0.46 to 0.50 mm
: 0.18to 0.25 M.F.D.
Telescopic, hydraulic damping
155 mm
Pivoted fork with shock absorbers
WM 2- 19
3.25
X 19Front)
3.50
X 19 (Rear)
17 X 40 X 12 mm (6203)or 6203 ZZ
Mechanical,internally expandingshoe type
178
mm X 38 mm Twln Leading shoes
153
mm X 25 mm Single Leading Shoe
: 14.5litres
: 1.25litres
: 2.25 litres, SAE 20 W 50
: 200 ml. on each leg. Hydraulic oil or SAE- 10W30
: 420 ml. approximately SAE2O W 40
: 700 grams of veedol'00' grease (fortopping up use SAE-20W501
: 172Kg.
: 14cm. (140mm)
: 212cm(2120mm)
: 75 cm (750 mm)
: 85 cm. (850 mm)
: 137cm (1370mm)

TECHNICAL SPECIFICATIONS - BULLET - 500 CC
8ingle Cylinder 4 8tr~ke with werheadValve
Cubic Capaclty : 499 CC
Stroke : 90mm
Bare-Nornlnal : 84mm
Actual : 83.96/83.97 mm
CornpresstDn Ratlo : 6.5:l
Compression Pressure : 110 f 5 PSI (Recommended]
Engine output
: 22 BHP/5400 RPM
Torque
: 3.5Kgm/3000RPM
Piston and piston rlngs :
IUng clearance in pxwes : (Dimensions for new components)
matn(2) : .001/.003-
*raper : .002/.004"
Rtng end gap Ln bore : .015/.020n
Maximum rlng gap permissfble : 0.038
Gudgeonpin diameter
-. . .7498/.7500"
Crank pln dlarneter : 1.24875/1.249"
Connecflngrod small end diameter : .7505/.7507
Crankshaft :
DrMng side Ball bearLng
: 25 X 82 X 17 mm (63051
Roller bearing
: 25 X 62 X 17 mm (NU 305 or N 3051
Tlming side Wer bearJng : 25~52~15mm(NU205orN205RI
Camm : -3125in
Valve lift : .3125in.
Valve thing dth .O1T clearance
Exhaustopens : 75" BTM)
Exhaust closes : 35"ATM)
Inlet opens : 3O0BTDC
Inlet clmes : 6O0ATDc
Rocker bearing inside diameh : .625/.626" [Dimensions for new Components]
Rocker spindle diameter : .6235/.6240n
Inlet valve stem diameter : .3425/.3430m
Exhaust valve stem diameter : .3405/.341OR
Vahre gulde internal diameter : .3437/.3447' -
Valve guide external diameter : .6270/.6275
Bppet guide internal diameter : .3752/.3760"
Tappet guide external diameter : .7505/.7510"
I~bricatim : Dry sump. Oil tank integral with crank case
Clutch : Wet multlplate, Oil lmmeraed
Englne sprocket : 25 teeth
Clutch
: 56 teeth
himarydrtvechaln : 3/8"pitch Duplex chatn.

Gear b~x :
Overall gear ratios
: 5.01, 6.83.9.22 & 13.93
Overall gear ratios
: Small - 6303
: Large - 6206
Ffnal drive chain : 17 teeth
Rear drive chain : 5/BWpitchchaln
Carburettor : Mikcarb-W-28
Malnjet : 110
FUot jet : 25
Contact Breaker (Coil ignition) :
Points gap : 0.14/0.16" (0.35to 0.4 mm)
Tfming before T.D.C : 1/32" (0.8 mm)
Spark plug
: NGK BR 8 ES or equivalent
sparkplug gap : 0.46 to 0.50 mm
Condenser(Capacitor) : 0.18 to 0.25 M.F.D
Snspdon :
Front : Telescopic. Hydraulic damping
Stroke : 155 mm
Rear : Pivoted fork with shack absorbers
Wheel Bfm Type : WM2- 19
mesize : 3.25 X 19Front)
: 3.50~19(Rear)
Wheel Bearings :
Front & Rear) : 17x40x12mm~6203)or6203ZZ
Brake : Mechanical. internally expanding shoe type
Front
: 178 mm X 38 mm Twin leading shoes
Rear : 153 mm X 25 mm Single lea- shoe
Fuel tank :
Full Tank Capacity : 14.5litres
Reserve capacity
: 1.25litres
Oil Capacity & grade :
Oil tar& : 2.25 litres. SAE-20W50
Fork
: 200 ml. on each leg. Hydraulfc Oil or SAE 10W30
Clutch : 420 m]. approximately SAE-20W40
Gear Box
: 700grams of veedollOO'grease(fortoppingupuse SAE 20W50)
Mmensione :
Weight (Dry) : 168 ~g. '
Pay load (Maxl : 172 ~g.
-
Ground clearance : 14 cm (140 mm)
Overall length : 212 cm (2120mml
Overall width : 75cm (750mm)
SaddleHeight : 85 cm (850 mm)
Wheel base : 137- (1370mm)
Electrlcals :
System : 12VDC