Royal Enfield ELECTRA User manual

Watsonian Squire Ltd, 70 Northwick Business Centre, Blackley, Glos, GL56 9RF
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Web site: www.royal-enfield.com
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PREFACE
Bullet Electra is fitted with a 500cc, four stroke, lean burn engine and a 5-speed gear box.
This Service manual has been prepared mainly
to acquaint the user to the construction of the
Royal Enfield product and to guide in the basic servicing, periodical maintenance, systematic
disassembly and inspection 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 Riding.
Service Head Quarters,
Royal Enfield
SRM ISSUE 2
Part No. 597394A
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FOREWORD
PREPARATION FOR SERVICE
Good preparation is very important for efficient service work. A clean work area at the start of
each job will allow you to perform the repair as easily and quickly as possible, and will reduce the
incidents of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned
before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and
any parts needed for the job should be gathered before work is started. Interrupting a job to
located tools
or parts is an unnecessary distraction and causes needless delay. Tools required
for special service work are listed
in Section 02.
USE OF GENUINE REPLACEMENT PARTS
When replacement parts are required, use only genuine 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 reference to explain and need not be exactly the same on the model
you own. Technical specification are subject to change without prior notice.
Because of changes that may occur
in the manufacturing process since the Service Manual was
printed, it is possible some instructions, illustrations, pictures or designs found within this manual
may differ
tom those found on the vehicle. However the technical information found within this
manual was correct at the time it was approved for publication.
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HOW TO USE YOUR SECTION FOUR 04
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SERVICE MANUAL
ENGINE
Your Service manual is divided into numbered Disassembly
r sections arranged for quick, easy reference.
Sections are subdivided into subjects. Subject Inspection
( information is presented in the following order: Assembly
SECTION ONE 01
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INTRODUCTION
SECTION FIVE 05
ELECTRIC START
( The manual and its arrangements
(
SECTION TWO 02
SECTION SIX 06
(·
GENERAL
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 Specifications
(_
Periodical maintenance
Cleaning and assembly precautions
SECTION TEN 10
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WHEELS & BRAKES
Front wheel & brake
(_
Rear wheel & brake
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SECTION ELEVEN 11
ELECTRICALS
Battery
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
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SECTION
ONE 01
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THE MANUAL AND ITS
ARRANGEMENTS
This manual is for service personnel
undertaking preventive and break down
maintenance of Bullet Electra motorcycle.
Pictorial presentation of various activities,
make this manual easyto understand and user
friendly.
PAGE NUMBERS
The topics in this manual are divided into 12
Sections 01 to 12. Page numbers for each
section starts with 01. Thus, page 05-10
indicates 10th page of section
5.
INDEXES
'Contents' provides subjectwise index.
WEAR LIMITS AND TORQUE
SPECIFICATIONS
Section 3 contains data pertaining to the wear
limits and the torque specification chart.
Wear limits are given as new min, new max
and service limits. Their significance.
-Life of the component
-Service limit
-New Max
-New Min
New components must be within new min and
new max limits. We
can reuse used parts within
service limits. Use of parts beyond service limit
reduces the operating life of the component
after the service.
NOTES give general information.
CAUTION relates to activities 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 for performing
service operations. Some of these service
operations require the use of tools specially
designed for the purpose. These special tools
should
be used when and as recommended.
SAFETY
Every care is taken to ensure that the
information given
in this manual are correct
and accurate. However, Royal Enfield does not
assume responsibility for any damage, loss or
injury caused to the vehicle or the service
person due to errors
or omissions in this
manual.
PRODUCT CHANGE
Continous product improvements may lead to
changes in parts used or service procedure
followed
on Bullet Electra without any notice
to the user
of this manual.
All images shown are for reference to explain
the service procedure and need not be exactly
the same for the model.
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SECTION
TWO 02
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SALIENT FEATURES OF
BULLET ELECTRA
1. LEAN BURN ENGINE that produces
1"!- 0 kw @ 5000 rpm output and gives
3"1 KPL under EEC Condition. A
combination made possible through the
state of art engine technology application.
2. RUGGED, RELIABLE AND
VERSATILE
MACHINE:
* 500cc engine that delivers 17.0kw @
5000 rpm output
P TCI (Transistorized Coil Ignition) : No
adjustments, strong spark intensity &
long arc duration to ensure total
combustion
* Sturdy tubular frame capable of
withstanding the most adverse riding
conditions.
* Heavy duty hydraulic front fork and
adjustable gas filled rear gas shock
absorbers.
3. STABLE AND SAFE
MOTORCYCLING :
* Broad Tyres (front 90/90, Rear 100/90)
for better
road holding
* Gas filled rear shock absorbers minimise
road 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
* Specially designed fulcrum lever on
stand to ger the bike 'ON'
and 'OFF' the
stand with utmost ease.
* Constant Vaccum Garb BS 29 to instant
start, mileage consistancy
* Cut off switch is provided in sidestand
for safety.
To startthe engine, side stand
has to be retracted. Otherwise ignition
-will not occur; only engine will crank.
5. HIGH PERFORMANCE
* 126 KPH top speed
* 40Nm @ 3000rpm engine torque for
excellent gradability and load carrying
6. PLEASING LOOKS
* High rise handle
* Flamboyant colours
* Step - up seat
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FOUR STROKE CYCLE OPERATION
SUCTION COMPRESSION POWER EXHA·UST
STROKE STROKE STROKE STROKE
Inlet Valve Open Closed Closed Closed
Exhaust Valve Closed Closed Closed Open
Piston Movement TDC 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.
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'-----+/
'<V
1st stroke
2nd stroke
Jrd stroke
4th stroke
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B.
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17.
. 18.
19.
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21.
22.
TECHNICAL SPECIFICATION
DIMENSIONS & WEIGHTS
Length 2200mm
Width 790mm
Height 1100mm
Wheel base 1370mm
Saddle height 820mm
Ground clearance 140mm
Vehicle weight
in running condition 187kg
Max. pay load 178kg
ENGINE & ENGINE SYSTEM
Engine type 4 Stroke, Spark ignition,
Air cooled, Single 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
Float height 17.1mm
Intake system Over head valve
Lubrication
Dry Sump Pressure feed
Cooling Natural Air Flow
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C PERFORMANCE
1. Cruising speed 70-80 Kmph
2.
Max speed 126 Kmph
3. ·Mileage under EEC conditions
31 Kmpl
D TRANSMISSION
1. Primary drive Duplexchain &
sprocket, pitch 3/8"
2. Engine/Clutch
drum sprocket teeth 25/56
3. Primary reduction 2.24:1
4. Clutch
Wet Multiplate
5. Gear box Constant mesh 5 spe~d
6. Gear ratios
1st
3.06: 1
2nd 2.01 : 1
3rd
1.52: 1
4th 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 fill shock
absorber
4. Front brake Disc brake
5. Rear brake
152mm x 25mm, Internal
Expanding
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17.
Rear brake pedal
Wheel bearinq front & rear
Rear sprocket bearing
Front tyre
Back tyre
Front tyre pressure solo
Front tyre pressure dual
Rear tyre pressure solo
Rear tyre pressure dual
Steerinq lock
CONTROLS
Steering
Accelerator
Clutch
Gears
Front brake
Rear brake
Decompressor
ELECTRICALS & IGNITION
Generation
System
Ignition
Ignition timing
Spark plug type
Spark plug 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
handle bar
Magneto Assembly
12V, 196W
12VDC
3 Phase TCI
5° BTDC
BoschW3CC / NGK B9ES
0.6 to 0.7mm
0.6-0.9mm
12V 14
AH
12V 60/SSW Halogen
12V
2W, 2Nos.
12V
4W, 1 No.
12V SW
12V 21W
12V 10W
12V 3,4W, 1 No.
12V 2W
12V
2W, 2 Nos.
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18.
Hi beam indicator 12V 3.4W
19. Neutral indicator 12V 2W, 2Nos.
20. Horn
12V. 2.5A (Max) DC
H OIL & PETROL
1. Engine oil 15W40
2. Performance rating APISG, JasomaT 903:MA Spec
3. Tank capacity 2.25 Litres
4. Front fork
oil
10W30
5.
Performance rating APISG, JasomaT 903:MA Spec
6.
Front fork oil capacity 200ml per leg
7. Clutch oil 15W40
8. Performance rating APISG, JasomaT 903:MA Spec
9.
Clutch oil capacity 420ml
10. Gear box
oil
EP 90
11. Performance rating API GL - 4
12. Gear box oil capacity 450 ml
13. Disc brake oil Brake oil Dot3 or Dot4
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 Main shaft sleeve (Inside) NEEDLE BEARING 2
7 Lay shaft (GB) . NEED~E BEARING 1
8 Carrier plate (GB) BALL BEARING 3203 C3 1
9
KS shaft (GB) NEEDLE BEARING 1
10 Sprocket hub bearing BEARING 6005 double side rubber sealed 1
11 Front & rear wheel (LH & RH)
(each 2 Nos.) BEARING 6203.RS1- C3 4
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LIST OF SPECIAL TOOLS AND ITS APPLICATION
PART NO. DESCRIPTION APPLICATION
·ST 25098 - 2 Extractor for engine sprocket Removal of engine sprocket
ST 25099 - 3 Extractor for clutch centre Removal of clutch centre and
back plate assy
ST
25101 - 2 Extractor for timing pinion Removal of timing pinion
ST 25102 - 1 Extractor for piston
pin
Removal of piston pin
ST25104-2 Clutch brake bar Holding the centre and back plate assy.
ST25105-2 Special spanner for Removal and fitment of valve port
front fork valve port
ST 25108 - 3 Front fork main tube spanner Loosen and tightening of front fork
main tube
ST25110-3 Guage for tightening chainstay Alignment of chain stay while
tightening
ST25112-4 Expander for front fork Oil seal Expander for oil seal while inserting
main tube into bottom tube of front fork.
ST 25113 - 4 Mandrel for oil seal 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 head nut.
ST25119-2 Extractor for tappet guide Removal of tappet guide
ST 25120 - 4 Adaptor for dial gauge fixing
To fit dial guage on cylinder head
ST 25123 - 1
Valve spring compressor
To compress the valve spring for
removal and fitting of valve
ST 25128 - 2 Magneto puller for
TCI
Removal of magneto rotor assy.
ST25151-4 Chain case outer puller (TCI) Removal of chain case outer
ST 25153 - 4 Extractor for Removal of rocker shaft pivot pin.
5 Speed gear box rocker
ST 25156 - 4 Guide for rocker
To prevent damage of rocker pivot pin
pivot
pin 'O' ring 'O'ring, to ensure fitment of pivot pin.
ST
25244- 4 Adjuster special spanner
To adjust gas filled shock absorber
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SPECIAL TOOLS AND ITS APPLICATION
ST 25098-2
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
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