ROYAL ENFIELD Bullet 500 Classic User Manual

Bullet Classic EFI (C5)

Bullet Electra EFI (E5)

Bullet EFI (G5)

SECTIONSECTION

SECTION

SECTIONSECTION

ONE 01ONE 01

ONE 01

ONE 01ONE 01

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

PREFPREF

PREF

PREFPREF

We are pleased to release this workshop manual for the new generation of Royal Enfield Motorcycles fitted with unit construction engine, electronically controlled “Engine Management System” and fuel injection technology.

We have endeavoured to make this manual user friendly. However, we welcome your valuable suggestions for improvements which you may write to us or email us at vvikram@royalenfield.com.

Service Head Quarters,

Royal Enfield Chennai.

CECE

All Rights Reserved. No part of this Service technical manual shall be copied, distributed or otherwise dealt, without the express permission in written from Eicher Motors Limited, Unit Royal Enfield, who remains the sole owner of this manual .”

Part No. 597451 / Qty. 500 / May ‘09

01-1

FOREWFOREW

FOREW

FOREWFOREW

ORDORD

ORD

ORDORD

PREPARATION FOR SERVICE

Good preparation is very important for carrying out correct service job. The motorcycle should be cleaned well before starting a repair job. Cleaning will occasionally uncover sources of trouble. Availability of tools, measuring instruments and parts should be ensured before commensing an overhaul, since Interruption to locate tools or parts can cause distraction and needless delay. Use of special tools will ensure a quality service.

USE OF GENUINE SPARE PARTS

Use only genuine Royal Enfield spares whenever replacing parts. Use of non genuine parts can seriously affect motorcycle performance and may result in costly rework, vehicle down time and above all customer dissatisfaction.

NOTE :

Proper service and repair is important for the safe and reliable operation of all mechanical products. The service procedures recommended and detailed in this manual will help to carry out correct repairs.

SAFETY

Every care is taken to ensure that the information given in this manual is correct at the time of going to print. However, Royal Enfield does not assume responsibility for any damage, loss or injury caused to the vehicle or to the person carrying out repairs, due to errors or omissions in this manual.

IMPORTANT NOTICE

All images shown are only for reference to explain and may not be exactly the same on the motorcycle. Technical specifications are subject to change without prior notice.

Because of changes that may occur in the manufacturing process, since this manual was printed, it is possible some instructions or illustrations found within this manual may differ from those found on the vehicle. However the technical information found within this manual is correct at the time, when it was approved for printing.

Future modifications, improvements etc will be communicated to our Authorised Distributors / Importers as and when changes are done to the motorcycle.

01-2

HOHO

W W

HOHO

W W

SERSER

SER

SERSER

Pictorial presentation of various activities, make this manual easy to understand and user friendly.

This service manual is divided into 10 Sections 01 to 10. Page numbers for each section starts with 01. Thus, page 05-10 indicates 10th page of section 5.

O USE O USE

O USE

O USE O USE

VICE MANUVICE MANU

VICE MANU

VICE MANUVICE MANU

OUROUR

OUR

OUROUR

ALAL

Engine breather System Clutch System Inlet manifold & Throttle body Blow up Charts.

SECTION FIVE 05SECTION FIVE 05

SECTION FIVE 05

SECTION FIVE 05SECTION FIVE 05 ENGINE DISMANTLINGENGINE DISMANTLING

ENGINE DISMANTLING

ENGINE DISMANTLINGENGINE DISMANTLING INSPECTION & INSPECTION &

INSPECTION &

INSPECTION & INSPECTION &

Torque Specification - Engine

ASSEMBLASSEMBL

ASSEMBL

ASSEMBLASSEMBL

The sections are subdivided into subjects and presented in the following order.

SECTION ONE O1SECTION ONE O1

SECTION ONE O1

SECTION ONE O1SECTION ONE O1 INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

The manual and its arrangements

SECTION TWO 02SECTION TWO 02

SECTION TWO 02

SECTION TWO 02SECTION TWO 02 GENERALGENERAL

GENERAL

GENERALGENERAL

Salient features of the Unit construction engine & engine management system

Four stroke cycle operation Basic terminology of automobiles Technical specifications Identification of Chassis No., Engine No., List of special tools and its applications Control cables and wiring harness routing.

SECTION THREE 03SECTION THREE 03

SECTION THREE 03

SECTION THREE 03SECTION THREE 03 SERSER

SER

SERSER

VICE DVICE D

VICE D

VICE DVICE D

Engine dismantling procedure

Vital parts - Description

Unidirectional fittings list Engine assembling procedure

SECTION SIX 06SECTION SIX 06

SECTION SIX 06

SECTION SIX 06SECTION SIX 06 ENGINE MANENGINE MAN

ENGINE MAN

ENGINE MANENGINE MAN SYSY

STEMSTEM

STEM

SYSY

STEMSTEM

Functional Diagram

Components description

Function of components

Identification of a malfunction in EMS

Do’s & Dont’s

Trouble shooting

SECTION SEVEN 07SECTION SEVEN 07

SECTION SEVEN 07

SECTION SEVEN 07SECTION SEVEN 07 WHEELS & BRAKESWHEELS & BRAKES

WHEELS & BRAKES

WHEELS & BRAKESWHEELS & BRAKES

Torque Specification - Chassis

Front wheel removal & reassembly

GEMENTGEMENT

GEMENT

GEMENTGEMENT

Service limits of components

Periodical maintenance chart

SECTION FOUR 04SECTION FOUR 04

SECTION FOUR 04

SECTION FOUR 04SECTION FOUR 04 ENGINEENGINE

ENGINE

ENGINEENGINE

Lubrication system Roller hydraulic Valve lifter (RHVL) Auto decompressor Electric starter system & sprag mechanism Auto Chain Tensioner Assembly

Disc brake

- General instruction

- Master Cylinder & Caliper overhauling

- Bleeding procedure

- Disc inspection Rear wheel removal & reassembly Rear Brake removal & reassembly

01-3

SECTION EIGHT 08SECTION EIGHT 08

SECTION EIGHT 08

SECTION EIGHT 08SECTION EIGHT 08 SUSPENSION ANDSUSPENSION AND

SUSPENSION AND

SUSPENSION ANDSUSPENSION AND STEERINGSTEERING

STEERING

STEERINGSTEERING

- Relay starter

- Starter motor

- IC Flasher

Front fork working principle

Front fork removal & reassembly

Steering stem removal & reassembly

Gas filled shock absorber

- Working principle

- Removal and assembly

- Adjustment of shock absorber

- Recharging of shock absorber

Swing Arm

- Removal

- Bush lubrication / replacement

- Reassembly

Centre Stand Removal & Reassembly

SECTION NINE 9SECTION NINE 9

SECTION NINE 9

SECTION NINE 9SECTION NINE 9 ELECTRICALSELECTRICALS

ELECTRICALS

ELECTRICALSELECTRICALS

Electrical symbols Battery

- Precautions

- Charging

- RR Unit

- TPS Unit

Electrical parts Inspection

- Clutch switch

- Starter switch

- Switch modules LH & RH

Do’s and Dont’s

Wiring Diagrams

- Ignition circuit

- Starter and charging

- Complete Wiring diagram

Trouble shooting

SECTION TEN 10SECTION TEN 10

SECTION TEN 10

SECTION TEN 10SECTION TEN 10 TRTR

OUBLE SHOOOUBLE SHOO

OUBLE SHOO

TRTR

OUBLE SHOOOUBLE SHOO

SAFETY DEFINITIONSSAFETY DEFINITIONS

SAFETY DEFINITIONS

SAFETY DEFINITIONSSAFETY DEFINITIONS

Important aspects to be noted are given as follows in the manual.

TINGTING

TING

TINGTING

- Maintenance

Spark plug maintenance & Inspecton

Checking procedure of electrical components:

- Starter coil

- Pulsar coil

- Ignition coil

- Suppressor Cap

- Battery

- Horn

NOTE

Provides important information that will have to be adhered to while carrying out repairs.

CAUTION

Indicates activities that are important to be

noted. Non-adherance may result in breakage and or functional failures of the assembly.

SPECIAL TOOLS

Contains details of the special tools and its usage, These tools have been specially designed for a specific purpose.

01-4

SECTIONSECTION

SECTION

SECTIONSECTION

TWO 02TWO 02

TWO 02

TWO 02TWO 02

GENERALGENERAL

GENERAL

GENERALGENERAL

SALIENT FEASALIENT FEA

SALIENT FEA

SALIENT FEASALIENT FEA

ENGINE & ENGINE MANENGINE & ENGINE MAN

ENGINE & ENGINE MAN

ENGINE & ENGINE MANENGINE & ENGINE MAN

TURES OF TURES OF

TURES OF

TURES OF TURES OF

THE UNIT CONSTRTHE UNIT CONSTR

THE UNIT CONSTR

THE UNIT CONSTRTHE UNIT CONSTR

GEMENT SYGEMENT SY

GEMENT SY

GEMENT SYGEMENT SY

STEMSTEM

STEM

STEMSTEM

UCTIONUCTION

UCTION

UCTIONUCTION

• HIGH TORQUE ENGINE

• ENHANCED POWER DELIVERY

• HYDRAULIC TAPPETS

• AUTO DECOMPRESSOR

• AUTO CHAIN TENSIONER FOR PRIMARY CHAIN

• HIGH CAPACITY TRACHOIDAL OIL PUMP FOR BETTER LUBRICATION

FOUR STRFOUR STR

FOUR STR

FOUR STRFOUR STR

SUCTION COMPRESSION POWER EXHAUST

STROKE

Inlet Valve Open Closed Closed Closed

OKE CYOKE CY

OKE CY

OKE CYOKE CY

STROKE STROKE STROKE

• IMPROVED ACCELERATION & HIGH SPEED CRUISING

• EXCELLENT COLD STARTING ABILITY

• ACCURATELY CONTROLLED, AIR FUEL MIXTURE & IGNITION TIMING BY THE ENGINE CONTROL UNIT

• IMPROVED PERFORMANCE AND FUEL EFFICIENCY THRO FUEL INJECTION SYSTEM.

CLE OPERACLE OPERA

CLE OPERA

CLE OPERACLE OPERA

TIONTION

TION

TIONTION

Exhaust Valve Closed Closed Closed Open

Piston Movement TDC to BDC BDC to TDC TDC to BDC BDC to TDC

Gas Flow Air Petrol Air Petrol Air petrol mixture Exhaust gas

mixture is mixture gets burns, gas

expands. flows out. drawn into compressed. Piston is cylinder Few degrees before pushed down.

BTDC, spark plug produces spark.

02-1

BASIC BASIC

BASIC

BASIC BASIC

TERMINOLTERMINOL

TERMINOL

TERMINOLTERMINOL

OGY OF OGY OF

OGY OF

OGY OF OGY OF

ENGINE :

The Engine helps to convert Chemical energy availbale in petrol into heat energy then to mechanical energy for motion. It is the heart of the vehicle in which power is generated for moving the vehicle.

BORE :

Bore is the inside diameter of the cyclinder block in which Piston moves up and down.

TDC :

TDC stands for Top Dead Center. It is the top most position to which the piston can travel in the cylinder barrel.

BDC :

AUTAUT

AUT

AUTAUT

Fuel

Air

OMOBILESOMOBILES

OMOBILES

OMOBILESOMOBILES

Power

BDC stands for Bottom Dead Center. It is the bottom most position to which the piston can travel in the cylinder barrel.

STROKE :

It is a distance travelled by piston from TDC to BDC or Vice Versa.

CUBIC CAPACITY / DISPLACEMENT :

It is a volume generated by piston when it travels from TDC to BDC. It is measured as Cubic Centimeter (CC). It can be mathematically arrived at with the radious of the piston and the stroke of the engine. (πr²× l, when ‘r’ is the radius of the piston and ‘l’ is the length of the stroke). It is also known as Swept Volume or Displacement volume.

CLEARANCE VOLUME :

It is the nominal volume of the space above the piston in the combustion chamber when piston is at the topmost position (TDC).

02-2

TOTAL VOLUME :

It is the sum of the swept voume (Displacement volume) and Clearance volume.

Total Volume = Swept volume + Clerance volume.

COMPRESSION RATIO :

It is a ratio between total volume in the engine to the clearance volume available at the end of

compression stroke.

Compression ratio =

Total volume of air fuel mixture

Clearance volume

VOLUMETRIC EFFICIENCY :

Volumetric efficiency is the ratio between the volume of air fuel mixture that actually enters the cylinder

and Swept volume.

Volumetric Efficiency

= Volume of air fuel mixture inhaled during suction stroke

Swept volume

HORSE POWER (HP OR PS) :

HP : Horse Power

PS : PFERDESTARKE is German unit of power. Horse Power is the ability of the engine to do a certain amount of work in a given time.

One Horse power is the power required for lifting a weight of 75 Kg. through vertical distance of one

meter in one second.

Conversion :

1PS = 0.986 HP = 0.735 KW 1 HP = 1.014 PS = 0.744 KW

1KW = 1.360 PS = 1.340 HP

02-3

IHP :

IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed inside the engine cylinder by combustion process. It is utilised to drive the piston.

1HP (Horse

Power Available

after explosion)

FHP :

FHP (Frictional

Losses)

FHP stands for Frictionl Horse Power.

It is the amount of horse power used or lost to overcome the friction between various engine components.

BHP :

BHP stands for Brake Horse Power

BHP (Horse

Power Avaiable at

Crankshaft)

Brake Horse Power is the amount of Power actually available at the crankshaft or output shaft. It is calculated by using dynamometer.

BHP = IHP - FHP

MECHANICAL EFFICIENCY :

Mechanical Efficiency is the ratio between Brake horsepower and Indicated horse power.

Brake horsepower = BHP Indicated Horse power IHP

TORQUE :

Torque is a twisting or turning force or effort. It is the product of a distance and force in circular motion.

In the picture shown the torque-applied is the product of distance (distance between the center of the bolt and point where force is acting) and the amount of force applied.

With the same force, if the distance is increased, the torque will also increase and if distance is reduced, torque applied will also be reduced.

CONVERSION :

1kg-m = 7.23 lb.ft = 9.81 N-m. 1lb.ft = 0.138 Kg-m = 1.356 N-m. 1 N-m = 0.102 Kg-m = 0.737 lb.ft

02-4

IGNITION TIMING :

Ignition timing is the timing at which spark commences so that the spark from the spark plug can ignite the mixture in the combusion chamber at the end of TDC during compression stroke.

If spark occurs earlier than specified ignition timing, it is called “Advance” timing.

If spark occurs after the specified ignition timing, it is called “Retard” timing.

IDLING SPEED :

It is the speed of the crankshaft (i.e. RPM) of the engine when the throttle is in closed pisition.

GEAR RATIO :

The relative rotation between “Driven Gear” and “Driving Gear” is known as the “Gear Ratio”. It is determined by number of teeth on the respective gears.

TDC Position

Ignition Timing

Position

Ignition Timing in

Degrees

Gear Ratio =

No. of teeth of Driven Gear No. of teeth of Driving Gear

In Fig. 1, the Gear ratio is 20 ÷ 10 = 2 : 1

In Fig. 2, the Gear ratio is 20 ÷ 20 = 1 : 1

Gear ratios multiply the engine torque to fulfil various demands for pulling the vehicle like.

- More effort is required during initial movement of the vehicle.

- More effort is required to climb an elevation.

- More effort is required while driving in muddy or sandy surfaces.

FINAL DRIVE RATIO :

It is a relative rotation between the engine sprocket and the sprocket on the rear wheel. Both the sprockets are connected through drive chain.

Final drive ratio further multiplies the torque available at the output shaft.

02-5

TECHNICAL SPECIFICATECHNICAL SPECIFICA

TECHNICAL SPECIFICA

TECHNICAL SPECIFICATECHNICAL SPECIFICA

TIONSTIONS

TIONS

TIONSTIONS

A. ENGINE AND ENGINE SYSTEMS

BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5)

1. Engine Type 4 Stroke Single Cylinder, Air cooled

2. Bore 84mm

3. Stroke 90mm

4. Displacement 499cc

5. Compression ratio 8.5:1

6. Max Power @ rpm 20.3 Kw @ 5250 rpm

7. Max Torque @ rpm 41.3 Nm @ 4500 rpm

8. Idle rpm 1050 ± 200 rpm

9. Starting Kick & Electric Start Electric Start

10. Air filter element Paper element

11. Lubrication Forced Lubrication, Wet Sump

12. Engine oil tank capacity 2.75 litres

13. Engine oil grade

JASO MA -15W-50, API SL Grade,

ESTER-Semi Synthetic Oil

14. Cooling Natural air flow

B. TRANSMISSION

1. Clutch Wet multiplate

2. Primary drive 3/8” Duplex chain & sprocket

3. Primary ratio 2.15 : 1

4. Gear box 5 Speed Constant Mesh

5. Overall Ratio

6. Secondary drive 5/8” Chain & Sprocket

3.063 : 1

2.013 : 1

1.522 : 1

1.212 : 1

1 : 1

7. Secondary ratio 2.235 : 1 2.11:1

8. Drive Chain links 101 Pitch 102 Pitch

02-6

C. CHASSIS

BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5)

1. Frame Tubular

2. Front Suspension Telescopic, hydraulic damping, Stroke 130 mm

3. Rear Suspension Swing arm with gas shock absorbers

4. Fr. Fork oil capacity 265 cc + 2.5 cc / each leg

5. Front fork oil SAE 10W -30

6. Front Brake Hydraulic, Hand operated, 280 mm dia ventilated disc

7. Rear Brake Mechanical, Foot operated, 153 mm internal expanding

8. Brake Oil Capacity 60 ml

9. Brake Oil Grade DOT 3 or DOT 4

10. Tyre size : Front 90X90 - 19” - 51V 90X90 - 18” 51V

3.25X19

Rear 100/90 - 19” - 57V 110/80-18” - 58V

3.5X90

D. TYRE PRESSURE

1. Solo : Front 18 PSI

Rear 28 PSI

2. With Pillion : Front 20 PSI

Rear 30 PSI

3. Steering lock In built

4. Fuel tank capacity 14.5 ±1 litres

5. Reserve 2.75 litres

E. ELECTRICALS

1. Generation Alternator

2. System 12V - DC

3. Battery 12V - 14 AH

4. Spark plug Mico - WR7 DDC 4

5. Spark plug gap 0.7 to 0.8 mm

6. Head lamp 12V, 60/55w

02-7

BULLET ELECTRA EFI (E5) BULLET CLASSIC EFI BULLET EFI (G5) (C5)

7. Tail / Brake Lamp 12V 5 / 21W

8. Speedometer lamp 12V, 3.4W

9. Hi beam indicator 12V, 2W

10. Neutral lamp Tell tale 12V, 2W

11. Turn Signal Tell Tale 12V, 2W

12. Turn signal 12V, 10W

13. Horn 12V DC

F. WEIGHTS

1. Mass of Vehicle in running order 187 Kg.

2. Max pay load 178 Kgs.

3. Max technical permissible mass 365 Kg.

G. DIMENSIONS

1. Length 2200 mm 2160 mm

2. Width 800 mm

3. Height 1100 mm 1050 mm

4. Wheel base 1370 mm

5. Ground clearance 140 mm

6. Saddle height 820 mm 800 mm

H. PERFORMANCE

1. Max. speed 132 Kmph (83 Miles)

NOTE :

1. Values given above are for your guidelines only

2. In view of continuous improvements, specifications are likely to change without notice

02-8

IDENTIFICAIDENTIFICA

IDENTIFICA

IDENTIFICAIDENTIFICA

TION OF CHASSIS NOTION OF CHASSIS NO

TION OF CHASSIS NO

TION OF CHASSIS NOTION OF CHASSIS NO

.,.,

ENGINE NO ENGINE NO

ENGINE NO

.,.,

ENGINE NO ENGINE NO

CHASSIS NO.

ENGINENO.

02-9

LIST OF SPECIAL LIST OF SPECIAL

LIST OF SPECIAL

LIST OF SPECIAL LIST OF SPECIAL

ST 25128-2

Magneto Puller for TCI

OOLS OOLS

OOLS

OOLS OOLS

Application : Removal of magneto assembly

AND ITS AND ITS

AND ITS

AND ITS AND ITS

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

TIONTION

TION

TIONTION

ST 25151-4

Chain case outer puller (TCI)

ST-25594-4

Clutch spring assy.

Application :To remove Crank case LH cover

Application : To compress clutch springs while removing & refitting Clutch plates.

02-10

LIST OF SPECIAL LIST OF SPECIAL

LIST OF SPECIAL

LIST OF SPECIAL LIST OF SPECIAL

ST-25591-4

Clutch centre nut

OOLS OOLS

OOLS

OOLS OOLS

Application : To hold Clutch Sprocket while removing / tightening the Clutch & Sprag Sprocket Nut.

AND ITS AND ITS

AND ITS

AND ITS AND ITS

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

TIONTION

TION

TIONTION

Oil seal adopter

ST 25118-4

Cylinder head nut tightening tool

Application : Fitment of gear shaft oil seal on crank case

LH cover.

Application : To remove and tightening of cylinder

head nut.

02-11

LIST OF SPECIAL LIST OF SPECIAL

LIST OF SPECIAL

LIST OF SPECIAL LIST OF SPECIAL

ST 25123-1

Valve Spring compressor

OOLS OOLS

OOLS

OOLS OOLS

Application : To compress the valve spring for removal

AND ITS AND ITS

AND ITS

AND ITS AND ITS

and fitting of valve.

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

TIONTION

TION

TIONTION

ST 25153-4

Extractor for 5 Speed Gear box Pivot Pin

ST 25

FD sprocket removal tool

Application : To remove Gear Rocker Shaft top pivot pin and Gear

Cam Plate pivot pin.

Application : To remove front drive sprocket

from Sleeve Gear.

02-12

LIST OF SPECIAL LIST OF SPECIAL

LIST OF SPECIAL

LIST OF SPECIAL LIST OF SPECIAL

Front fork main tube spanner

OOLS OOLS

OOLS

OOLS OOLS

Application : Loosening and tightening of front fork main

AND ITS AND ITS

AND ITS

AND ITS AND ITS

tube with fork end

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

TIONTION

TION

TIONTION

ST 25112-4

Expander for front fork oil seal

ST 25114-4

Extractor for Fork oil seal

Application : Expander for oil seal while inserting main

tube into bottom tube of front fork

Application : Removal of oil seal in front fork bottom tube

02-13

LIST OF SPECIAL LIST OF SPECIAL

LIST OF SPECIAL

LIST OF SPECIAL LIST OF SPECIAL

ST 25113-4

Mandrel for oil seal

OOLS OOLS

OOLS

OOLS OOLS

Application : Fitment of oil seal in front fork bottom tube

AND ITS AND ITS

AND ITS

AND ITS AND ITS

APPLICAAPPLICA

APPLICA

APPLICAAPPLICA

TIONTION

TION

TIONTION

ST 25110-3

Gauge for tightening chain stay

ST 25244-4

Adjuster Special Spanner

Application : Alignment of Swing Arm while tightening

Application :To adjust gas filled shock absorber

02-14

CONTROL CABLES AND WIRING HARNESS ROUTINGCONTROL CABLES AND WIRING HARNESS ROUTING

CONTROL CABLES AND WIRING HARNESS ROUTING

CONTROL CABLES AND WIRING HARNESS ROUTINGCONTROL CABLES AND WIRING HARNESS ROUTING

ALL CONTROL CABLES & WIRING HARNESS ROUTING

UNDER TANK AND SEAT TOP VIEW

UNDER TANK LH VIEW

UNDER TANK RH VIEW

02-15

GENERAL GENERAL

GENERAL

GENERAL GENERAL

VEHICLE INFORMAVEHICLE INFORMA

VEHICLE INFORMA

VEHICLE INFORMAVEHICLE INFORMA

TIONTION

TION

TIONTION

HARNESS ROUTING STEERING RH

PLUG WIRE ROUTING

MAGNETO WIRES ROUTING

STARTER RELAY CABLE ROUTING

02-16

GENERAL GENERAL

GENERAL

GENERAL GENERAL

VEHICLE INFORMAVEHICLE INFORMA

VEHICLE INFORMA

VEHICLE INFORMAVEHICLE INFORMA

TIONTION

TION

TIONTION

FUSE CARRIERS ARRANGEMENT (E5 & G5)

FUSE CARRIERS ARRANGEMENT (C5)

HORN WIRE ROUTING

HANDLE BAR WIRES ROUTING

02-17

GENERAL GENERAL

GENERAL

GENERAL GENERAL

VEHICLE INFORMAVEHICLE INFORMA

VEHICLE INFORMA

VEHICLE INFORMAVEHICLE INFORMA

TIONTION

TION

TIONTION

TAIL LAMP & TRAFFICATOR WIRES ROUTING

ECU MOUNTING BULLET ELECTRA EFI (E5 & G5)

THROTTLE BODY MOUNTING WITH CABLES

ECU MOUNTING BULLET CLASSIC EFI (C5)

02-18

SECTIONSECTION

SECTION

SECTIONSECTION

THREE 03THREE 03

THREE 03

THREE 03THREE 03

SERVICE DSERVICE D

SERVICE D

SERVICE DSERVICE D

SERSER

SER

SERSER

VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS

VICE LIMITS OF COMPONENTS (All units in mm unless specified)

VICE LIMITS OF COMPONENTS VICE LIMITS OF COMPONENTS

WEAR LIMITS

Wear limits are given as new min, new max and service limits.

New components must be within the limits specified. Components within service limits may be reused after careful inspection. Use of parts beyond service limit can reduce the operating life of the component and may affect the motorcycle performance seriously.

Cylinder bore

New Min.

New Max.

Service Limit

Cylinder bore :

Point of measurement

B C

84.045

84.075

84.190

Piston

Ring to groove clearance : Comp. Top rings

New Min.

New Max.

Service Limit

Ring to groove clearance comp rings - Middle

0.03

0.07

0.11

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

83.940

83.970

83.890

Piston to bore clearance

0.095

0.115

0.30

New Min.

New Max.

Service Limit

Ring to groove clearance : oil ring

New Min.

New Max.

Service Limit

0.03

0.07

0.15

0.06

0.15

0.21

03-1

Piston ring end gap : compression

From top 1st 2nd New Min. 0.20 0.35 New Max. 0.35 0.50 Service Limit 0.70 0.85

New Min.

New Max.

Service Limit

Piston Pin diameter

19.992

19.997

19.982

New Min.

New Max.

Service Limit

Piston ring end gap - Oil Ring

0.20

0.70

0.90

Small end bore inner diameter

New Min.

New Max.

Service Limit

Big end axial play

0.20

0.55

0.65

Crank shaft : Run out

New Min.

New Max.

Service Limit

20.007

20.016

20.046

New Min.

New Max.

Service Limit

0.00

0.04

0.08

03-2

Connecting rod bend

Valve stem OD (Inlet)

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

0.00

0.05

0.08

Cylinder Head warpage

0.00

0.05

0.07

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

6.965

6.980

6.955

Valve to guide (inlet) clearance

0.02

0.05

0.08

New Min.

New Max.

Service Limit

Valve guide bore

7.00

7.015

7.25

New Min.

New Max.

Service Limit

Valve stem OD (Exhaust)

6.945

6.960

6.935

03-3

Valve to guide (Exhaust) Clearance

Hydraulic Tappet OD

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

0.04

0.07

1.00

Valve Spring : length

42.80

44.80

41.50

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

21.387

21.405

21.380

Hydraulic Tappet guide bore

21.417

21.438

21.450

New Min.

New Max.

Service Limit

Push rod run out

0.00

0.02

0.05

Hydraulic tappet to guide clearance

New Min.

New Max.

Service Limit

0.012

0.051

0.060

03-4

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