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Bullet EFI
Service Manual
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Royal Enfield Bullet EFI, Bullet Classic EFI, Continental GT Service Manual

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EURO IV - VEHICLE SERVICE MANUAL
Continental GT
Bullet EFI
Classic Bullet EFI
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1
PREFACE
“FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction.
Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy trouble free performance at all times.
This Maintenance and service manual is specifically for the following EURO IV Regulation models being currently sold only in UK & European countries.
BULLET EFI
BULLET CLASSIC EFI
CONTINENTAL GT
This Manual is intended for use primarily by a person who is well versed with basic repair technique of a motorcycle & usage of general purpose tools and special service tools & diagnostic tools, while basic & routine service maintenance may be in the event of not having possibility in carrying out using basic tools, required tools it is recommended that the motorcycle may please be get inspected and serviced through an Authorized Royal Enfield Service Station.
This manual will help in guide in the basic servicing, periodical maintenance, systematic disassembly, Parts inspection and assembling procedures of various mechanisms / systems of the motorcycle which has to be carried out in Royal Enfield Authorised Dealership or Service Station.
While this manual is updated with latest Information and Specifications, at the time of going to print, due to continuous improvements being done to improve performance, some of the data, illustrations etc., in this manual may differ from the actual parts fitted in the engine.
Subsequent & continuous improvement that may be done on the motorcycles to enhance customer satisfaction, will be uploaded also in the RMI portals & also available with Royal Enfield Authorised dealer & Service Station.
Please do feel free to write to us at support@royalenfield.com, if you have any queries, clarification, suggestions or feedback.
With warm regards
SERVICE HEAD QUARTERS Royal Enfield, A Unit of Eicher Motors Limited, Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. E-mail: Support@royalenfield.com Website: www.royalenfield.com
Part No: 888569 / Feb. ’17
01
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ROYAL ENFIELD VE HICLE SERVICE MANUAL - EURO IV
2
EURO IV BIKES – VEHICLE VIEWS
ROYAL ENFIELD VE HICLE SERVICE MANUAL - EURO IV
02
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TABLE OF CONTENTS
SL.NO. DESCRIPTION PG.NO.
SL.NO. DESCRIPTION PG.NO.
03
1. Technical Specifications ............................................ 4
2. Periodical Maintenance ............................................. 6
3. Special Tools Usage List ............................................. 8
4. Engine Removal from Frame ..................................... 9
5. Vehicle Aggregagetes
5.1 Cables ............................................................... 11
5.2 Airfilter Paper Element .................................. 16
5.3 Fuel Tank .......................................................... 23
5.4 Seat Assembly ................................................. 30
5.5 Exahust Pipe & Silencer ................................. 39
6. Front Suspension
6.1 Front Wheel ..................................................... 46
6.2 Front Mudguard .............................................. 54
6.3 Handle Bar ....................................................... 60
6.3 Front Fork ........................................................ 70
6.4 Steering Stem .................................................. 87
7. Rear Suspension
7.1 Rear Wheel ....................................................... 103
7.2 Rer Sprocket / Drive Chain Adjustment ....... 111
7.3 Rear Shockers .................................................. 113
7.4 Rear Mudguard / Rear Number Plate ........... 119
7.5 Swing Arm ........................................................ 126
8. ABS ........................................................................... 133
9. EVAP ........................................................................... 167
10. EM S ........................................................................... 174
11. NACS II DIAGNOSIS ..................................................... 213
12. Electricals
12.1 Battery .............................................................. 233
12.2 Bulbs ................................................................. 239
12.3 Electrical Components ................................... 261
12.4 Wiring Diagram ............................................... 277
13. Trouble Shooting ........................................................286
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SECTION 01 - TECHNICAL SPECIFICATION
TECH SPEC POINT
BULLET
CLASSIC EFI
CONTINENTAL GT
BULLET EFI
04
ENGINE
Engine 4 Stroke, air cooled, single cylinder 4 Stroke, air cooled, single cyl., OHV, SI Capacity 499 cc (Displacement) 535 cc Bore 84 mm 87 mm Stroke 90 mm 90 mm
Compression ratio 8.5 : 1 8.5 : 1 Max. Power @ RPM 20.3 Kw @ 5250 RPM 21.4 kw @ 5100 RPM Max. Torque @ RPM 41.3 Nm @ 4000 RPM 44 Nm @ 4000 RPM Air filter Element Paper Element Paper Element Lubrication Forced Lubrication, Wet Sump Forced Lubrication, Wet Sump Fuel Supply Electronic Fuel Injection Electronic Fuel Injection
IGNITION SYSTEM
Ignition system Digital Electronic Ignition Electronic Ignition Spark plug gap 0.8 mm 0.8 - 0.9 mm Spark plug WQR8DC (Bosch) WQR8DC (Bosch)
TRANSMISSION
Clutch Wet Multiplate Wet Multiplate (7 Plates) Drive Chain links 102 pitch 101 pitch 101 Pitch Primary drive Duplex Chain drive 3/8” pitch Duplex Chain Gear box 5 Speed Constant Mesh Constant Mesh 5 Speed
Gear Ratios
I - 3.063 : 1 I - 3.063 : 1
II - 2.013 : 1 II - 2.013 : 1 III - 1.522 : 1 III - 1.522 : 1 IV - 1.212 : 1 IV - 1.212 : 1
V - 1.000 : 1 V - 1.000 : 1 Primary Drive Ratio 2.15 : 1 2.15 : 1 Secondary Drive Chain Drive 18 Teeth (F.D. Sprocket) Secondary ratio 2.235:1 2.12:1
ELECTRICALS
Generation Alternator Alternator System 12V DC 12V DC Battery 12V - 14 AH 12V - 14 AH Head lamp 12V, 60/55 W 12V, 60/55 W, Halogen Bulb Tail / Brake lamp 12V, 5/21 W 5/21 W Turn signal 12V, 10W X 2 Nos. 12V, 10W X 4 Nos. Pilot lamp 12V, 2 W X 2 Nos. / 12V, 4 W X 1 No. NA Instrument Cluster NA Digital instrument Cluster with LCD High beam indicator NA 12V, 0.2W (LED) Neutral Indicator NA 12V, 1.12W Horn 12V, 2.5 Amp (Max.) 12V, 2.5A (Dual tone-LT, HT) Starter Motor NA 12V, 0.9 KW
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Values / Dimensions mentioned above are for reference only.In view of continuous improvements being done on our motorcycles, the specifications are subject to change
without prior notice.
CHASSIS
Frame Tubular Frame Tubular steel double cradle Tyre size
Fr : 90 / 90-19”-52 V 3.25 X 19” 110/90-18 M/C 56H
Rr : 110 / 80-18”-58 V 3.50 x 19" 130/70-18 M/C 63H
Tyre pressure
Front-Solo: 18 PSI Front- Solo:1.41 Kg/cm2 (20 PSI)
Pillion: 20 PSI Pillion:1.55 Kg/cm2 (22 PSI)
Rear-Solo: 28 PSI Rear- Solo:2.11 Kg/cm2 (30 PSI)
Pillion: 30 PSI Pillion:2.25 Kg/cm2 (32 PSI)
Fuel tank capacity 14.5 + 1 Litres 13.5 Litres***
Suspension
Front: Telescopic, Hydraulic Damping Front:Telescopic, Stroke 110mm
stroke 110 mm
Rear: Swing arm with gas filled shockabsorbers
Rear:Twin - Gas Charged,
with adjustable 5 step spring tension load. Stroke 80 mm Front fork oil capacity 430 ml per leg 430 ml per leg Front fork oil Gabriel Fork Oil 2W 35 Gabriel Fork Oil 2W 35
Hydraulic Disc Brakes Front & Rear Hydraulic Disc Brakes Front & Rear
with ABS System with ABS System
Brakes Front: 300 mm dia disc with twin Front:300 mm dia floating disc,
piston caliper twin piston floating caliper
Rear: 240 mm dia disc with single piston & Rear:240mm dia disc, single piston
floating caliper floating caliper Brake oil grade DOT 4 or above DOT 4 or above Brake oil capacity Front:60 ml Rear: 100 ml Front:50 ml Rear: 100 ml Speedometer lamp 12V, 3.4 W X 1 No. NA Turn signal /
12V, 1.7 W each NA
High beam indicator Neutral Indicator 12V, 1.7 W X 1 No. NA
DIMENSIONS
Length 2140 mm 2060 mm Width 800 mm 760 mm Height 1080 mm 1070 mm Wheel base 1360 mm 1360 mm Saddle height 805 mm 790mm 810 mm Ground clearance 140 mm 140 mm
WEIGHTS
Mass of motorcycle in running order 270 Kg 267 Kg Max pay load 95 Kg 98 Kg Max technical permissible mass 365 Kg 365 Kg
PERFORMANCE
Maximum Speed 128 kmph 137 Kmph
TECH SPEC POINT
BULLET
CLASSIC EFI
CONTINENTAL GT
BULLET EFI
05
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The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the Intervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your motorcycle meticulously.
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice.
A : Ad just C : Cle an D : De-carboni se I : Inspec t L : Lubri cate R : Replace
S. No.
DESCRIPTION
SCHEDULE
SECTION 02 - PERIODICAL MAINTENANCE
NOTE :
For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in consultation with a Royal Enfield Authorized Dealer.
BULLET CLASSIC EFI & BULLET EFI
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
1 Engine Oil
R R R R R R
Check level every 500 Kms or earlier as required 2 Engine oil filter element R R R R R R 3 Engine sump filter (oil strainer) C C C C C C
4
Magnetic drain plug under gear box and secondary C C C C C C
drain plug under crankshaft in crankcase right 5 Spark plug A A A A A R A A A A R 6 HT lead I I I I I I I I I I I 7 Fuel hose I I I I R I I I R I I 8 Fuel Pump Check for screw tightness in all services 9 Accelerator cable play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold / Adaptor I I I I R I I I R I I 12 Airfilter paper element C C C C R C C C R C C 13 Inlet/Exhaust valve seating (compression/vaccum test) I I
14 Cylinder head D
15 Exhaust system D
16 Clutch free play Adjust every 1000 Kms or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L 18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C 19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet (behind battery carrier) I I
21 Rear Wheel Drive Chain
Lubricate & Adjust every 1000 Kms/Clean, Lubricate &
Adjust every 3000 Kms or earlier as required 22 Front Fork oil R R R 23 Rear brake play Adjust every 1000 Kms or earlier as required
24 Rear brake cams L L L L L
25 Steering ball races play I A L A L A L A R A L
26 Spokes tightness / Wheel rim run out front & rear I I I I I I
27 Pivot-Side Stand, Center Stand, Pillion Foot Rest L L L L L L L L L L L
28 Tyre wear pattern (Front & Rear) I I I I I I I I I I I 29 Hand levers pivot Lubricate every 1000 Kms or earlier as required 30 Front Disc Brake Oil level check I I I I I R I I I I R
31 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I
06
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CONTINENTAL GT
The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the Intervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your motorcycle meticulously.
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice.
A : Ad just C : Cle an D : De-carboni se I : Inspec t L : Lubri cate R : Replace
NOTE :
For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in consultation with a Royal Enfield Authorized Dealer.
S. No.
DESCRIPTION
SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
1 Engine Oil
R R R R R R
Check level every 500 Kms or earlier as required 2 Engine oil filter R R R R R R 3 Engine sump filter C C C C C C 4 Magnetic drain plug under gear box on crankcase right C C C C C C 5 Spark plug C&A C&A C&A C&A C&A R C&A C&A C&A C&A R 6 HT lead I I I I I I I I I I I 7 Fuel hose I I I I R I I I R I I 8 Fuel Pump Check for screw tightness in all services 9 Accelerator cable play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold I I I I R I I I R I I 12 Airfilter element C C C C R C C C R C C 13 Inlet / Exhaust valve seating I
14 Cylinder head D
15 Exhaust pipe D
16 Clutch free play Adjust every 1000 Kms (600 Miles) or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L 18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C 19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet contact I I
21 Rear Chain
Adjust every 1000 Kms (600 Miles) or earlier as required
Lubricate every 3000 Kms (1800 Miles) or earlier as required 22 Fork oil R R 23 Steering ball races A L A L A
24 Spokes tightness I I I I I I
25 Wheel rim run out I I I I I
26 Tyre wear I I I I I I I I I I
27 Hand levers & Kick starter pivot Lubricate every 1000 Kms or earlier as required
28 Brake Oil level check / Replacement I I I I I I I R I I I 29 Pivot-Side Stand L L L L L L L L L L L 30 Center Stand pivot L L L L L L L L L L L
31 Pillion Foot rest pivot L L L L L L L L L L L
32 Swing arm bearings L L
31 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I
07
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SECTION 03 - SPECIAL TOOLS USAGE LIST
ST-25834-2
Front fork Dismantling tool To hold pipe seat of front fork while
dismantling & tightening of front fork main tube with bottom case (fork end assy.).
ST-2511 4-4 Extractor for fork oil seal
To remove oil seal in front fork bottom case.
ST-2511 3-4 Mandrel for oil seal
Fitment of oil seal into front fork bottom case.
ST-2511 2-4 Expander for front fork Oil
Expanding the oil seal lip while
seal inserting main tube into bottom case
of front fork
ST-25110-3 Gauge plate for tightening
Alignment of Swing Arm while
chain stay mounting tightening into chassis.
ST-25244-4 Special spanner adjuster To adjust gas filled shockabsorber
spring load.
ST-25833-4 Front Fork Tool 1/2 SD To Loosen and tightening of front fork
assembly from the head lamp casing.
ST-26461-2 Front Fork Assembling & To hold pipe seat of front fork while
Dismantling Tool dismantling & tightening of front fork
main tube with bottom tube (fork end).
ST-26485-3 Front Fork Oil Seal Driver Fitment of slide bush and fork oil seal
(Dia 41mm) into front fork bottom case.
PART NO. DESCRIPTION PHOTOS APPLICATION
08
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SECTION 04 - ENGINE REMOVAL FROM FRAME
09
Bullet Classic EFI / Bullet EFI / Continental GT
Disconnect alternator leads. Disconnect the spark plug suppressor cap. Disconnect the fuel pipe. Remove throttle body along with throttle cable. Remove the air filter assy. Remove the exhaust pipe and silencer. Disconnect the engine steady bolt. Remove the rear chain. Remove the LH Foot rest. Support the engine on a suitable box or wooden block. Remove the center stand and the stand stop. Remove the front engine plates and the small bolt fixing the stand spring bracket. Remove the stud securing the rear engine plate to the frame Slide out the engine.
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SECTION 05 - VEHICLE AGGREGATES
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SECTION 5.1 CABLES
1
2 3
S. NO.
DESCRIPTION
QTY.
1 Throttle Cable Assembly (Twin Cable) 1
2 BI Starter Cable 1
3 Clutch Cable Assembly 1
EXPLODED VIEWS
BULLET CLASSIC EFI / BULLET EFI / CONTINENTAL GT
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S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
5.1 Clutch Cable
Assembly Bullet Classic EFI/
Bullet EFI/ Continental GT
Dismantling
5.1 Throttle Cable
Assembly (Twin Cable)
Bullet Classic EFI/ Bullet EFI/ Continental GT
Dismantling
Slacken the adjusters at
the throttle body end for both cables.
Gently remove t he
Throttle cable assembly.
Slacken the adjuster at
the clutch cover end and disconnect t he cable from the lever.
Gently pull out part of
the clutch cable from the cover.
Remove the clutch cable
from the clutch lever at handle bar end.
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S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
5.1 Bi Starter Cable
Bullet Classic EFI/ Bullet EFI/ Continental GT
Dismantling
Slacken the adjuster at
the Bi starter cable end and disconnect the cable from the lever.
Gently pull out the part
of Bi starter cable.
Remove the Bi starter
cable from the clutch lever at handle bar end.
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S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
5.1 Clutch Cable
Assembly Bullet Classic EFI/ Bullet EFI/ Continental GT Assembling
5.1 Throttle Cable
Assembly (Twin Cable)
Bullet Classic EFI/ Bullet EFI/ Continental GT
Assembling
Locate the clutch cable in
clutch lever at handle bar end.
Loca te pa rt of clutch
cable in the cover.
Slacken the adjuster at
the clutch cover end and Connect the cable in the lever.
Loca te the Throttle
cable assembly.
Slacken the adjusters at
the throttle body end for both cables.
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S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
5.1 Bi Starter Cable
Bullet Classic EFI/ Bullet EFI/ Continental GT
Assembling
Loca te the Bi start er
cable in the clutch lever at handle bar end.
Loca te the pa rt of Bi
starter cable.
Slacken the adjuster at
the Bi starter cable end and Connect the cable in the lever.
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EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
SECTION 5.2 - AIR FILTER PAPER ELEMENT
4
20
19
18
3
2
11
5
6
7
5
6
7
1
16
11
12
13
14
15
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Air Filter Box Assembly with sticker 1 2 Air filter element 500cc 1 3 Cover Filter element 1 4 Hex Nylock Nut M8X9.5 1 5 Hex Screw M6 X 14 2 6 Lock Washer M6 3 7 Plain Washer M6 1 8 Plain Washer M6 1 9 Hex Nut M6 X 1 X 7 1 10 Hex.Bolt M6 X 1 X 12 1
11 Inlet Bellow 1 12 Clip Hose - Inlet Bellow 1 13 Hexagon Socket Head Cap screw-M5X.8X20 2 14 TA Sensor 1 15 Gasket - Air Temp Sensor 1 16 Rubber Tube - Air Filter 1 17 Beading Box Cover 1 18 Beading Cover Air Filter 1 19 Cover Assembly - Air (Plastic) 1 20 Washer - Cover M10 1
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1
11
10
9
8
8
8
8
6
7
2
3
A1
4
5
CONTINENTAL GT
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Air Filter Box 1
2 Clamp 1
3 Pipe Outlet 1
4 TA Sensor 1
5 Hex Socket Head Cap Screw M5 X 16 2
6 Drain Pipe 1
7 Clip 1
8 Pan Head Screw M5 X 12 4
9 Inlet Cover 1
10 Seal 1
11 Element Air Filter 1
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5.2 Air Filter Element
Bullet Classic EFI/ Bullet EFI
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
S.
No.
Hex Nyloc Nut M8
Loosen hex Nylock nut
Gently pull out the cover
assembly.
Re move cover filter
element.
Remove the Air filter
Element.
Un lock and open the
Filter box RH.
CAUTION:
Ensure the pillion footrest is in extended pos ition to avoid damage to filter box lid
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S.
No.
5.2 Air Filter Element
Continental GT
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
Pan Head Screw M5 X 12 Screw Driver
NOTE:
Remove rubber seal from the cover.
Pan Head Screw M5 X 1 Screw Driver
CAUTION:
Ensure Purge valve is placed safely to preven t from damage.
Remove airfilter element
from the housing.
Remove the side panel
from the frame.
Remove the 4 pan head
scre ws on the airfilter cover.
Loosen and remove the
pan head screw in side panel RH bottom.
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CAUTION :
Do not wash filter element using water, gasoline or any solvents as it will damage the paper element.
INSPECTION
Inspect air filter element carefully for any deformation, damages, heavily clogged with dirt, soggy condition, and
/ or foreign particles embedded in the element. Replace if any of these conditions are observed.
Inspect rubber seals, hoses, for cuts, cracks, damages. Replace seals and rubber parts whenever the induction
system is serviced.
FOR CONTINENTAL GT MODELS
Inspect air filter housing and cover forany damages, cracks etc and replace entire assembly if damaged.
CLEANING
Gently Tap filter element with minimum force to dislodge heavy / embedded dust particles.Using low pressure compressed air :
- blow air from INSIDE to OUTSIDE for Bullet EFI, Bullet Classic EFI Models.
- blow air from OUTSIDE to INSIDE for Continental GT Models. to remove the fine dust particles. DO NOT WASH THE ELEMENT IN WATER, GASOLINE OR ANY SOLVENTS.
Clean Airfilter element every 3,000 Kms OR more frequently if motorcycle is used in dusty / Off road conditions.Clean the airfilter housing internals, retainer plate etc, with a soft damp cloth to remove the dust.
REPLACE
All ‘O’ rings, rubber beadings, seals, gaskets, rubber parts etc, whenever the airfilter assembly is serviced.Airfilter element evedry 12,000 Kms (7,500 Miles) or earlier if motorcycle isused in dusty / Off road conditions.
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5.2 Air Filter Element
Bullet Classic EFI/ Bullet EFI
Loca te the Air filte r
element inside filter box RH.
Loca te Cove r filter
element over filter element.
Ensure rubbe r rin g is
located in plastic cover assembly.
Loca te Plastic cover
assembly over air filter element in filter box RH.
Position washer on the
mounting stud.
Locate nyloc nut on stud
and tighten sufficiently till it is completely resting on the washer and resi stan ce to tighten further is felt.
Ensure beading is
correctly located on the filter box lid.
Close filter box lid and
lock in place.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Nyloc Nut M8
CAUTION:
Ensure the pillion footrest is in extended position to avoid damage to filter box lid.
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S.
No.
5.2 Air Filter Element
Continental GT
Locate Filter inside air
filter box.
Ensure rubbe r rin g is
correctly seated in the cover air filter.
Ensure cover air filter is
located properly on the filter box and the cover is correctly located at the mounting peg in the housing.
In stal l the 4 pan head
screws on the cover and tighten evenly.
Ensure the rubber
grommets are in place in the side panel RH. Locate side panel RH in the frame, ensuing the pegs in the frame are seated in the grommets.
Tighten the RH side
pane l at the bottom using pan head screw.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Pan Head Screw M5 X 12 Allen Key 4mm
Pan Head Screw M5 X 12 Allen Key 4mm
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16
15
14
13
11
19
18
9
8
7
6
5
4
3
2
1
17
17
12
11
10
11
10
12
12
10
10
12
11
11
12
20
10
SECTION 5.3 - FUEL TANK ASSEMBLY
EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Fuel Tank With Sticker - Black 1 2 Cap-Fuel Tank 1 3 Thigh Pad R H 1 4 Flanged Hex Bolt M6X1X27 2 5 Washer-Tank 2 6 Sleeve-Tank Mtg Rear 2 7 Rear Damper-Tank 2 8 Thigh Pad L H 1 9 PA Tube Assembly 1 10 Hex Socket Button Head Cap Screw M6X12 5
11 Washer 5 12 Washer 5 13 Clamp Plate - Fuel Pump 1 14 Fuel Pump 1 15 O Ring 1 16 Low Fuel Sensor 1 17 Front Damper-Tank 2 18 Quick Connector 1 19 Fuel Hose (Pa Tube) 1 20 Cap,Injector 1
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CONTINENTAL GT
19
18
20
12
11
10
10
11
13
13
10
10
13
13
11
10
11
9
8
7
6
14
15
15
14
16
17
3
4
5
4
5
2
1
3
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Cap-Fuel Tank 1 2 Fuel Tank Assy With Sticker (Red) 1 3 Front Damper-Tank 2 4 Flanged Hex Bolt M6 X 1 X 27 2 5 Bush - Fuel Tank 2 6 Rear Damper-Tank 2 7 O Ring 1 8 Fuel Pump 1 9 Clamp Plate - Fuel Pump 1 10 Washer 5
11 Washer 5 12 Fuel Hose Assembly 1 13 Hex Socket Head Cap Screw M6 X 16 5 14 Hex Screw M6 X 12 4 15 Punched Washer-Fuel Gauge Mtg 4 16 Fuel Gauge Unit 1 17 O’ Ring-Fuel Gauge 1 18 Quick Connector 1 19 Fuel Hose (PA Tube) 1 20 Cap, Injector 1
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5.3 Fuel tank -
Dismantling Bullet Classic EFI/
Bullet EFI
Remove Seat Assembly.Disconn ect f uel hose
from the Fuel tank.
Remove 2 Hex bolts from
the rear end of fuel tank along with washers,seals and rear dampers.
Ensure the handle bar is
held at stra ight ahead position.
Place a piece of cloth
betw een handle bar clamp bolt and fuel tank.
Gently lift up fuel tank at
the rear end to:
- Disconnect low fuel sensor coupler.
- Discon nect EVAP hose from the Fuel tank.
Slide fuel tank towards
rear to release fron t locking clamp from the rubber supports in frame.
Remove fuel tank from
frame carefully.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
CAUTION:
Drain the fuel completely from the fuel tank.
S.
No.
Hex Flange Bolt M6 Socket Spanner 10 mm
CAUTION:
Do not lift tank too high to
- Pr even t accidental damage to the fron t end of the fuel tank.
- Prevent damage to low fuel sensor coupler
- Prevent damage to EVAP hose
CAUTION:
Ensure Ignition switch and Kill switch is in OFF Position before disconnecting hose from fuel ta nk or before draining the fuel.
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26
5.3 Fuel tank ­Dismantling
Continental GT
Remove Seat Assembly.Disconn ect f uel hose
from the Fuel tan k by removing the quick connector from the fuel pump end
Remove 2 Hex bolts from
the rear end of fuel tank.
Ensure the handle bar is
held at stra ight ahead position.
Place a piece of cloth at
the front end of the fuel tank to prevent damage whil e lifting a nd removing tank.
Gently lift up fuel tank at
the rear end to:
- Disconnect low fuel sensor coupler.
- Discon nect EVAP hose from the Fuel tank.
Slide fuel tank onwards
rear to release fron t locking clamp from the rubber supports in frame. Remove tank from frame carefully.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
CAUTION:
Drain the fuel completely from the fuel tank.
S.
No.
Hex Flange Bolt M6 Socket Spanner 10 mm
CAUTION:
Do not lift tank too high to
- Pr even t accidental damage to the fron t end of the fuel tank.
- Prevent damage to low fuel sensor coupler.
- Prevent damage to EVAP hose.
CAUTION:
Ensure Ignition switch and Kill switch is in OFF Position before disconnecting hose from fuel tank or before draining the fuel.
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27
INSPECTION
Carefully inspect fuel hose and vent hose for damage, cuts, cracks or general deterioration. Replace if necessary.
WARNING
Gasoline is extremely flammable and highly explosive, which could result in serious injury.Do not smoke or allow open flame or sparks in the vicinity.Store the fuel carefully to avoid spillage.
Aggregate Component Fastener
Torque Range
NM Kg-M
Fuel Tank Fuel tank Mounting Flanged hex bolt M6 * 30 5 0.5
TORQUE CHART
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28
5.3 Fuel tank ­Assembly
Bullet Classic EFI/ Bullet EFI
Ensure t he handle bar is held at straight ahead position.
Position fuel tank on
frame such that the front mounting locate on the rubber supports in the frame.
Gently lift up fuel tank at
the end to:
- Con nect low fuel sensor coupler wire.
- Connect EVAP hose to the Fuel tank.
Connect fuel hose to the
fuel tank.
Ensure the two dampers
and mounting sleeves are properly located in the mounting slots.
Ensure the mounting
are aligne d and asse mble 2 h ex bolts with large washers.
Tighten the two bol ts
evenly.
Assemble Seat.Fill fuel in the tank.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Place a piece of cloth on the top, front portion of the fuel tank to avoid damage due to touching of t he handle bar clamp on fuel tank.
S.
No.
Hex Flange Bolt M6 Socket Spanner 10 mm
Torque 5 Nm
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29
5.3 Fuel tank ­Assembly
Continental GT
Loca te over flow tube
carefully into the Fuel tank.
Install the fuel tank
towards front to mount into front locking clamp into the frame.
Place a piece of cloth
betw een handle bar clamp bolt and fuel tank.
Gently lift up fuel tank at
the end and
- Con nect low fuel sensor coupler wire.
- Connect EVAP hose into the Fuel tank.
- Con nect fuel hose into the Fuel tank.
Install 2 Hex bolts at the
rear end of fuel tank along with washers,seals and rear dampers.
Assemble Seat.
Fill fuel sufficiently.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Flange Bolt M6 Socket Spanner 10 mm
Hex Flange Bolt M6 Socket Spanner 10 mm Torque 5 Nm
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30
SECTION 5.4 - SEAT ASSEMBLY
EXPLODED VIEWS
BULLET EFI
6
2
2
3
5
5
6
7
7
10
8
9
9
8
4
4
1
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Complete Seat Assy 1
2 Flanged Hex. Bolt M 6 X 20 4
3 Pillion Handle 1
4 Hex Nut With Nylon Insert, M6 4
5 Flanged Hex. Bolt M8 X 20 2
6 Hex Nut With Nylon Insert, M8 2
7 Flanged Hex Nut M8 X 7.7 X 8 2
8 Stud M8 2
9 Plain Washer M8 4
10 Rubber Support Seat Front 1
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31
BULLET CLASSIC EFI
1
4
3
2
4
13
12
14
16
17
18
15
22
21
20
19
20
16
22 17
23
9
10
11
4
5
7
6
4
8
4
9
10
124
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Split Seat Assy-Rider 1 2 Silent Block Bracket Assy 1 3 Silent Block Seat 1 4 Hex. Nut with Nylock insert, M8 X 9.5 8 5 Seat Hinge Mounting Assembly 1 6 Spring Washer M8 4
Spring Washer M8 - Special 4 7 Flanged Hex. Bolt M8 X 60 1 8 Stud - Seat Mounting 1 9 Hexagonal Bolt M8 X 45 2
Domed Cap Bolt M8 X 45 (chrome) 2 10 Washer (Classic Models) 2
Plain Washer (Chrome) 2 11 Spring Bush 2
12 Bush - Seat Spring 4 13 Spring 2 14 Split Seat Assy. Pillion 1 15 Sub Frame - Black 1 16 Flanged Hex Bolt M6 X 1 X 35 2 17 Flanged Hex Bolt M6 X 1 X 27 2 18 Flanged Hex Bolt M8 X 170 1 19 Hex. Nut With Nylon Insert M8 X 9.5 1 20 Plain Washer 2
Spring Washer 2 21 Flanged Hex Bolt M8 X 1.25 X 16 2 22 Hexagonal Nut M6 X 1 X 7 2 23 Pillion Handle for Rear Seat - Black 1
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32
CONTINENTAL GT
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Single Seat Assembly with Cowl - Red 1
2 Plain Washer 3
3 Cross Recessed Pan Head Screw M6X14 3
4 Rubber Support-Rear 2
5 Rubber Support-Middle 2
6 Rubber Support-Front 2
1
2
3
3
3
2
2
4
4
6
6
5
5
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33
5.4 Seat - Dismantling Bullet Classic EFI Rider Seat Removal
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
S.
No.
Hex Nut with Nyloc Insert M8
Socket Spanner 13 mm
Hex Flange Bolt M8 Socket Spanner 13 mm
Flange Hex Bolt M8 Socket Spanner 13 mm
Hold n ut and remove
long mounting bolt from the sub frame.
Rear Seat Removal
Gently remove the rider
seat from the frame.
Remove the seat spring
mounting bolts on LH & RH side.
Loosen hex bolt at the
front end of the seat.
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34
Bullet EFI
Remove front Hex nut
mounted on LH & RH side of the seats.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
S.
No.
Hex Flange Bolt M8 Socket Spanner 13 mm
Remove rear hex bolt on
LH & RH side of the seats. Gently lift the seat from the rear end.
Domed Hex Nut M8 Double end ring spanner
17 mm
Flange hex Bolt M8 Socket Spanner 13 mm
Remove Rear shockers
mounting Domed h ex nut from LH & RH side and loosen the bolt.
Hex Flange Bolt M8 Socket Spanner 13 mm
Loos en the 2 hex bolt
under the rear seat to remove seat from Sub frame.
5.4 Seat - Dismantling Bullet Classic EFI Rider Seat Removal
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35
5.4 Seat -Dismantling Continental GT
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
S.
No.
Remove the seat
assembly.
Gently pull seat latch to
release seat.
SEAT LATCH
Unlock & Remove Side
panel LH.
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36
5.4 Seat - Assembling Bullet Classic EFI Rider Seat Assembly
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Nut with Nyloc Insert M8
Socket Spanner 13 mm
Hex Flange Bolt M8 Socket Spanner 13 mm
Flange Hex Bolt M8 Socket Spanner 13 mm
Rear Seat Assembly
Tighten the 2 hex bol t
under the rear seat to assemble seat into Sub frame.
Tighten the seat spring
mounting bolts on LH & RH side.
Tighten hex bolt at the
front end of the seat.
Position the rider seat on
the frame.
CAUTION:
Please take care not to damage the fuel tank while assy
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37
Bullet EFI
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Flange Bolt M8 Socket Spanner 13 mm
Remove front Hex nut
mounted on LH & RH side of the seats.
Flange Hex Nut M8 Double end ring spanner
17 mm
Hex Flange Bolt M8 Socket Spanner 13 mm
Locate nut and tighten
long mounting bolt into the sub frame.
Flange hex Bolt M8 Socket Spanner 13 mm
Loca te the seat in to
front end tighten rear hex bolt on LH & RH side of the seats.
Tighten Rear shocker s
mounting Domed h ex nut & Bolt from LH & RH side.
5.4 Seat - Assembling Bullet Classic EFI Rider Seat Assembly
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38
5.4 Seat -Assembling Continental GT
Locate front end of the
seat tab in the bracket in the frame. Ensure th e lock pin is posi tion on the cente r of the se at latch.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Locate the Side panel LH
and lock in the seat.
Gently press the seat
rear end to lock the seat.
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39
EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI, CONTINENTAL GT
SECTION 5.5 - EXHAUST PIPE & SILENCER
3
3
3
3
6
3
3
2
5
4
4
9
17
4
4
16
8
10
11
12
13
14
1
1
7
1
13
7
3
3
15
4
4
9
5
10
11
3
4
1
14
12
Bullet & Classic EFI
Continental GT
3
6
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Flanged Hex. Nut M8 X 1.25 2 2 Exhaust Pipe -Guard 1 3 Philips Pan Head Screw M6 X 6 5 4 Flanged Hex. Bolt M8 X 20 4
Flanged Hex. Bolt M8 X 20 2 Flanged Hex. Bolt M8 X 20 3
5 Flanged Hex. Bolt M6 X 35 1 6 Combined Heat Shield/Silencer Guard 1 7 Silencer CAT Assy. 1 8 Bracket front silencer 1
9 Bracket -Silencer Mounting /Bracket Silencer 1 10 Gasket - Exhaust pipe & Silencer 1 11 Hex. Nut M6 1 12 Clamp -Silencer 1 13 Exhaust Pipe Assy. 1 14 Exhaust Gasket (Copper) 1 15 Hex. Nut with Nylon Insert, M8 1 16 Flange Hex. Bolt M10 X 1.5 X 35 1 17 Hex. Screw M8 X 16 1
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40
5.5 Exhaust System Bullet Classic EFI/ Bullet EFI
Disconnect HEGO sensor
connector from the exhaust pipe by loosen­ing the nut.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
Hex Flange Bolt M8 Socket Spanner 10 mm
S.
No.
Hex Flange Bolt M8 Socket Spanner 10 mm
Flange Hex Nut M8 Socket Spanner 10 mm
Remove the c enter
silencer bracket mount­ing scre w with plain washer.
Remove the rear mount-
ing nut at the pillion foot rest end mounte d on silencer.
Remove the flange hex
nuts from cylinder head.
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41
5.5 Exhaust System Continental GT
Disconnect HEGO
sensor connector from the exhaust pipe.
Re move silence r
mounting bolt & nut from the frame.
Remove the 2 Hex flange
nuts holding exhaust pipe to cylinder head.
Gently remove t he
silencer assembly with Exhaust pipe.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
S.
No.
Hex Flange Bolt M8 Socket Spanner 10 mm
Flange Hex Nut M8 Socket Spanner 10 mm
NOTE :
Ensure the copper gasket is removed from the cylinder head / exhaust pipe.
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42
INSPECTION
Inspect Silencer and Exhaust assembles for any deep scoring / damages / dents as it might cause damage to the
internals and the catalytic converters.
Inspect silencer and exhaust pipe joint for any signs of exhaust gas leakage.
CAUTION :
Do not clean the silencer and exhaust internals with any solvents, gasoline etc as it will damage the catalytic
converters.
REPLACE
Gasket between the silencer and exhaust pipe joint whenever the silencer / exhaust pipe are dismantled.Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder
head.
Copper gasket in HEGO sensor whenever exhaust pipe / hego sensor is dismantled.
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43
5.5 Exhaust System­Assembling
Bullet Classic EFI/ Bullet EFI
Loca te g asket o n
Exhaust pipe.
Position exhaust pipe
on the cylinder head assembly.
Tighten two flange hex
nuts on e xhaust pipe into cylinder head.
Tighten the rear Mount-
ing nut at the pillion foot rest end.
Tighten the center
silencer bracket mount­ing scre w with plain washer.
Connect HEGO sensor
connector to the exhaust pipe.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm
Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm
Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm
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44
5.5 Exhaust System­Assembling
Continental GT
Loca te g asket o n
exhaust pipe.
Position exhaust pipe
on the cylinder head assembly.
Tighten two flange hex
nuts on e xhaust pipe into cylinder head.
Tighten the rear
Mounting nut at the pillion foot rest end.
Connect HEGO sensor
connector from the exhaust pipe.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
S.
No.
Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm
Hex Flange Bolt M8 Socket Spanner 10 mm Torque 25 Nm
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45
SECTION 06 - FRONT SUSPENSION
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46
1
2
3
4
4
6
7
8
9
10
5
12
11
13
14
15
16
20
19
18
8
7
17
EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Hex Socket Button Head Screw M6*1.0 4 2 Toner Front Wheel 1 3 Spindle 1 4 Socket Button Head Cap Screw 6 5 Disc Front 1 6 Spacer, Disc Side 1 7 Grease Seal, 25 X 40 X 7 2 8 Wheel Bearing 6203 (17 X 40 X 12 ) 2 9 Spacer Assy 1 10 Front Hub 1 11 Brass Nipples 40
12 Spokes Front 40 13 90/90 - 19 52 V Front Tyre Import 1 14 Tube(Tyre) 3.25X19 1 15 Wheel Rim (1.85 X 19'’ -1.5 Thk) 1 16 Rim Tape 1 17 Spacer Speedodrive 1 18 Speedo DrIve Assy Disc Brake 1 19 Plain Washer,M16 1 20 Hex U Nut M16 X 1.5 1
SECTION 6.1 - FRONT WHEEL
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47
1
2
3
4
5
4
6
7
8
9
10
8
12
11
13
14
15
16
17
18
CONTINENTAL GT
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Hex U Nut M16 X 1.5 1 2 Washer 1 3 Spacer Disc Side 1 4 Hex Flange Bolt M8 X 25 6 5 Toner-Front Wheel 1 6 Front Disc 1 7 Grease Seal,25 X 40 X 7 1 8 Deep Groove Ball Bearing 6203 (17X 40 X12) 2 9 Bearing Spacer Assy 1 10 Hub-Front 1 11 Spokes Front 36
12 Nipple 3.6 mm 36 13 Tyre-Front 100/90-18" 1 14 Tube -Front 100/90-18" 1 15 Rim Front Aluminium(2.5X18") 1 16 Rim Tape 1 17 Spindle-Front Wheel 1 18 Wheel Speed Sensor Assy 1
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48
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.1 Front Wheel Dismantling
Bullet Classic EFI/ Bullet EFI / Continental GT
Place the motorcycle on
its center stand on a firm and flat surface.
Provide a suitable
support below the front end of the engine such that the front wheel is about 4 inches (10 cms) above the ground.
Disconn ect spee do
cable at speedo drive.
Disconnect wheel speed
sensor coupler near head lamp housing.
Hex Bolt M8, Hex Nut M8 Ring Spanner 13 mm Double end Ring Spanner
13 mm
Loosen the pinch bolt on
the right side fork end.
Hold the axle on the right
side and loosen the axle nut on the left side.
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49
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.1 Front Wheel
Dismantling Bullet Classic EFI/
Bullet EFI / Continental GT
Hex Socket Screw M8 Allen Key 6mm Torque 25 Nm (2.5 Kg-m)
Hex Nut M16 Double end Spanner–
24mm
Remove the axle nut and
washer.
Tap the axle out gently
from the left side and remove completely from the right side.
Slide out the wheel from
the fork legs.
Remove the speedo
drive after removing wheel from the fork legs.
Remove the wheel
speed sensor and spacer afte r removing w heel from the fork legs.
CAUTION:
Do not depress the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper.
NOTE:
Place a 4 mm thick wooden pie ce or cardboard sheet between the brake pads to avoid pads activation in the event the front brake lever is Accidently depressed.
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50
INSPECTION
Inspect tyres for any side wall crack stone hits, bulge, proper seating in rim.Tyres button to be above the tyre wear indicator mark on the side walls.Inspect spokes for any loosening / breakage.Inspect hub or any damage.Inspect Toner ring for any damage.Axle & nut for thread damage.Inspect wheel rim for run out / “jump” it should not exceed 2 mm.
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51
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.1 Front Wheel Assembling Bullet Classic EFI/
Bullet EFI / Continental GT
Remove the wooden
piece / card board sheet placed between the brake pads.
Locate spacer & speedo
drive on the right side in the hub.
Locate stepped spacer
in the left side (disc side) of the hub with its larger face outside.
Loca te front wheel
between the fork ends duly ensuring the spacers and the speedo drive do not fall off and the bra ke disc is correctly positioned betw een the brake pads.
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52
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.1 Front Wheel Assembling Bullet Classic EFI/
Bullet EFI /
Ensure the peg in the
Speedo drive is correctly positioned in the slot in the right side fork end.
Continental GT
Position wheel s peed
sensor such tha t th e wire coupler can be connected and the wire is not stretched.
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53
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.1 Front Wheel Assembling
Bullet Classic EFI/ Bullet EFI
Hex nut M16 Double end spanner 17mm Torque – 70 Nm
Ensure all the mounting
bolts are aligned.
Locate washer and nut
on the left side.
Hold the axle from the
right side and tighten nut on left side.
Hold the pinch bolt and
tighten the nylock nut on the right s ide fork end. (Only Bullet Classic EFI / Bullet EFI)
Tighten h ex socket
screw on fork end RH. (Only for C ontinental GT)
Rota te the whee l and
chec k for smoot h rotation.
Connect the s peedo
cable to spe edo drive and check for proper working of speedo meter.
Depress brake lever 2 or
3 times to chec k front brake efficiency.
Torque 25Nm
NOTE:
Insert axle through the right side fork end and gently tap it in fully.
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54
SECTION 6.2 - FRONT MUDGUARD
3
4
2
8
7
6
9
10
10
2
8
7
6
12
9
6
7
8
9
10
5
5
6
7
9
10
6
7
8
2
15
14
13
1
8
7
6
11
2
10
LH side
RH side
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Front Mudguard-Black 1
2 Mudguard Stay Front Black Mod 4
3 Mudguard Stay Center LH Black New 1
5 Hex Flanged Bolt M8 X 1.25 X 38 2
6 Phillips Round Head Machined Screw M6X 13 6
7 Lock Washer M6 6
8 Hex Nut M6 X 1 6
9 Flanged Hex Bolt M8 X 20 6
10 Spring Washer 6
11 Cable Guide 1
12 Clamp - Front Caliper Brake Hose 1
13 Cross Recessed Pan Head Screw M6 X 14 1
14 Plain Washer M6 1
15 Hex. Nut M6 X 1 X 5 1
EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
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55
CONTINENTAL GT
2
6
6
6
3
8
8
8
8
1
4
4
4
4
7
5
7
7
5
5
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
A1 Front Mudguard Mud Flap,Extension Kit 1 1 Front Mudguard 1 2 Mud - Flap Front 1 3 Fork Brace 1 4 Hex. Socket Button Head Screw M6X1 4 5 Lock Washer Internal Teeth 3
6 Pan Head Screw M5 X 0.8 X 12 3 7 Hex. Nut M8 3 8 Hex. Socket HD. Cap Screw M6X20
Stainless Steel 4
A1
Key Nos. 2, 5, 6 & 7
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56
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.2 Front Mudguard Bullet Classic EFI /
Bullet EFI
Re move Front whe el
as described in Fron t
Wheel section
Re lease B rake hose
grommet from the holding clip in front mudguard.
Loosen and remove the
4 flanged hex bolts along with spring w ashers, holding front mudguard, front, centre & rear stays to fork end RH.
Loosen and remove:
- 2 flange d hex bolts along with spring washers, holding front mudguard centre stay & front brake caliper to fork end LH.
- 2 flange d hex bolts along with spring washers, holding front mudguard front an d rear stays to fork end LH.
Loos en wheel spe ed
sensor screw and remove sensor along with screw.
Gently rotate th e
mudguard stays into the mudguard and slide out of the fork legs.
Flanged Hex bolt: M8 Socket Spanner: 12 mm
Flanged Hex bolt: M8 Socket Spanner: 12 mm
Socket head cap Screw: M6
Allen Key : 5 mm
CAUTION:
Ensure mudguard does not get scratched while tilting and removing.
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57
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.2 Front Mudguard Continental GT
Re move Front whe el
as described in Fron t
Wheel section
Loosen and remove the
4 socket head cap screws on the fork brace between the fork legs RH & LH.
Gently lift up and
remove mudguard from the fork legs.
Socket head cap Screw: M6
Allen Key : 5 mm
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58
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.2 Front Mudguard Bullet Classic EFI /
Bullet EFI
Locate Mudguard stays
along with mudguard and slide into the fork legs.
In stal l whe el speed
sensor screw and locate sensor along with screw.
Install and locate:
- 2 flange d hex bolts along with spring washers, holding front mudguard centre stay & front brake caliper to fork end LH.
- 2 flange d hex bolts along with spring washers, holding front mudguard front an d rear stays to fork end LH.
Install and locate the 4
flanged hex bolts along with spring w ashers, holding front mudguard, front, centre & rear stays to fork end RH.
Loca te Brake hose
grommet in the holding clip in front mudguard.
Assemble Front whe el
as described in Fron t
Wheel section.
CAUTION:
Ensure mudguard does not get scratched w hile assembling.
Socket head cap Screw: M6
Allen Key : 5 mm Torque : 25Nm
Flanged Hex bolt: M8 X 38 & M8 X 20
Socket Spanner: 12 mm Torque : 10 Nm
Flanged Hex bolt: M8 X 20
Socket Spanner: 12 mm Torque : 10 Nm
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59
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.2 Front Mudguard Continental GT
Gently lift down and
locate mudguard on the fork legs.
Socket head cap Screw: M6
Allen Key : 5 mm
Install and locate the 4
socket head cap screws on th e fork brace between the fork legs RH & LH.
Locate Front whee l as
described in F ron t
Wheel section.
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60
SECTION 6.3 – HANDLE BAR
7
5
10
9
12
13
14
8
2
1
3
2
1
17
18
4
ES
6
11
A1
16
15
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
A1 Handle Bar Assembly Complete 1 1 Hex Socket Head Screw M8 X 50 2 2 Damper Weight 2 3 Hand Grip LH 1 4 Cable Strap 6" 2
Cable Strap 8" 3
5 Handle Bar Complete 1 6 Rear View Mirror LH 1 7 Rear View Mirror RH 1 8 Grip Complete - Throttle RH 1
9 Lever & Holder Assy. LH 1 10 Clutch Lever 1 11 Switch Module LH 1 12 Switch Module RH 1 13 Rotor Plate 1 14 Pan Head Screw M5 X 10 1 15 Front Brake Lever kit 1 16 Add On Lead, Front Brake Switch 1 17 Add On Lead, Clutch Switch 1 18 Clutch Switch 1
EXPLODED VIEWS
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61
CONTINENTAL GT
A1
Key Nos.
1 & 2
A2
Key Nos.
24 & 25
4
5
3
6
LH
8
3
3
2
1
7
9
10
11
12
13
14
A2
25
15
24
16
4
5
23
A3
16
15
17
4
5
18
19
20
10
9
21
22
RH
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
A1 Mirror Set OE - Continental GT 1 A2 Clutch Switch Repair Kit 1 A3 Clutch & Front Brake Lever Kit (Clear Coated) 1 1 Rear View Mirror - LH 1 2 Rear View Mirror - RH 1 3 Hex. Socket Head Screw M8 X 35 6 4 Grommet - Clip ON 2 5 Hex. Socket Head Cap Screw M6 X 20 4 6 Top Yoke 1 7 Handle Bar Assy. - LH 1 8 Handle Bar Assy. - RH 1 9 Counter Weight Assy. 2 10 Mirror Dummy Ring 2 11 Handle Grip - LH 1
12 Switch Module - LH 1 13 Lever & Holder Assy. - LH 1 14 Handle Bar Complete - LH 1 15 Hex. Socket Head Bolt M8 X 40 2 16 Rubber Sleeve - Handle Bar 2 17 Handle Bar Complete - RH 1 18 Master Cylinder - Front 1 19 Switch Module - RH 1 20 Grip Complete - Throttle RH 1 21 Rotor Plate - Throttle Cable 1 22 Pan Head Screw M5 X 10 1 23 Add On Lead, Brake Switch 1 24 Clutch Switch 1 25 Add On Lead, Clutch Switch 1
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62
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.3 Handle Bar Bullet Classic EFI /
Bullet EFI
Remove Headlamp from
the headlamp casing and disconnect wire terminals.
Philips head screw driver
Double end spanner 15mm
Disconnect wire couplers
from handle bar inside the head lamp casing.
Remove Rear view
mirrors LH & RH.
Disconnect all control
cables from the handle bar.
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63
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
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Instructions
6.3 Handle Bar Bullet Classic EFI /
Bullet EFI
Remove the 2 hex bolts
on the clamp holding Front brak e master cylinder to handle bar.
CAUTION:
Ensure the brake lever is not depressed while removing from handle bar.
Hex SS Bolt : M12 Socket spanner: 14 mm
Hex bolts: M6 Socket spanner: 10 mm
Hex Nut: M8 Socket spanner: 12mm
Remove master cylinder
asse mbly from the handle bar and support suitably to prevent hydraulic oil leak from master cylinder.
Loos en and remove 2
Hex bolts along with washers from the handle bar clip top.
Loos en and remove 2
hex nuts along with washers from the handle bar clip bottom.
Remove handle bar clip
from the stu ds in the headlamp casing and the handle bar.
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64
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
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Instructions
6.3 Handle Bar Continental GT
Remove Headlamp from
the headlamp housing and disconnect wire terminals.
Philips head screw driver
Double end spanner 15mm
Disconnect handle bar
LH & RH wire couplers inside the he ad lamp housing.
Remove Rear view
mirrors LH & RH.
Disconnect all control
cables from the handle bar.
Remove the 2 hex bolts
on the clamp holding Front brak e master cylinder to handle bar.
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65
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.3 Handle Bar Continental GT
Remove master cylinder
asse mbly from the handle bar and support suitably to prevent hydraulic oil leak from master cylinder.
Hex bolts: M6 Socket spanner: 10 mm
Hex. Socket Head Screw: M8
Allen Key: 6 mm
Hex. Socket Head Screw: M6
Allen Key: 5 mm
Loosen the hex socket
scre w clamping the handle bar assemblies LH & RH to the fork main tubes.
Re move the 2 r ubber
grommets on top of the handle bar LH & RH and remove the 2 hex socket head cap screws.
Remove handle bar LH &
RH form the fork main tubes.
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66
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Locate handle bar clip on
the studs in the headlamp casing and the handle bar.
Install and locate 2 hex
nuts along with washers on the handle bar clip bottom.
Install and locate 2 Hex
bolts along with washers on the handle bar clip
top.
Locate master cylinder
assembly on the handle bar and support suitably to prevent hydraulic oil leak from ma ster cylinder while locating.
Install the 2 hex bolts on
the clamp holding Front brake master cylinder to handle bar.
6.3 Handle Bar Bullet Classic EFI /
Bullet EFI
Hex SS Bolt : M12 Socket spanner: 14 mm
Hex Nut: M8 Socket spanner: 12mm
CAUTION:
Ensure the brake lever is not depressed while removing from handle bar.
Hex bolts: M6 Socket spanner: 10 mm
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67
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Connect all control
cables on the handle bar.
Locate Rear view mirrors
LH & RH.
Connect wire couplers
on handle bar inside the head lamp casing.
Locate Headlamp in the
headlamp casing an d connect wire terminals.
6.3 Handle Bar Bullet Classic EFI /
Bullet EFI
Double end spanner 15mm
Philips head screw driver
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68
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Locate handle bar LH &
RH on the fork main tubes.
Loca te the 2 rubber
grommets on top of the handle bar LH & RH and Install the 2 hex socket head cap screws.
In stal l the hex socket
scre w clamping the handle bar assemblies LH & RH to the fork main tubes.
Locate master cylinder
assembly on the handle bar and support suitably to prevent hydraulic oil leak from ma ster cylinder.
6.3 Handle Bar Continental GT
Hex bolts: M6 Socket spanner: 10 mm
Hex. Socket Head Screw: M8
Allen Key: 6 mm
Hex. Socket Head Screw: M6
Allen Key: 5 mm
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69
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Install 2 hex bolts on the
clamp holding Front brake master cylinder to handle bar.
Connect all control
cables from the handle bar.
Locate Rear view mirrors
LH & RH.
Connect handle bar LH &
RH wire couplers inside the head lamp housing.
Locate Headlamp on the
headlamp housing and Connect wire terminals.
6.3 Handle Bar Continental GT
Philips head screw driver
Double end spanner 15mm
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70
SECTION 6.4 – FRONT FORK
22
21
20
19
18
17
16
12
10
13
14
15
11
24
23
26
27
28
25
24
1
2
A1
22 21
A2
4
3
5
6
7
8
9
A1
Key Nos.
1 to 3, 5 to 20
A3
Key Nos.
Qty 2 Nos. 2, 7, 9,
11, 15 & 20
A2
Key Nos.
1, 2, 4 to 20
A4
Key Nos.
Qty 2 Nos. 2, 7, 9,
15 & 20
A5
Key Nos.
Qty. 2 Nos. 16,
20 & 22
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
A1 Front Fork Assy - LH 1 A2 Front Fork Assy - RH 1 A3 Fork Pipe Spining Replacement Kit 1 A4 Fork Oil Seal, ‘O’-Ring & Piston Ring Kit 1 A5 Main Spring Front Fork Replacement Kit 1 1 Socket Headed Bolt 2 2 Copper Packing Washer 2 3 Outer Tube M/C - RH (Fork End) 1 4 Outer Tube M/C - LH (Fork End) 1 5 Guide Bush 2 6 Plain Washer Big 2 7 Oil Seal - LH & RH Front Fork 2 8 Oil Seal Stopper - LH & RH 2 9 Dust Seal - LH & RH 2 10 Slide Bush 1 11 Fork Pipe Spining - Inline Fork 2 12 Cap Oil Lock (Spindle Tapper) 2
13 Rebound Spring 2 14 Seat Pipe 2 15 Piston Ring - Front Fork 2 16 Main Spring 2 17 Washer - Fork Main Spring 2 18 Spacer Tube - Front Fork 2 19 Fork Bolt - Top 2 20 ‘O’ Ring - Fork Bolt Top 2 21 Plain Washer - Fork Bolt 2 22 Flange Bolt 2 23 Hex Nylock Nut M8 X 9.5 1 24 Punched Washer 2 25 Flanged Hex. Bolt M8 X 55 (Special) 1 26 Reflex Reflector (Amber) 2 27 Wheel Speed Sensor-ABS 1 28 Hex.Socket Button Head Screrw M6X1X16 1
EXPLODED VIEWS
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71
CONTINENTAL GT
25
26
24
22
A2
2
A1
3
18
15
16
17
14
13
12
4
10
20
21
1
19
11
9 8
7
6
5
23
26
25
24
A2
Key Nos.
All Except 1 & 19
A3
Key Nos.
Each Qty. 2 Nos. 3, 7, 9, 11, 17 & 20
A1
Key Nos.
All Except 2
A4
Key Nos.
QEach Qty. 2 Nos.
7, 9, 11, 17 & 20
A5
Key Nos.
(Qty. 2 Nos. 13),
16 & 17
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
A1 Fork End LH assy 1 A2 Fork End RH assy 1 A3 Fork Pipe Spinning Replacement Kit 1 A4 Fork Oil Seal, ‘O’ Ring & Piston Ring Kit 1 A5 Main Spring Fork Major Kit 1 1 Outer Tube - RH 1 2 Outer Tube - LH 1 3 Inner Tube Assy. 2 4 Piston - Front Fork 2 5 Bush (Outer Tube) 2 6 Bush Washer 2 7 Oil Seal 2 8 Circlip (Snap - Ring) 2 9 Dust Seal 2 10 Spindle Taper 2 11 Gasket 2 12 Bolt M10X1 2
13 Spring – 1 2 14 Washer Spring Top 2 15 Spacer 2 16 Bolt Cap 2 17 ‘O’ Ring 2 18 Washer - 2 2 19 Bolt M8 X 1.25 X 45 2 20 Piston Ring 2 21 Spring - 2 2 22 Cable Guide - Brake 1 23 Cable Guide - Speedo Cable 1 24 Hex. Bolt M6 X 12 2 2 25 Plain Washer 2 26 Lock Washer, M6 2 27 Reflex Reflector Amber 2 28 Wheel Speed Sensor-ABS 2 29 Hex.Socket Button Head Screrw M6 X1 X16 1
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72
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.4 Front Fork LH & RH Bullet EFI / Bullet
Classic EFI
Remove Front wheel as
described in F ron t
Wheel section 6.1.
Remove front mud-
guard as deta iled in Section 6.2.
Ensure wheel speed
sensor is removed from the fork end LH.
Discon nect Trafficator
couplers LH & RH inside headlamp casing.
Loosen Hex Nylock nuts
on steering stem pinch bolt L H & RH remove trafficator assembly with bracket on LH & RH side.
Hold the pinch bolts LH
& RH and loosen hex nut Loosen nut by holding fork pinch bolt in bottom yoke (steering stem) on RH & LH side.
Hex Nylock Nut: M8 Ring spanner: 12mm
Hex bolt M8 Hex Nylock Nut: M8 Double end spanner:
12mm Ring spanner: 12mm
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73
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.4 Front Fork LH & RH Bullet EFI / Bullet
Classic EFI
Loos en and remove 2
Hex socket screws from the top of the front forks on the head lamp casing.
Gently rotate and
remove the fork assembly LH & RH from the head lamp c asin g and the steering stem.
Hex Hd Cap screw M10 Allen Key 8 mm
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74
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.4 Front Fork LH & RH Continental GT
Hex bolt M8 T spanner 12 mm
Hex. Socket Screw M8 Allen key 6 mm
Remove Front wheel as
described in F ron t
Wheel section 6.1.
Remove front mud-
guard as detailed above in Section 6.2.
Ensure front brake
caliper is disma ntle d from the fork LH.
Ensure wheel speed
sensor is removed from the fork end LH.
Remove Headlamp from
the headlamp housing and disc onne ct all elec trical connections inside headlamp housing.
Loosen and remove the
2 hex bolts holding head lamp housing to the holder RH & LH.
Loosen the 2 hex socket
screws inside the head lamp holder R H & LH. Ensure the head lamp holders are free on the front fork main tube.
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75
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.4 Front Fork LH & RH Continental GT
Loosen the 4 hex socket
head cap bolts (2 each on LH & RH sides) from the steering stem.
Loosen the 4 hex socket
head cap bolts (2 each on LH & RH sides) from the top yoke.
Gently rotate and
remove the forks LH & RH f rom the s teering stem and top yoke.
NOTE:
Support the head la mp holders with the trafficators while removing the forks LH & RH from the steering stem.
Hex Screw M6 Allen key 5 mm
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76
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork LH & RH Bullet EFI / Bullet
Classic EFI
Gently rotate and locate
the fork assembly LH & RH on the head lamp casing and the steering stem.
Install and locate 2 Hex
socket screws in the top of the front forks on the head lamp casing.
Hex Screw M10 Allen Key 8 mm
Hex Nylock Nut: M8 Ring spanner: 12mm
Hex bolt M8 Hex Nylock Nut: M8 Double end spanner:
12mm Ring spanner: 12mm
Hold the pinch bolts LH
& RH and Install hex nut Loosen nut by holding fork pinch bolt in bottom yoke (steering stem) on RH & LH side.
Install Hex Nylock nuts
on steering stem pinch bolt LH & RH and locate trafficator assembly with bracket on LH & RH side.
Connect Tra fficator
couplers LH & RH inside headlamp casing.
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77
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork LH & RH Bullet EFI / Bullet
Classic EFI
Ensure wheel speed
sensor is located in the fork end LH.
Locate front mudguard
as detailed above.
Assemble Front whe el
as described in Fron t
Wheel section 6.1.
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78
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork LH & RH Continental GT
Locate the fork assem-
bly LH & RH on the head lamp casing and t he steering stem.
Gently rotate and locate
the forks LH & RH on the steering stem and top yoke.
Install the 4 hex socket
head cap bolts (2 each on LH & RH sides) on the top yoke.
NOTE:
Support the head la mp holders with the trafficators while removing the forks LH & RH from the steering stem.
Hex Socket Screw M6 Allen key 5 mm
Hex Socket Screw M8 Allen key 6 mm
Install the 4 hex socket
head cap bolts (2 each on LH & RH sides) on the steering stem.
Install the 2 hex socket
screws inside the head lamp holder R H & LH. Ensure the head lamp holders are fixed on the front fork main tube.
Install and locate the 2
hex bolts holding head lamp housing to the holder RH & LH.
Locate Headlamp in the
headlamp housing and connect a ll electr ical connections inside headlamp housing.
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79
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork LH & RH Continental GT
Ensure wheel speed
sensor is located in the fork end LH.
Ensure front brake
caliper is located in the fork LH.
Locate front mudguard
as detailed above.
Assemble Front whe el
as described in Fron t
Wheel section 6.1.
Hex bolt M8 T spanner 12 mm
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80
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.4 Front Fork Oil Draining
Hold the fork assembly
in bench vice with soft jaws, approx imately 6 inches from the top and loosen top nut.
Remove fork assembly
from the bench vise.
Hold upright and gently
remove fork top nut with washer, allowing spring to expand slowly.
Hex nut M16 Double end spanner
24 mm
Remove washer, spacer
and washer spring top from the inner tube.
NOTE:
Replace all Rubber parts, , plastic bushe s, O rings, washers whenever they are removed.
Re move long spring
from inner tube.
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81
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No.
Fastener, Size, Tool Usage, Precautions, Photos
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Instructions
6.4 Front Fork Oil Draining
Invert the fork assembly
to drain out the oil from the fork.
Gently pump main tube
into the bottom tube to drain out the oil completely.
Repeat the above process
to drain oil from t he other fork assembly.
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82
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork Oil Filling
Fill Fork oil 195 ml/leg
(For Bullet & Classic Models) and 430 ml/leg (For Con ti-GT Model) with 2W 35 Grade.
Locate long spring into
the inner tube.
NOTE:
Replace all Rubber parts, , plastic bushe s, O rings, washers whenever they are removed.
Locate washer, space r
and washer spring top in the inner tube.
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83
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.4 Front Fork Oil Filling
Locate fork top nut with
washer, allowing spring to compress slowly.
Repeat the above
process to fill oil and assemble the other fork assembly.
Hex nut M16 Double end spanner
24 mm
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84
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble/
Instructions
6.4 Front Fork Assembling
Remove the pinch bolt
and nut on Fork RH.
Loca te s pecial tool
inside inner tube such that it engages with the nut on th e seat pipe inside.
Loosen and remove the
hex socket head nut inside the outer tube.
Hex bolt & nut: M6 Ring spanners: 10mm
Special Tool: ST-25834-2 Allen Key: 10mm
Remove the special tool
from the inner tube.
Remove the dust seal,
reta iner clip, and fork seal from the outer tube.
Pull out the inner tube
from the outer tube sharply to remove the inner tube along with the guide bush, sea t pipe asse mbly, rebound spring and cap oil lock.
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85
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
6.4 Front Fork Dismantling
Pull in the inner tube on
the outer tube sharply to locate the inner tube along with the guide bush, seat pipe assembly, rebound spring and cap oil lock.
Loca te the dust s eal,
reta iner clip, and fork seal in the outer tube.
Locate the special tool in
the inner tube.
Loca te and in stal l the
hex socket head nut inside the outer tube.
Loca te s pecial tool
inside inner tube such that it engages with the nut on the seat pipe inside.
Loca te the pinch bolt
and nut on Fork RH.
Special Tool: ST-25834-2 Allen Key: 10mm
Hex bolt & nut: M6 Ring spanners: 10mm
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86
INSPECTION
Inspect front fork inner tube for any damages and bends. Inspect front fork outer tube for any damages, cracks at oil seal seating area.
WEAR LIMIT
Main tube straightness
Fork spring long
Long Pitch
Short Pitch
Spring Length ------ mm
Fork spring short
Service Limit: 0.15 mm
Guide Bush
Length New Spring: --------mm Service Limit: -------mm
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87
8
7
8
7
9
6
9
1
2
4
1
4
5
3
3
22
23
24
22
24
23
26
27
25
20
19
18
28
14
15
16
14
15
16
12
10
11
13
12
17
21
SECTION 6.5 – STEERING STEM
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Cover 2 2 Ball Race, Head Lamp Casing 1 3 Steering Stem Ball Cage 2 4 Ball Race, Frame 2 5 Ball Race, Fork Crown 1 6 Steering Stem Assy. 1 7 Flanged Hex Nut M8 x 7.7 X 8 2 8 Hex Nut with Nylock insert - M8 X 9.5 2 9 Flange Bolt (M8 × 75) 2 10 Stem Lock Nut 1 11 Steering Stem Lock Nut Washer 1 12 Washer 2 13 Hex SS Bolt M8 x 48 2 14 Stud (M8×32) 2
15 Washer 2 16 Nut 2 17 Clip, Handle Bar 1 18 Sleeve, Threaded 1 19 Sleeve, Plain 1 20 Hex Socket head Cap Screw M10 x 1.5 x 35 1 21 Adaptor AHO 1 22 Rubber Spacer 2 23 Bush 2 24 Cover Tube 2 25 Head Lamp Casing 1 26 Rr Cover Comp C5 1 27 Slotted Rd. Hd.Screw 2 28 Rubber Grommet 2
EXPLODED VIEWS
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88
CONTINENTAL GT
1
6
7
10
11 12
3
3
9
8
8
5
4
7
3
3
2
S. NO.
DESCRIPTION
QTY. S. NO.
DESCRIPTION
QTY.
1 Lock Nut 1
2 Top Yoke 1
3 Hex. Socket Head Bolt M8 X 35 8
4 Ring Nut 2
5 Dust Cap - Top Yoke 1
6 Ball Race - Top Yoke 1
7 Steering stem - Ball Cage 2
8 Ball Race - Frame Head Tube 2
9 Dust Cap - Frame 1
10 Steering Stem Assembly 1
11 Ball Race - Bottom Yoke 1
12 Dust Seal - Bottom Yoke 1
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89
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Steering Play Adjustment
Bullet Classic EFI / Bullet EFI
Rock the front end and
feel the play at stem top end.
NOTE:
Every 6,000 KMS, Steering Ball race adjustment should be done and on Ever y 12,00 0 Km Lubrication is recommended.
Lock Nut M20
Socket Spanner - 30 mm
Dome Lock Nut M24 Socket Spanner – 30 mm
Torque – 50 Nm
Finally tighten all the
nuts and bolts in reverse order.
If felt, adjust as follows: Loosen steering bottom
bridge pinch bolt and nuts of Right & Left side.
Loosen the stem lock nut
and then tight steering stem tapper n ut t o adjust excess play.
Again re-check play, it
should be free without any play.
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90
S.
No.
6.5 Steering Play Adjustment Continental GT
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
Place Motorcycle on
Center Stand.
Ke ep a wooden plank
under the stand to Rise the Front Wheel.
CAUTION:
Do not Use Sockets Directly.
Hex Socket Screw M5
Allen Key 6mm
Steering Dome Nut
X
Don’t
CAUTION:
Do n ot Use Sockets Directly.
Dome Lock Nut M24 Socket Spanner – 30 mm
If felt, adjust as follows : Loos en the steeri ng
dome nut with long extension rod.
Loosen the pinch bolts in
bottom yoke on LH and then RH side.
Hold the Fork pipe (Main
Tube ) pull and push simultaneously lift the front whe el upw ards and check for Steering play.
Rock th e fr ont wheel
down wards and feel the play / sound at stem top dome nut by fingers.
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91
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Steering Play Adjustment Continental GT
C Spanner
CAUTION:
Do not use Ring spanner directly to tig hten dome nut.
Dome Lock Nut M24 Socket Spanner – 30 mm
Torque – 50 Nm
Loosen the lock ring nut
before a djusting Steering play.
Again check and confirm
the steering free play.
After adjusting the play
then tighten Dome nut to Torque.
After adjusting the play
then tighten loc k nut against ring nut.
In case of excessive
steering play tighten the stee ring ring nut by using spe cial tool (C spanner).
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92
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Steering Play Adjustment Continental GT
Hex Socket Screw M5 Allen Key 6mm
Torque 25 NM
NOTE:
Take a small test ride to ensure that
- Steering free movement.
- No dragging.
- No sound from steering stem / mounting area.
Now check the handle
bar free movement by turning extreme Left to Right side.
Tighten the pinch bolts
in bottom yoke LH and then RH by using Allen key.
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93
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI / Bullet EFI
Disconnect speedometer
ca ble fr om t he spee dometer.
Disconn ect wiring
couplers of the speedo­mete r, MIL meter, ignition switch a nd parking lamps from the main wiring harness.
Re move the clu tch,
thrott le and bi-starter cables from the hole in the headlamp casing.
Loos en & remove the
hex Nylock nut and bolt holding RR cover and cover tube to th e steering stem.
Hex Soc Hd Cap screw: M10
Allen key 12 mm
Loosen and remove the
steering stem lock nut from the headlamp casi ng along with the washer.
Remove the fork cover
tubes LH & RH along with the rubber spacers and plastic bushes.
Loos en soc ket head
screw in the head lamp casing inner side by 3 to 4 threads.
Support t he ste ering
stem at the bottom.
Hex nut (Steering stem lock nut) : M24
Ring spanner: 30mm
KS MOTORCYCLES - http://ksmotorcycles.com
94
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI / Bullet EFI
Gently lower the
stee ring ste m and remove from the frame.
Remove the Headlamp
casing from the frame.
Using a long chisel, gently
tap and drive out the top and bottom races from the frame h ead tube along with the dust cap.
Re move the top and
bottom ball cage from the ball races.
Using a short chisel, drive
out the ball race along with dust cap from the headlamp casing and the ball race from steering stem.
KS MOTORCYCLES - http://ksmotorcycles.com
95
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI / Bullet EFI
Using a short chisel, drive
in the ball race along with dust cap on th e headlamp casing and the ball race in steering stem.
Loosen and remove the
steering stem lock nut from the headlamp casi ng along with the washer.
Remove the fork cover
tubes LH & RH along with the rubber spacers and plastic bushes.
Loca te stee ring stem
and assemble on the frame.
Using a long chisel, gently
tap and drive in at the top and bottom races on the frame h ead tube along with the dust cap.
Loca te the top and
bottom ball cage from the ball races.
Loca te the Headlamp
casing in the frame.
KS MOTORCYCLES - http://ksmotorcycles.com
96
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI / Bullet EFI
Loca te the fork cover
tubes LH & RH along with the rubber spacers and plastic bushes.
Loca te and in stal l the
steering stem lock nut in the headlamp casing along with the washer.
In stal l socket head
screw in the head lamp casing inner side by 3 to 4 threads.
Locate & Install the hex
Nylock nut and bolt holding RR cover and cover tube to th e steering stem.
Loca te the fork cover
tubes LH & RH along with the rubber spacers and plastic bushes.
Loca te and in stal l the
steering stem lock nut in the headlamp casing along with the washer.
Hex Soc Hd Cap screw: M10
Allen key 12 mm
Loca te the clutch,
thrott le and bi-starter cables on the hole in the headlamp casing.
Connect wiring couplers
of the speedometer, MIL meter, ignition switch, and parking lamps in the main wiring harness.
Connect speedom eter
cable from the speedo­meter.
Hex nut (Steering stem lock nut) : M24
Ring spanner: 30mm Torque: 70 Nm
KS MOTORCYCLES - http://ksmotorcycles.com
97
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle /
Instructions
6.5 Top Yoke & Steering Stem
Continental GT
Disconn ect a ll wirin g
couple rs of th e inst rument cluster to main wiring harness.
Re move speed se nsor
wire coupler from wiring harness.
Remove the top lock nut
on the top yoke.
Re move the top yoke
along with th e instrument cluster and ignition switch.
Support steering stem
and th e bottom and loosen and remove the top ring nut first and the second ring nut next.
KS MOTORCYCLES - http://ksmotorcycles.com
98
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
6.5 Top Yoke & Steering Stem
Continental GT
Gently lower the
stee ring ste m and remove from the frame.
Re move the top and
bottom ball cage from the ball races.
Using a long chisel, gently
tap and drive out the top and bottom races from the frame h ead tube along with the dust cap.
Using a short chisel, drive
out the ball race along with dust cap from the top y oke and the ball race from steering stem.
KS MOTORCYCLES - http://ksmotorcycles.com
99
S.
No.
Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Assemble /
Instructions
6.5 Top Yoke & Steering Stem
Continental GT
Using a short chisel, drive
in the ball race along with dust cap in the top yoke and the ball race on steering stem.
Using a long chisel, gently
tap and drive in at the top a nd bottom ra ces from the frame head tube along with the dust cap.
Loca te the top and
bottom ball cage in the ball races.
Loca te stee ring stem
and assemble on the frame.
NOTE:
Replace all Rubber parts, , plastic bushe s, O rings, washers whenever they are removed.
KS MOTORCYCLES - http://ksmotorcycles.com
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