Royal Enfield continental gt euro iii training guide 21.02.2014 Service Manual

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SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

PREFACE

Royal Enfield is pleased to release the service training manual on Continental GT model. This

guide contains specifications/values, function, check/test methods and troubleshooting /diagnosis

skills for various components of this model.

Royal Enfield is committed to upgrade the knowledge and skills of Technician who ever repair

our products.

While this guide is updated with latest information and specification of the bike, the data, diagram

etc., in this guide may not be similar to what appear on the actual bike due to continuous

improvement happening in our bike.

However if you have any queries, clarification, suggestions/feedback, please write to us or

e-mail at “customerservice@royalenfield.com”

Best Wishes

Service Training Centre

Royal Enfield

SERVICE HEAD QUARTERS

Royal Enfield, A Unit of Eicher Motors Limited, Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. Phone : 044 - 4223 0400, Fax : 044 - 4201 1719 E-mail : customerservice@royalenfield.com Website : www.royalenfield.com

Training Manual shall be copied, distributed or otherwise dealt without the express permission in

written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of this manual.”

Revision 1.0 / Feb. ‘14

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

CONTENTS

Technical Specification-Continental GT 3

General Vehicle Information 5

Salient Features - Contin ental GT 6

Torque Values - Continental GT

Right Side View 10

Left Side View 11

Periodical Maintenance Chart 12

Periodical Maintenance

Throttle cable free play adjustment 13

Spark plug 14

Air Filter Paper Element 14

Steering Stem Play Adjustment 15

Rear Wheel Dismantling & Assembling, 17 Brake Pad Replacement

Engine Dis-Mounting from Frame Assy. 48

Engine Management System (EMS) 50

EFI Testing Procedure 52

a. Visual Method 52

b. Test Pin Method

c. Diagnosis Online (DOL) Tool 53

Do’s and Dont’s 54

Trouble Shooting 55

Electricals & Electronics

Electrical Symbols 57

Battery 57

Various Electricals & Electronics 58 Components Inspection

Engine Compression Test 61

Drive Chain Free Play 20

Chain Lock Fitment 21

Front Wheel, Fork Oil Replacement & 22 Front Fork Overhauling

Service Limits of Various Components 32

Exploded Views

Front Fork (GIL) 37

Steering Stem Assy. & 38 Handle Bar Assembly

Rear Wheel Assy. 40

Rear Master Cylinder Assy. 42

Rear Caliper Assy. 44

Engine Mounting on Frame Assy. 46

Anti skip Mechanism 48

Wheel Speed Sensor 62

Instrument Cluster 62

Changing Electrical Components

Head Lamp Bulb Replacement 63

Tail Lamp Bulb Replacement 64

Trafficator Bulb Replacement 64

Fuel gauge Float Unit 65

Wiring Diagrams Complete- 66 Continental GT EURO III

List of Special Tools & Its application 67

PDI Check List 70

Personal Information 74

Guidelines for Undergoing Training Course 75

Nomination Form 76

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

TECHNICAL SPECIFICATION - CONTINENTAL GT

ENGINE

Type Single Cylinder, 4 stroke, Air cooled

Displacement 535 cc

Bore x stroke 87mm x 90mm

Comp ression Ratio 8.5:1

Maximum Power 29.1 bhp (21.4 kW ) @ 5100 rpm

Maximum Torque 44 Nm @ 4000 rpm

Ignition System Digital Electronic Ignition

Clutch Wet, multi-plate

Lubrication Wet sump

Engine Oil 15 W 50 API SL JASO MA EASTER Semisynthetic Oil

Engine Oil Capacity 2.75 Ltrs., (2.5 Ltrs. during oil filter element & oil replacement)

Fuel Supply Electronic Fuel Injection Programmed (PGM-EFI)

Air Cleaner Paper Element Filter Type

Engine Start Electric / Kick

Idle Speed 1050 + 200 RPM

TRANSMISSION

Clutch Wet Multiplate (7 Plates)

Primary drive Duplex Chain

Primary Drive Ratio 2.15 : 1

Gear box Constant Mesh 5 Speed

Gear shift pattern 1 - N - 2 - 3 - 4 - 5

Gear Ratios 1st: 3.06:1 / 2nd: 2.01:1 / 3rd: 1.52:1 / 4th: 1.21:1 / 5th: 1:1

Secondary Drive (F.D. Sprocket) 18 Teeth

Rearl W heel Driven Sprocket 36 Teeth

Final Drive Ratio 2.00:1

Drive Chain Links 100 Links

CHASSIS & SUSPENSION

Frame Type Cradle frame - Twin downtube type

Fuel tank capacity 13.5 Litres***

Low fuel warning 3.00 Litres***

Su spen sion

Front fork oil capacity & grade 430 ml per leg & Oil Grade - Gabriel Fork Oil 2W 35

Rear: Gas charged shock absorbers with adjustable preload, 80mm travel

Front: Telescopic, 41mm dia fr. forks, Stroke 110mm travel

Note: ***Fue l tank capacity given here is approx imate. It can vary ma rginally fr om this s pecified value.

TYRES & BRAKES

Tyre Front 100/90-18, 56 H Pirelli Sport Demon

Tyre Rear 130/70-18, 63 H Pirelli Sport Demon

Brake Front 300mm dia Floating Disc, 2 Piston floating caliper

Brake Rear 240mm dia Disc, Single Piston floating caliper

Brake oil capacity Front: 50 ml Rear: 100 ml

Brake oil grade DOT 3 or DOT 4

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ELECTRICALS

Electrical System 12 volt - DC, Alternator Battery 12 volt, 14 AH Head Lamp Non MFR headlamp, 12V H4 Bulb 60 / 55W Brake / Tail Lamp 12V 21W/5W Turn Signal Lamp 12V 10W ( 4 Nos) Instrum ent cluster Digital instrument Cluster with LCD High beam indicator 12V, 0.2W (L.E.D.) Term signal telltale 12V (L.E.D.) Neutral Telltale Bulb LH & RH 12V, 1.12W Horn (Dual) 12V, 2.5A (dual tone - LT, HT) Starter Motor 12V, 0.9KW

DIMENSIONS

W heelbase 1360 mm

Ground Clearance 140 mm Length 2060 mm Width 760mm (Without Mirrors) Heig ht 1070mm (Without Mirrors) Seat Height 800 mm Kerb W eight (Engine Oil & 90% Fuel capacity) 185 Kgs Gross Vehicle W eight 365 Kgs

WARNING

Using bulbs / other electrical gadgets other tha n specif ied rating may lead to over loading / erratic behaviour / premature failure of electrical sy stem.

Modific ations on the bike which are not approved by Roy al Enfield may not only dis qualify for warran ty , but also affec ts performan ce o f the bike.

VEHICLE OVERALL DIMENSIONS

W = 760 MM



140

ALL DIMENSIONS ARE IN ‘mm’



H = 1070 MM

WB = 1360 MM

L = 2060 MM



SH = 800 MM



NOTE :

1. Above Values / Dimensions are given for your guidelines / reference only.

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

GENERAL VEHICLE INFORMATION

CHASSIS NO.

VIN INFORMATION ENGINE NO.

VEHICLE IDENTIFICATION NUMBER - DETAILS

The VIN is a 17 digit number punched on the right side

Sample VIN :

Manufacturer’s code

Type of Frame Type of Engine

Variant / Version

Ignition System

Transmis sion Type

Production Year

(2010-A, 2011-B and so on)

Assembly factory

(C-Chennai, K-Kanchipuram )

Production Serial No.

C LME 3

TEE

XXX XXX

ENGINE NUMBER - DETAILS

The engine number is punched on the left hand side Crankcase - below the Cylinder barrel. It is the means of identification of the Engine and its production

S 5 F 0 D B

Engine Family

Engine Capacity

Type of Start

Transmission

Fuel Feed

Ass embly Factory

(0-C hennai, 1-Kanchi puram)

Year of Manufacture

( 2009-9, 2010-A, 2011 -B,....)

Production Month

(A - Jan., h - Aug., K - Sep., N - DEC.)

Production Serial Nos.

X X X X X X

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SALIENT FEATURES - CONTINENTAL GT

 Unique Silencer assembly.  Unique Rear Disc Brake (unique rear

wheel hub, Sprocket, brake and rear swing arm)

 Sports Racing Style fuel tank.  Digital Instrument Cluster (MPH & KMPH

Speedometer)

 New design air filter box.

 Seat with saddle lock (Cable type)

 Combination lock (Ignition & steering lock

combined in one set)

 Foldable type footrest - Rider & Pillion.

 41 mm robust straight front fork

 Gas charged Rear Shock Absorbers.

FRONT WHEEL

Front tyre : 100/90 -18”, 56H Pirelli Sport Demon

Front hub : New design hub integrated with adaptor disc,

Powder Coated - Dark Metalic Silver colour

Spokes & Nipples : Straight stainless steel spokes & brass nipples

Qty. 36 Nos.

Front brake : Disc - M/s. Brembo 300mm Dia - Brass Gold

Powder coat. Floating Type Disc - 2 Piece construction + 6 rivets. Double Piston (Dia 30 & 32mm) Floating Caliper with brass gold powder coat & Metal braided hose.

Ø32mm

Ø30mm

Wheel Rim : Aluminium Spokes Rim 2.15 X 18”

Front fork cut section

FRONT SUSPENSION

Steering stem assy. : Dark metallic silver coated bottom yoke with

double steering ring nut.

Fork LH & RH assy. : New fork assy. with 41mm dia pipe-non

threaded type, Friction reduction bushes (Guide bush & Slide bush type)

Front mudguard : Top Mounting Mudguard Plastic (ABS) in

Fork Brace + Detachable extension in black colour

Friction Reduction Bushes

Fork Brace : Aluminium Brace for extra reinforcement.

Wheel speed sensor : Electronic wheel speed sensor - position

guided in fork.

BENEFITS

 Improved ride comfort

 Better handling

 Higher rigidity of front end

 Improved Fork life

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SALIENT FEATURES - CONTINENTAL GT

REAR WHEEL

Rear Tyre / Make : 130 / 70-18”, 63H Pirelli Sport Demon

Rear Hub : Powder Coated - Dark Metalic Silver colour

Spokes & Nipples : Stainless steel spokes (Qty. 18 Nos. each

inner and outer) and brass nipples

Rear Brake : Disc brake - M/s. Brembo 240mm disc

(Brass Gold Powder Coat) Single Piston (Dia 32mm) floating Caliper with Metal braided hose.

Wheel Rim : Aluminium Spokes Rim 3.0 X 18"

ADVANTAGES

 Improved brake feel & less Operator fatigue

 Positive braking in rainy weather

 Auto-Adjustment for brake pad wear

 Easy pad replacement

 Maintenance free working

SWINGARM & SPROCKET

Rigid oval section swingarm with needle roller bearing pivot system.

Aluminium adaptor with detachable steel driven sprocket (36 Teeth).

HANDLE BAR

New design CLIP ON handle bar LH & RH split type with spring mass damper handle bar.

Vibration Damper Assem bly

Spring Mass

Rub ber

ADVANTAGES

 Mounted above top bridge plate with guide

screw for handle bar position.

 New type spring mass damper will reduce

vibrations in handle bar assy., will enhance riding comfort.

BENEFITS

 Improved handling  Prolonged life of chain and sprocket

TRAFFICATORS

New stylish trafficators.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SALIENT FEATURES - CONTINENTAL GT

FUEL SYSTEM

Fuel Tank : New Sports look tank, rubber mountings

on frame.

Fuel Gauge : New Fuel gauge -

Bar code display in Instrument cluster.

Fuel Pump : Electrical sub-

merged pump mounted under the tank.

INTEGRATED IGNITION SWITCH & STEERING LOCK

New Integral ignition switch cum steering lock.

FUEL LEVEL INDICATION

Drain Tube

Fuel Hose

FRAME

Cradle type - twin down tube frame.

REAR SHOCK ABSORBERS

Gas charged rear shock absorbers - Paioli. Travel 80mm stroke (Adjustable by thread & special nut)

GEAR CHANGER

Universal joint operated gear changer. Height adjustable according to rider comfort by rod and adjuster nut.

ADVANTAGES

 More stability and rigid.

 Reduced vibration.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SALIENT FEATURES - CONTINENTAL GT

AIR FILTER BOX

New designed air filter box. Improved volume to

4.5 litre (approx.) capacity.

To PAV

ADVANTAGES

 Better acceleration and pickup.

DIGITAL INSTRUMENT CLUSTER

Stepper motor driven speedometer & tachometer.

LCD FEATURE

TRIP A

ODOMETER

TRIP B

LCD DISPLAY PATTERN

ODOMETER

TRIP A

TRIP B

FUEL LEVEL INDICATION

SET - <1SEC

SET - <1SEC RE-SET >3 SECS

SPEEDO METER

LCD DISPLAY

TELL TALES

TURN LEFT

MIL

SET/RE-SET

SWITCH

(PUSH BUTTON)

HIGH BEAM

LOW BATTERY

TACHO METER

TELL TALES

TURN RIGHT

NEUTRAL

SET - <1SEC RE-SET >3

ODOMETER

SECS

OTHER PUSH BUTTON MANAGEMENT

1. Turn on Ignition Switch

Switch-KM to Mile

Software Version

Display

2. Keep LCD in ODO Mode.

3. Press set switch for >20+

1. Battery to be connected.

2. Turn Off ignition s witch.

3. Press set switch +

4. Softwa re ver sion will be

2 Secs.

di splayed for 2 Sec s and initial operation (ZPD) will be perf ormed.

NOTE:

Both Unit change over and software version display key operation usage is restricted to assembly operators and service personnels. Not to be shares with customers.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

TORQUE VALUES - CONTINENTAL GT

RIGHT SIDE VIEW

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

TORQUE VALUES - CONTINENTAL GT

LEFT SIDE VIEW

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

PERIODICAL MAINTENANCE - CONTINENTAL GT

The maintenance schedule detailed here will help you maintain your CONTINENTAL GT Motorcycles meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the Kms at which regular inspections, adjustments, replacements and lubrications are to be carried out.

The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dusty environment, severe cold, extreme heat, bad roads, standing water etc.,

No.

1 Engine Oil

2 Engine oil filter element R C R R R R R

3 Engine sump filter (oil strainer) C C C C C C C

Magnetic drain plug under gear box and secondary drain plug under

cranksharft in

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 for crack I I I I I I I I I I I

7 Fuel hose & clip / Injector ‘O’ Ring / Seal Ring I I I I R I I I R I I

8 Fuel Pump Check for screw tightness in all services

9 Accelerator & Throttle pully cable free 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 Air filter paper element C C C C R C C C R C C

13 Inlet / Exhaust valve seating I I

14 Cylinder head (Combustion chamber) D

15 Exhaust pipe D

16 Clutch lever 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 contact (below ECU Mounting) I I

21 Rear W heel Drive Chain

22 Front Fork oil / leak I I I R I I I R I I I

23 Steering ball races / play adjustment A L A R A L A R A L

24 Spokes tightness / W heel rim run out front & rear I I I I I I

25 Rear wheel cush rubbers I & R I & R

26 Tyre wear front & rear 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 I R I I

29 Pivot-Side Stand / Center Stand pivot L L L L L L L L L L L

30 Rider & Pillion Foot rest pivot L L L L L L L L L L L

31 Swing arm needle bearings and spindle L L

32 Vent Pipe under air filter box I & C I & C I & C I & C I & C I & C I & C I & C I & C I & C

33 Throttle body - cleaning spray* C C C C C

34 PAV pipes & hose clip I I I I I I I I R I I

35 Front & Rear brake hose and Banjo Bolt I I I I I I I I I I R

DESCRIPTION

Kms (x 1000) 0. 5 3 6 9 12 1 5 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

crankcase RH

FREE SERVICE

Whichev er is earl ier

R R R R R R

Check level at every 1000 Kms or earlier as required

C C C C C C C

Adjust every 1000 Kms or earlier as required

Lubricate every 3000 Kms or earlier as required

PAID SERVICE

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace NOTE :

For Maintenance after 30,000 Kms, Please repeat the same frequency specified above. Do not mix DOT 3 and DOT 4 brake fluid together. *Carbo cleaner / Carbclik or Fuel Line Cleaner Spray. (Make - W urth or ITW Chemin)

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

PERIODICAL MAINTENANCE

THROTTLE CABLE FREE PLAY ADJUSTMENT (CONTINENTAL GT)

(A ) ADJUSTMENT OF FREE PLAY AT ROTOR THROTTLE) GRIP FREE PLAY : 2 TO 3 MM

Check throttle radial free play 2-3 mm. If excess play then adjust throttle cable as shown Fig.

Slide the rubber boot, use 10 mm double end spanner to adjust cable outer and lock the nut. Adjust both cables uniform and tighten the lock nuts. After adjustment move the rubber boot over the lock nuts.

Loosen the lock nuts on both the cables.

Adjust both cables free play uniform and tighten the lock nuts.

Check point – after adjustment of throttle cables (Top & Bottom), start the bike and turn the handle bar from left to right side extremely. Ensure that there is no change in idle rpm or cable stretch / cable pulling.

(B) CHECKING PROCEDURE OF THROTTLE BODY ROTOR CABLES FREE PLAY

To achieve proper response from EFI Throttle body, fuel injection and ignition timing change over after 15% operation of rotor grip. Adjustment in the throttle body bracket v/s rotor pulley.

For checking remove RH side panel, it is recommended to maintain 1mm free play in inner cable end.

Adju. Nut

Lock Nut

THROTTLE CABLE ASSY. REPLACEMENT (CONTINENTAL GT)

While replacing throttle cable following procedure is recommended

(A) Re mo v e RH side c o ve r an d seat

assembly while replacing throttle cable.

(B) Connect throttle cables to Rotor / throttle

grip assembly at handle bar.

body rotor pulley and ensure the recommended free play.

(D) Route them and strap it the cables

properly.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SPARK PLUG - M14 (WQR8DC)

CLEAN AND ADJUST : EVERY 3000 KMS

Clean insulator tip and electrodes using a pointed scrapper or plug cleaning sand blaster machine.

Measure and adjust the gap.

Gap 0.80 mm

AIR FILTER PAPER ELEMENT

CLEAN AND REFIX : EVERY 3000 KMS

Remove the screw from the side cover bottom side and then take out RH side cover.

Takeout air filter paper element and check for dirt. Gently tap it as shown in fig and fix it back .

NOTE :

It is adviceable to replace air filter paper element once in 10,000 KMS. In case of vehicle running in dusty / mud road condition it may be replaced as earlier as required.

Usage of high pressure compressed air is not recommended to clean air filter paper element.

Fitment of air filter paper element is reverse order of removal process.

BRAKE FLUID

FRONT

Remove the air filter cover screws and then takeout air filter box cover.

Vent Pipe

Transparent Vent Pipe to be check in all services. In case of oil / water found clean & refix.

Max

Min

REAR

Max

Min

Check if oil is below “MIN” level. To top up, remove cover with diaphragm and top up with either DOT 3 or DOT 4 as specified.

CAUTION :

Please take care that it does not spill over on any other parts of the motorcycle. Please wipe the spilled brake fluid immediately, if there is any spill over, using a soil cloth (preferably a wet cloth) to avoid damage to paint work or other parts.

Don’t Mix DOT 3 & DOT 4 Brake Fluid together.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

STEERING STEM PLAY ADJUSTMENT

Place Motorcycle on Center Stand

Keep a wooden plank under the stand to Rise the Front Wheel

Hold the Fork pipe (Main Tube) pull and push simultaneously lift the front wheel upwards, check Steering play as shown in Fig. A.

Loosen the pinch bolts in bottom yoke by using Allen key 6mm LH and then RH side.

Loosen the lock ring nut before adjusting steering play.

Rock the front wheel down wards and feel the play / sound at stem top dome nut by fingers as shown in above fig B.

If felt, adjust the steering free play as per following procedure.

Loosen the steering dome nut by 30 mm socket with long extension rod and tommy bar as shown in fig.

CAUTION :

Do not use socket directly

In case of excessive steering play tighten the steering ring nut by using special tool (C spanner)

After adjusting the play then tighten lock nut against ring nut as shown in fig.



Steering Dome Nut

Don’t

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

After adjusting the play then tighten Dome nut to Torque 5.0 kg/Nm.

Again check and confirm the steering free play.

Tighten the pinch bolts in bottom yoke LH and then RH by using Allen key 6mm

(Torque 25 N-m).

Now Check the handle bar free movement by turning extreme Left to Right side.

CAUTION :

Do not use Ring spanner directly to tighten dome nut.

NOTE :

Take a small test ride to ensure that

- Steering free movement.

- No dragging.

- No sound from steering stem / mounting area.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

REAR WHEEL DISMANTLING & ASSEMBLING / BRAKE PAD REPLACEMENT

REAR WHEEL DISMANTLING

Place the vehicle on center stand on a firm and flat surface.

Observe and mark the alignment index marks in the both sides of swing arm.

Index mark

Remove axle nut on the RH side.

Remove the distance collar. Tilt the motorcycle and take out the rear

wheel assembly conveniently.

CAUTION :

Do not press the rear brake pedal when wheel is removed as this will result in the brake pads coming too far out of the brake caliper.

Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the rear brake pedal is accidently pressed.

REAR BRAKE PAD REPLACEMENT

PAD DISMANTLING

QD spindle nut

Remove wheel spindle from LH side.

Remove the caliper assembly by pulling out from the swing arm slot.

Remove the wooden piece / card board sheet in between the brake pads.

Remove the clip hanger from the caliper assembly by using combination plier.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Remove the pad pin from the caliper assembly by using combination plier.

Remove the worn out brake pad from the caliper assembly.

PAD ASSEMBLING

Place the new brake pad into caliper assembly as shown.

Insert the pad pin in caliper assembly by using combination plier.

Pad Service Limit 3.8mm

Steel back plate

Pad

3.8mm (Min) Worn Pad thickness

Clean the caliper assembly by dry / clean cloth.

Insert the clip hanger in caliper assembly.

Place the wooden piece / card board sheet in between the brake pads.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

REAR WHEEL ASSEMBLING

Before fix the wheel assembly into the vehicle check the rim run out by wheel truving guage and wheel bearings play.

Play

Axial

Service Limit : Axial 2mm Radial 2mm

Remove the wooden piece / card board sheet placed between the brake pads.

Position the rear wheel with cush rubber on the rear driven flange.

Play

Remove the wooden piece / card board sheet in between the brake pads.

Radial

Ensure the four cush rubbers are in position inside the rear wheel hub.

Cush Rubbers

Tilt vehicle to right and insert wheel assembly between the swing arms.

Insert the caliper assembly by pushing in the projection given inside the swing arm. Ensure the brake d isc is located in between the brake pads.

Align the caliper bracket, wheel and swing arm holes in-line and ensure distance collar is placed in hub dust seal.

Befo re insert th e front wheel spindle ch eck the spindle run out.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Insert and tap the rear wheel axle gently.

CAUTION :

Do not force the spindle into the wheel as the threads may get damaged. Tap it through the wheel gently.

Ensure the index marks alignments on both sides of the swing arm are in same position for proper wheel alignment.

Drive chain slack

adjusting nut

Index mark

Swing Arm reference mark

Tighten the axle nut firmly by holding another end of axel as shown in fig.

Adjuster Lock nut

CAUTION :

Please check brake hose pipe routing from reservoir to master cylinder, master cylinder to rear wheel caliper.

Their should not be any twist or pinch in routing which may affect braking performance.

DRIVE CHAIN FREE PLAY (PLAY 20 TO 25 MM)

Place motor-cycle on its center stand on a firm & flat surface.

Shift the gear into the neutral position

Drive chain slack

adjusting nut

Index mark

Swing Arm reference mark

Adjuster Lock nut

Ensure that swing arm end plate is seated properly and the chain adjuster nuts are correctly tightened and Locked.

WARNING

Ensure the vehicle do not come out of center stand while dismantling and assembling the

wheel assembly. Failure to adhere could result in damage or injury.

Measure the drive chain free play as shown. The drive chain free play is 20 to 25 mm.

1. If the drive chain free play is incorrect adjust as follows:

a. Loosen the axle nut of the rear wheel axle.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

b. Loosen the sprocket QD spindle nut.

c. Loosen the lock nut at both end of the swing

arm.

d. To reduce the free play, turn the drive chain

slack adjusting nut in clockwise direction.

i. Tighten the adjuster lock nut by 13mm

spanner against chain slack adjusting nut.

WARNING

Chain slackness beyond 30mm will lead to chain slippage.

Maintain drive chain slackness within the specified limits at every 1000 kms interval.

Please Check the front and rear wheels are correctly aligned, after the chain adjustment.

e. To increase the free play, turn the drive chain

slack adjusting nut in anticlockwise direction and push the rea r wheel f orward.

f. Later adjust the nut on Lh side by matching

the index mark with respect to Rh side index.

g. Ensure that both the sides are in same index

marks.

h. Finally torque the spindle and axle nuts to 7

kgm.

CHAIN LOCK FITMENT

The open end of the chain master link lock should face opposite to normal direction of chain rotation.

WARNING

The fitment of lock in wrong direction other than shown above can lead to its falling off, and thus can cause the sudden disconnection of the chain during the drive.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT WHEEL, FORK OIL REPLACEMENT & FRONT FORK OVERHAULING

FRONT WHEEL REMOVAL

Place the vehicle on center stand

Place a wooden block the front end of engine to support the vehicle.

Remove the axle nut along with washer.

Tap and remove the front wheel spindle.

Loosen the pinch bolt on the RH fork guide by 6 mm allen key. Hold the axle head by double end spanner while loosening the axle nut.

NOTE :

In case of not holding axle head by double end spanner may cause fork bottom lug fork ovality and create sound.

Tilt the vehicle to RH Side and take out the wheel along with wheel speed sensor and LH side spacer.

Locating TAB

CAUTION :

Do not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper.

Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the front brake lever is accidently pressed.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK DISMANTLING

Place motorcycle on centre stand.

Remove front wheel (ref page no. 22)

Remove the clip - speedo drive wire guide from RH front fork.

Remove the front caliper top and bottom mo u nti n g bo lts by using 13 mm T spanner. Gently take out caliper brake hose from the hose guide hook above front mudguard.

Remove head lamp holding bracket RH mounting bolt and then LH. Loosen both side bracket pinch bolt.

80mm Gap

Loosen the top yoke fork two pinch bolts on LH and then RH by using Allen key 6mm.

NOTE :

place the wooden or cardboard sheet in between brake pads.

CAUTION :

Care to be taken not to operate disc brake.

By using 5 mm allen key to remove the brace cum mudguard mounting bolts (4 Nos.) from the fork bottom leg and take out mudguard along with fork brace gently (without scratching paint).

Remove CLIP-ON handle bar LH & RH mounting screw by 5mm allen key.

Shake and turn to take out CLIP-ON handle bar RH then LH as shown in fig.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Loosen the fork cap nut in vehicle itself, by using 22 mm socket with tommy bar.

Loosen the fork pinch 2 bolts each from steering bottom yoke RH and then LH.

FRONT FORK OIL REMOVAL

Re mo v e the fork c a p nut with ‘O’ ring and Plain washer (fig. 1).

Expand the cap nut ‘O’ ring and remove from the cap nut (fig. 2).

Remove the spacer (fig. 3), washer spring top (fig. 4) and main spring (fig. 5) from fork.

Remove the front fork assy. left and then right. Take care of head light assy. and head lamp holders & wiring couplers properly.

For Front fork refitting process Ref. page no. 28.

Remove the fork oil from the front fork by push and pull several times, so that complete oil will drain out.

For Front fork oil refilling process Ref. page no. 27.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK OVERHAULING

FRONT FORK DISMANTLING

Pla ce the fo rk - outer tube bo ttom rectangle section in bench vice and remove the allen fork piston mounting Allen bolt as explained below process.

NOTE :

To avoid crack / scratch in fork bottom tube use cloth while fixing to bench vice

Insert the special tool into the fork inner tube to lock the piston head and remove the Allen bolt and washer by using 8mm Allen key.

NOTE :

Pull out the inner tube with big washer and slide bush with outer tube.

In case of found difficulty, it is adviced to warm up by electrical stove or heater/hot plate, then apply pressure for pulling outside.

Remove the cap oil lock (fig. 6), piston sub assembly (fig. 7) and piston ring by expanding the ring (fig. 8)

Remove the dust seal and circlip from the outer tube then take out fork oil seal.

Seperate the inner tube from outer tube

Bush

Bush Outer tube

Washer

Exploded View

NOTE :

While overhauling the front fork, always replace piston ring (plastic), oil seal, dust seal, cap bolt “O” ring and bottom allen bolt copper washer along with fork oil is recommended.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK ASSEMBLING

Expand and fix the new plastic piston ring on fork piston as shown in fig.

Check the piston sub (rebound) spring length with vernier caliper.

Fix rebound spring on the piston sub assembly fig. C.

Place the fork inner tube upside down (fig. D) and then assemble cap oil lock piece (fig. E) as shown in fig.

Check the inner tube run out (keeping guide bush area away from the ‘V’ Block)

Service Limit: 0.15 mm

Guide Bush

Length

New Spring: --mm

Service Limit: ---mm

Hold the fork special tool in bench vice as shown in fig A.

Place the piston sub assembly on fork tool fig. B.

NOTE :

Ensure the special tool tip square 22mm has been properly seated inside the piston.

Place the fork outer tube upside down (fig. F), fix the allen bolt with new copper washer (fig. G) and tighten the allen bolt by using 8mm allen key (Torque 30 N-m) (fig. H).

Remove the front fork from the special tool.

Fix the slide bush (fig. I) and big washer (fig. J) on outer tube by using special tool

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK OIL FILLING

Pour new fork oil 430 ml per leg (Make Gabriel fork oil, Grade - 2W 35 )

Smear grease inside the new oil seal then fix and outer tube by using special tool - oil seal driver. Drive the oil seal into fork outer tube.

Fix the circlip and then dust seal.

Place the main spring (fig. K) , washer spring top (fig. L) and spacer tube (fig. M) into the inner tube as shown in fig.

K L

NOTE :

Place the Main spring long coil pitch facing updwards as shown in fig. K.

Check the main spring length, if length difference is more than 5mm in between new and old spring, then replace both side fork springs.

Spring Length --- mm

Long Pitch

Short Pitch

Place the plain washer (fig. N) and cap nut with new “O” ring (fig. O), then tighten the cap nut (fig. P) properly.

Finally tighten fork top nut on

the bike (Torque 20 Nm)

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK OVERHAULING / OIL REPLACEMENT

FRONT FORK REFITTING

Refix the front fork leg assy. RH an d then LH.

NOTE :

Take care of head light assy., head lamp holders & Wiring harness / couplers are routed inside rubber grommet properly.

Fix the head lamp holder bolt and nut and tighten them.

80 mm

Tighten the pinch bolt in steering bottom yoke.

NOTE :

Ensure that 80mm approximate gap between headlamp holder and steering stem bottom yoke as shown in above fig.

Place the mudguard with brace gently (without scratching paint). In between both front fork legs.

Fix the mudguard mounting allen screw (4 Nos.) from the top side on the front shock absorber by using 5 mm allen key.

Place the CLIP-ON handle bar LH and then RH. Tighten the pinch bolts in top yoke by using Allen key 6mm (Torque 25 N-m).

NOTE :

Ensure that CLIP-ON handle bar top surface aligned with fork top nut level then tighten the top yoke 2+2 pinch bolt.

Check the alignment of head lamp holder LH & RH in both directions to get proper headlight focus.

Refix the front caliper top and bottom mounting bolts by using 13 mm T spanner. Gently routing caliper brake hose to the hose guide hook on the front mudguard

CAUTION :

Care to be taken not to operate disc brake.

In case of shims observed fix it back in the same location while mounting caliper assy on front fork.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT WHEEL REASSEMBLY

Remove the wooden piece / card board sheet placed between the brake pads.

Before fixing the front wheel assembly into the vehicle, check wheel rim run out by wheel truving gauge & wheel bearings play.

Play

Axial

Play

Radial

Service Limit : Axial 2mm Radial 2mm

Place the wheel speed sensor in fork guide position.

Locating TAB

Insert and tap the front wheel axle gently inside.

Refit the washer and tighten the nut by using 24mm socket RH end by using 16mm double end spanner (Torque 70 N-m)

Tighten the pinch bolt on the RH fork guide.

NOTE :

Ensure slot on hub and speedo sensor is matched correctly.

Insert the wheel along with wheel speed sensor & LH spacer between the front fork ends. Ensure the brake disc is located in between the brake pads.

Rotate the wheel and check for smooth rotation.

Ensure wheel speed sensor wire coupler is being connected to cluster unit and then check for proper working of speedo meter.

Press brake lever 2 or 3 times to check front brake efficiency.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

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

New Min.

Cylinder bore :

Point of measurement

UCE 535

87.045 mm

87.074 mm

87.190 mm

Piston

UCE 535 UCE 535

86.940 mm

Ring to groove clearance : Comp. Top ring

UCE 535

New Min.

New Max.

Service Limit

Ring to groove clearance: Comp. ring - Middle

New Min.

0.03 mm

0.07 mm

0.11 mm

0.05 mm

New Max.

Service Limit

New Min.

New Max.

Service Limit

86.970 mm

86.890 mm

Piston to bore clearance

UCE 535 UCE 535

0.095 mm

0.114 mm

0.30 mm

New Max.

Service Limit

Ring to groove clearance : Oil rings

New Min.

New Max.

Service Limit

0.09 mm

0.15 mm

0.16 mm

0.38 mm

0.44 mm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

Piston ring end gap : compression rings

UCE 535

From top 1st 2nd

New Min. 0.20 mm 0.35 mm

New Max. 0.35 mm 0.50 mm

Service Limit 0.70 mm 0.85 mm

Piston ring end gap oil rings - Top and

bottom rail

New Min.

New Max.

Service Limit

Piston Pin diameter

UCE 535

19.992 mm

19.997 mm

19.982 mm

Valve stem OD (Inlet)

41.3mm

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

UCE 535

0.20 mm

0.70 mm

0.90 mm

Valve stem OD (Exhaust)

UCE 535

6.945 mm

6.960 mm

6.935 mm

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

UCE 535

6.965 mm

6.980 mm

6.955 mm

Valve to guide (inlet) clearance

UCE 535

0.02 mm

0.05 mm

0.08 mm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

Valve to guide (Exhaust) Clearance

New Min.

New Max.

Service Limit

UCE 535

0.04 mm

0.07 mm

1.00 mm

Valve guide bore

New Min.

New Max.

Service Limit

Throttle cable free play

UCE 535

1 mm

2 mm

Drive chain : slackness

New Min.

New Max.

Service Limit

Spark Plug Gap (M14 - WQR8DC)

New Min.

New Max.

Service Limit

UCE 535

7.00 mm

7.015 mm

7.25 mm

535CC

0.80 mm

0.90 mm

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

UCE 535

20.00 mm

25.00 mm

30.00 mm

Rear Sprocket chain pull off

UCE 535

5.00 mm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

GOOD

New Min.

New Max.

Service Limit

FD and Rear Driven - Sprocket

REPLACE

UCE 535

Sharp, bend

broken teeth

Drive chain length across 21 pins

Front fork (GIL) assembly spring : length

UCE 535

New Min.

New Max.

Service Limit

Front Caliper Bore Inner Diameter (Brembo)

Difference between old and new spring length 5mm

New Min.

New Max.

Service Limit

Front Fork Main tube (GIL) - Run out

New Min.

New Max.

Service Limit

UCE 535

320 mm

322 mm

328 mm

UCE 535

0.00 mm

0.04 mm

0.15 mm

UCE 535

A B

New Min. - -

New Max. 30.00 mm 32 mm

Service Limit - -

Front Caliper Piston Outer Diameter (Brembo)

UCE 535

A B

New Min. 30.00 mm 32 mm

New Max. - -

Service Limit - -

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

Front Master Cylinder piston OD (BBI)

New Min.

New Max.

Service Limit

UCE 535

12.64 mm

Front Master Cylinder Bore (BBI)

Pad

New Min.

New Max.

Service Limit

Steel back plate

3.8mm (Min) Worn Pad thickness

Rear brake pad lining

Steel back plate

Pad

3.8mm (Min) Worn Pad thickness

Front brake

pad lining

(Brembo)

UCE 535

3.8 mm

New Min.

New Max.

Service Limit

New Min.

New Max.

Service Limit

UCE 535

13.00 mm

12.76 mm

Front / Rear Tyre tread : Depth

UCE 535

1.00 mm

New Min.

New Max.

Service Limit

Tyre wear indicator

New Min.

New Max.

Service Limit

UCE 535

3.8 mm

Front / Rear Wheel

TWI

UCE 535

1.00 mm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

New Min.

New Max.

Service Limit

Front Disc thickness

(BBI)

UCE 535

5.00 mm

4.2 mm

Rear Disc

Thickness (BBI)

Service Limit : Axial 2mm Radial 2mm

New Min.

New Max.

Ax ial & Radial Service Limit

Rear wheel run out

Play

Axial

Play

Radial

UCE 535

2.00 mm

UCE 535

New Min.

New Max.

Service Limit

5.00 mm

4.5 mm

Final Driven Sprocket 36T-Flatness & Run out

UCE 535

New Min. Flatness

New Max. Flatness

Service Limit : Run out

0.00 mm

0.40 mm

0.35 mm

Service Limit : Axial 2mm Radial 2mm

New Min.

New Max.

Ax ial & Radial Service Limit

Front wheel run out

Play

Axial

Play

Radial

UCE 535

2.00 mm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

SERVICE LIMITS OF VARIOUS COMPONENTS

Rear wheel disc flatness & run out

UCE 535

A B

New Min. Flatness 0.00 mm 0.00 mm

New Max. Flatness - 0.10 mm

Service Limit : Run out - disc

BRAKE PADS

Wear indication marks on pads

Front wear Pad Rear wear Pad

BRAKE DISC

Minimum disc thickness marked on disc

Front Disc

Front wheel disc flatness & run out

UCE 535

A B

New Min. Flatness 0.00 mm 0.05 mm

New Max. Flatness - 0.08 mm

Service Limit : Run out - disc

Rear Disc

NOTE :

1) Ensure free sliding of caliper on caliper bracket- if necessary lubricate using silicon base grease.

2) Inspect during every service Rubber & Plastic parts, If found any cracks, broken & damages to be replace.

BRAKE FLUID

Replace brake fluid every two years. (In severe operating conditions - replace every year)

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

FRONT FORK (GIL)

Key Nos.

All Except 2

Key Nos.

All Except 1 & 19

Each Qty. 2 Nos.

3, 7, 9, 11, 17 & 20

Key Nos.

8765

Key Nos.

QEach Qty. 2 Nos.

7, 9, 11, 17 & 20

Key Nos.

Each Qty. 2

Nos. 13 & 21

Key Nos.

Each Qty. 2

Nos. 2, 7, 9, 11,

12 & 20

Key Nos.

1, (Qty. 2 Nos.

7, 9, 11, 12,

19 & 20

1617

KEY

NO.

A1 Front Fork Assy. LH - Continental GT 1

A2 Front Fork Assy. RH - Continental GT 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

A6 Bottom Tube LH Sub Assy. Kit 1

A7 Bottom Tube RH Sub Assy. Kit 1

1 Outer Tube - RH 1

2 Outer Tube - LH 1

3 Inner Tube Assy. 2

4 Piston 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 Oil Lock 2

DESCRIPTION

QTY.

REMARKS

KEY

NO.

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 M8X1.25 X45 1

20 Piston Ring 2

21 Spring – 2 2

22 Cable Guide - Brake Hose 1

23 Cable Guide - Speedo Cable 1

24 Hex. Bolt M6 X 12 2

25 Plain Washer 2

26 Lock W asher, M6 2

27 Oil 2

DESCRIPTION

QTY.

REMARKS

STEERING STEM ASSEMBLY & HANDLE BAR ASSEMBLY

Key Nos.

3, 4, 6 & 7

(Qty. 38 Nos. 5)

7 5

4 3

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

STEERING STEM ASSEMBLY HANDLE BAR ASSEMBLY

KEY NO.

A1 Ball Race Kit with Cover - 1

Continental GT 535cc

1 CABLE GUIDE-SPEEDO CABLE 1

2 Steering Stem Assembly 1

3 Dust Seal - Bottom Yoke 1

4 Ball Race 1

5 Ball Dia 6.35 (Dia ¼”) 38

6 Dust Cap - Top Yoke 1

7 Ball Race - Top Yoke 1

8 Ring Nut 2

9 Lock Nut 1

10 Hex. Socket Head Screw 4

M8 X 1.25

DESCRIPTION

QTY.

REMARKS

KEY

NO.

A1 Spring Mass Vibration Damper Assy. Kit 2 Replace along with

1 Handle Bar Assy. - LH 1

2 Handle Bar Assy. - RH 1

3 Top Yoke 1

4 Hex. Socket Head Screw M8 X 35 4

5 Ignition Switch with Steering Lock Assy. 1

6 Hex. Socket Head Cap Screw M6 X 20 4

7 Instrument Cluster 1

8 Rear View Mirror - RH 1

9 Rear View Mirror - LH 1

10 Hex. Socket Head Bolt M8 X 35 2

11 Soc. HD Cap Screw M6 X 16 4

12 Grommet - Clip ON 2

DESCRIPTION

QTY.

Key No. 1 or 2

REMARKS

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

11 Bracket - Number Plate Front 1

12 Number Plate - Front 1

13 Hex. Flange Bolt M5 X 12 2

14 Hex. Nut M5 2

15 Hex. Bolt M6 X 1 X 12 3

13 Screw Countersunk - Long 1

14 VibrationDamper - Chrome Plated 1

15 Rubber Mass 2

16 Sleeve (Pipe) 1

17 Washer 2

18 Flanged Hex. Nut 1

N.S. Service inKit Ref. A1

REAR WHEEL ASSEMBLY

Key Nos.

11, 12, 13, (Qty. 18 Nos.

14 & 15),18 to 24

Key Nos.

21, (Qty. 2 Nos. 22)

Key Nos.

16 & 17

Key Nos.

21, (Qty. 2 Nos. 22),

27 & 28

Key Nos.

(Qty. 18 Nos. 14,

15), 18

Key Nos.

3 & 10

Key Nos.

7 to 9

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

REAR WHEEL ASSEMBLY

KEY NO.

A1 Rear Wheel Sub Assembly without 1

Tyre & Tube

A2 Rear Wheel Bearing Kit 1

A3 Rear Wheel Tyre & Tube Kit - 130/80 - 18” 1

A4 Bearing and Seal Kit Rear Wheel - 1

Continental GT

A5 Wheel Spokes and Nipple Kit - 1

Continental GT

A6 Short Spindle and Nut Kit 1

A7 Rear Spindle, Washer and Nut Kit 1

1 Rear Wheel Assy. 1

2 Rear Sprocket – Adaptor Assy. 1

3 Spindle - Short 1

4 Spacer - Sprocket Side 1

DESCRIPTION

QTY.

REMARKS

KEY

NO.

12 Rear Disc Plate 1

13 Rim Rear (Steel) 3 X 18" 1

14 Spokes Inner - Rear 18

15 Spokes Outer Rear 18

16 Rear Tube - 130/80-18" 1 N.S., Served in Ki

17 Rear Tyre - 130/80-18" 1 N.S., Served in Kit

18 Brass Nipples 36

19 Head Socket Head Screw M6 X 14 6

20 Rim Tape 1

21 Grease Seal 1

22 Deep Groove Ball Bearing 6203 2

(17 X 40 X 12) (Double Side Rubber Sealed)

DESCRIPTION

QTY.

REMARKS

Ref. A3

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

5 Spacer – Disc Side 1

6 Caliper Assy. - Rear 1

7 Washer 1

8 Spindle - Long 1

9 Hx. Lock Nut 1

10 Hex. Nut M16 X 1.5 1

11 Centre Hub - Rear 1

23 Rear Hub Spacer Assembly 1

24 Cushion Rubber 4

25 Sprocket - Rear Drive 1

26 Adaptor – RD Sprocket (Metalic Silver) 1 Alt. No. 585310/A

27 Bearing 6005 C3 (25 X 47 X 12) (Double 1

Side Rubber Sealed)

28 Dust Seal - RD Sprocket 1

29 Socket Button Head Cap Screw 6

REAR MASTER CYLINDER ASSEMBLY

Key Nos.

1 to 15

Key Nos.

16, (Qty. 2 Nos. 17),

(Qty. 4 Nos. 18)

Key Nos.

24 & 25

Key Nos.

20, 21 & 22

2 to 5, 8 & 9

Key Nos.

2 to 9 & 10E

Key Nos.

12 & 13

Key Nos.

17 (Qty. 2 Nos. 18)

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

4 5

10A

10C

10B

REAR MASTER CYLINDER ASSEMBLY

KEY NO.

A1 Rear Master Cylinder Assembly 1

A2 Rear Brake Hose Assy Kit with Banjo Bolt 1

A3 Reservoir Tube Kit Rear M/C 1

A4 Reservoir Kit Rear M/C Threaded 1

A5 Minor Kit Rear M/C 1

A6 Major Kit Rear M/C 1

A7 Connector Kit Rear M/C 1

A8 Banjo Bolt Kit (Disc Brake) 1

1 Master Cylinder M/C - Rear Body 1 N.S., Ref. A1

2 Spring Rear M/C 1 (N.S.) Served in Kit,

3 Spring Guide Rear M/C 1 (N.S.) Served in Kit,

4 Primary Seal Rear M/C 1 (N.S.) Served in Kit,

5 Primary Washer 1 (N.S.) Served in Kit,

6 Pisto n - Rear Master Cylinder 1 (N.S.) Served in Kit,

7 Seal (‘O’ Ring) Rear M/C 1 (N.S.) Served in Kit,

8 Spacer Rear M/C 1 (N.S.) Served in Kit,

9 Circlip Rear M/C 1 (N.S.) Served in Kit,

10 Push Rod Assembly Kit Rear M/C 1 (N.S.) Served in Kit

10 A Push Rod Rear M/C 1 (N.S.) Served in Kit,

10 B Fork Push Rod Rear M/C 1 (N.S.) Served in Kit,

10 C Lock Nut Rear M/C 1 (N.S.) Served in Kit,

DESCRIPTION

QTY.

REMARKS

Ref.A6, A7

Ref. A7

Ref.A6, A7

Ref. Key 10

KEY

NO.

10 D Push Rod Assembly Rear M/C 1 (N.S.) Served in Kit,

11 Boot Rear M/C 1 (N.S.) Served in Kit,

12 Bush Rear M/C 1 (N.S.) Served in Kit,

13 Connector Rear M/C 1 (N.S.) Served in Kit,

14 Cap - Dust Protector 1 N.S .

15 Thread Protector 1 N .S .

16 Brake Hose Rear (Metal Braided) 1 (N.S.) Served in Kit,

17 Banjo Bolt (Black Tri-Valent) 2 (N.S.) Served in Kit,

18 Copper Washer Disc 4 (N.S.) Served in Kit,

19 Hex. Socket Button Head Screw M6 X 1 1 (N.S.) Served in Kit,

20 Reservoir Rear (Threaded) 1 (N.S.) Served in Kit,

21 Diaphragm Rear Disc Reservoir 1 (N.S.) Served in Kit,

22 Lid Reservoir Threade d 1 (N.S.) Served in Kit,

23 Clip (Reservoir) 2 (N.S.) Served in Kit,

24 Rubber Tube - Rear Disc 1 (N.S.) Served in Kit,

DESCRIPTION

QTY.

REMARKS

Ref. Key 10

Ref. A1

Ref. A8

Ref. A2

Ref. A2, A9

Ref. A4

Ref. A4, A5

Ref. A3

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

REAR CALIPER ASSEMBLY

Key Nos.

A2,

(In Page No. 116 -

A1, 16, (Qty. 2 Nos. 17 & 24),

(Qty. 4 Nos. 18), 20 to 23 & 25)

Key Nos.

10, 15, 17, 18,

19 & 21

Key Nos.

1 to 20

Key Nos.

6 & 7

Key Nos.

2, 3, 4, 10, 12,

13, 14 & 21

Key Nos.

2, 3, 10, 12,

13, 14 & 21

(Qty. 2 Nos. 9)

Key Nos.

11, 12 & 21

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

REAR CALIPER ASSEMBLY

KEY NO.

A1 Disc Brake Assembly Rear - BBI 1

A2 Caliper Assembly Rear - BBI 1

A3 Disc Pad Kit Rear Caliper - BBI 1

A4 Major Kit Rear Caliper 1

A5 Minor Kit Rear Caliper 1

A6 Pad Pin Kit Rear Caliper 1

A7 Primary Pin Kit Rear Caliper 1

A8 Bracket Sub Assembly Rear Caliper 1

1 Caliper Body (Brass Gold P.C.) 1 (N.S.) Served in Kit,

2 Piston Seal Rear Caliper 1 (N.S.) Served in

3 Scrapper Ring Rear Caliper 1 (N.S.) Served in

4 Piston - Rear Caliper (Dia 32mm) 1 (N.S.) Served in

5 Pad Spring Rear Caliper 1

6 Pad (Piston Side) Rear Caliper 1 (N.S.) Served in Kit,

7 Pad (Opposite Piston Side) Rear Caliper 1 (N.S.) Served in Kit,

DESCRIPTION

QTY.

Ref. A1

Kit,Ref. A4, A5

Kit,Ref. A4

Ref. A3

REMARKS

KEY

NO.

10 Insulator Rubber Rear Caliper 1 (N.S.) Served in

11 Primary Pin Rear Caliper 1 (N.S.) Served in Kit,

12 Dust Cover Rear Caliper 1 (N.S.) Served in Kit,

13 Bleeder Screw Rear Caliper 1 (N.S.) Served in

14 Bleeder Cap Rear Caliper 1 (N.S.) Served in Kit,

15 Bracket Sub Assembly Rear Caliper 1 (N.S.) Served in Kit,

16 Thread Protector 1 N.S., Ref. A2

17 Wear Pad Rear Caliper 1 (N.S.) Served in Kit,

18 Bracket Machined Rear Caliper 1 (N.S.) Served in Kit,

19 Secondary Pin Rear Caliper 1 (N.S.) Served in Kit,

20 Pad Spacer 1 N.S., Ref. A2

21 Grease Pouch (Reference Only) (N.S.) Served in

DESCRIPTION

QTY.

REMARKS

Kit,Ref.A4,A5,A8

Ref. A7

Ref.A4,A5,A7

Kit,Ref. A4, A5

Ref. A4, A5

Ref. A2, A8

Ref. A8

Kit,Ref. A4,A5,A7,A8

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

8 Pad Pin Rear Caliper 1 (N.S.) Served in Kit,

Ref. A6

9 Clip Hanger Rear Caliper 2 (N.S.) Served in Kit,

Ref. A6

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MOUNTING ON FRAME ASSEMBLY

Fit the ignition coil on the frame.

NOTE :

Be ensure that before fixing the engine on frame, throttle body, breather pipe, nipple and rear mounting brackets are removed, other wise engine entering in to frame will be difficult.

Insert the engine assembly on the frame (during that time sligtly tilt the engine).

Route the relay starter harness & alternetor wires below the engine Rr mounting bracket.

Fix the engine rear mounting bracket “R” Index Mark facing right side as shown.

Fix the engine front mounting bracket on the engine along with horn bracket.

Fix the engine rear mounting bracket on the frame with slight lifting the engine.

Fix the side stand with bracket on the LH side of frame and engine rear bottom mounting bracket on the RH side.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Insert the engine rear bottom mounting bracket “R” Index Mark facing right side as shown in fig and then fix axle in to the frame.

Fix the engine eye steady mounting bracket “R” Index Mark facing right side as shown in fig on the frame.

Fix the front engine mounting spacer as shown in fig.

Fix the engine front mounting bolt and nut tightened to Torque TT - 70 Nm.

Fix the engine eye bolts and nut tightened to Torque TT - 25 Nm.

NOTE :

Fit the throttle body assembly on the cylinder head and then tighten allen screw M6 (1.0 Kgm).

“O” Ring

NOTE :

Ensure “R” facing bracket curvature located towards cylinder head as shown in above fig.

Ensure that “O” Ring insualtor facing towards the cylinder head as shown in above fig.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Fit the engine breather hose and adopter on the engine

Ensure the engine tightening torque as specified (Ref. Page 10 & 11).

Connect the all wiring couplers such as magneto, injector, TPS, MAP, neutral switch, starter motor. etc...

ANTI SKIP MECHANISM

Arm - shift camplate stopper

ENGINE DISMOUNTING

FROM FRAME ASSEMBLY

Engine Dismounting from the frame is the reverse procedure of the fitting.

Remove Throttle Body Complete Assy From The Cylinder Head.

Remove Engine bottom bedding bolt.

Striker-Gear Change

Cam Plate assy.

Spring Pawl

Roller Type Pawl Camplate

Cam Plate

Plate - Anti skip

Bolt Anti Skip

Gear Changer Assy.

Plate Anti Skip

Spring

Pawl Bolt

Remove Engine bottom bedding mounting bracket bolts from the Frame RH & LH 2 Nos. each.

Copper Washer

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Loosen the engine front top mounting bolt and nut.

Disconnect all wiring couplers such as magneto, injector, TPS, MAP, neutral switch, starter motor. etc.. and chain master link.

Remove engine rear mounting as shown in fig.

Remove the horn bracket both the side.

Re move the engine front mounting brackets LH & RH side from the engine.

Disconnect engine breather pipe from the engine RH cover and then remove the breather adopter nipple.

Re mo v e the eng ine rea r moun ti n g brackets LH & RH side from the engine.

Take out engine assy from the frame gently.

NOTE :

Care to be taken, while taking out engine fro m chassis to avoid scratch / dent.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

ELECTRONIC CONTROL UNIT (ECU)

Manual Bi-starter

MAP Sensor

4a 4b

THROTTLE BODY ASSEMBLY (Venturi dia 34mm)

TPS Sensor

Pressure

Regulator

FUEL PUMP MODULE

Pulsar Coil

5b 5a

CRANK POSITION SENSOR (CPS)

Filter

Injector

FUEL INJECTOR ASSEMBLY

ENGINE OIL TEMPERATURE (EOT) SENSOR

ROLL OVER SENSOR (ROS)

EFI COMPONENTS MOTORCYCLE LAYOUT

MALFUNCTION INDICATOR LAMP (MIL)

LAMDA (O2) SENSOR

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

1 ELECTRONIC CONTROL UNIT (ECU)

Operating Voltage : 8 – 16 V.

Sensor Supply Voltage : 5 V.

Operating temperature : –10º C to + 60º C.

Storage Temperature : –20º C to + 80º C.

Current Consumption : Less than 0.3AMP

(Excluding source current)

2 FUEL PUMP MODULE

Operating Voltage : 6 – 14 V,

Operating temperature : –20º C to + 60º C.

Controlled Pressure Regulator : 294 KPa.

Inbuilt Filter Capability : Upto 10 Microns

Delivery Flow = 25 Ltr. / Hr. @ 294 Kpa.

Current : 2.2 AMP Max.

5 CRANK POSITION SENSOR (CPS)

5a. ROTOR ASSEMBLY

23 Short Pegs for Speed sensing

1 Long Peg for Ignition index reference

5b. PULSAR COIL ASSEMBLY

Resistance : 215 ± 21.5 Ohms

Output Voltage : 3 to 5 Volt AC

6 ENGINE OIL TEMPERATURE SENSOR (EOT)

Operating temperature : –30º C to +150º C

Operating Voltage : 5 ± 0.5 V.

Resistance Value w.r.t. Temperature

º C Resistance K Current Amp –20º C 18.80 Kilo Ohms 10 + 40º C 1.136 Kilo Ohms 100 + 100º C 0.1553 Kilo Ohms 100

3 FUEL INJECTOR

Operating Voltage : 10 – 14 V DC

Operating temperature : –30º C to + 120º C.

Fuel Injection pressure : 343.2 Kpa

Solenoid Operating Resistance : 10.3 ± 0.5 Ohms

4 THROTTLE BODY ASSEMBLY - 535cc

4a. MANIFOLD ABSOLUTE PRESSURE SENSOR

4b. THROTTLE POSITION SENSOR (TPS)

Operating Voltage : 5 V.

Out Put Voltage : 0 – 3.8V.

Throttle Angle : 0 – 80º

Throttle Resistance Maximum : 5 Kilo Ohms

Throttle Out Put Voltage at Idling : 0.6 ± 0.02V.

Storage Temperature : –20º C to + 80º C

4c. Venturi Dia : 34mm

7 ROLL OVER SENSOR (ROS)

Operating Voltage : 12V.

Operating Angle : 60° + 10°.

Operating Temperature : –20°C to + 85°C.

8 MAL FUNCTION INDICATOR (MIL)

Operating Voltage : 12 V.

Bulb Rating : LED 12V, 0.25W X 1 No

9 O2 SENSOR

Operating Voltage : 16V (Max)

Operating tepm : 600 - 950º C

Tightening torque : 24.5 ± 4.5 Nm

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

EFI TESTING PROCEDURE

There are three levels of identifying a malfunction in the ECU or the sensors.

a. Visual Method

This is indicated by the lamp in the MIL glowing continuously. Check for any sensor loose connections and plug in properly. If still MIL GLOWS, then check for the the problem by Test Pin or by DOL TOOL.

MIL

b. Test pin method

An open single pole connector (Black Colour) is provided close to the ECU. By inserting a piece of wire into this connector and grounding it to an earth, the defective sensor can be identified by the following frequency of the MIL blinking.

TEST PIN

EARTH POINT

CONNCTING WIRE

MIL BLINK MAL FUNCTION INDICATION

MIL will glow continuous. Engine will start but not perform to its potential.

LONG 0 SHORT 6 Throttle Position Sensor (TPS) circuit malfunctioning

LONG 0 SHORT 9 Manifold Absolute Pressure (MAP) circuit malfunctioning

LONG 1 SHORT 1 Engine oil Temperature (TE) circuit malfunctioning

LONG 1 SHORT 7 O2 Sensor circuit malfunctioning

LONG 4 SHORT 5 O2 Sensor heater circuit malfunctioning

MIL will glow continuous. Engine will NOT Start but will crank.

LONG 1 SHORT 5 Rollover Sensor circuit malfunctioning

LONG 3 SHORT 3 Injector circuit malfunctioning

LONG 3 SHORT 7 Ignition Coil circuit malfunctioning

LONG 4 SHORT 1 Fuel Pump circuit malfunctioning

LONG 6 SHORT 6 Crankshaft position circuit malfunctioning

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

c. DIAGNOSIS ONLINE (DOL) Tool

This is done by connecting a DOL tool to the connector (Covered K-Line Coupler)near the ECU. This will accurately determine the defective sensor and show the details on the diagnostic screen. A detailed code list is given in Next page.

MAIN COMPONENTS

Communication Adaptor (A link between ECU & Computer System)

RS 232 Cable (DHOD - 003 37R) for ECU Coupler (KLine) to Communication Adaptor

USB Cable for Communication Adaptor to Computer System

DOL Tool K-Line Coupler

Starting Window

Diagnostic Menu

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

Fuel injection time from the injector in

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

DIAGNOSTIC SCREEN DIAGNOSTIC TROUBLE CODE

Code De s cription Specification

NCS Non Conformance Sensors 0

RPM Revolution Per Minute 1050+/- 50

EOT Engine Oil Temparature

IG1 Ignition timing 5+/-2 degrees

O2 HT1 O2 Sens or heater circuit ON

T1OUT1

MAP1 Manifold Air Pressure in Kpa 27.2+/-2 Kpa

TP Throttle possition angle in percentage 0.5+/- 0.5 %

TPAD Throttle possition angle in Voltage 0.61+/- 0.5V

AP Atmospheric pressure in Kpa 101+/- 3 Kpa

O2 AD1 O2 Sens or operating voltage 0.1 - 0.8 V

VB Battery charging voltage 13.5+/-2 V

FP Fuel pump ON

REVCRK Reverse Cranking Protection Normal

ROLL OVER Roll ov er sensor Normal

TEST Test condition Open

milli s econds

80+/-5 degree centigrade

2.5+/-0.5 Msecs

P Code MAL FUNCTION INDICATION

MIL will glow continuous. Engine will start but not perform to its

potential.

P0120 Throttle Position Sensor (TPS) circuit

malfunctioning

P0105 Manifold Absolute Pressure (MAP) circuit

malfunctioning

P0195 Engine oil Temperature (TE) circuit

malfunctioning

P0130 O2 Sensor circuit malfunctioning

P0135 O2 Sensor heater circuit malfunctioning

Engine will NOT Start but will crank. MIL will glow continuous

P1630 Rollover Sensor circuit malfunctioning

P0201 Injector circuit malfunctioning

P0351 Ignition Coil circuit malfunctioning

P0230 Fuel Pump circuit malfunctioning

P0335 Crankshaft position circuit malfunctioning

DO’S

 DO start the engine only when it is in centre stand

or when rider sitting on the vehicle with both the stands retracted.

 Switch ON the ignition key and wait (for app. 3

Sec) until the MIL (MALFUNCTION INDICATOR LAMP) comes ON and goes off, Start the engine only after this happens.

DONT’S

 DO ensure the battery is in good condition & fully

charged.

 DO NOT remove the fuel hose (high pressure)

from the fuel pump to fuel injector, when engine

DO’S & DONT’S

 DO NOT remove any of the sensor connections /

couplers / Battery connections when the Ignition switch is ON OR when the engine is running.

is running OR when ignition switch is ON. Fuel flows at a very high pressure during such time.

 DO NOT use a booster or high voltage-charging unit

instead of a battery. Use only a good, correctly charged battery to start OR check the motorcycle.

 DO NOT rev the engine fully – immediately after

starting OR just before shutting off the engine.

 DO NOT use high pressure water jet to clean the

ECU / Throttle Body / any of the sensors. Keep them well protected while washing the vehicle.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

TROUBLE SHOOTING (EMS)

S No Symptom Possible Cause Remedy

Engine stop switch is in OFF Switch engine stop switch ON position

1 MIL does not glow when

ignition key switched ON & Sp. gravity. Recharge battery

2 MIL glows Continuously

A E Start related connection. proper tightness.

B Ignition Related loose connections replace if found to be faulty.

C Fuel Pump resistance. Replace relay if defective

D Fuel Related clogged / plunger stuck in cold are clean. Check proper working of

Battery discharged

Fuse blown.

Sensor couplers / Check all sensor and wiring harness wires loose contact. connections for proper connectivity

Battery discharged

Starter motor cables loose Check cable connections for

Relay starter not working.

Starter motor does not rotate

Ignition coil power relay defective / Check power relay connection or

Roll over sensor not connected / Check roll over sensor coupler loose connection. connection

Fuel pump relay does not work

Fuel pump clogged / internal short

Fuel air mixture too rich due to Hold throttle fully open. Hold Manual extreme cold weather & repeated Bi starter and start engine. Release cranking without using Manual throttle as soon as engine starts. Bi starter.

Manual Bi starter vent hole Clean Throttle body to ensure vents

position due to extreme cold Bi starter plunger. condition/icing

No pressure buildup in fuel Check fuel pump for proper working. main line Correct fuel hose if kinked /jammed /

Check battery electrolyte level

Check all fuses. Assess cause of failure, rectify & replace fuse

Check battery electrolyte level & Sp. gravity. Recharge battery

Check resistance across relay starter (between blue & white wire) Replace relay starter if faulty.

Check for firm wire connections. Check if motor is jammed. Replace starter motor.

Check proper connectivity in wiring harness & coupler continuity with voltmeter. Check fuel pump relay

Check for proper connectivity in wiring harness & continuity with voltmeter. Check fuel pump resistance. Repair electrical connections/loose contact. Replace pump if defective

leaking at joints. Correct as necessary.

SERVICE TRAINING GUIDE - CONTINENTAL GT EURO III

ENGINE MANAGEMENT SYSTEM - EMS (535CC)

S No Symptom Possible Cause Remedy

Spark plug Fouled Replace spark plug

Spark plug cap shorting Replace spark plug cap

Ignition coil wire loose connection Check for proper wire connection. or broken. Replace damaged wire connections

E Ignition related

3 Vehicle Starts but Switches Crank speed sensor loose Check Crank sensor & its connections

off connections/ faulty

4 High fuel consumption / Stuck butterfly in throttle body / Check & correct

Uneven Idling / Poor Pick up / broken throttle Cables

Smoky Exhaust / Engine Loose connections or problem in Check continuity and correct runs badly throttle position Sensor. Check & correct

5 Battery discharging in magneto (10V -16v AC @ 1000rpm)

frequently Poor charging by RR Unit Check RR unit & Replace

6 Battery not Charging No output from RR Unit. Poor Check & correct / replace RR unit

Faulty HT coil power relay.

Faulty H T coil Replace H T coil

No output from Magneto

Roll over Sensor Loose Check Roll over sensor & its connections / connections

Injector holes clogged Replace injector.

Loose inlet manifold / Leak in Check & correct inlet manifold

Loose connections or problem in Check continuity and correct manifold pressure sensor

Defective temperature sensor. Check & correct

Poor Output from charging coils Check Output voltage

Weak battery cells Replace the battery.

Charging circuit fuse Blown

Low or weak electrolyte. Check battery & correct

Cells weak Check battery & replace

connection/RR unit failed

No output from magneto Check for loose connections / burnt coils in magneto unit

Check power relay resistance / wire connections. Replace if faulty.

Check pulser coil / Magneto output connections

Check wiring harness connections & replace fuse

NOTE :

During trouble shooting of EFI Model. It is advised to begin a) With discussion / interview with customer. b) A check of the Petrol level in the Fuel Tank. c) Check of battery voltage, terminal loose connection / sulphation.

SERVICE TRAINING GUIDE - CONTINENTAL GT

ELECTRICALS & ELECTRONICS

01. Alternating current (AC)

02. Direct curre nt (DC)

03. Wired across

04. Connected Wires

05. Switch

06. Two way Switch

07. Push Switch

08. Ground

09. Cell

10. Battery

11. Bulb

12. Coil

13. Resistor / Resistance (R)

14. Capacitor

15. Armature and brush

16. Fuse

BATTERY

CONSTRUCTION

Positive Plate - Porous mass of lea d

dioxide (Pbo active material)

Negative Plate - Porous mass of spongy

Lead (Pb) (Negative active material)

Electrolyte - Diluted sulphuric acid

2SO4

)

Separator - Micro p orous, acid

resistant e lectric al insulator between positive & negative plates

Container - Polypropylene casing to

house the plate group & electrolyte

Cover - To seal the ba tte ry

container

) (Positive

17. Volt meter

18. Amme ter

19. Transf ormer / H.T.Coil

20. Transistor

21. Rectifier / Diode

22. Zener Diode

23. Silicon Controlled Rectifier

24. Buzzer / Beep

25. Rectified DC Current

26. Ohm

27. Volt

28. Ampere

Filling Plugs - To facilitate filling of

electrolyte and water topping up.

Gang Piece - To vent gases through

common manifold and exhaust nozzle

Terminals - To make connections to

the electrical loads.

Intercell Poles - To connect the cells in

series internally.

Exhaust Tube - To discharge the vent

gases.

Exhaust Seal Cap - To protect the dry charged

plates from oxidation.

SERVICE TRAINING GUIDE - CONTINENTAL GT

VARIOUS ELECTRICALS & ELECTRONICS COMPONENTS INSPECTION

STARTER RELAY

Give 12V DC supply to the starter relay coupler and check for the continuity between the two bolted terminals. If continuity shows then component is OK.

E- STARTER MOTOR

IC FLASHER

CHECKING PROCEDURE

Ensure Battery voltage > 12 V, all indicator bulbs are ok. Then starts the vehicle and turn the indicator switch to LH or RH mode.

If indicators not functional replace it by a new IC Flasher.

CAUTION :

Never try to repair / tamper IC Flasher.

RR UNIT

SPECIFICATION

Resistance 0.3 to 0.5 ohms.

CHECKING PROCEDURE

Set the multimeter in resistance mode. Check the Resistance between motor terminal & aluminium body.

STARTER MOTOR

Connect DC supply +ve to the motor terminal and -ve to the body of the motor.

Direction of rotation - Clockwise

CHECKING PROCEDURE

Set the multimeter in voltage mode (DCV 20). Connect the multimeter to Battery terminals and then check the voltage as shown in Fig.

a. When Ignition switch is “OFF” condition. Check voltage 11.5 to 12.5 as per figure.

Sample Reading (A): 12.55

b. Now Turn Ignition switch is “ON” condition. Check voltage 11.5 to 12.5 as per figure and note down reading.

SERVICE TRAINING GUIDE - CONTINENTAL GT

VARIOUS ELECTRICALS & ELECTRONICS COMPONENTS INSPECTION

 In case there is marginal variance observed

upto 0.1 to 0.5 volt (=Sample Reading ASamples Reading B).

Then bike electricals are O.K., wiring harness O.K. (Good Condition) RR unit is also O.K. may be battery needs bench charging OR replacement of battery.

Sample Reading (B): 12.44

c. Again Turn back Ignition switch to “OFF” condition. Now Check voltage 11.5 to 12.5 as per figure and note down reading.

Sample Reading (C): 12.55

 In case there is no marginal change in voltage

0 to - 0.2 V then RR unit defective (Internal Short Circuit) OR wiring harness problem, may be some main wire insulation damage OR exposed to earth which causes voltage leak.

Sample Reading: 11.99

ONLINE CHARGING TEST

Start and accelerate upto 2000 RPM and then check online voltage inbetween 11.98 to 14.5 voltage with “HEADLIGHT ON” Position.

Sample Reading: 14.00

Sample Reading: 12.44

NOTE :

Repeat the above test with head light on and OFF condition. If RR unit is defective will not fall above specified voltage.

SERVICE TRAINING GUIDE - CONTINENTAL GT

VARIOUS ELECTRICALS & ELECTRONICS COMPONENTS INSPECTION

CLUTCH SWITCH

Check the continuity for the following wires

Clutch lever in normal condition : Brown and Black ; if no continuity, switch is not ok.

Clutch lever in pressed condition : Black and Green; if no continuity, switch is not ok.

CHECK THE CONTINUITY FOR OTHERS SWITCHES

E-STARTER & IGNITION KILL SWITCH

Check the continuity between Red/Blue wire and Blue/white wire of Switch module RH coupler when switch is pressed.

SERVICE TRAINING GUIDE - CONTINENTAL GT

ENGINE COMPRESSION TEST

STEP-A

Start and warmup the engine to normal running temperature.

Remove the spa rk plu g & connect

compression gauge.

Please ensure that

a) Choke “OFF” position (normal

running condition)

Choke “OFF

a) Remove spark plug & put few drops of

engine oil into the combustion chamber.

b) Connect compression gauge & repeat

above said procedure as explained in the step-A.

b) Ignition & engine Stop switch “OFF”

condition.

Kill switch “OFF”

Ignition switch “OFF”

Hold throttle / rotor grip at “FULL” position & then kick several times (5 to 6 times).

Note down the reading and repeat the above process 3 times. Take the average mean reading to know actual compression pressure. Specified engine compression pressure 80 to 145 PSI.

STEP-B

In case compression pressure less than 80 PSI, then refit spark plug & start again to warmup the engine.

If compression pressure reading

increases, then check for

- Improper alignment of piston ring end gap position.

- piston ring jamed in groove.

- scoring / seizure of cylinder barrel / piston

- worn out piston/rings

- worn out cylinder barrel

If compression pressure does not

increase, then check for

- blown out cylinder head gasket

- improper torque of Rocker bearing bolts or cylinder head nuts.

- valve seat damage / leakage

- valve stem bend

- cylinder head warpage

- improper valve timing

- Auto decompressor

STEP-C

In case compression pressure is more than 145 PSI then e n g ine re q u ires De ca rbonisat ion of cylinder h e a d / pis to n (combustion ch a m b e r). Also check for smoky exhaust problem.

SERVICE TRAINING GUIDE - CONTINENTAL GT

WHEEL SPEED SENSOR

BLOCK DIAGRAM

‘T’

ON ‘T’ OFF

(Vo lts)

V O L T A G E

GND

OUTPUT WAVE FORM OF SPEED SENSOR

‘T’

TIME (SEC)

VOC

3.3 K

VO L

VOH



VOP

SENSOR

GROUND

Working System - HALL SENSOR TYPE

INSTRUMENT CLUSTER

PUSH BUTTON MANAGEMENT AND LOW BATTERY INDICATION

LOW BATTERY INDICATOR : RED LED

LED glow based on low battery indication function. Driven by software controlled

Input signal: Battery +ve and RPM

IG “ON” +0 and no

RPM

Low battery indicator :

“ON”

Ignition “ON” and RPM >

+ / - 160 for 2.5+0.5 sec

1. Low battery indicator : “OFF” if battery voltage >

2. Low battery indicator: “ON” if battery voltage <12V

12V

+0.3 V

-0.3 V

700

for 2.5+0.3 sec

PUSH BUTTON MANAGEMENT

Management by one (set / Reset) push button placed on Bottom of cluster.

Ignition “ON” and RPM < = 500 + / -

160 for 2.5+0.5 sec

Low battery indicator : “ON”

SIGNAL

Function

ODO

Trip A

Trip B

Pressure Time (Sec)

0.2 < t < 1 ODO > TRIP A > TRIP B > ODO

> 3 No function

0.2 < t < 1 Move to:

> 3 TRIP A RESET

0.2 < t < 1 Move to:

> 3 TRIP B RESET

Action

TRIP A > TRIP B > ODO > TRIP A

TRIP > ODO > TRIP A > TRIP B

SERVICE TRAINING GUIDE - CONTINENTAL GT

CHANGING ELECTRICAL COMPONENTS

HEADLAMP BULB REPLACEMENT

Loosen the rim holding screw on top and take out the head lamp dome.

Disconnect electrical connections.

Position new bulb inside the reflector such that the three projections on the bulb align with the slot on the reflector.

Refix the bulb holding clamp.

Connect the Electrical connections.

Thumb push and remove the bulb holding clamp.

Remove the bulb.

NOTE :

Always hold the bulb with paper or clean dry cloth during handling.



Position head lamp doom on to the head lamp shell and tighten the mounting screw on top.

NOTE :

Never touch the bulb with your fingers. Finger prints will etch the glass and decrease bulb life.

SERVICE TRAINING GUIDE - CONTINENTAL GT

TAIL LAMP BULB REPLACEMENT

Unlock the battery cover and remove.

Remove the seat assembly by pulling seat lock cable.

Replace the bulb 12V 21 / 5W.

Assemble back the tail light glass in the reverse order of dismantling process.

TRAFFICATOR BULB REPLACEMENT

Remove the screw from the trafficator housing back side.

Remove the tail light glass by unscrewing its mounting screws.

Hold the bulb, press inside & rotate anticlockwise to remove the bulb from its holder.

Open the Indicator housing.

Take out the bulb holder with help of is screw driver.

SERVICE TRAINING GUIDE - CONTINENTAL GT

Take out the bulb and replace the same.

Fix the rubber gasket cover.

Assemble back the indicator housing cover.

FUEL GAUGE FLOAT UNIT

It is recommended to check float unit resistance @ Empty, Reserve, Half & Full conditions by multimeter as shown (Ref. resistance spec.).

Refit the holder fitting its lock in proper position.

RESISTANCE SPEC.

Sl.

No.

1. 1st Segment blinking 110+3 Reserve

2. 2nd Segment on 103+3

3. 3rd Segment on 83+2.5

4. 4th Segment on 68+2.5 Half

5. 5th Segment on 55+2.5

6. 6th Segment on 40+2

7. 7th Segment on 10 to 20+

Indication

Resistance

Value

Tank

Level

2 F ull

SERVICE TRAINING GUIDE - CONTINENTAL GT

WIRING DIAGRAM COMPLETE - CONTINENTAL GT EURO III

SL.

N O .

SERVICE TRAINING GUIDE - CONTINENTAL GT

LIST OF SPECIAL TOOLS & ITS APPLICATION

PART N O. D ESC RIP TIO N APPLICATION

1 ST-26199-3 Cylinder head nut tightening tool

2 ST-25123-1 Valve spring compressor

3 ST-25612-4 Rotor tightening & loosening tool To hold magneto rotor while loosening

4 ST-25128-2 Puller for magneto rotor

5 ST-25592-4 Connecting rod locking tool To hold connecting rod in its top position.

6 ST-25151-4 Puller for chain case outer

7 ST-25591-4 Sprocket & Clutch tightening tool To hold the clutch housing and sprag

8 ST-25594-4 Clutch plate tightening tool To compress clutch springs while

ST-25153-4 Extractor for gear box rocker

pivot pin

To remove and tightening of cylinder head nut.

To compress the valve spring for removal and fitting of valve.

magneto nut.

Removal of magneto rotor assy.

To remove Crankcase LH cover.

sprocket while dismantling & assembly.

dismantling & reassembling of clutch plates.

Removal of rocker shaft spring top pivot pin and camplate pivot pin.

10 ST-25835-2 Front drive sprocket removing To remove FD sprocket on the sleeve

tool gear.

ST-25244-4 Special spanner adjuster Rear Shox To adjust gas filled shock absorber

spring load.

12 ST-26461-2 Front Fork Assembling & To hold pipe seat of front fork while

Dismantling Tool Dia 41mm dismantling & tightening of front fork main

tube with bottom tube (fork end end)

13 ST-26485-3 Front Fork Oil Seal Driver Fitment of slide bush and fork oil seal

(Dia 41mm) into front fork bottom case.

14 ST-26455-4 Steering Ring Nut ‘C’ Spanner To adjust steering free play by ring

nut setting.

15 Idle Adjusting Tool To turn the idling adjuster screw in

throttle body while setting idel RPM

16 Swing Arm NRB Puller To remove defective needle roller bearing

from swing arm while replacement

SERVICE TRAINING GUIDE - CONTINENTAL GT

Cylinder head nut tightening tool

ST-26199-3

Application : To remove and tightening of cylinder head nut.

Valve spring compressor

ST-25123-1

Application : To compress the valve spring for removal and fitting of valve.

Connecting rod locking tool

ST-25592-4

Application : To hold the connecting rod in its top position.

Puller for chain case outer

ST-25151-4

Application :To remove Crank case LH cover.

Rotor tightening & loosening Tool

ST-25612-4

Application: To hold magneto rotor while loosening of magneto nut.

Puller Magneto (Rotor Extractor)

ST-25128-2

Application : Removal of magneto rotor assy.

Sprocket & clutch tightening tool

ST-25591-4

Application : To hold Clutch housing & sprag sprocket while dismantling / tightening the Clutch & Sprag Sprocket bolt.

Clutch plate tightening tool

ST-25594-4

Application : To compress clutch springs while dismantling & reassembling of clutch plates.

SERVICE TRAINING GUIDE - CONTINENTAL GT

Extractor for Gear box rocker pivot pin

ST-25153-4

Application :To remove gear rocker shaft spring top pivot pin and gear cam plate pivot pin.

FD sprocket removing tool

ST-25835-2

Application : To remove front drive sprocket from Sleeve Gear.

Front Fork Oil Seal Driver (Dia 41mm)

ST-26485-3

Application : Fitment of slide bush and fork oil seal into front fork bottom case.

Steering Ring Nut ‘C’ Spanner

ST-26455-4

Application : To adjust steering free play by ring

nut setting.

Special spanner adjuster Rear Shox

ST-25244-4

Application : To adjust gas filled shock absorber spring load.

Front Fork Assembling & Dismantling Tool Dia 41mm

ST-26461-2

Application : To hold pipe seat of front fork while dismantling & tightening of front fork main tube with bottom tube (fork end).

Idle Adjusting Tool

PHOTO

Application : To Turn idling adjuster screw in thtottle body while setting idle RPM.

Swing Arm NRB Puller

PHOTO

Application : To remove defective needle roller bearing from swing arm while replacement.

SERVICE TRAINING GUIDE - CONTINENTAL GT

PDI CHCEKLIST - CONTINENTAL GT

SERVICE TRAINING GUIDE - CONTINENTAL GT

NOTES

PERSONAL INFORMATION

Name : ...........................................................................................................................................

Address : .............................................................................................................................

..................................................................................................................................................

Contact Phone No. : ....................................... Mobile : ..........................................................

E-mail : ...........................................................................................................................................

D.L. No. : .............................................................................. Renewal Due : ..............................

In emergency Contact Mr. ..............................................................................................................

Insurance Policty No. : ...........................Amount Rs. ............... Premium Due Dt : ..............

........................................................................................................................................................

Vehicle Registration No. .................................................... Make : ...........................................

Vehicle Insurance No........................Amount Rs. ............... Renewal Due Dt : ..............

Passport No. : ..................................................................... Validity : ........................................

Blood Group : .......................................................Specs Lense L/R: .................................................

Alergic Medicines : .....................................................................................................................

Height: .................................... Weight: ............................ On Date:...........................................

SERVICE TRAINING CENTRE

GUIDELINES FOR UNDERGOING TRAINING COURSE

Name ( with Surname)

Batch Code :

• Report to Training Center / Venue before 9:00 am in the morning & leave only after taking permission of the RE trainer.

• Lunch & Tea will be provided by RE at Training Centre / Venue.

• Carry your Identity card / Address, contact phone number for any Emergency purpose.

• Alcohol consumption is strictly prohibited during Training period.

• Do not move at the place of training as a single person, move in a groups to visit plant / factory or practical test.

• It is advisable to take safety measures while doing practicals or test ride the Motorcycle to avoid any personal injury or accident.

• Do not bring camera, mobile cum camera inside the RE TVT / Training Centre / Venue. Photography prohibited during RE Training.

• It is advised to not to attend mobile phone calls during training session.

• Any activity beyond mentioned by the Training Centre / Venue is restricted & is not the responsibility of RE.

Herewith I read & understood the above guidelines & promise to abide by the same. In case I am found guilty, company is free to take any action against me.

PLACE : ............................ (Signature & Name of Candidate)

DATE : ............................ (Designation)

SERVICE TRAINING CENTRE

NOMINATION FOR SERVICE TRAINING PROGRAMME

Name (with Surname)

Father’s name

Attach 3 Passport Size Photographs

1 for Nomination Form 2 for ID Card 3 for C ertificate

Age & Date of Birth

Yrs.

DD MM YYYY

Driving Licence No. Blood group

Workshop Name & Place

Personal Address & Phone / Mobile No.

JOB EXPERIENCE

Brand Store /

Dealership / ASP /

Own workshop Name

No. of years

worked

Job / Worked Duration

From

Designation

Make &

Models,

Jobs attend.

EDUCATIONAL QUALIFICATION

Class / Degree Year of (Highest Low) passing Place Name of the Institute / School

RSM / TSM / ASM Comments Candidate Signature

Trainer Comments / Observation Trainer Name / Signature

Grade Allotted Attendance Test marks

P/A scored

(TRAINING MANAGER)

Royal Enfield continental gt euro iii training guide 21.02.2014 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual