Royal Enfield 350 BULLET 1989, Workshop Maintenance Manual

Page 1: ...WORKSHOP MANUAL BULLET Page 1 WORKSHOP MAINTENANCE MANUAL FOR THE Enfield India 350 BULLET upto 1989 MAN 15 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 2: ...ERATION ENGINE REMOVED FROM FRAME 27 30 GEAR BOX 31 35 LUBRICATION SYSTEM 37 39 FRAME REAR SUSPENSION 41 42 FRONT FORK HYDRAULIC 43 46 WHEELS 47 58 TYRES REMOVAL AND REPLACEMENT 56 58 IGNITION AND LIGHTING SYSTEM 59 67 CARBURETTER VILLIERS 68 71 CARBURETTER BING 73 75 CARBURETTER MIK CARB 77 80 TROUBLE SHOOTING 81 101 TORQUE VALUE CHART 103 SPECIAL TOOLS 105 110 METRIC CONVERSION TABLE 111 w w w h...

Page 3: ...TIONS Observe the following points without fail when dismantling and reassembling Motor cycle parts Be sure to replace packings gaskets circlips 0 rings and cotter pins with new ones for safe riding Tighten bolts nuts starting from the larger diameter ones to the smaller diameter and from inside to outside diagonally with specified tightening torque Always use genuine spares and recommended grade ...

Page 4: ...ets older or used under particularly adverse conditions it would be advisable to reduce the period between each check For ease of reference each service operation is described in detail under the relevant heading In order to carryout the routine maintenance tasks a good selection of general workshop tools is absolutely essential Included in the kit must be a range of metric ring or combination spa...

Page 5: ...sure when the tyres are cold It is worth purchasing a small pocket pressure gauge which can be relied upon to give consistent readings than garage forecourt gauges which tend to be less dependable Tyre Pressure Front 32 PSI Rear 36 PSI Check tyres for foreign materials and remove them to prevent possible punctures Check for adequate fuel in the petrol tank for the journey planned Check for proper ...

Page 6: ...fork oil level Check all electrical connections and functions of head light trafficator horn speedometer etc Six monthly 6000 miles 10 000 kms Carry out all the operations mentioned for Tri monthly service and check the following Change oil engine clutch Clean or replace oil filter Change front fork oil Check front rear brake linings and replace if necessary Check for play in steering head bearing...

Page 7: ... pitch Duplex chain Cubic Capacity Stroke Bore Nominal Actual Compression Ratio Compression Pressure Engine output Torque Piston and piston rings Ring clearance in grooves Plain 2 Scraper Ring end gap in bore Maximum ring gap permissible Gudgeon pin diameter Crank pin diameter Connecting rod small end diameter Crankshaft Driving side Ball bearing Roller bearing Timing side Roller bearing Cam lift ...

Page 8: ... 80 14 80 Small 6303 Large 6206 16 teeth 5 8 x 94 pitch chain 38 teeth Mikcarb VM 24 90 25 0 14 0 16 0 35 to 0 4mm 1 32 0 8 mm retarded 14 mm diameter B7HS NGK or equivalent 0 46 to 0 50mm 0 18 to 0 25 M F D Telescopic hydraulic damping 155mm Pivoted fork with shock absorbers WM 2 19 3 25 x 19 Front 3 50 x 19 Rear 17 x 40 x 12 mm 6203 or 6203 ZZ Mechanical internally expanding shoe type 178 mm x 3...

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Page 10: ... Crank Case Rear Joint 39 Nut Crank Case Rear Joint 40 Stud Crank Case Rear Joint 41 Washer Crank Case Rear Joint 42 Nut Crank Case Rear Joint 43 Stud Chaincase attachment 44 Oil Seal Retainer 45 Nut Oil Seal Retainer 46 Distributor flange pin 47 Distributor flange pin Washer 48 Oil filler cap 49 Tappet cover stud 50 Washer Tappet Cover Stud 51 Tappet Cover 52 Washer Fibre Tappet Cover Stud 53 Was...

Page 11: ...ressor valve 129 Washer Decompressor body 130 Washer Decompressor body 131 Washer Plain Decompressor body 132 Decompressor body 133 Spring Decompressor 134 Spring Cap Decompressor 135 Cable block 136 Cable block split pin 137 Decompressor cable assembly 138 Timing cover 139 Timing cover joint washer 140 Distributor pinion nut 141 Distributor pinion 40T 142 Idler pinion 40T 143 Idler pinion bush 14...

Page 12: ...l tank to the frame and pull the tank upwards 2 Removal of the Cylinder head Remove the engine steady eye bolt Disconnect the high tension lead from the spark plug Remove rocker oil pipe Remove the exhaust pipe and silencer Remove the air filter by undoing the bolts on the sides of the air filter body Push the carburettor back clear of the studs after removing the fixing nuts Remove the rocker box...

Page 13: ...Removal of Valves To remove the valves from the cylinder head first lift off the end caps from the valve stems If this has stuck it can be removed by a screwdriver Using compressing tool 2018 compress the valve springs and remove the split collars from the valve tip Slacken back the compressing tools and release the springs Withdraw the valve and place its springs top spring collar bottom collar t...

Page 14: ... 003 If the grooves show a wear of 005 the piston should be replaced 7 Big end bearing inspection Examine the condition of the big end while the piston is removed About 010 020 end float is permissible and it will be possible to rock the connecting rod slightly The big end has a floating bush with an original clearance of approximately 003 However if a DEFINITE up and down play can be felt engine ...

Page 15: ... bar with the end turned down to 1 3 diameter for a length of 1 2 Support the cylinder head on the tube which fits over the collar of the valve guide Using the mandrel force the guide out of the head with a hand press or by using a hammer To fit a new guide support the head at the correct angle and use a hand press and the same mandrel If a hand press is not available the guide can be replaced usi...

Page 16: ... and space the ring gaps The second ring is a taper ring and is marked TOP on the upper surface WARNING This mark should be on top when fitted Reversing the ring will result in pumping of oil into the cylinder and consequent smoking Place the piston over the connecting rod small end ensuring the split skirt is facing the front and insert the gudgeon pin Secure the gudgeon pin with the circlips Oil...

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Page 18: ...cover tapping it lightly if necessary with a wooden mallet While refitting the timing cover ensure that the joint washer is correctly located over the oil holes using a little grease not compound to hold it in position Ensure that the cork plug is in position in the hole in the pump worm If the plug is damaged it should be renewed to ensure oil flow to the big end bearing NOTE The filter chamber s...

Page 19: ...ut five minutes to ensure that oil reaches the big end If the timing cover has been removed fill the filter chamber with clean oil before replacing the cover The feed and return filters are fixed on the drain plugs in oil sump and crank case These can be cleaned by rinsing in a solvent and during reassembly ensure the filters are not twisted 3 Overhauling of Oil feed and return Pumps Remove the ti...

Page 20: ...l Having assembled the pumps lay the timing cover flat and fill the oil ports using an oil can Turn the pump spindle with a screwdriver in a clockwise direction and it can then be checked whether the pumps are operating correctly Before replacing the timing cover on the engine fill the filter chamber with clean oil and fit the filter element NOTE With the engine running the oil feed to the big end...

Page 21: ...ided with timing marks to set proper valve timing The procedure is detailed below Bring the piston to TDC position Match the exhaust cam provided with two sets of punch marks with the timing pinion so that the two punch marks coincide on both Match the inlet cam to the exhaust cam so that the single punch marks coincide on both Push the cams home towards the crankcase 7 Tappet Adjustment Cold It i...

Page 22: ...tes and four driving plates including the friction disc on the sprocket 9 Removal of the Clutch Remove the LH front footrest Place a tray beneath the primary chain case to collect the oil in the chain case Remove the centre nut in the chain case outer and remove the cover To remove the clutch unscrew the clutch spring pins Lift away the spring cap springs clutch front plate clutch pad in main shaf...

Page 23: ...nt plate 5 Clutch sprocket friction disc rivet 15 Clutch spring 6 Clutch sprocket ball cage N S 16 Clutch cap 7 Clutch sprocket ball cage rivets N S 17 Clutch spring screw 8 Clutch sprocket balls 3 16 dia N S 18 Clutch pad 9 Clutch retaining spring 19 Clutch rod 10 Clutch intermediate plate dished 20 Washer main shaft spring 11 Clutch plate Insert type 21 Nut main shaft Nyloc CLUTCH ASSEMBLY w w w...

Page 24: ...ting inwards friction plate bonded clutch front plate 3 springs on the clutch centre lugs The other three springs are located by means of bosses on the clutch cap Tighten the spring pins as far as they will go If the clutch lifts unevenly it is probable that one of the springs has taken a set in which case new spring should be fitted The friction plate with inserts should be renewed if badly worn ...

Page 25: ... after adjustment has been made 14 Adjustment of the Clutch control It is essential that there should be about 3 to 4mm free movement in the clutch cable to ensure that all the spring pressure is exerted on the plates There are 2 points of adjustment on the clutch cable The first is the midway adjuster at the middle CLUTCH ADJUSTMENT ON GEARBOX of the cable just above the chain case The adjustment...

Page 26: ...d look for chipped or worn clutch rod ends and free rotation of the clutch adjuster ball Smear multipurpose grease on the clutch rod and reassemble into the mainshaft Smear grease on the clutch adjuster ball and carefully reassemble in its location Adjust the adjuster to ensure free play is maintained on handle bar end and tighten lock nut 15 Fitting the Alternator The alternator consists of two p...

Page 27: ...se the same such that all the strips become free Tighten the stator nuts and ensure the strips move freely Gently crank engine recheck the strips are free Repeat this process at 3 or 4 places and then withdraw the strips 16 Function of Breather The efficient operation of the breather is of paramount importance to the performance of the engine because it acts as a non return valve between the crank...

Page 28: ...sing Remove the nuts on the driving side of the engine from four fixed studs at the rear of the crankcase Remove six studs passing through the crankcase by undoing nuts The two halves of the crankcase can then be separated The driving side outer race of bearings will remain in the driving side half of the crankcase The driving side bearing inner race and the inner distance piece will remain on the...

Page 29: ...the Cam Idler Spindles When wear is noticed or step formation seen on the spindle it should be replaced To remove the cam spindle heat the crankcase and tap the spindles out from inside To remove the idler pinion spindles heat the crankcases as before hold the spindles in a vice and tap the crankcase lightly with a nylon wooden hammer To replace the cam spindles locate the spindles in respective h...

Page 30: ...crankpin into the timing side flywheel making sure that the oil hole is in the correct position and the thrust washer is facing the right way ie with chamfer away from the flywheel Test the oil passages using an oil can to make sure that they are clear Assemble the floating bush over the crankpin Assemble the connecting rod over the floating bush and smear engine oil Place the other thrust washer ...

Page 31: ...ring facing in to the timing cover 8 Re assembly of the Crankcase Replace the bearings etc in the crankcase halves after heating the crankcase as described earlier Refer page No 29 Fit the inner distance piece in the driving side crankcase Fit the thrust washer on the drive shaft Fit the bearing inner race on the drive shaft Assemble the flywheel into the bearing if necessary using the sprocket nu...

Page 32: ...ed which however should be done before taking off the gear box inner cover The top gear pinion and dog will come away with the mainshaft The layshaft can then be removed and the second and third gears drawn off the final drive sleeve together with the operator fork NOTE To take out the main shaft sleeve the final drive sprocket must be removed and this is preferably done before removing the inner ...

Page 33: ...h gear and K S 6 Main shaft high gear pinion dog wheel 25T 7 Main shaft high gear pinion 15 T 14 Lay shaft 8 Main shaft oil thrower inner GEAR BOX WITH CONTINENTAL CONTROLS 4 1 Gearbox with Continental controls The procedure for dismantling the gearbox with continental controls is the same as described earlier While dismantling the gear change mechanism care should be taken to disconnect the foot ...

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Page 35: ...in 83 Gear Indicator 17 0i1 thrower inner shaft 84 Washer for neutral lever 18 F s spindle distance washer 51 Main shaft nut LH Thread spring 19 Lay shaft high gear K s F s end 85 Neutral lever spring wheel 25T 52 Ball bearing cap 86 Spring cap 20 Third gear pinion 22T 53 F s return spring 87 Neutral lever securing pin 21 Second gear pinion 54 Cap pin Long 88 Foot change lever 22 Layshaft 55 Cap p...

Page 36: ...jointing compound Make sure that all parts are clean before commencing assembly The gear box should be packed with soft grease veedol 00 grease or equivalent filled up to the correct level On no account must heavy yellow grease be used 6 Adjustment of the Neutral Finder The neutral finder is adjusted by means of an eccentric stopper secured to the front of the gear box cover by a bolt which limits...

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Page 38: ...alve spring mechanism and flows down though the push rod tunnels into the timing cover chest From here the drained oil is pumped back to the oil tank through a hole drilled in the RH crankcase by the two idler pinions The return pump has a capacity of approximately double that of the feed pump which ensures that oil does not accumulate in the crankcase If allowed to accumulate it will lead to smok...

Page 39: ...e oil filter element Position 2 As the pump spindle rotates further the plunger A is pushed into the pump disc C The delivery port R in the pump disc registers with the delivery port X in the timing cover The oil in the pump disc is forced out through these ports by the plunger for supply to the oil filter element and to the big ends Simultaneously the through hole Z in the pump disc registers wit...

Page 40: ...the delivery port X in the timing cover The movement of the plunger forces the accumulated oil in the annular space in the timing cover to be delivered to the cylinder head Position 2 As the pump spindle rotates further the plunger A is pushed into the pump disc C The delivery port R in the pump disc registers with the delivery port X in the timing cover The oil in the pump disc is forced out thro...

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Page 42: ...t if it is necessary to replace the bushes the inner sleeves will have to be pressed out first on a press The rubber can then be taken away from the outer sleeves by pliers The outer sleeves can be driven out by means of a hammer and a suitable drift Replace the rubber bonded bushes in the swinging arm using a suitable drift press one bush from one end of the pivot bearing tube under a press until...

Page 43: ...inging arm pivot 4 Centre Stand To remove the centre stand take out the split pins washers from both the ends of the stand spindle Drift out the spindle and withdraw the stand complete after disconnecting both the ends of the stand springs Bullets made before 1982 have nuts on both sides of the spindle in place of the split pins w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 44: ...wo oil seals A stud known as the spring stud is fitted in the lower end of the bottom tube and a valve port is secured to the lower end of the main tube As the fork operates oil is forced between the spring stud and the bore of the valve port forming a hydraulic damping system A compression spring is fitted inside the main tube between the upper end of the spring stud and the upper end of the main...

Page 45: ... the main counter bore of the valve port thus forming a hydraulic cushion to prevent metal to metal contact MAIN TUBE SPANNER 2036 3 Dismantling the Fork Place the machine on the centre stand disconnect the front brake control cable speedometer connection and remove the front wheel and mudguard complete with stays Unscrew the bottom spring stud nut which will allow oil to run out of the fork down ...

Page 46: ... machine if necessary by adopting the following procedure The leads to the lighting switch and ammeter should be disconnected at their lower ends or by means of the plug and socket connectors when these are provided Disconnect the speedometer drive from the speedometer head Remove the two plug screws and loosen the steering head clip bolt and the two fork crown clamp bolts Unscrew the fork main tu...

Page 47: ...d fork crown clamp bolts Before tightening the latter make sure that the cover tubes are located centrally round the main tubes so that the bottom tube does not rub inside the cover tube A pair of split bushes as shown in figure is useful to ensure centralisation of the cover tubes ADJUSTMENT OF HEAD BALL RACE SEQUENCE FOR ADJUSTMENT 1 Loosen the Head lamp casing clip bolt by using an Allen key Si...

Page 48: ...the lever after which the cam can be withdrawn from its housing The brake shoe pivot pin can be removed after unscrewing the nut which secures it to the cover plate To remove the hub spindle and bearings having first removed the brake cover plate unscrew the retaining nut by holding the spindle on a benchvice with soft jaws Remove speedo drive assembly and the felt washer from the other side of th...

Page 49: ... cam lever 7 dia S L 24 Washer front brake operating cam lever S L 25 Nut front brake operating cam lever S L 4 Re assembly To refit the bearings in the hub two hollow drifts Special Tool No 2011 are required One bearing is first fitted to one end of the spindle by means of the hollow drift The spindle and bearing are then inserted into one end of the hub barrel which is then supported on one of t...

Page 50: ...The range of adjustment can be extended by moving this lever on to a different spline NOTE Before replacing the felt washers which form the grease seals pack all bearings with medium lime soap or aluminium soap greases or multipurpose grease The use of H M P greases which have a soda soap base is not recommended as these tend to be slightly corrosive if any dampness finds its way into the hubs Mak...

Page 51: ... buttons provided in the rubber blocks thus the rubbers are prevented from falling down when wheel is removed or refitted RE ASSEMBLY OF CUSH DRIVE 3 Removal and re assembly of rear wheel sprocket Removal of sprocket is necessary only if replacement of sprocket or attention to brakes is required Remove the wheel as described above Remove the brake rod nut and disconnect the brake rod from the oper...

Page 52: ... 10 Rear hub grease seal small 31 Rear brake operating cam bush pin long 11 Rear hub journal bearing 32 Rear brake operating cam bush pin short 12 Rear hub grease seal small 33 Rear brake operating cam bush pin locknut 13 Rear hub spindle long 34 Rear brake return spring 14 Rear hub sprocket cush rubber 35 Rear brake operating cam lever assy 15 Rear hub sprocket 38T 36 Washer rear brake lever 16 R...

Page 53: ... of the spindle with a brass hammer or mallet thus driving it out of the bearing Now the grease seal and the bearing from the brake drum can be removed one after the other The fit of the bearings in the hub barrel is important as in the case of front wheel To fit the bearings in the hub use the two hollow drifts proceed as follows In order to make sure that there is clearance between the inner fac...

Page 54: ...on its centre stand on a firm flat surface Unfold and remove the split pin 1 on the castle nut on LH side of rear wheel Loosen the castle nut 2 Loosen the stub axle nut 3 and rear brake anchor pin nut 4 Move the cam adjusters to the same number of notches on either side of the axle Rotate the rear wheel and check the chain tension on the top run of the chain The minimum free play of the chain shou...

Page 55: ... marks can be used as reference marks and the chain adjusters must be moved by the same number of notches from this punch mark to ensure proper wheel alignment 9 General 1 Wheel Rims The rim fitted to the wheel is WM 2 19 pierced with 40 holes for locating the spoke nipples 2 Spokes The spokes are of plain type 4mm dia with 90 degree counter sunk heads angle of bend 80 to 95 degree Thread diameter...

Page 56: ... for Front 3 50 19 for Rear When removing the tyre always start close to the valve and see that the edge of the cover at the other side of the wheel pushed down into the well If the correct method of fitting and removal of the tyre is adopted it will be found that the covers can be manipulated quite easily with the small tyre levers The use of long levers and or excessive force is liable to damage...

Page 57: ...nd deflate the tube Dry the tube and clean the area around the puncture with a petrol soaked rag When the surface has dried apply rubber solution and allow this to dry before removing the protective sticker from a patch and applying the patch to the surface 7 It is best to use a patch of the self vulcanising type which will form a very permanent repair Note that it may be necessary to remove anoth...

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Page 59: ...nder or over inflate See specifications for recommended pressures 15 Tyre replacement is aided by dusting the side walls particularly in the vicinity of the beading with a liberal coating of French chalk 16 Never replace the inner tube and tyre without the rim tape in position If this precaution is overlooked there is a good chance of the ends of the spoke nipples chafing the inner tube and causin...

Page 60: ...ights are in use the alternator output is sufficient only to trickle charge the battery When the light switch is turned to pilot or head positions the current increases proportionately 2 Alternator The alternator comprises of two main components a stator and a rotor The stator carries three pairs of series connected coils The rotor is a permanent magnet The stator and rotor can be separated withou...

Page 61: ... LIGHTING SWITCH 4 Emergency Starting An EMERGENCY starting position is provided on the ignition switch for use if the battery has become discharged and a normal start cannot therefore be made Under these conditions the alternator is connected direct to the ignition coil allowing the engine to be started independent of the battery It should be noted that with the ignition switch at EMG and the eng...

Page 62: ...bulb should not light c Connect bulb wire to one of the A C input terminals and battery positive to the centre terminal of the rectifier plates The bulb should light Inter change the rectifier connections The bulb should not light d Repeat test c for the other A C input terminal i e connect bulb wire to A C input terminal and battery positive to centre terminal of the rectifier plates The bulb sho...

Page 63: ...etween the contacts Slacken the screw A securing the fixed contact plate and adjust the position of the plate until the gap is the thickness of the feeler gauge and tighten If the gap is correct the gauge will be a sliding fit Setting ignition timing To check or reset the ignition timing rotate the crankshaft in the normal direction until the piston is just before TDC and the contact breaker point...

Page 64: ...e the crank shaft in the opposite direction such that the piston will be 0 8mm before TDC This can measured on the dial gauge Now reset the base plate so that the points just commenses to open This can be checked by connecting a 12v bulb and the CB point in series with a battery When the points are in contact the bulb will glow and when they just open the bulb will not glow Lubrication every 5 000...

Page 65: ...WORKSHOP MANUAL BULLET Page 65 6 VOLTS POSITIVE EARTH SYSTEM w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 66: ...WORKSHOP MANUAL BULLET Page 66 12 VOLTS NEGATIVE EARTH SYSTEM w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 67: ... inner surface is formed of a series of lenses which determine the spread and pattern of the light beams In the event of damage to either the lens or reflector a replacement light unit must be fitted Slacken the securing screw at the top of the headlamp rim Remove the front rim and light unit assembly Withdraw the adaptor from the light unit by twisting it in an anti clockwise direction and pullin...

Page 68: ...ttery but could cause trouble from excessive heat affecting the plastic cover At the same time the 6 watt filament if used as a stop tail light will be ineffective in bright sunlight or at night when the tail light filament is illuminated 14 Horn The machine is fitted with a 6V x 3 Amps D C Horn This is a sealed unit and should never be tampered A nut is provided with a locking plate at the back o...

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Page 70: ...piece is a press fit in the carburetter body and should not be removed unless absolutely essential If replacement is necessary the old one may be removed by tapping the thread end inwards with a mallet RE ASSEMBLY Clean the various components and make sure that the tickler vent hole is clear Check whether the passage in the jets are free by blowing air Replace float in correct position this is mar...

Page 71: ...lted to the frame behind the carburetter Periodically once in every 3 000 Kms the air filter element should be cleaned It can be removed from the air filter body by undoing the nut inside the body In case of paper element if fitted it should not be washed The dust on the faces can be blown off lightly with air and refitted During water wash and servicing of the vehicle care should be taken to see ...

Page 72: ...tle spring 14 Throttle No 6 15 Throttle guide screw 16 Throttle stop screw 17 Spring 18 Carburetter body 19 Body clip screw 20 Body clip 21 Banjo union 22 Banjo screw 23 Banjo washer small 24 Banjo gauze 25 Banjo washer large 26 Float 27 Float cup 28 Float cup washer 29 Pilot jet spring 30 Pilot jet needle 31 Pilot jet 50cc 32 Main jet 120cc 33 Tickler with cap 34 Tickler spring 35 Tickler spring ...

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Page 74: ...gged or is filled with petrol due to inclination of the vehicle The needle valve in conjunction with the float serves only to regulate the fuel feed and not as a tap with a stopped engine Tiny foreign bodies may settle between needle seat and needle preventing a complete closing of the valve Therefore when stopping the engine the fuel tap of the tank should always be closed The fuel should be clea...

Page 75: ...clockwise by 2 turns The setting indicated can give only general data Sometimes it may be necessary to readjust This should always be done when the engine is warm Select the desired idling speed with the throttle stop screw as described above The air adjusting screw is now opened anti clockwise till the speed increases slightly Then close the screw again a quarter turn The adjusting screw for cabl...

Page 76: ...ing 17 Air Regulating Screw 18 Carburetter Body Sub Assembly 19 Throttle Slide 20 Jet Needle 21 Lock Washer 22 Disc 23 Spring 24 Cover 25 Starting carburetter Plunger with Rubber Pad 26 Starting Carburetter Plunger Spring 27 Starting Carburetter Plunger Washer 28 Starting Carburetter Plunger 0 Ring 29 Starting Carburetter Fixing Bracket 30 Starting Carburetter Lever Pin 31 Starting Carburetter Ope...

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Page 78: ...rb carburetters fitted to 350ce and 500cc Bullet Motorcycles the atomisation and mixing of fuel and air is carried out by three systems viz STARTING JET SYSTEM or CHOKE SYSTEM PILOT JET SYSTEM MAIN JET SYSTEM 1 Starting Jet System The starting jet system provided in this carburetter is to aid starting under adverse condition such as that experienced during cold winter mornings The starting jet sys...

Page 79: ...le slide is lifted When once the main jet system becomes functional it provides to the by pass circuit for the pilot jet system As such the pilot jet system becomes totally inoperative during main jet system operation This main jet system comprises of the main jet the needle jet and the taper needle The fuel flows through the main jet also known as metering jet during the main jet operation The ta...

Page 80: ... cap 1 15 141957 Piston valve 1 16 141958 Throttle adjuster 1 17 141959 Spring plate 1 18 141960 Starter plunger spring 1 19 141961 Starter plunger cap 1 20 141962 Guide holder 1 21 141963 Spring washer 4 22 141964 Screw 4 23 141965 Spring clip E clip 1 24 141966 Washer M J 1 25 141967 Valve seat packing 1 26 141968 Float chamber body assy 1 27 141969 Needle valve assy 1 28 141970 Float assy 1 29 ...

Page 81: ...l care must be exercised while mounting the carburetter Ensure positioning of carburetter is vertical and the gasket O Ring is serviceable to prevent any air gas leak In 500cc models Rubberised Inlet Manifold is fitted To check the condition for any crack or otherwise a cracked manifold will result in starting trouble and erratic idling speed 6 Setting Idling It is always recommended to set idling...

Page 82: ...ssion rings Oil ring scraper ring 0 150 0 187 0 006 0 007 0 178 0 229 0 007 0 009 11 Valve stem to valve guide clearance Inlet Exhaust 0 075 0 10 0 003 0 004 0 075 0 10 0 003 0 004 12 Valve spring free length Inner Outer 48 20 50 04 1 897 1 970 48 20 50 04 1 897 1 970 13 Clutch steel plate distortion 0 15 0 006 0 15 0 006 14 Clutch friction plates Thickness Bonded with Insets 4 00 4 30 0 157 0 169...

Page 83: ...ean and fit Glazed cylinder Rebore the cylinder to next o s Leaky decompressor Check and change the gaskets Lap the decompressor valve Loose cylinder head nuts Tighten the nuts 3 Kick starter pawl slipping Change the pawl spring Cranking pressure OK 2 Remove the fuel hose from the carburettor Turn the fuel tap to On Reserve Does fuel flow to carburettor No it doesn t No fuel in the tank Blocked fu...

Page 84: ...alve Less petrol flow to the bowl Blocked carburettor fuel inlet Stuck closed float needle Float height too high Blocked pilot jet pilot discharge orifice Warped inlet flange Loose inlet fasteners Free the slide valve Clean the passage Clean and free float needle Adjust float height Clear the jet discharge orifice Face the flange Tighten fasteners b Heavy petrol smell Petrol wets thumb Too rich ai...

Page 85: ...cked HT lead Change the spark plug Tighten connections Clean and adjust the gap Change the HT lead d Light blue solid spark 7 Is the spark plug of right specification No Shorter reach spark plug Replace with right plug Yes 8 Is the ignition timing correct No Too far advanced retarded Ignition timing Adjust ignition timing Yes it is correct Then now engine should start easily NOTE 1 Combustion elem...

Page 86: ...lve Punctured float Faulty float height adjustment Adjust air screw Clean needle valve and seat Replace float needle valve Replace float Correct float height c OK 3 Is the engine low idle rpm higher a Yes it is higher No throttle cable free play Throttle stop screw fully in Stuck throttle inner cable Partly stuck open slide valve Restricted fuel flow to float chamber Aux air screw move out Air scr...

Page 87: ...ing Check and correct No Engine would now low idle smoothly NOTE Find out induction leakage by METHOD 1 Pour some petrol at the suspected joint If engine cuts off there is suction leakage at that joint METHOD 2 Pour some lube oil or apply grease at the suspected joint If the slow running improves there is leakage at that joint COMPLAINT LOW IDLING PROBLEM w w w h i t c h c o c k s m o t o r c y c ...

Page 88: ...moke a Excessive smoke Adulterated petrol Carburettor flooding Blocked air bleed holes Blocked air jet Stuck open choke plunger Chocked air filter Weak spark Too far retarded ignition timing Poor compression Replace Petrol Check and correct Clean the bleed holes Clean the air jet Check and correct Clean air filter Check and correct Adjust ignition timing Causes remedies as given for weak compressi...

Page 89: ... bush Replace the crank shaft Tighten them in sequence after loosening them by 1 4 turn Replace the gasket Change the crankcase Excessive oil throw from breather through out the engine operation Air vent in lube oil dip stick cover blocked Return pump not operating Blocked return pump passages Excessive blow by Clean the vent hole Check and correct it Clean the blockages Check and correct No oil t...

Page 90: ... timing chest to crank case 7 If oil get collected and oil level in sump is unchanged then leakage is from T chest f Method of checking return pump operation 1 Ride the vehicle for one or two kms or start and run the engine for 10 mts 2 Keep the motor cycle on stand and switch off the engine 3 Remove the return pump filter plug and collect the draining oil in a bowl 4 About 50 to 75 ml oil will no...

Page 91: ...isfy customer Avoid congested traffic Select reliable fuel pump Park it in shade Check and correct Replace tyres Inflate tyres Yes he does 2 Is the engine over loaded Yes it is over loaded Excessive pay load Tight primary secondary chain Too much thick oil in clutch or gear box Sticky wheel bearing Under inflated tyres Binding brakes Wheel misalignment Carry correct pay load Adjust chain tension D...

Page 92: ...nge the spark plug Defective condenser Replace the condenser Dirty pitted C B points Clean and adjust the points Defective HT coil Replace them Too rich air petrol mixture Check and correct No it doesn t 7 Is there starting problem poor pickup and more smoke Yes Weak spark Too far retarded ignition timing Low compression Check and correct Check and adjust ignition timing Check and correct Too much...

Page 93: ... timing Excessive carbon deposit in cylinder Characterised by post ignition Decarbonise the engine Dirty Blocked cooling fins Clear and clean the fins Oil starvation Check and correct Wrong grade oil Change the oil Engine over loaded Reduce the load Wrong spark plug Replace it with correct plug Less working clearances between moving parts Check and correct ENGINE OVER HEATING w w w h i t c h c o c...

Page 94: ...n bush Adjust the tappets Check and change the worn part Check and lubricate Change the cap Change the cam wheels Change the bush No 5 Is there a continuous grinding like noise Yes Worn out ball bearing Replace them No 6 Does the knock reduce with increasing engine temperature Yes Too much clearance between piston and cylinder Change the worn out part No 7 Does the noise increase with temperature ...

Page 95: ...4 Does the engine over heat Yes For causes and remedies refer to engine over heating complaint No 5 Does the engine produce unusual sounds or knocks Yes Excessive clearance loose adjustments Worn out bearings component surfaces Check and correct Check and correct No Keep the causes of premature wear away to ensure long life for engine components Note Use of non genuine parts causes premature wear ...

Page 96: ...1 Does the road speed increase with engine rpm No Clutch slippage No clutch lever free play Worn out clutch plates Weak pressure springs Glazed steel plate clutch plates Distorted pressure plates Adjust clutch cable free play Replace clutch plates Replace springs Replace the glazed plates Replace the distorted plates Yes Then there is no clutch slippage COMPLAINT FLAME AT THE SILENCER AFTER FIRE C...

Page 97: ...ter Check and adjust Replace steel plates Replace with SAE l0w 30 oil Replace the broken plates Replace the damaged part No Then there is no clutch dragging CAUSES REMEDIES Clutch drag Check and correct Tight gears Check and correct Faulty selector adjustment mechanism adjuster plate adjustment Check and adjust Too tight gear operator selector assy adjustment Check and adjust COMPLAINT CLUTCH DRAG...

Page 98: ...YRE TUBE DAMAGES PREMATURELY INDICATIONS CAUSES REMEDIES Excessive wear at the tread edges Low tyre inflation pressure Inflate the tyres to the right pressure Tyre side wall cracks Low tyre inflation pressure Inflate the tyres to the right pressure Tube inner nozzle snaps Low tyre inflation pressure Inflate the tyres to the right pressure Excessive wear at tread centre Excessive tyre inflation pre...

Page 99: ...spring Too tight brake adjustment Adjust the brakes correctly Jammed cams Lubricate the cams Brake pedal jam Lubricate Bent brake rod Straighten the brake rod CAUSES REMEDIES Dust in brake drum Clean the brake drum Glazed brake shoes drum Roughen the shoe face drum face Bent back plate Change the plate Water on brake shoes Apply the brake several times Misaligned wheel Align the wheel Hard brake s...

Page 100: ...eplace it with new Loose main tube fitment Tighten the main tubes CAUSES REMEDIES Loose wheel axle nut Tighten the nuts Loose spokes True the wheels Bent wheel rim Replace the wheel rim Re treaded tyre Replace with new tyre Loose steering adjustments Adjust steering properly Worn out chain stay pivot bushes Change the bushes Loose wheel bearing Change the wheel bearing COMPLAINT FRONT FORK HITTING...

Page 101: ...qually CAUSES REMEDIES Lower electrolyte level Top up with distilled water Shorting in the DC circuit Check and correct Internal shorting in battery Replace the battery Sulphated or hydrated plates Replace the battery Over charging causing shedding and buckling Replace the battery Lower magneto output voltage Check and rectify Topping up with acid or tap water Always top up with distilled water Fa...

Page 102: ...right voltage bulb Lower wattage bulb Use right wattage bulb Faded reflector Change reflector Incorrect focusing Adjust focus of the light CAUSES REMEDIES Poor quality bulb Use of lower voltage bulb Defective voltage regulator AC DC Fit genuine bulbs Use bulbs as per specification Replace regulator COMPLAINT DIM HEAD LIGHT COMPLAINT FREQUENT BULB FUSING w w w h i t c h c o c k s m o t o r c y c l ...

Page 103: ...w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 104: ...20 277 0 Front Engine Plate Stud Nut 1 2 3 20 277 0 Rear Engine Plate Stud Nut Bot 3 8 2 00 175 0 Rear Brake Cam Lever Nut 7 15 2 00 175 0 Chainstay Stud Nut 1 2 3 50 300 0 Front Fork End Cap Nut 5 16 1 30 112 0 Rear Wheel Lock Nut M22 7 50 650 0 Rear Wheel Spindle Castle Nut M16 6 50 565 0 Rear Shock Absorber Upper 3 8 Lower Nut 3 8 2 50 215 0 Front Mudguard Stay Screw Nut 1 4 0 30 25 0 Front Eng...

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Page 106: ...WORKSHOP MANUAL BULLET Page 106 SPECIAL TOOLS LIST COMMON FOR 350cc and 500cc w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 108: ...WORKSHOP MANUAL BULLET Page 108 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 109: ...WORKSHOP MANUAL BULLET Page 109 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

Page 110: ...WORKSHOP MANUAL BULLET Page 110 w w w h i t c h c o c k s m o t o r c y c l e s c o m ...

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Page 112: ... 4375 1 1 1 125 10 0 39370 1 25 4 29 64 0 453125 1 1 5094 11 0 43307 2 50 8 15 32 31 64 0 46875 0 48375 1 1 9062 12 3031 12 0 47244 13 0 51181 3 76 2 4 101 6 33 64 0 5 0 515625 12 7000 13 0969 14 0 551 18 15 0 59055 5 127 0 6 152 4 17 32 0 53125 13 4937 16 0 62992 7 177 8 35 64 0 546875 13 8906 17 0 66929 8 203 2 9 16 0 5625 14 2875 18 0 70866 9 228 6 37 64 0 578125 14 6844 19 0 74803 10 254 0 19 ...

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Page 114: ...AL HITCHCOCK S MOTORCYCLES ROSEMARY COURT OLDWICH LANE WEST CHADWICK END SOLIHULL B93 0EY ENGLAND TELEPHONE 01564 783 192 FAX 01564 783 313 E MAIL info hitchcocksmotorcycles com WEB hitchcocksmotorcycles com w w w h i t c h c o c k s m o t o r c y c l e s c o m ...