Royal Enfield BULLET ELECTRA, Owner'S Manual

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Page 3: ...n efficient operation and maintenance We ve also included tips on riding safely as well as suggestions to enhance your motorcycling experience Your safety is of prime concern to us and we urge you to be a responsible rider Please select your riding gear carefully in accordance with your terrain style and weather conditions And ensure the same for your pillion rider as well Respect the law of the l...

Page 4: ...hout prior notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold All images shown are for reference to explain and need not to be exactly the same on the model you own Technical specification are subject to change without prior notice Copyright 2006 Royal Enfield All Rights Reserved No part of this manual shall be copied distributed or oth...

Page 5: ...art 28 Recommended lubricants 31 Do it yourself 32 Washing procedure 45 Storage precautions 46 Long trip precautions 48 Caring for Mileage 49 Complete Wiring diagram Kick Start 52 Complete Wiring diagram Electric Start 53 Trouble shooting 54 Warranty terms conditions 61 Emission Warranty 63 All India Road Signs 67 Regional Area Offices 68 Log Book 69 Free Service coupons 70 Paid Service Maintenanc...

Page 6: ...O N Vehicle Installation Form VIF No Name Door No Street Locality City State Pin Contact Nos Res Off Mobile Email Engine No Battery No Frame No Battery make Reg No Licence No Date of Sale Valid till dt Model Key No Tyre make Colour Sold by Dealer Code ...

Page 7: ...of satisfactory services kindly return the free service coupon duly filled in and signed to the service outlet Availing the free services in the specified time is a prerequisite for warranty consideration The cost of fuel oil oil filter element grease etc used for all free services are chargeable to the customer Note Please ensure that the free service details are recorded in this sheet immediatel...

Page 8: ...4000 IDLE RPM 1050 200 Starting Kick Start E Start Air filter element Paper element Lubrication Wet sump Forced lubrication Engine oil capacity 2 75 Litres Carburator UCAL BS29 Engine oil grade Motul 3000 4T Plus 15W50API SL Grade JASO MA Cooling Natural air flow TRANSMISSION Clutch Wet multiplate Primary drive Duplex chain drive Primary ratio 2 15 1 Gear box Constant Mesh 5 Speed Gear Ratio 1st 3...

Page 9: ...m ventilated disc Rear Foot operated 153 mm single lead internal expanding Brake oil Capacity 60 ml Brake oil grade DOT 3 or DOT 4 Tyre size Front 3 25 19 4 6 PR Rear 3 25 19 4 6 PR TYRE PRESSURE Solo Front 20 psi 1 41 kg cm2 Rear 30 psi 2 11 kg cm2 With Pillion Front 22 psi 1 55 kg cm2 Rear 32 psi 2 20 kg cm2 Steering lock In built Fuel tank capacity 13 5 litres Min Reserve 2 Litres approx ELECTR...

Page 10: ... 35 35 W Tail lamp 12V 5W Brake lamp 12V 21W Parking lamp 12V 2W 2 Nos Speedometer lamp 12V 3 4W Hi beam indicator 12V 2W Turn Signal Tell Tale 12V 2W Turn signal 12V 10W Horn 12V 2 5 Amp Max Starter Motor for E Start 12V 0 7KW S P E C I F I C A T I O N S WEIGHTS Kerb weight 90 fuel Oil E Start 183 Kgs Kick Start 180 Kgs Max pay load 350 Kgs DIMENSIONS Length 2140 mm Width 810 mm Height 1120 mm Wh...

Page 11: ...NING Indicates a potentially hazardous situation Disregarding this message may result in injury to rider or other persons CAUTION This message if disregarded may result in damage to the vehicle NOTE Indicates important and useful messages for clearer understanding All Images shown are for reference to explain and need not to be exactly the same on the model you own Technical specification are subj...

Page 12: ...rect sitting posture is a pre requisite for stable and safe riding Sit Straight with your shoulders completely relaxed Keep your elbows close to your body Keep your toes in straight ahead direction Slightly press the petrol tank with the knees Hold the handle grip close to its inner end Look extensively including rear view mirror without turning the head BRAKING Use both front and rear brakes toge...

Page 13: ...11 FRAME NUMBER Punched on steering head tube RH side V E H I C L E I D E N T I F I C A T I O N N U M B E R S ENGINE NUMBER Punched on top of the engine LH side ...

Page 14: ... 3 Cluth Lever LH 4 Head Lamp Dip Switch 5 Ignition Switch 6 Speedo Meter 7 Ammeter 8 Engine Kill Switch 9 Brake Lever RH 10 Pilot Head Lamp Switch 11 E Start Switch 12 Petrol Tank Cap L O C A T I O N O F K E Y P A R T S 2 5 4 3 1 6 7 8 9 10 12 11 ...

Page 15: ...3 4 5 6 8 9 11 10 13 2 12 7 LEFT SIDE VIEW 1 Front Trafficator LH 2 Pilot Lamp LH 3 Fuel Tank 4 Fuel Tap 5 Battery Box Cover 11 Centre Stand 12 Gear Shift Lever 13 Horn 6 Seat 7 Tail Lamp 8 Rear Trafficator LH 9 Number Plate Rear 10 Side Stand ...

Page 16: ...tart Lever 12 Shock Absorber Gas filled 1 Rear Trafficator RH 2 Tool box 3 Air filter box 4 Carburetor 5 Pilot Lamp RH 6 Head Light 7 Front Number Plate 8 Front Trafficator RH 9 Steering lock 10 Brake Pedal 1 6 8 7 9 10 11 12 5 2 4 3 RIGHT SIDE VIEW ...

Page 17: ...15 IGNITION SWITCH OFF ON FUEL TANK CAP l Turn Key Clockwise to open l Turn Key Anti Clock wise to close O P E R A T I O N O F C O N T R O L S ...

Page 18: ...e to open NOTE Key is common for ignition petrol tank cap steering lock and tool boxes Key for fuel tank and tool boxes can be removed from the lock only in locked position STEERING LOCK Turn Clockwise to lock Turn Anticlockwise to Unlock NOTE Turn handle bar to extreme left before attempting to lock steering ...

Page 19: ...O N T R O L S HORN Press HEAD LIGHT SWITCH OFF Pilot ON Head lamp ON ELECTRIC START SWITCH E START BUTTON Presss fully to start NOTE Press E Start Button fully till engine develops cranking speed Not to make half hearted attempt ...

Page 20: ...18 DIMMER SWITCH High beam Low beam Day flash O P E R A T I O N O F C O N T R O L S ENGINE STOP SWITCH ON OFF ...

Page 21: ... OFF Push to off Right turn signal ON Left turn signal ON CAUTION Choke should be used only to start a cold engine Riding the motorcycle with the choke ON will increase pollution and result in high fuel consumption and loss of power ON OFF CHOKE Pull Out Press ...

Page 22: ... TAP OFF Main ON Reserve ON Front Brake Rear Brake CHECK FOR 1 Petrol level in the tank and leakage if any 2 Operate and free play of front and rear brakes Brake Pedal 3 Free play and smoothness of all operating cables 4 Free movement of steering ...

Page 23: ...el MIN M A X 5 Battery electrolyte level 6 Any cuts cracks in the tyre and correct tyre pressure 7 Operation of all electrical parts 8 Brake fluid is above the min level in the master cylinder MIN 9 Lub oil level should be in between MAX MIN Level Top up if necessary Do not overfill above maximum level ...

Page 24: ...g of a new motorcycle 1 During the first 2000 Kms of run do not exceed the following speed limits Vehicle Speed Gear First 500 kms 501 2000 kms 1 15 KMPH 20 KMPH 2 25 KMPH 30 KMPH 3 30 KMPH 40 KMPH 4 45 KMPH 55 KMPH 5 60 KMPH 70 KMPH 2 Do not exceed maximum pay load as specified 3 Warm up the engine for a few minutes to allow oil for all engine parts before riding the bike 4 Do not ride in constan...

Page 25: ...ated by neutral light on the cockpit To shift into neutral move the motorcycle back and forth gently while shifting the gear CAUTION 1 Attempting to shift gears without moving the motorcycle back and forth may damage gears 2 Slightly crank engine further till compression eases over Start the motor cycle with a p o w e r f u l swinging kick Release the choke if applied USING KICK START Pull Out ...

Page 26: ...ess starter button and release once the engine starts NOTE If the engine does not start wait for 30 seconds before pressing the starter button again CAUTION Please ensure that the gears are in neutral before starting the motorcycle Press Starter button and release starter switch once the engine starts A Clutch switch is provided in the system for the safety of the rider When the vehicle is in gear...

Page 27: ...s the gear pedal with heel NOTE Gear shift pedal is on the left side of the motorcycle Turn the ignition switch to OFF position Turn fuel tap OFF To stop the vehicle close throttle apply front brake with right hand and rear brakes with right leg simultaneously Shift gears into neutral before the motorcycle just comes to a complete stop ...

Page 28: ...resting on firm ground Apply pressure on the fulcrum lever on the centre stand and pull vehicle backward WARNING Ensure both the stands are retracted fully before riding the motorcycle Please exercise extreme care while parking and ensure it is parked firmly to avoid the motorcycle from falling over and causing injury to you or to others and damage to the motorcycle parts PARKING VEHICLE ON CENTRE...

Page 29: ...end spanner 10 X 12 2 1 Antiseptic cream 5 gms 1 2 Wash proof plaster 1 9 cm x 7 2 cm 2 3 Gauze bandage 5 cm x 2 cm 1 4 Sterilized Gauze Swab 5 cm x 5 cm 2 5 Sterilized elastic plaster 7 cm x 6 cm 1 6 Elastic Gauze bandage 8 cm x 1 mtr 1 7 First aid kit pouch 1 3 1 2 3 4 5 6 S No Description Qty S No Description Qty 1 5 6 7 2 4 ...

Page 30: ...usty environment Contact the nearest Royal Enfield Authorised service centre for expert advice and to carry out the required maintenance S No DESCRIPTION FREE SERVICE whichever is earlier PAID SERVICE A Adjust C Clean D De carbonise I Inspect L Lubricate R Replace Kms x 1000 0 5 3 6 9 12 15 18 21 24 27 30 Months 1 5 3 6 9 1 Engine Oil R I R I R I R I R I R Check level at every 500 Kms or earlier a...

Page 31: ...Accelerator and carburetor cable play Adjustment A A A A A A A A A A A 12 Rubber hose Air filter to Carburetor I I I I R I I I R I I 13 Rubber hose Inlet manifold I I I I R I I I R I I 14 Inlet Exhaust valve seating I I 15 Cylinder head D 16 Exhaust system D 17 Clutch free play Adjust every 1000 Kms or earlier as required 18 Rear brake pedal pivot L L L L L L L L L L L 19 Battery terminals apply p...

Page 32: ...place 22 Rear Chain Lubricate Adjust every 1000 Kms or earlier as required R Clean Adjust Lubricateevery3000Kmsorearlieras required 23 Front Fork oil I R I R I Check level every 3000 Kms or earlier as required 24 Hand levers kick starter pivot Lubricate every 1000 Kms or earlier as required 25 Rear brake play Adjust every 1000 Kms or earlier as required 26 Rear brake cam L L L L L 27 Steering ball...

Page 33: ...t performance NOTE Recommendation subject to change without notice Common oil for Engine Gear box Clutch Engine Oil Grade MOTUL 3000 4 T Plus 15 W 50 API SL Grade JASO MA Capacity 2 75 Litres Front Fork Oil Grade Royal Enfield Front Fork Oil Endurance 1F grade Fork Oil Capacity 195 ml leg Brake Fluid Grade DOT 3 or DOT 4 Capacity 60 ml ...

Page 34: ...d you to get in touch with an Authorised Service Centre CONTROL CABLES Lubricate after using the motorcycle in rain after waterwash or if used in dusty conditions HAND LEVER KICK STARTER PIVOTS Wipe the area free of dirt grease Apply a few drops of oil on the pivots CENTRE SIDE STAND PIVOTS Apply a few drops of oil on the pivots after cleaning the area of dirt ...

Page 35: ...neously rotating the rear wheel Wipe off the excess oil OIL LEVEL INSPECTION Place motorcycle on its centre stand on a firm surface Warm up engine for a few minutes switch off before checking oil level The level is correct if the oil level is in the middle of the oil level window Top up with recommended oil if required CAUTION Use of wrong grade or spurious oil can seriously affect m o t o r c y c...

Page 36: ...ct the tyres periodically for tread wear cracks and cuts Check and remove stone splinters nails or other particles embedded in the tyre treads Bald spots swelling may be caused by internal damage Replace the tyres if defective Periodically inspect wheels for spokes breakage and wheel rim run out Check proper seating of the tyre beading on the rim whenever the tyre is reassembled Whenever a new tyr...

Page 37: ...h washer Tap and remove the front wheel spindle Tilt the vehicle to RH Side and take out the wheel along with speedo drive and RH side spacer Take out Speedo drive and bush on the RH side FRONT WHEEL REMOVAL Place the vehicle on center stand Place a wooden block the front end of engine to support the vehicle Disconnect speedo cable Loosen the pinch bolt on the RH fork guide ...

Page 38: ...g locked CAUTION Do not press the front brake lever when wheel is removed as this will result in brake pads getting locked FRONT WHEEL REASSEMBLY Remove the wooden piece card board sheet placed between the brake pads Place the speedo drive bush in position and place speedo drive over it Insert the wheel along with speedo drive and RH spacer between the front fork ends ensuring that the brake disc ...

Page 39: ...REAR WHEEL REMOVAL Place vehicle on center stand on a firm and flat surface Note and mark the position of the chain adjuster butting with the stopper on the right side Remove split pin and castle nut on the RH side Remove wheel spindle from LH side along with chain adjuster taking care not to drop the wheel collar and spacer from the RH side of the wheel Tilt vehicle to LH side and slide out rear ...

Page 40: ...een the swing arms Position the rear wheel with cush rubber on the rear chain sprocket Hold wheel collar and spacer in position Insert the wheel spindle along with chain adjuster from the LH side of vehicle and gently tap it through the wheel Ensure that the mark on the chain adjuster notch butts with the stopper Tighten the castle nut firmly and ensure that the hole on axle shaft and the slot on ...

Page 41: ...ear wheel rotates freely DRIVE CHAIN TENSION Play 25 30mm Remove rear wheel split pin Loosen castle nut spindle nut anchor nut and brake rod nut Turn the adjuster cams on both sides till 25 to 30 mm slackness is achieved Check and ensure that the number of notches from the punch mark on the cam to the notch resting on the pin are equal on both sides Apply brake and tighten all nuts ...

Page 42: ...ive notches To carry out the adjustment proceed as follows D O I T Y O U R S E L F WHEEL ALIGNMENT Hold the vehicle upright off the stand on a level ground Stretch a string about 100 mm above the ground along the wheels If the string touches two points on the rear wheel and two points on the front wheel 4 point contact then the wheels are aligned If the string touches only three points on the two ...

Page 43: ...pin in both WARNING Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident D O I T Y O U R S E L F REMOVAL OF BATTERY FROM THE VEHICLE Insert the key into the battery cover lock LH Side turn anticlock wise and hold it there Remove the battery cover o u t w a r d s bringing down off from the lock peg on top Disconnect both the te...

Page 44: ...ctrolyte as it will spill ot through the over flow pipe and cause corrosion to vehicle parts BATTERY MAINTENANCE The vehicle is provided with 12V 14 AH for E Start and 12V 5 AH for Kick Start P e r i o d i c a l l y check the Battery for Cleanliness and corrosion free terminals Electrolyte level in each cell If electrolyte level is low top up with distilled water CAUTION Electrolyte shall be fille...

Page 45: ...MP BULB CAUTION Never touch the bulb with your finger Finger prints will etch the glass and decrease bulb life Hence it is recommended to grab the bulb with paper or clean dry cloth during handling REMOVING THE HEADLAMP Loosen the rim holding screw on top and take out the headlight reflector Unscrew and remove the bulb holder D O I T Y O U R S E L F Pull out the bulb Replace bulb and assemble in t...

Page 46: ...and assemble in the reverse order TRAFFICATOR BULB Remove the screws take out trafficator glass cover Press bulb gently Turn anticlockwise to take out the bulb Position the new bulb inside holder ensuring that the holder ensuring that the pins in the bulb match with the slots in the holder Press the bulb and turn clockwise to lock the bulb in the holder Refit the t r a f f i c a t o r cover and sc...

Page 47: ... parts Use luke warm water and mild detergent on the painted components to remove dirt etc Rinse vehicle thoroughly with plain water to remove the detergent and wipe vehicle dry If possible use compressed air and blow off water particles from the obscure areas of the vehicle electrical connections etc AFTER WASHING Ensure the vehicle is throughly dry by wiping with a clean soft absorbent cloth or ...

Page 48: ...oil Remove battery from the bike Clean the terminals free of corrosion Maintain electrolyte level between max or min mark by adding distilled water and wipe the battery dry Store the battery in a cool dry and well ventilated place Do not place the battery in direct sun light near open flame or where temperature is above 40o C or below 0o C Cover the silencer with plastic bags to prevent moisture e...

Page 49: ...n and remove the motor oil from tank and fill tank with fresh petrol Clean carburettor and air filter Remove plastic covering from the silencer Remove spark plug on cylinder head and pour in a few drops of engine oil Crank engine a few times to lubricate cylinder walls and piston Clean spark plug and refit Switch on ignition switch Start vehicle and warm up engine for a few minutes before riding t...

Page 50: ...y 1500 kms of run Tightness of all fasteners Tyre tread condition and wear of tyres Battery condition and electrolyte level Working of all lights and horn Correct oil level in engine Proper chain tension Items to be carried Tool kit First aid kit Bulbs for Headlight Trafficator light Rear Tail Lamp and Fuse Accelerator Clutch and Speedo Cable Rear chain link master lock assembly Spare tube tyre pu...

Page 51: ... and exhaust system and low mileage Wrong grade and inferior quality oils do not lubricate well The moving parts wear prematurely Always use recommended fuels and oils only RIDE AT COST EFFECTIVE SPEED Cost effective speed in top gear is 45 to 50 Km per hour Both lower and higher road speeds cause low kilometers per litre of petrol PERFORM PREVENTIVE MAINTENANCE AS PER RECOMMENDATIONS REGULAR PREV...

Page 52: ...s wastes 100 ml of petrol STOP BRAKE RIDING Brake riding pushes the brake shoes pads to come in contact with revolving drum disc To overcome the resulting frictional load engine burns additional petrol Result Low mileage loss of power faster wear of brake shoes pads and drum disc NEVER CLUTCH RIDE Clutch riding slips the clutch engine drive does not get totally transferred to the rear wheel Beside...

Page 53: ...icle speed with throttle and gear like smart riders always do AVOID OVER LOADING Over loading tires the engine wears the parts faster and reduces mileage PARK YOUR VEHICLE IN SHADE WHEN NOT IN USE Petrol is highly volatile It evaporates under normal atmospheric temperature The evaportion increases with temperature Prevent this loss by always parking your vehicle under shade Too few Kms running per...

Page 54: ...52 COMPLETE WIRING DIAGRAM K I C K S T A R T ...

Page 55: ...53 COMPLETE WIRING DIAGRAM E L E C T R I C S T A R T ...

Page 56: ...uretor clean jets passages 6 Carburetor float stuck in closed position Ensure correct movement of float 7 Spark plug cap lead not connected Fix cap lead firmly 8 Loose HT connections Fix connections firmly 9 HT Lead Damaged Replace HT Lead 10 Spark plug electrode dirty fouled Clean spark plug Reset gap 11 Spark plug insulation cracked Replace spark plug 12 Poor compression Auto Decompressor not wo...

Page 57: ...rburetor petrol tank Fill tank with fresh petrol 2 Leak through intake hose Tighten rubber hose suitably Replace if necessary 3 Loose spark plug cap Fix cap lead firmly 4 Spark plug fouled insulation broken Clean reset gap or replace 5 Poor Compression Auto decompressor sticky or not working III ENGINE STARTS BUT RUNS IRREGULARLY STOPS 1 Faulty fuel supply Clean the fuel line tap vent hole 2 Very ...

Page 58: ...Choked air filter Clean Replace air filter 4 Loose carburetor mounting Tighten clamps firmly 5 Brakes adjusted too tight Re adjust properly 6 Rear chain adjusted too tight Re adjust properly 7 Clutch Slipping Adjust clutch cable free play 8 Under inflated tyres Inflate to correct pressure 9 TPS setting Retard Wrong setting V WHITE BLUE SMOKE 1 Oil level in RH Crankcase cover window above MAX line ...

Page 59: ...Incorrect carburetor adjustments Check and correct 5 TPS setting Advance wrong setting VII EXCESSIVE FUEL CONSUMPTION 1 Fuel leakage Check and rectify 2 Worn out carburetor jets Change the defective jets 3 Incorrect carburetor adjustments Check and adjust correctly 4 Choked air filter Clean Replace 5 Poor compression Auto decompressor sticky or not working properly 6 Under inflated tyres Inflate t...

Page 60: ...djusted properly Adjust properly 2 Oil grease on lining or drum or disc Clean and refit 3 Linings worn uneven worn Replace lining pad 4 Drum scored uneven wear Rectify or replace drum X VEHICLE WOBBLES 1 Wheel rim runout Rectify 2 Loose Broken spokes Tighten Replace spokes 3 Tyres not fitted correctly Refit tyres correctly 4 Wheels misaligned Ensure proper alignment 5 Under inflated tyres Inflate ...

Page 61: ...and correct 2 Requires tuning Tune horn 3 Switch Defective Replace Trafficators not working 1 Loose improper connections Check and correct 2 Bulb fused Replace 3 Switch defective Replace 4 I C Flasher defective Replace Brake light remains on 1 Switch not adjusted properly Adjust switch properly 2 Switch sticky Replace switch CAUSES REMEDIES Contact Dealer Authorised Service Centre T R O U B L E S ...

Page 62: ...Connection Check Correct 4 Starter relay not working Check Replace 5 Malfunctioning of clutch switch Check Replace 6 Malfunctioning of Starter switch Check Replace 7 Battery discharge Check Recharge 8 Motor not working Check Replace 9 Battery not fully charged Check charge 10 Failure of sprag clutch Check replace CAUSES REMEDIES Contact Dealer Authorised Service Centre T R O U B L E S H O O T I N ...

Page 63: ...wner s manual from RE Dealers authorised service points 4 During the warranty period RE s obligations shall be limited to repairing replacing free of charge such part or parts of the vehicle which on examination to have manufacturing defect Such defective part parts which have been replaced become property of RE 5 Cost of oil oil filter fuel and other consumables are chargeable to the customer 6 C...

Page 64: ...cle such as slight vibration oil leakage blue discoloration of exhaust bent pipe silencer soft hard shock absorber etc i Defects arising from fitment of unauthorised additional Electrical loads j Vehicle serviced repaired at unauthorised service points k Vehicle used for competition racing l Electrical component likes bulbs fuses etc m Normal maintenance operations like adjustment of brakes cleani...

Page 65: ... of the emission control system to meet the required emission standards The method s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfield and or our authorised service centers and results of such examination will be final and binding If on examination the warranty conditions of the part s is are not establis...

Page 66: ...e motorcycle will have to be borne by the customer Emission warranty will be applicable irrespective of the change of ownership of the vehicle provided all the conditions as laid down in this document are met from the date of original sale of the motorcycle The warranty shall apply if the customer Observes all the important instructions and any other precautions listed in the owner s manual Under ...

Page 67: ... The motorcycle is not serviced by authorised service centers as per the service schedule described in the maintenance chart The motorcycle has been subjected to abnormal use abuse neglect and improper maintenance or has met with an accident Replacement parts not specified and approved by Royal Enfield have been used The motorcycle or parts thereof has been altered tampered with or modified or rep...

Page 68: ...re of the emission warranty is not entered in the log book Tips to be on the right side of Law Always get your vehicle checked to meet the emission regulations through and authorised emission checking center Always carry a valid Pollution Under Control certificate with you at all times during the validity of the emission warranty 30 000 Kms 3 years from the date of first sale Tips to reduce pollut...

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