Royal Enfield Bullet, Workshop Manual

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Page 2: ...E OPERATION ENGINE ON F W E SERVICE OPERATION ENGINE REMOVED FROM FRAME G M BOX FRAME REAR SUSPENSION FRONT FORK HYDRAULIC WHEELS ADJUSTMENT OF BRAKES TYRES REMOVAL AND REPLACEMENT IGNITION AND LIGHTING SYSTEM WIRING D L A G W S ELECIIUCAL CONNECTION DETAILS CARBURETTOR SERVICE LIMITS TROUBLE SHOOTING TORQUE VALUE CHART SPECIALTOOLS 101 106 METRlC CONVERSION TABLE 107 ...

Page 3: ... the following points without fail when dismantling and reassembhg 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 specffied tightening torque Use always genuine spares and recommended grade of oils only Wh...

Page 4: ...e tasks serves only as a guide As the machine gets older or used under particularly adverse conditions it would be advisable to reduce the period between each check For ease of referenceeach serviceoperation is described in detail under the relevantheading In order to c u t the routine maintenance tasks a good selectionofgeneralworkshop tools is ab olutel essential Included in the kit must be a ra...

Page 5: ...re cold It is worth purchasing a small pocket pressure gaugewhich can be relied upon to give consistent readings than garage forecourtgauges which tend to be less dependable G i air r 6z7 as G x 2 p p 2 2 q 2 s 3 P X T E pT3 n zg g gss gon 3 Psr Rear G z 2 a 42 G c e 2 z 2 2 v L g E 5 z s 2 136 PSI o Check tyres for foreign materials and remove them to prevent possible punctures Check for adequate...

Page 6: ...brakes Check front fork oil level Check allelecmcalconnectionsand functionsofhead Light trafficator horn speedameter etc Carry out alI the operatiom mentionedfor hf monthly suvfce and check the following Change ofl engine clutch Clean or replace ofl fflter Change front fork ofl Check front rear brake linings and replace lf necessary Check for play in steering head bearings and adjust Check operati...

Page 7: ...arLng 25 X 62 X 17mm 63051 Roller bearing 2 5 x 6 2 17 mm NU305 orN 305 Timing side Roller bearing 2 5 x 5 2 15mm NU205orN205R CamW 3125 in Valve lift 3125in Valve tizuing with 012 clearance Exhaust opens 75 BTL C Exhaust closes 35 ATDC Inlet opens 30 BTDC Inlet closes 60 ATDC Rocker bearing inside diameter 625 626 J3irnensions for new Components Rocker spindle diameter 6235 624 Inlet valve stem d...

Page 8: ...Wheel base Electxicals System 5 32 7 26 9 80 14 80 Small 6303 Large 6206 16 teeth 5 8 pitch chain 38 teeth M i k d W 2 4 90 25 0 14 0 16 0 35 to 0 4 mm 1 32 0 8 mm 14 mm diameter B7HS NGKI or equivalent 0 46 to 0 50 mm 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 ...

Page 9: ...de Ball bearLng 25 X 82 X 17mm 63051 Roller bearing 25 X 62 X 17mm N U 305 or N 3051 Tlming side W e r bearJng 25 52 15mm NU205orN205RI C a m m 3125in Valve lift 3125in Valve thing dth O 1 T clearance Exhaust opens 75 BTM Exhaust closes 35 ATM Inlet opens 3O0BTDC Inlet clmes 6O0ATDc Rocker bearing inside diameh 625 626 Dimensionsfor new Components Rocker spindle diameter 6235 6240n Inlet valve ste...

Page 10: ... Wheel Bfm Type WM2 19 m e size 3 25 X 19 Front 3 5 0 19 Rear Wheel Bearings Front Rear 17x40x12mm 6203 or6203ZZ Brake Mechanical internally expanding shoe type Front 178mm X 38 mm Twin leading shoes Rear 153mm X 25 mm Single lea shoe Fuel tank Full Tank Capacity 14 5litres Reserve capacity 1 25litres Oil Capacity grade Oil t a r 2 25 litres SAE 20W50 Fork 200 ml on each leg Hydraulfc Oil or SAE 1...

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Page 12: ...rank CaseRscu Jolnt 67 Connectfng rod 14 Distance tube outer 68 Connectfng r o d m t i r t gbush 15 Distance tube Inner 69 Crank pln 16 Roller bearing 1 7 Stud Crank Case Neck 18 Washer Crank Case Neck Stud 70 Thrust washer 42 Nut Crank Case Rear Joint 71 Cmnk pln nut 72 Crankpin o U hole grub m e w 73 Crankpin nut keeper screw 74 Thrust wzsher 44 Oil SealRetainer P 19 Nut Crank Case Neck Stud 45 ...

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Page 14: ...9 Washer Oil Plpe banjo Union 131 Washer Plain 163 011cleaner spring 101 Cylinder head 102 Valve auLde 103 Stud Rocker Box 104 Stud Rocker Bearinq l 05 Washer Rocker Bearing 1G6 Nut Rocker Bearing Decompressor M y 132 Decompressor M y 133 Spring Decompressor 134 Spring Cap Decompressor 135 Cable block 136 Cable block spllt pin 137 Decompressor le assembly 164 Washer O U Cleaner Cap 165 011 cleaner...

Page 15: ...he petrol 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 a i r filter by undoing the bolts on the sides of the air filte body Push the carburettor back clear of the studs after removing the fudng nuts Remove the ro...

Page 16: ...dirt 4 Removal of Valves VALVE SPRING COMPRESSOR 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 screw driver Using compressing tool PED 2018 ST ampress the valve springs and remove the split collars from the valve tip Slacken back the ampressing tools and release the springs Withdraw the valve and place its spri...

Page 17: ...al size of the cylinder bore is 2 751 69 875rnm If the wear at any point in the bore exceeds 008 the cylinder should be rebored to 020 and an oversize piston fitted It should be rebored to 040 er a further 008 Wear Piston sizes available are 020 and 040 oversize The original side clearance between the piston rings CRANKSHAFT BIG END BEARING and grooves is 003 If the grooves show a wear of 005 the ...

Page 18: ...rel about 4 long made fYom 9 16 diameter bar with the end turned down to 1 3 S S O R Y diameter for a VALVE L length Support of 1 2 the CABLEADJ USTINC SCREW cylinder head on the tubewhich 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 Tofita newguide supportthe head at the correct angle and use a hand press and the ...

Page 19: ...d 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 Reversingthe ringwill 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 the ...

Page 20: ...sary with a woo8 dlafrf While refitting the timing cover ensure that theJoint wasH ris correctly located over the ofl holes using a little grease not compound to hold it in position xw c y Ensure that the cork p ug is in position in the hole in the pumpworm If the plug is damaged it should be renewed to ensure oil flow to the big end bearing NOTE The Alter chamber should be Wed with clean oil befo...

Page 21: ...utes to ensure that oil reachesthebig end If the tfming cover has been removed f i l l the filter chamber with clean oil before replacing the cover The feed and return filters are fked on the drain plugs in oil sump and crank case These can be cleaned by rinsing in a solventand during reassembly ensure the filters are not twisted VALVE TIMING MARKS FELT WASHER 4 I METAL WASHER SPRING 3 Overhauling...

Page 22: ...amber with clean oil Having assembled the pumps lay the timing cover flat and the oil ports using an oil can Turn the pump spindle with a screwdriver in a clockwise direction and itcanthen be checkedwhether the pumps areoperatingcorrectly Beforereplacing the timing cover on the engine i l l the filter chamber with clean oil and fit the filter element NOTE With the engine running the oil feed to th...

Page 23: ...ing The procedure is detailed below Bring the piston to TDC Match the exhaust cam providedwith two setsof punch marks with the timing pinion so that the two punch marks coincideon both Match the inlet cam to the exhaust cam so that the singlepunch mark coincideon both Push the cams home towards the crankcase MARK ON INLET CAM B MARK ON EXHAUST CAM C MARK ON TIMING PINION 7 Tappet Adjustment Cold I...

Page 24: ...imilar to that of 350cc except that there are six driven plates and five driving plates Also the lugs on the clutch sprocket and the splines on clutch centre are longer 9 Removal of the Clutch Remove the L H front foot rest 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...

Page 25: ...IN S1 8 Clutch sorocket balL5 13 16 dial N SL 9 Clutch retatnlna spring 10 Clcrtch tntermedlote wlore ldtshedl U Clutch plate insert t 12 CIutch intermediate plaWfZaU 13 Cltltch b d e d plate ossprnbly 17 Clrrtch s r i n a screw 38 Clutch p J 9 Clutch rod 20 Washer matn shaft f s m 21 Nut matn short INlrlocl CLUTCHASSEMBLY S W CC ket 56 T d r w P rivet 8 2 SWr o c k e tbaILs dd al fN SL v rite ...

Page 26: ... 3 springs on the clutch centre lugs CLUTCH ASSEMBLY In the case of 500cc one more plain flat plate and one friction plate will also have to be fixed aftkrthe plate with inserts has been assembled The other three springs are located by means of bosses on the clutch cap Tighten the spring pins asfar as they will go If the clutch lifts unevenly it is probablethat one of the springshas taken a set in...

Page 27: ...ere are two o i n t s of adiustment on the clutch cable The first is the midway adjuster at A CillTCH ADJUSWEhT ON GEAR BOX the middle of the cable just above the chain case The adjustment is made by screwing the adjuster screw in or out of the adjuster body Tightenthe locknut on the screwed collar after adjustment has been made The other point is at the handle bar end Loosen the lock nut and thre...

Page 28: ...uster and 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 i n its location Adjust the adjuster to ensure free play is maintained on handle bar end and tighten lock nut 15 Ntting the Alternator The dternator consists o...