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    10 views66 pages

    Bullet Service Guide PDF

    Uploaded by

    Asefsha

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Bullet Service Guide SOME TERMS AND DEFINITIONS Boro: Internal diameter of a eylinder ‘Top Dead Centre (TDC) : The extreme upward traval limit of piston. Bottom Dead Centre (BDC) : ‘The extreme downward travel limit of piston. Stroke : Movement of piston from one dead centre to the other. Stroke length : ‘The distance between top and bottom dead centres. ‘Cubic Capacity (Swept Volume) : ‘The Volume the piston displaces when it moves from one dead centre to other. m2 a where, = = 22/7, D = Bore, /= Stroke length Clearance Volume : Volume of the Cylinder above the pision when it is at TOC. Total Volume Volume of the cylinder above the piston when itis at BDC = Swept Volume + Clearance Volume Compression Ratio (CR) : It is the ratio of the total volume to the clearance volume. = Total volume ; Clearance volume Torque (Turning Effort) : ‘The work crank shaft is capable of doing = Cr. arm length x Force. Maximum torque gocurs when maximum fuel burns per cycle in the cylinder in @ given engine. Power : The rate of doing work. Bullet Service Guide SOME TERMS AND DEFINITIONS Horse Power : (HP) Mechanical unit of power 1 HP = 746 watts. Brake Horse Power : (BHP) HP available at the crank shaft for doing usefull work BHP = Torque x Engine speed. For any given cubic capacity engine, the BHP can be increased by 1. increasing the torque by arranging to burn more fuel per cycle. 2. shifting the peak torque to higher rpm A Typical BHP, Torque curve : Max. torque Torque Curve Max. BHP [-—| Power Curve 1 i Low | Peak High idele | torque | Rated idle rpm rpm rem rpm Load Nil Full Full Nil Throttle Fully Full Full Full Position Closed | Open | Open | Open MAC A 350 950 3500 | 5500 7500 BULLET 350 950 2875 | 5675 7500 BULLET 500 950 3000 | 5500 - | LIGHTNING 535 950 4000 | sso0 ‘Valve Timing : Toe Four Stroke Engines vaive EELAPCg VO = _—_ Inlet Valve Opening ” ee VC = Inlet Vaive Closing \VOP - Inlet Value Open Period EVO - Exhaust Valve Opening EVC - Exhaust Valve Closing ‘f EVOP - Exhaust Valve Open Period * i, Mismatehing ef timing marks and incorrect tappet adjustment : si ‘Change valve timing. Bullet Sei ice Guide FOUR STROKE CYCLE OPERATION SPARK IGNITION ENGINES SUCTION COMPRESSION| POWER EXHAUST STROKE STROKE STROKE STROKE Iniet Valve Open Closed Closed Closed Exhaust Valve Closed Closed Closed ‘Open Piston Movement | TDC to BDC BoC to TOC | TOG te BOC BDC to TOC Gas Flow Air petrol Air petrol Petrol burns. Exhaust gas mixture is mixture gets Gas expands. flows out. drawn inte compressed. Piston is Towards stroke cylinder Fewdegrees | pushed down. end, fresh charge BTDC, spark plug flows in, produces spark. ti) SL wh atvoke ‘and etree Ath stroke Gas 0...120°C 300...600°C 2000...3000°C 1300...1600°C Temperature Pressure load 0 to 0.8 kg/cm? 8 to 15 kg/cm? 30 to 50 kg/icm? | 4 to 5 kg/cm? + o ~ 180" to ET i" ‘40° 720°] Crankengle yoo "wpe Crankshaft revolutions ad Bullet Service Guide TECHNICAL SPECIFICATION [Sto _lemDeseription DIMENSIONS AND WEIGHTS: Length wie Height Wheat base ‘Saddle height Ground clearance Vohicta Ory weight Maxpay load ENGNE ANO ENGINE SYSTEMS Engine Type Fool used Colalvtc converter Boe sucke Swap solume Compression ratio Max Power @ rpm specticHF. ‘Max Torque @ mpm Low Idle rpm ‘Starting (Cr Sha LH besring Ce. Shalt RH Bearing sir ter ‘carburetor Main Jet Pio jot ‘Staring jt st back Neodie Nese lock groave from to Ai srw tars out (ii) Fat height Intako eystem Lvbrication Coating 27.6 Nm @ 2878 36.9Nm@ 3000 38Nm @ 4000 27.6 Nm Gi 2675 Bull 350 Bullet $00 Lightaings35 Bullet Mac 250 2120mm —————————+ —_—_—_—$§ 150mm + —— 100mm ————— 1372mm ————__——+ 650. mm —_—— 760mm ————_+ —— 140mm ——_—_—_———+ 183k9, 4+ 18 8kg —__+ 163%9 178h9 —— 185% —- 475kg +4 Stroxe, sparit ignition, air cooled, single eysinger —e Unie asers potion —————+ oo Hot tube type —+ Nil Tom Bamm 87mm 7omm << 90m Mec0 499ce 535ce 34Bee — 65:1 724 asst 48 BHP. 5625 22BHP.@ S400 25BHP @ £500 18 BHF @ 5500 52.02 44.08 46.72 52.02 +—————— 80010 1000 Wick Start +——————_ 05 8 nv 05 ——_ Nu 205 R +——Nu 205 £6 ANA + +——— Colton Gauze ————+ Polyuratnane Micarb VM- 24 + Micard VM-28—> PHBH 28 90 10 75 105 ———— 5 ——— 38 — «# ——— 70 — os ———— DHS 4047-4 sOHW 2647 " w 4" —— 15 ———> 1 <——— 28 0 30mm ——+ BS 10. 24Smm +. overhead vave —————+ + Dy sump pressure teed —————+ + Natural air ows —————_ Bullet Servicé Guide TECHNICAL SPECIFICATION No ler Deserintion Bullet 350 Bullet $00 Lightning §35 Bullet Mac 350, © PERFORMANCE 1 Grulsing speed 40-50 2 Max.Speed 100 125 130 120 3 Mileage under nocmat riding conditions 35-40 3035 34-38 40.45 D TRANSMISSION 4 Primary Drive + 386" Duplex chain & sprocket ————+ 2 Engine/ Clutch Drum Sprkt Teeth ——— a6 3. Primary Reduetion —\!___ 2a ——> 4 Guten + Wo mtiptatas ——————+ 5 Gear Box 4+ Gonstant Mesh 4 Spas —————+ 6 Gear ratios: <2, ——_____- 0-121 ——_——— << - 1.264 ——_—_—+ + ts 7 Secondary dive Chain and sprocket 5/8" pitch ————+ B WhesvFD.Sp&t toot 386 sen7 gene aaie % Secondary Ratio 2a7s:t 2235:1 ant 237521 40 vive Chain links a4 + 5 04 11 Overaitrato hax sare: 13.907 54 w343st sa770 4 42° Overall allo - Min, saa 5.008 1 472621 52:4 13° Main shaft RH bearing + 0 —_____—— 14 Main shaft LH bearing — 6203 )=——______+ CHASSIS: 1 Frame +<———_ tau, welded —————+ 2 Front suspension + Telescopic, Hydraulic damped ————+ 3 Rear suspension 4+ Swing acm with hydraulic shock absorbers ——» 4 Front brake 178 men X 38 mm Twin lead, Internal expanding —* 5 Rear brake +153 mm X 25 mm. internal expanding ———+ 6 Rest brake pedal + tr site 7 Wheel bearing Fr & Rr —__—_—_———_ 603), ——_______> 8 Rr. Sprocket bearing ———_ 50s. ——___+ 9 Fronttyre +<——— 325 x 19-6 PR ——+ 30. RearTyre 3.25% 19-6PR + 3.50 x 19.6 PR ———+ 41 Front tyre Pressure -Selo 4+ 18 Pi (1.27 Kpfem) —————+ 42 Front tyre Pressure -Dual +20 (1.41 Kiem’) 43 Rear tyre Pressure Solo + 281 (200 Kgfem) —————> 14 Rear tyre Pressure -Oual + 0p (2.11 Kafe) ————+ 15° Steering lock + now FESORS Bullet Service Guide ISKEA TECHNICAL SPECIFICATION Bullet 350 SLNo Item Description ‘Bullet 500 Lightning 535 Bullet Mac 350 F CONTROLS 1 Steering Handte Bar 2 Accelerator + Twist orp on sight nand side of handle bar ———+ 3) Gluten + Hand levar on LH side of handle bar ————» 4 Gears, + Feet ever o RH side —_______+ 5S Front brake: + Hand lever on RH side of handie bar —___. 6 Rear brake + Fool lever on tH side. ——————+ 7 Decomprasser + Thum laver'on LH side of handia bar ————+ G ELECTRICITY ANDIGNITION 1 Generation + Alternator 12v 80W 2 System + v- acne 3 Ignition + Contact breaker ——» col System 4 Ignition timing. — eae a— 4.8mm BTOC 5 Spark plug type micow 14sz1 “Ml NGKBREES — MICOWSDG 6 Spark plug gap +—____ 0.80mm______+ 0.70mm 7 Rotor to stator gap <——— 015 to 025mm ———+ 025 0.5 mm & Battery + trv san —_____+ 9 Haad lamp vaso ——_____+ 10 Pilot Lamp +A EW 2ros—s 12V,34W 1202 2 nos 11 Tall Lamp $$ vw —______+ 12° Grake lamp 190,210 13° Tum sign =. tw —______+ 44 Speedometer lamp 12K 15 Ammeter Light — 12x34 ————> 16. Tum signal Indice $$ 12x .4w —____+ 17 Hi Beam indicator << 12x 3.4w —______+ 18 Hom + av 300¢ ————+ 12 3A00- 2ros 1H OWANDPETROL 1 Engine oil ———— sae 200-80 ————* SAE 2OW.40 2 Performance 1 +———._ ser ———+> APLSF 3 Tank capocity — 225 Litres ———+ 1.68 Lives 4 Front fork ol —— 0.30 ——____—+ 5 Fr.Forkelt eapaciy + 200m per teg ———+ 6 Clutch of <———— a8 10Ww.s0 ———+ zow-40 7 Clutehvoil Capacity ——————_ 20m 8 Gear Box Grease (initia! fling) + Veedot'00" Grade grease ————+ 8 Box capacity 100 Gms —___ 10 Fuol tank capacity ————— 14 51 itres ————___+ 11 Reserve + 1.251 tres ———_____+ Bullet Service Guide MAJOR AGGREGATES - ENGINE ] 348 CG, AIR COOLED, 4 STROKE, SPARK IGNITION ENGINE TIMING SIDE DISTRIBUTOR SHAFT GEAR TintiNG CHEST COVER OLE GEARS, O1L FILLER CAP ‘TAPPET GUIDE EXHAUST CAM WHEEL INLET CAM WHEEL | RETURN PUMP \_Tuane pinion ot FILTER reed puMP DRIVING SIDE CYLINDER BLOCK DUPLEX CHAIN CHAIN CASE INNER CLUTCH ASSEMBLY STATOR ‘CHAIN CASE OUTER Bullet'Service Guide aaa rr aa | INSIDE VIEW | CRANK SHAFT ASSEMBLY CONNECTING ROD Bullet Service Guide CLUTCH | HAIN CASE OUTER, nen! BALL AACE | om seat FRONT PLATE _4 CLUTCH SPRING cure car. CLUTCH PAD ‘STEEL PLATES. “CLUTCH CENTRE STEEL PLATE caren hue 7 CLUTCH PLATES CLUTEN CLEARANCE ICAP) CHAIN CASE INNER | | | | Engaged Disengaged } GEAR BOX | | HIGH GEAR ON MAIN SHAFT HIGH GEAR 000 ON MAIN SHAFT | 1ST GEAR MAIN SHAFT SLEEVE | 2NOGEAR 90 GEAR) ‘iL GROOVE | | (CLUTCH ROO! | BEARING | | er aan on LAY SHAFT, | LAYSHAFT STARTER SPINDLE 2ND-GEAR DOG” FORK 43RD GEAR 006. 2ND GEAR ON Lay SHAFT KIGK STATER GEAR RD GEAR ON LAY SHAFT 12 Bullet Service Guide GEAR BOX OPERATION First gear Second gear = cuuTeH = SUEEVE = GEAR! onowzEr xtra ™mone> = GEAR Third gear Top gear ASSEMBLY = MAIN SHAFT = DRIVE SPROCKET ON SLEEVE = tis GEAR ON SLEEVE = lr GEAR ON SLEEVE = GEAR OPERATORINSIDE = GEAR OPERATOR SELECTOR ASSEMBLY = HIGH GEAR = KICK STARTER GEAR LAY SHAFT = HIFGEAR DDG = mr CeAR = RS GEARDOG = IRGEAR Bullet Service Guide f LUBRICATION SYSTEM ‘DAY SUMP PRESSURE FEED SYSTEM 1 Oil is stored in a oil tank of 2.25 litre capacity. Dipstick with filler cap is provided to check the level and top up as needed 2, There are two pumps in this system : A Feed Pump and | B. Return Pump 3. Feed pump flow cireuit * — Oil tank ---> Drilled passage ---> Primary gauze filter ---> Feed Pump ---> Oil filter assembly ---> Feed plug on crank shaft---> Drilldd passages on crank shaft ---> Bigend bearing ---> Drains to crank case. I that drains from big end is thrown around In crank case by the rotating crank shaft ireate cylinder walls, piston rings, and the main bearings. % Bulk of the oil thrown en cylinder wall is scrapped down by oil scrapper ring. * ~~ The drained oil aets accumulated in crank case. 4, Return pump flow circuit %* — Crank case ---> Orilled passage ---> Gauze filter --» Return pump ---> External pipeline ---> Rocker shaft bush %* From rocker shaft, oil flows to valve assembly ---> push rod tunnel -~-> Timing chest. * — The rotating gears in the timing chest carry ail to lubricate all gears. | | Then the oil lows too tank througn tne o1| return hole on the érank case | | Bullet Service Guide FRONT FORK ASSEMBLY FORK SPRING. ain TUBE f | SPRING GUIDE ‘08 CONTAL COLLAR | ‘WHEEL AND HUB ASSEMBLY - FRON’ 4. FrontWheel nm 2-19) Froth! spates FronWhet pokes ies ‘rontnup seems ronal bearing (5203) Frettus inde Front ttretane Front et vaster mi) Frontihub cover plate distance collar Fronthub felt washer (speedo side) Front hub felt washer retainer (speedo side) Fronthuo speedo die spacing clar ‘Speedo drwe complete Frontbrake shoe ehing Fronttbrake shoo spring Fronteaka cover piste Frontbrake soe pn Washer fed irae hoa pn tron rake shoe pn Fronteakecpering con Nut ten hub cover ice Front pine pend ie) Fronteata operating camiever Wass ont bake pecag cam levee Nuttont rake opeatingcaraleved SA 15 Rusllot Sarvina Guide WHEEL AND HUB ASSEMBLY - REAR Rese whe! im Wie 219 Rear whee! spokes (dust cover sie-cutet) ar wha! ppoke (dust cover sige-inne iar whee! spokes hippies Gare nub witn barrel Faas bub beasing spacer assy. Rea: bub dust cove Rear Pub cust cover rem 9 Rear hub bared" ng 40. Rearhub grease seal (smat 11. Rearhubjoural being 42 Rearhub grease seal (na) Rearhub spinde (ong) “14 Rar hut aprochateush rabbar ‘eat hub aprockt 387 Rear nub pind (sho) . Rear brake oper |. Rear brake eperating car bush pia Jong) Rear brake operating car bush pia (snot) eae Brake retotn see . Rear brake operating Cam Lave: Assy Nut ear brake lever Reartusbeaing fe) Ooatance cor out coe ig ie) Reach cto colar(dstenver oaese) rata shoe cme odes) ahs sping Fear rote cover ssa stance cate Rearbrate cover patesisend) | Rearhub distance colar rum see) | Rear brake se pin Nit ea trae toe in Washo rear rahe shoe po an) Shoe pin nut rest bake noche a Rear Rear beake eam buh ‘Rear brake operating cara bush pin eck rut ‘washer rear brake lever Rear bub acjusies (Rt) Rear bub adjusies (LH) LLecknult (Rear Pub sie) Nutrear hub spindie Rear hub spindie sott pin TWIN LEAD BRAKE 16 Bullet Service Guide f PERIODICAL MAINTENANCE The maintenance schedule detalled here will help you maintain your Bullet motorcycte 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 inspectians, adjustments, replacements and lubrications are to be carried out. The frequency of the maintenance must be shortened depending upon the severity of the driving conditions or if the motorcycle Is used in a very dusty environment, Contact the nearest Royal Enfield Authorised service centre for expert advice and to carry oul the required maintenance. FREE SERVICE PAID SERVICE DESCRIPTION Kms (x 1000) 18 [21 | 24 | 27 | 30 Months R[rRi[ri[rir ‘Check level every 500 Kms or earloras required r[ [re] [Rr R z R ‘Check level every 500 Kms or earlier es required 1] Engine Oil (Bullet 350 / Electra / 500) 2| Engine Ot (Bullet Machismo) Engine oil fter (Bullet 350 / Electra / 500) Engine oil fter (Bullet Machismo) Engine oll strainer (Guillet 350 / Electra / 500) Engine oll strainer (Bullet Machismo) 5 | Tappets [6 | €B points (350/500 6c) 7 | tgnition timing (260 / $00 CC) a 2 io i Kins c c c ‘Automatic advance system (350 500 CC) ‘Spark plug HT lead for erack Air fiter element 12 | Carburetor cd 13 | Fue! fter (350 Electra / Bullet Machismo) ele|ri{[clalctalcir R id | Fuel tank ¢ ¢ c c c 15 | Breather Box (Bullet Machismo) Drain Every 3000 Kms 16 | Fuai hose a7 ‘accelerator cable ple Rubber hose, Air filter to Carberetor 19 | Auxikary alr regulatin pipe (Bullet 350 / Electra) 20 | Braided Hose (500 CC) crack /leaks 21 | Hose PAV to Inlet manifold (600 CC) cracklleaks| 22 | U metalic pipe in Inlet Flange (500 CG) crackileaks| arbonise F:Faco/ Run out 1: Inspect L: Lubricate R: Replace [Note '30,000 Kms pls repeat the same frequency levels specified above, ‘consultation with a Royal Enfield Authorised service centre 7 1 A l t t i V -|>|-|>[=)> [>] iS) ape | ie Bullet Service Guide FREE SERVICE Dacompressor cable play DESCRIPTION ce PAID SERVICE Kis (x 1000) 9 [12] 15/18] 21] 26] 27] 30 Months 9 Rubber Inlet manifold (Bullet Machismo / 500 CC) racklvake ' RyfifafifRyrdaye Inlet / Exhaust val ‘Cylinder head eating Exhaust system Primary Chain tension Clutch oil ‘Clutch free play Gear box grease / oll Check level every 500 Kms or earlier as req Adjust every 1000 Kms LT Te Check level every 1000 Kms or earlier as required Clutch actuating arm Rear brake pedal pivot Battery terminals (apply petroleum jelly) Battery Electrolyte level Earth wire eyelet (behind battery carrier) teehee epeeee L eh A [a7 | Rear Chain Lubricate every 3000 Kms or earlier a5 reqi 38 | Fork oll ‘Gheek level every 1000 Kms or earlier as required [39 | Front brake play ‘Adjust every 1000 Kms or earlier as required 40 | Rear brake play Adjust every 1000 Kms or earlier as required 41 | Front / Rear brake cams L 42 | Stoering ball races 23 | Spokes tighiness ‘aa | Wheel rim runout 45 | Tyre wear fas [Hand levers & ak sara pivot A: Adjust €: Clean |: Inspect L: Lubricate Note Lubricate every 1000 Kms or earlier as required F : Face / Run out D:: De-carbonise Ri Replace For maintenance after 30,000 Kms pls repeal the same frequency levels specified abave, in consultation with a Royal Enfield Authorised service centre. 18 PERIODICAL MAINTENANCE ENGINE OIL Viscosity - SAE 20W-50 APlrating - SEorabove | LEVEL CHECK ¥ Right Level : Between ‘H’ and ‘L’ of dipstick ¥ Remove the filter ¥ Top up, if required upto ‘H’ mark on dipstick ¥ Clean the filter Bullet Service Guide HANGE : (EVERY 3000 KMS) one { Note : Replace oil filter element every | ¥ Keep vehicle on level ground 42000 Kms. | “Start the engine and warm up before sai => | WA | ' | i Drain the oil from oil tank and sump ¥ Soak the filter in oil for 15 mts. 19 Fill up with SAE 20W-50 oil Capacity : 2.25 Lits Check level Oil level should be upto ‘H' mark TAPPETS ADJUS™ENT (EVERY 3000 KMS) Ensure engine is cold Bullet Service Guide ¥ Bring piston to compression stroke ToC Set by nating the ammeter needle lection from negative to zero, ¥ Remove tappet cover and check push rods. ¥ Push rods to be thumb free without up & down play. Y incorrect, adjust as follows : Y Adjust the screw for zero clearance and thumb push rotation ¥ Tighten lock nut and check DECARBONISING (Every 12,000 KMS) Cylinder hoad 4K Serub out carbon with a scraper Similarly, decarbonise piston and barrel also. EXHAUST BEND PIPE MECHANICAL METHOD ¥ Take 6 mm wire rope of 70cm length ¥ Loosen out splines at one end. ¥ Fitthe other end to a drill gun OnLL GUN emu wine ROPE Pee 2 —<—" ¥ Ingartitinto the pipe and operate the rill. + The loose splines of the wire rape will cut and remove the carbon Chemical method SARS 241 Bullet Service Guide With a potato, close the tube at one end Prepare a solution by mixing 1 kg. Caustic soda with 8 Itrs. of water. Nate : Prepare the solution in plastic container. Do not allow caustic soda or the solution to come in contact with skin or cloth. Fill the pipe with the sotution Keep for 45 to 60 minutes Remove the solution Clean the pipe thoroughly in running water. AIR FILTER CLEANING (EVERY 3,000 KMS) Blow compressed alr (15 PS!) from inside out | 7 Use light to check for cracks / holes / clogging ¥ Itdefective, replace with new CARBURETTOR CLEANING (EVERY 3,000 KMS) Remove the main and pilot jets. Clean with compressed air FLOAT HEIGHT ADJUSTMENT (EVERY 3,000 KMS) | | | Float Height : 28 to 30 mm ¥ Remove the float chamber body and gasket Hold the mixing chamber body in inverted position ¥ Hold the float so that contacts the spring loaded plunger of the float needle valve. Ensure that the spring loaded plunger is not depressed. js tongue just ¢ With a Vernier Caliper, measure the height from the mixing chamber body face to top of the float. 22 Bullet Service Guide Y If, the float height is incorrect, correct it by bending the float assembly tongue. Check the float height again. LOW IDLE ADJUSTMENT (EVERY 3,000 Kms) ¥ Tighten the air screw fully and loosen it ‘out by one and half turn, ¥ Tighten Auxiliary air screw fully. ¥ Start and warm up the engine. ¥ Set engine speed to 1300 RPM by ‘screwing in throttle stop screw. ¥ Loosen the air screw to get highest ‘engine speed ¥ Loosen the stop screw and set low idle speed to 900 to 1000 RPM pl ¥ Loosen the auxiliary air screw by halftum. Engine RPM increases. ¥ Loosen the throttle stop screw and set Idle speed to 900 to 1000 RPM Repeat the above two steps until turning ‘out auxilary air screw does not increase engine RPM THROTTLE CABLE FREE PLAY ADJUSTMENT Free Play: 1 to 2mm ¥ Loosen the lock nut ¥ Screw in the cable adjuster to increase the play and screw out the cable adjuster to reduce the play. ¥ Tighten the lock nut SPARK PLUG CLEAN AND ADJUST: EVERY 3000 KMS: ¥ Clean inside with a pointed scraper S Measure and adjust the gap to 0.5 mm 23 Bullet Service Guide GREASING DISTRIBUTOR SHAFT : (EVERY 3000 KMS) ¥ Grease with a grease gun IGNITION TIMING ADJUSTMENT (EWERY 3000 KIS) ony tor BULLET 350,520, Lighiniog 535 | ¥ Remove spark plug ¥ Fitdlal gauge with adaptor ¥ Put a wooden plank under centre stand legs so that rear wheel is lifted from the ground. ~ Engage fourth gear by rotating the rear wheel and shifting the gear lever simultaneously ¥ Rotate the rear wheel as shown and bring the piston to TDC in compression stroke Bullet Service Guide 4 Maximum clockwise reading of dial gauge indicates TDC. ~~ Ensure CB back plate screws are at the centre of back plate slots. MOVABLE JAW HOLOING ¥ Clean the CB points ¥ Leosen the movable jaw holding ¥ Adjust the gap. Use @ serew driver to move the CB paint movable Jaw 24 ¥ ‘a Set the gap to 0.35 to 0.40 mm Check with a feeler gauge Tighten the screw, Tur the wheel as shown until the dial gaug needle makes 3 full anticlockwis revolutions. Turn igni deflect to - ve side, switch 'ON', ammeter wi | ¥ ... Till the needle makes 2.2 clockwise revolution (i.e. 0.8mm. before TOC Needle position as shown above.) Note: Take care not to cross ‘20° reading Note: If the needle crosses '20' reading repeat the above four steps to eliminate timing gears backlash effect en ignition timing. SRE PATE HOLDING SCREW ¥ Loosen the backplate holding screws and adjust back plate, such that CB point just opens... Bullet Service Guide «As indicated by ammeter just deflecting back to zero | RETARDING & ADVANCING Forretarding Reduce the CB point gap. Move base plate in clockwise direction. Foradvancing. Increase the CB point gap Move the base plate in anticlockwise direction. 25 ¥ Remove the strips, ¥ Rolate the engine to ascertain that the rotor does not come in contact with the stator. PETROL TANK CLEANING (EVERY 6.000 KMS) ¥ Remove the petrol tank ~ Plug the drain hole oo t ¥ Pour 500 mi of kerosene CO ¥ Put a handful of carpenter screws in igorously shake the tank for 2 to 3 minutes. Bullet Service Guide ¥ Drain and remove kerosene and the screws. ¥ Pour 500 ml of fresh kerosene, shake and rain. ¥ Blow compressed air to dry the tank, CLUTCH OIL LEVEL CHECK (EVERY 1000 KMS) ¥ Loosen / remove the level plug. ¥ The clutch oil should siowly ooze out ¥ Ifnot, top up with SAE 10 W - 30 oil, 27 Bullet Service Guide eee ¥ Remove the strips. Rotate the engine to ascertain that the rotor does not come in contact with the stator, a PETROL TANK CLEANING (EVERY 6,000 KMS) ¥ Remove the petrol tank Drain and remove ¥ Plug the drain hole ue screws. ¥ Pour 500 ml of fresh kerosene, shake and ¥ Pour 500 ml of kerosene rain, ¥ Blow compressed air to dry the tank. CLUTCH OIL LEVEL CHECK (EVERY 1000 KMS) G ¥ Puta handful of carpenter screws in it < *. ¥ Loosen / remove the level plug ¥ The clutch oil should slowly ooze out “ Vigorously shake the tank for 2 to 3 minutes. “ Ifnot, top up with SAE 10 W - 30 oil, 27 wR OIL CHANGE : (Every 3000 KMS) —_ ruven PAu even PLUG Keep the vehicle on level ground Drain the oil by loosening the chain case cover outer Tighten the chain case cover holding nut Remove the level plug Remove the filler plug Pour SAE 10W - 30 oll through the filler plug Till the oil 0026s out from the level plug hole Bullet Service Guide ¥ Tighten filter and level plugs. CABLE END OILING : (EVERY 3000 KMS) “Lubricate the cable end with a oil can. GREASING ¥ With a grease gun, grease the clutch actuating ARM through the grease nipple ¥ Remove the adjuster ¥ Remove the ball and clutch rods from main shaft. Apply grease on then. ¥ Refit them. CLUTCH GABLE FREE PLAY : (EVERY 1000 KNS) Free play : 2-3 mm luton came 28 Bullet Service Guide WITH ADJUSTER SCREW “Ensure cable adjuster Is fully in. ~w Loosen the lock nut Tighten the screw till resistance is felt Now, loosen out by % turn Tighten lock nut sss WITH ADJUSTER ON CABLE ¥ Loosen the lock nut ¥ Serew out the adjuster ta reduce the play. ¥ Screw in the adjuster to increase the play. ¥ Tighten the locknut, PRIMARY CHAIN TENSION ADJUSTMENT (EVERY 3000 KMS) Check the slackness al the centre of the top run. ¥ If more, adjust as follows ¥ Remave the level plug Loosen adjuster lock nut Screw out the adjuster till the right slackness is achieved Tighten the tock nut. VALVE TIMING Punch marks on crank shaft pinion, exhaust cam wheel and inlet cam wheel are to aligh when piston is at TOC Bring the Piston to TOG (The Timing pinion key way will be at 12 ‘O° clock position) Position the Exhaust cam, aligning its two punch marks with the twa punch marks on the timing pinion, a, Place the inlet cam, aligning its single punch mark with the single punch mark ‘on the exhaust cam. (GEAR BOX LUB : LEVEL CHECK : (EVERY 3,000 KMS) | ¥ The Grease should ooze out. ¥ LUBRICANT CHANGE : (EVERY 12,000 KMS) | ¢St#ano warm up tne engine Qo Orain the tubricant Tighten the drain plug ¥ Remove the filler and level plugs. Bullet Service Guide ¥ Use VEEDOL ‘00’ grease, TOO grams ¥ Fill the gear box with veedo! “00 grade grease ... ¥ Till the grease starts oozing out from the level plug hole. Tighten the fil! rnd level plug SELECTOR ADJUSTER PLATE ADJUS™ENT SELECIOR ASSY. ¥ Remove the gear box end cover Bullet Service Guide Fee eee Le ss “ v Remove the nuts and the foot contro! stap plate. Loosen the adjuster plate pins. Move the adjuster plate as required Move the adjuster plate i * Anticlock wise directon to make 1st gear engagement easier * Clock wise direction to make 2nd, 3rd and 4th gear engagement easier. Tighten the adjuster plate pin. Fit foot control stop plate and nut. Fit the gear box end cover GEAR OPERATOR SELECTOR ASSEMBLY ADJUSTMENT Loosen the lock nut Tighten the gear operator selector assembly fully. Loosen the gear operater selector til it clicks two times. Tighten the lock nut. Check gear shifting. If tight, loosen the gear operator by one more click. NEUTRAL FINDER AOJUSTMENT Shift Gear to 4th Depress the neutral lever, while gently turning rear wheel, gear from 4th must fall into the neutral. ¥ ¥ v If it does not fail into the neutral, the neutral lever travel is less. If it crosses through neutral to first gear, the neutral lever travel is more, Loosen the screw of neutral stopper eccentric cam and turn the cam to correct the travel of the neutral finder lever. REAR CHAIN SLACKNESS ADJUSTMENT : Check slackness Slackness to be 25 to 30 mm If more or tess, adjust as follows : Loosen Axle nut Loosen spinale nut Bullet Service Guide Turn the adjuster cams on both sides til 28 to 30 mm chain slackness is achieved. Check and ensure that the number of notches from the punch mark on the cam to the notch resting an the pin are equal ‘on both sides. ¥ Apply brake and tighten all the nuts. REAR CHAIN CLEANING AND LUBRICATION (EVERY 1000 KMS) ~ Glean the chain using @ clean piece of cloth. ¥ Apply SAE 20W - 50 oil liberally on the chain. ¥ Rotate the wheel to run the chain several times, ¥ Wipe offthe excess oll using a clean dry cloth, AFTER REMOVAL : (EVERY 3000 KMS) Brush and clean the chain in kerosene 32 “Hang the chain for 5 minutes to allow the kerosene to drain. ¥ Heat grease (multipurpose) to 120°C (Appx) ¥ Place the chain in the molten grease. ¥ Allow the grease to caol, ¥ Remove chain tram the grease. ¥ Remove the excess grease and clean the chain with a piece of dry cloth Bullet Service Guide ¥ While refitting, ensure correct direction of lack tink. FRONT FORK LEVEL CHECK : (EVERY 3000 KMS) “Remove plug screw ¥ Check oil level with a 5 mm dia rod The level to be 37 to 38 mm ¥ Top up, ifrequired. Bullet Service Guide ¥ Remove spring stud nut and drain oi ¥ Tighten the spring stud nut. Pour 200 ml of SAE 10 W- 30 oillin each OIL CHANGE : (EVERY: 12,000 Kms) ¥ “ ¥ ¥ ~ Bump front fork several times 34 SHOCK ABSORBER ADJUSTMENT _SPrubg TENSIO# Remove plug screw and check level Top up, if required. The adjuster at the bottom of the spring has five notches, For normal use, keep the adjuster at 3rd Aotch. Kg ox ‘To montase ‘Tum the adjuster as shown in the picture for increasing or reducing the spring tension, Increase the spring tension for heavy load and rough road operation. Reduce the spring tension for smooth road and low load eperation, Solect the same adjuster position for both LH & RH shock absorbers. WHEEL RIM FACE OUT CHECKING wary ) Pre load the dial gauge on to the face of the rim Slowly rotate the wheel. ‘The total indicated reading is the face out. 2mm Service Li RUN QUT CHECKING Pre load the dial quage on to the rim inner face. Slowly rotate the wheel. The total indicated readings the runout. Service Limit : 2 mm. Bullet Service Guide REAR SPROCKET DRUM BEARING GREASING (EVERY: 12,000 KMS) Remove the sprocket drum assembly. Pack Grease. Replace grease seal with new. SANS Refit the sprocket assembly. FRONT BRAKE ADJUSTMENT "| 20-90 Mea i Depress front brake lever fully and check if distance between handgrip and lever is 20-30 mm. If gap is less adjust as follows. ¥ Loosen the lock nut at the LH fork end and turn out the adjuster screw till the distance from brake lever to hand grip comes to 20 to 30 mm TWIN LEAD BRAKE ADJUSTMENT ¥ Keep the brake in released condition. 35 Bullet Service Guide REAR BRAKE PEDAL HEIGHT ADJUSTMENT ¥ Loosen link rod auts 1 & 3, Turn link rod 2 as shown above 3 times. ~The short leverd moves towards release Loosen the lock nut. position. ~ Turn in J out the pedal stop pin till the Y Apply the brake and keep it applied. pedal and foot rest are atthe same level. ¥ Tighten the lock nut. @ svonr Leven PEDAL PLAY ADJUSTMENT Pedal play -26 to 35 mm que @uowa vever ¥ Turn the link red 2 as shown above. ¥ This would move the short lever 4 towards apply direction. ¥ > Stop turning link rod 2 when high resistance is felt for turning Turn infout the adjuster nut for correct Tighten the link rod nuts 1&3. pedal play. BRAKE PEDAL BUSH LEVER PIVOTLUBRICATION GREASING (EVERY 3,000 KMS) (EVERY 3,005) on = “Apply few drops of engine oll at the lever pivot. ¥ Grease the nipple with @ grease gun. Bullet Service Guide BRAKE CAM GREASING {EVERY 6,000 KMS) ¥ Remove the brake cover plate. Y Clean the brake cam and apply grease. ¥ Refit the cover plate. STEERING PLAY ADJUSTMENT (EVERY 3,000 KMS) ‘Check play. ¥ Keep a wooden plank under the stand. “Rock the front end and feel the play at es Nee ene Steering to be free with out any play. stem tap end, ¥ If felt, adjust.as follows : ¥ Tighten headlamp casing allen screw. ¥ Tighten crown plate bolts, ¥ Loosen head lamp casing allen screw. 37 Bullet Service Guide STEERING BALL RACE LUBRICATION DEGOMPRESSOR CABLE {EVERY 12,000 KMS) PLAY ADJUSTMENT Y Remove steering stem assembly. | | | | | | ¥Leosun the ek aut | +>claan-ond check iba’ balls and veces Adjust with adjuster screw til 4 to § mm throughly for damages / pittings / play atiever is achieved discolouration. ¥ Tighten the lock nut ‘Change if defective. CABLE CLEANING ¥ Remove the dirt with kerosene as shown, KEROSENE. it Pack grease on the bottom ball race. ed 9 g Lubricate with fresh lubricating oil. WHEEL ALIGNMENT CHECK SS Pack grease on the top ball race. ‘Assemble the steering stem ¥ Hold the vehicle upright off the stand ‘ana level ground 38 Bullet Service Guide ¥ Stretcha string about 100mm above the ground along the wheels. ¥ Ifthe siring touches only three points on the two wheels, the alignment is Y Ifthe string touches two points on the rear incorrect wheel and two points on the front wheel ¥ > Adjust the rear wheel, with chain (Four point contact) then the wheels are adjuster cam till the string touches four aligned points. 39 12, 14. 14, 15. 16. Bullet Service Guide CLEANING AND ASSEMBLY PRECAUTIONS Ensure, the vehicle needs the service you contemplate by proper investigation and analysis Keep the vehicle on a ramp so as to stand and work. People work faster this way. Arrange parts removed in trays, neatly. Inspect all parts, decide the parts you need for servicing and procure it. Only then start assembly Clean all components (except rubber and ‘electrical parts) in clean kerosene ail mixed with 2% Engine oll, Never use petrol for cleaning. It is costlier and hazardous. Apply lubricating oil on piston, piston ring, and eylinder bore before assembly. Apply oil on threads of bolts and nuts. Replace washers, seals, gaskets and circlips ‘while overhauling. Always use right tools while working to make the ‘work faster, safer and dependabl Use impact screw driver for loosening jammed screws, Heat the aluminium bearing bores for removal and assembly of bearings. Ensure sealing surfaces are clean and free from scoring and warpage. ‘When using liquid gasket, ensure it does not flow into the threaded holes. ‘While assembling, ensure %* Arrow mark on the piston, faces exhaust side. x The open end of the chain lock to face opposite to normal direction of chain rotation. * ‘The numberof notches from the punch marks of the chain adjuster cams to the notch resting on the pin are to be equal at LH & RH sides. 40 WoRNG WITH WOTOR 17. Check for correctness of assembly after each stage, 18, Tighten all nuts and bolts to correct torques. 19. Always smear oll or grease on the oil seal lips before installing. 20. Apply specfit on outer surface of seals to achieve better sealing. 21. Use only recommended oils and grease. 22. Wear goggles and gloves while using grinding machine 23. Use rubber aprons while working an batt 24, Keep a bottle of washing soda water solution (Ratio - 50 gms to one litre water) handy at battery charging area (o rinse in case of accidental battery acid spillage. ies. a Bullet Service Guide. Bullet Service Guide COMPONENTS INSPECTION UNIT : mm CLEANING + Mix 2% engine oll with clean kerosene oil j + Clean all components in the above solution + Dry them with dry compressed air Fics Piston diameter INSPECTION Visually inspect the components for the following + Breaks Bul 350] 500 | Lightning 655] A950 | * Cracks [Rew Min. 69.766 | 63.68 6.88 aaa | & Scoring [New Max [oo836| 8301 | 52 | e307 | Scuffing Seven tr] e966 | 63.705 | 8073 | wots | Selzre marks Piston te bore elewrance * Bend + Twist Pitting ‘* Corrossion * Discolouration Iffound ok, check dimensional limits as follows: [fie se ee | New components’ dimensions to be between [eur s50] 560 | Uighening $35] new minimum and new maximum ia = | LL) a + Replace old parts beyond service limits jaw Max soo |. ur ge-f Dimensions are in millimeters (mm) CS a Pet = Cviinder bore] | Pies Ring te greave elesrance : camp rings | | | | | Ba 36] B00 | Uahining S35] ATED Ga 0] 500 _| Uphining 535] A350 [emf eae | aaasr Taro | 7000 Tas [0.038 | aoe [ozs [RewNac—| 60.09 | #3968 | eos | 7003 aore_| 007s | 08s [01 [Senice link 70.06 | 64.128 | e718 —] 7015 ors | 0178 | otfe [018 Pied ‘Cylinder bore : paint of measurement | [Picé Ring te groove clearance : comp.rings - Migale | t t 500] ghuning 695 | AED Bai S| B00] Ughining 535] Az56 [New Min. New Min. 0.025 | 0.038 Coz | O02 {Rew Wa Theee points 28 shown Newhax | 0076 | 007 | 00s? | aor sence init Senice inal 815 | 0178 | —o17e [01s 42 Bullet Service Guide UNIT: mm. Per Ring 19 groove clearance : Pett Pisten Pin diameter a CE Ew [ase Tawa | 005] 00s] 0.051 | 008 | [Newsen | 18.907 | 10.007 Newhax—[ 010] 0.20] 0.005] 0.10] [NewMax_| 18.992 | 10.092 19.997 [Service imi ots | 0229 | | 0.18 | [Service tm} 10.982 | 16882 | 18.982 | 18882 Pee Piston ring end gap: Compression | [ Pic 12 Bigend frreeness | | | [ear 380] 600 | Lightning 695] A350 Fat 350] 00] Uphining 535] Aze0 New Win] 020 | 0.30 030 0.26] [New tin: New Max. [0.39 | 0.50 0.58 050_] [Newnan ‘Connecting red to rotate trevly Serves Foi] 0.78 | 100 ‘Ors Da] [Service tnt [Fea Piston Rng end gap: OWlring | [Pie 13 Bigend axial play | , | Bul 350[ 500] Ugnining 585] A350 Bul $50] 800 _| Lighining 635] ASSO New Wea] 020 | 030 025 | 030] [NewMin | 0.15 | 0.15 0.15 0.25 New Max. | 0.33] 050 040 | 6.80] [NewMex | 0.33] 0.35 033 0.50 serico eat] 0-78 | 100] 100 | 0.76 | [sence eri 0.08 | 035 055 360] | Pie 10 ‘Small end bore | [ Plc 14 Crank shaft : Run out [B00] Tiphinng 55 [A380 Bar 350] 600 | Uphinng 55] AGED Tew Wis ioe [Tacs | 20.01] [Newmin. | 000 | 0.00 3.00 [065 ior | 19.07] 20.02] [NewMax | 0.04 | 0.08 0.04 [0.08 Tet 19.11 | 20.05 ] [Serco ti] 0.08 | 0.08 0.08 3.08 43, Bullet Service Guide [Pets ‘Connecting red: Bend | [Pic 18 Valve ater to guide (inlet): eesrance | | | [eur 3e0] _600_| Ughining £35] Asoo Gui 350] 500] Ughining 838] A380 arin | 000 | 0.00 300000] [Rew Doe | oor | ove | 002 | [New Max [005 | 0.05 0.05 [New Ma 0.055 | 0055 | 0.08 aoe} [Senice nl 0avs | ore | o.o7e [Series ini] 0.078] 007s | 0.08 Lp oR | [ree Crank chat Ral play | [PicQ0 Valve atom to guide (Exnavsl) : Clearance | | four 380] $00] uightning 635 Bur 360] 600 | tahening £55[ ABO | [Newman | 173 | 495] 173 173 O0es | Oey | O08 004 [NewMax | 230 | 230 | 230 [230 0.081 | 0.081 0.07 OF [Senne Tie 280 7a | 2.80 [286 010 | O10 0.09 00 Pet? ~ Gylinder block & Head warpage | [Pic 21 Wale spring (inner): length | | | | | | | [our 360] 500_| uighining 655] A350 | Ba sca] 600 girs BY Aen (New Win | 000-000 700 | 0.00] [Wewhin | S128 | 61.25 25 | 180 Iewniax | a0? | 002 az “O0a—] [New Max 51.38 | 81.38 ise | 4480 | ‘Sandee Wri a.08 | 0.05 TE] OO] [Serves taal 40.20 | 4820 | 4820 | 4.50 Pie 18 Worpage removal | [ Pic? Valve epring (outer) feng | titi | | | | / | | i = [a as0[ 300] Upining S55] ABO | | Tigniniag 535] A356 | Tew Wa 320 | 4200 | Face the aurfece a¢ shown on the emery aera | ee paper, spread an surface plate Sani Bal “S008 4150 a4 Bullet Service Guide UNIT: mm Fe Bahtbe Rivet] [Pets ‘Spark Plog: Elecuods gap [eer 350] 500 | Uphining 638] A850 | Gul 350] #00 | Uphining 695] A380 iNew in| 0.00 0.00 | [Newhin | OS 05 os OF (New Wax] “0.02 002] [Newax | 08 | 05 a6 a8 [Senice ul] 0.68 0.05] [Serece era Pic 24 Valve : Clearance Pe 28 Duptex chain : Slacknes i Bul 350 Uphining $35] A380 Bui 360] —600_| Lightning £95] A350 [Rew Rin New win |_6006_| 5.00 3.00 5.00 [New Max. ‘Thump free(cold) Push tube New Max. 6.00 6.00 6.00 6.00 (Seen a Service Tri Pie 28 Roloc coll; Clearance | [Pe 29 ‘Duplex chain | Lengih eeross 21 pine f [eu 350] 500 | Liohining S35] Aza 306] Uphiring 535] ASSO [hearin [0.15 [0.15 0.15 0.25 | [New Mo. 790.00 790.00 | 180.05 [Rew Max [025 | 0.28 025 O50] [Now Bax 191.00 | 193,00 | 191.00. Senice al Service fn] 195,00 | 195.00 | 185.00 _| 196.00 [ Pie Te Pomt:Gep | [Peso Fricion plate : Thickness a oo] £00 | tptnng 25] A [Tee aso] 00 [ tighaning 638] A350 | ew in| 035 | 035, 035) WA_| [NewMin [470 | 470 270 70 Newiax | 0.40 | 0.40 2A) HA] [NewMar [480 | 4.60 %.80 4.20 {Senice a TONA] [Borvieo ii £00 2.08 4.00 45 Bullet Service Guide UNIT: mm Rear sprocket: Chain pull off Feat Friction plate with insert: thickness Pic 35 | | i Bui 350] 500 | Lightning $38] A380 | Bul 350] 500 | Lightning $35 [ A350 New Nin. 480 480 180 | 480 New Min. | | NewMax | 510 | 8.10 B10 | 5.10] [NewMax | | Saree til 230 | 430 430 | 430] [Service wna] 500 | 500 Ea IG Bese [exe Brive chain Siackness | Bui 356] 800] Ughining 555] A350 Bul 360] 600 | tighmning $35] A350 Rew tie] 6.10 | 6.10 “10 | 610] [Rewmn | B00 | 2060 | 2000 [2000 iNewhiax [6.2% | 627 822 [822 | [Rewhiax [30.00 | 30.00 [29.00 Serves tral 6.00 | 600 6.00 [6.00] [Bence inal ess Clutch steel plaie Disionion | [ Pie ST Drive chain engin enrons 91 pine | [Jour 360] 00 | tigrining $85] A550] | Bui 350] £00] tighining £95] A360 | New Wi a 0.00 1:00. G00} [Newen | $20 | 320 | 520 320_] [Newmax | 0.08 | 0.08 0:63] 0.05-] [NewMax_—[ se] 922 322 32 Serves ban] 01 | OTe 0.18 | 015 | [Service inm] 828 | S28 328 326 | Pic 34 (Gluten spring : Length ~ ‘Sprocket coop REPLACE YE | : | scan? Bul S50] 500 | Lighining $38] A350 [eur sso] S00 J Uiontning 638] A350 New Min, 30.60 | 30.00 30.00 | 30.00 Sa bceaas [New Max. S175 | 37s as 7S Siieep, Bont, Brcken teal Service ina] 2550] 2560] 25.50 | 25.60 - | Bullet Service Guide UNIT: mm Pie 39 Brake drum front : internal diameter Pie 43 Wheel: Face out/ Run out “Tear sso] 500 | Canny 538] Ass0 Tae] 500 [ping sao Rew Nin] 177.80 | 177.80] 177.80 } 177.80| [Newhin. | 000 | 0.00 ooo | 8.00 New Max [177-90 [177.90 | 177.90 | 177.90] [NewMax._| 0.10 | 0.70 3.10] 0.10 Sonos i S80 [TEED | Tree —| es0] [Sewce wml O20] a2 | 920 | ozo Pee Brake drum ear ilemal damier | [Pew Sang erat Rm ot [oar ses] 555 ign #58 [ Ae Bul 360] $00 | Upwinng 658| AIS Hew Min | 152,40 | 152.40 192.40 | 152.40 ‘New Min. ooo | OOo 0.00 eatin [189 0 tee-s0_ | —ve260 | Y5280] [New nae [Bawar tna veneo-[ T380-[ isso | Te320} [Sees ima] Oas | ooe [eee | 0s Fea Brake tring /Themness | [Pleas Tian ube Ron | { [Bui 380] 500 | Lightning 535] 350 Bul 360| 500 | Lightning S35] A250 [New Min [380 [380 3.80 3.80 [Mew Kain. 0.00 0.00 0.00 0.00 [New Max [4.06 _| 4.06 8 706] [Rew Max. = T | [aa zee ao | zoo —] B00] [Seniesa ee | aes | aa] Pic 62 Aste Shaft: Run out Pic 46 Front fork assembly ‘spring : Length | t [eat 360| #00] Lgpnng S55] ABO Bai 360] 500 _| Lighining 535] A360 [Rewnin | 000 | 0.00 0.00 700] [Newnen | 538] 538 | 538 | S38 jrawminc_[-ear_[oor_| oat [oor | [rawr [sea] ses_| 548 | 8 & oS ae 2 = - Bullet Service Guide UNIT: mm Pica? ‘Clutch cable : Free play Pic 49 ‘Tyre tread = Depth ne Uphining #95] A350 Ba 386] S00] Ughinng 355] ASO sane 2s] AS ae =) [Rewwax [Serica te] 100-100 | 1.08 —} 1 Pea ‘eseleraio catia Free play | [ Pie 50 ‘Docomprassar eabia Free play Ba 360] 600 | Ughining 695] ASO Newt | FP 7 | [Rew New Wax [2 | 2 z Z| [Reetiax Senvice Wa Service Tr Bullet Service Guide CARBURETION INDICATIONS OF TOO RICH AND TOO LEAN AiR PETROL MIXTURE. TOO RICH TOO LEAN 1 1, Engine snatches and revolutions sound heary | 1. Engine over heats Engine running becomes worse on warming up Engine runs better after it warms up eon 4, Excessive bluish white smoke 2 Black carbon accumulation on spark plug tio =| 3. Whitish spark plug tip 4, Enratic engine running and jerking 5. 5. Performance improves on removal of air filter Engine runs better when choke is ‘ON’: to: wei ax, Pew aintore EP ses zz an Ecenamy a | misture 8:4 - a 2 0 cy co ‘Theote vabve sparing % ————> FUNCTION: To maintain a predetermined level of petrol in float chamber. FUEL FLOW : Petrol tank + Tap=--* Hose =“ Carburetor intet ---+ Float Valve ——~ Float chamber ¢----------- 1. Neecte vatve seat 2. Needle valve 2. Float 4. Float chamber Bullet Service Guide STARTING SYSTEM FUNCTION : To supply additional petrol to compensate the condensation of petrol when engine is cold, FLOW: cay [Arter (Petrol). Venue Startret Emulsion tube Float chamber Aina port ‘Choke chamber FUNCTION : ‘To supply Air petrol mixture to the engine from 0 to ¥6 throttle positior FLO (ai) Pilot air Air res, |e} screw | >| Pilot Avtomiser (Petrol) Float |gp| Pilot chamber Jet Pilot Discharge orifice Bullet Service Guide Torte volve Venturi Bypass once Pilot discharge once Pieot Ar scrom 4, detroedia 2. Main siachaige once 3. Mainjet 4, Emulsion woe 6. 6 Main air passage Alejo FUNCTION : To supply air petrol mixture to the engine from ¥4 to full throttle pen position, FLOW: (Air) (Petro) = Air = Petrol mb Air Petrol mixture TEMS THROTTLE POSITION Fully Fully closed 44 OPEN (OPEN GIS OPEN open pilot jet 2. Throttle valve 3 Jetneodia © Main jet 5 Airjet 6. Float system | 1. Air screw and Bullet Service Guide IGNITION AND ELECTRICALS )RETARDED IGNITION TIMING « rs ea ry . SE os - 0 < s rn * = . = = 7 A- Tao far advanced timing, Causes detonation, pinking and engine overheating. B-Normal timing \C- Teo far retarded timing, Causes incomplete combustion, black smoke, bend pipe over heating and high fuel consumption Lead Acid Battery has Positive plates = Lead peroxide ‘Separator = Made of insulating material Negative plate = Sponge lead Electrolyte = Sulphuric acid + Distilled water. Baitery stores electrical energy in the form of chemical energy. Fully charged battery voltage 2.2 per cell Fully discharged battery voltage 1.75 per cell ‘Ampere Hours (AH) indicate the capacity of the battery, ‘Ampere Hour (AH) = Discharging current (A) x Discharging hours (H) Eg: 10 AH means that ittakes 10 Hrs fora fully charged battery to-come to fully discharged condition when discharged continuously at a constant rate of one ampere. 82 Bullet Service Guide Preparation : SULPHURICACIO \ JOXSTILLED WATER | NOTE : Itis important to ensure that the sulphuric acid is added to the distilled water and nat vice versa, Stir and check the specific gravity of elecvelyte and add sulphurie acid tl the | specific gravity becomes 1.240 Temperature of electrolyte Cool the electrolyte te about 40 deg. C betore filling it in the battery upto the maximum level indicated oF 2 to 4mm above the plates. Soaking period ; keep the battery with electrolyte filled for about half an hour before commencement of charging. Top upthe level with electrolyte if necessary. Then put them on charge, Battery Duration Charging Curt 12V 5 Ah 410 hours 0,5 Amps. fwcharging : ‘TScharge a used battery when the specific gravily of electrolyte is less than 1.220 ‘Charging Procedure : Top up the electrolyte level with distilled water 2. Connect the positive and negative terminals of battery to the positive and negative terminals of the constant current battery charger. Keep all battery filler caps open. ‘Switch on the power ON/OFF switch and ensure that the charger is ‘operative. ‘Switch on the charging ON/OFF switch Disconnect the battery from the charger when fully charged. eaae 53 Bullet Service Guide Indication of full charge : 4, Free gassing from electrolyte for more than 90 minutes 2, S consecutive reading taken in intervals of 30 minutes each to read constantly 1.240 specific gravity, 3, Voltage : 6V Battery - 6.6 V; 12V Battery - 13.2 (eee Wear rubber apron while working at battery charging Use only constant current batlery charger of correct éharging rate. Never remove the filler cap seals, till you are ready to charge the battery. Hydration may oecur when atmospheric air contacts the plates. 4. Keep the filler caps removed while charging. 5. Use only distilled water to top up the level after the initial charging. 6 During charging, the electrolyte temperature should not exceed 45°C If necessary, discontinue the charging to.coo! the electrolyte. Ensure that the batteries are kept on @ non-metallic surface while charging. a Keep fire and spark away from battery charging area. Be sure to connect the long vent tube to the battery. While fixing it to the motorcycle route it correctly. 10. Avoid running the matorcycle withaut connecting the battery. 4. Check the electrolyte level and top up, if necessary to the mark or 2 to 4 mm above the separator with distilled water every week Important Note : For topping up, use only distilled water. 2. Keep the battery surface clean and dry. 3. Never over charge the battery - it damages the battery. 4, Remave the battery from the motorcycle and store it separately when the motorcycle is net in ‘operation for more than one month. 8, Recharge stored batteries once a month. 6. Check the terminals and cables for corrosion. Apply petroleum jelly on terminals to prevent corrasien. 54 Bullet Service Guide Hydrometer is used to check specific gravity of electrolyte. The float graduation in level with the electrolyte in it, is the specific gravity of the eleciralyte. The active materials in the plates are converted into lead suphate during discharge. This lead sulphate is reconverted to active materials during recharge. If the battery remains in discharged condition for Jong periods or excess quantity of acid is used in the electrolyte, the lead sulphate is converted to hard trysialline substance. This is sulphation. Sulphated batteries do not take normal charging |.e, during charging the lead sulphate will not get reconverted to active materials. Such batteries may show normal voltage with out load, but do not take load, ‘The positive and negative plates remain submerged in electrolyte. However, when electrolyte level is Jess than the minimum Indic: the active materials on the plate get exposed to atmospheric air. The active materials, then reacts with water vapour of the atmosphere, forming white spots on the plate. This is hydration. Hydration reduces the active area on the plates for chemical reaction. This reduces battery capacity. The active material of the plates falling off is shedding. Over charging and rough handling are the main causes for it, Over charging of the battery also may cause buckling of the plates, rendering the battery unserviceable, Over charging means charging of the battery with excessive current. Bullet Service Guide Hot plug aid pug ‘Spark plug is a vital part of ignition system, They are subjected to high combustion pressure (around 40 times the atmospheric pressure), intense heat (more than 2000 dag.c. temperature) and severe vibrations. Use of specified spark plug is therefore very importan! for geod performance of an engine. AT RANG ‘The spark plug is selected such thatits elektrodes withstand the operating temperatures of the engine - hat enough to prevent fouling but cold enough to avoid auto ignition, ‘reser Ti Ent chvctras. Gola siectil. ‘Spark plug with large insulator tip surface area. Central electrode remain hotter. ‘Spark plug with less insulator tip surface area. Central electrode: ‘coals faster. Vehicle Usage |__ Spark Plug Recommended 4. Normal driving, both in city end highway Normal recommendation 2, Mostly stop and go city driving Use hotter plug 3, Mostly heavy loading, sustained high speed Use colder plug Bolow 450.deg.C Rapid spark plug fouling leading to misfiring Cause - Use of spark plug colder than required 480deq = Self cleaning temperature. 450 to-850deg.¢ = Normal. Burns combustion resicues that come in contact with electrode: Remain clean for long periods. B50deg.C = Auto temperature. Above 850degg.C - Causes pre-ignition, electrode melting and blisters on insulator surface. Cause = Use of spark plug hotter than required, 56 Bullet Service Guide @ Correct plug seat GASKET! | (2) Carbon deposit on exposed thread. Removal of plug trom cylinder head damages cylinder head thread, Earth electrode gets over heated. Two Gasker |S) Results in cylinder threads becoming filed with combustion residue. Noe Over heating * * Prelgnition Damage to piston * ‘Spark plug removal difficult * Starting problem * Mis-firing x Dilficult in fitmet of new spark plug due to residue on cylinder head threads. | Spark plug Tip colour indication Figure | La 1. Darke Brown Brown % Normal combustion = Yellow Brown, % Correct running of engine Light Brown, | Greyish Brown 2. Shining black wet ® Oil fouling | | carbon depoists 1% Oil leakage to combustion chamber. | |" Whish Brown to % Engine Is running in slightly aver heated A | Whitish Grey condition | 87 Bullet Service Guide 4, Dull black, veivetty Incomplete combustion of fuel due to = carbon deposits & Too rich air petrol mixture * Retarded ignition timing + Continuous low speed operation + Excessive electrode gap a * Colder spark plug + Low H.T. voltage & Melted electrode ‘Over heated engine and overheated spark and blistered porcelain | plug due to: insulator tip + Too lean air petrol mixture + Use of hot spark plug + Use of longer reach spark plug * Excessive carbon deposit in cylinder or exhaust system. + Too far advanced ignition timing. SPARK PLUG MAINTENANCE Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long period, the electrode gradually burns away and carbon builds up along the inside part. Once in 3000 Kms or earlier, the plug should be remove forinspection, cleaning and resetting the gap. ‘Carbon deposits on the spark plug establishes a "shunt" between center and earth electrodes, that prevents good sparking and causes misfiring. Clean the deposits off periodically, with a spark plug cleaning tool/machine. ‘Check spark plug for worn out earth and center electrodes. If the earth electrode has worn aff to.a knife edge and center electrode has reduced in height, replace it with new. ‘Spark Plug cleaning Electrode Gap checking Bullet Service Guide ELECTRICAL COMPONENTS INSPECTION 12, AC / DC 12V, DC ¢ coil output wire colours vwa Voo- Violet - White - Green G) - Yellow = Amber YAW w:-G YES OK yA L > [ves 7-H w-v bo ves |-— [ox ] e-v }o ves | ILNO, open Cireult. Check & Correct v-y [+ [no | [ox ILYES, short circuit, Check & Correct | =e woe} [ve Tenn wov} [ves}— IES, short circuit. Check & Correct. v-v |— 0.5 to 0.7 Ohms | w-G 0.5 to 1.0 Ohms — y-a_ | 05 to 0.7 Ohms | wv [> [1.0to 2.0 Ohms Across “Y" & ‘A’, with head lights on, at 2000 pm, minimum out put - 13 volts. Connect 'V' with ’G’, Across VG & W, withhead Across'V’ & 'V’, with Tratficator and stop lamp lights on, al 2000 rpm, minimum autput - 13 volts cn at 2000 rpm - minimum output - 13 Volts. 59 Bullet Service Guide ENG ‘OFF ON, ‘cumouseatcH Rape TRTR CONTINUITY CHECK Continuity between terminals as shown —— SWITCH ok SWitcH Continuity between terminals not connected SHORTING ——— | not ox No continuity between terminals connected OPERN CIRCUIT. —— = Clean the electrodes and set gap to 0.5 mm - Clean the plug in a ‘Spark plug cleaner cum Tester’ - Test the plug for proper sparking in the tester Light blue, solid, continuous spark seen in the mirror of the tester ‘Yellow or red spark; Intermitiant or no spark: ‘SPARK PLUG ‘or side spark as seen in the tester mirror NOT OK VOLTAGE CHECK ‘SPECIFIC GRAVITY (SG) CHECK an Bullet Service Guide VOLTAGE ‘SPECIFIC GRAVITY Fully charged Fully discharged Fully charged Fully discharged [rev Batory 73.2 108 134 722 Primary winding resistance (A-B) 3 to 4 Ohms Secondary winding resistance (A-C) 7 to 8 Kilo Ohms (RECTEER| CONTINUITY CHECK Eire (CONDENSER Select OHM meter {Ohm Scale) in multimeter Discharge the condenser by tounchin its body with its lead Touch condenser’s body with one prabe and condenser’s lead with the other probe of the multimeter ‘The multimeter needle deflects and returns. ——+ ‘The needie does not move at all . —— [NOT OK) ‘The needle moves and remains there Co MULTIMETER VETO | +VETO [INDICATION TOUCH TOUCH |SHOULD BE 8 ON OFF ON Vv 8 v OFF v Vv B Vv 8 RY ON Vv RY [av OFF S ‘ON v | RY OFF Bullet Service Guide ELECTRICAL SYMBOLS [01.| connection om | pet 02.| Ground 03.| Coil — eo 04.| Resistor a | AWA 05.| Capacitor ~ ke 06.| Battery we | falile Celt isp 0.| Armature and brush 6- 09.) Voltmeter wo | Qe. 4 10.| Ammeter 11.| Wired across ‘Switch Transformer Bulb 16.) Recitifier Zener diode Silicon controlled rectifier ... 19.] Transistor 20, Alternating current 21.] Direct current 7

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