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Royal Enfield
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350 BULLET 1989
Royal Enfield 350 BULLET 1989 User Manual
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WORKSH
OP
MAN
U
AL
B
ULLE
T
Page 1
WORKSHOP
MA
INTENANCE M
ANU
AL
FOR THE
Enfield
India
350 BULLE
T upto 1989
MAN 15
www.hitchcocksmotorcycles.com
2
Table of Contents
Index
2
Precautions and General Instructions
3
Buying Spare Parts
3
Routine Maintenance
4
Introduction
4
Daily
5
Monthly - 300 Miles/500 Kms
5
Tri Monthly – 3000 Miles/5000 Kms
6
Six Monthly – 6000 Miles/10,000 Kms
6
Technical Specifications - Bullet - 350 CC
7
Engine
7
Single Cylinder 4 Stroke with Overhead Valves
7
Engine Parts
10
Decarbonising
12
Removal of the Petrol Tank
12
Removal of the Cylinder Head
12
Removal of Cylinder and Piston
13
Removal of Valves
13
Valve Spring Compressor
13
Decarbonising the Cylinder Head - Combustion Chamber
14
Piston and Rings
14
Big End Bearing Inspection
14
Crankshaft Big End Bearing
14
Valves, Valve Guides and Springs
15
Valve & Spring Assembly
15
Decompressor
15
Re-Assembly after Decarbonising
16
Service Operation - with Engine in Frame
18
Removal of the Timing Cover
18
Oil Filter Element in Timing Cover
18
Overhauling of Oil Feed and Return Pumps
19
Removal of Pump Worm and Timing Pinion
20
Removal of Contact Breaker Housing
21
Valve Timing
21
Tappet Adjustment – Cold
21
Cam Timing Marks
21
The Clutch
22
Removal of the Clutch
22
Removal of Engine and Clutch Sprockets
24
Removal of Final Drive Sprocket
24
Re-Assembly of the Clutch Plates
24
Primary Chain Adjustment
24
Adjustment of the Clutch Control
25
Clutch Adjustment on Gearbox
25
Fitting the Alternator
26
Function of Breather
27
Gear Box
27
Service Operations
28
Engine Removed from Frame
28
Removal of the Engine from the Frame
28
Removal of the Gearbox
28
Timing Side Roller Bearing Assembly
29
Driving Side Bearing Assembly
29
Replacement of the Cam Idler Spindles
29
Connecting Rod
29
Flywheel Assembly
30
Flywheel in a Jig
30
Re-Assembly of the Crankcase
31
For 500Cc
31
Crankcases
31
Removal of Gear Box from Engine
32
Dismantling the Gearbox
32
Removal of the Ball Bearings
32
Gear Change Mechanism
32
Gearbox with Continental Controls
33
Gearbox Descriptions
35
Re-Assembling the Gear Box
36
Adjustment of the Neutral Finder
36
Lubrication of the Gear Box
36
Lubrication System
38
Oil Filter
38
Oil Pump Diagrams
39
Feed Pump Ports in the Timing Cover
39
Feed Pump Ports in Feed Pump Disc
39
Return Pump
40
Frame Rear Suspension
42
Description of Frame
42
Removal of Rear Spring Box Unit / Servicing Rear Spring Box
42
Removal of Swinging Arm Chain Stay
42
Swing Arm Assembly
43
Position of the Spring Box
43
Centre Stand
43
Front Fork
44
Operation of the Fork
44
Dismantling the Fork
45
Main Tube Spanner 2036
45
Spring
46
Re-Assembly
46
Removal of Complete Fork Assembly
46
Lubrication
46
Steering Head Races
47
Sequence for Adjustment
47
Adjustment of Head Ball-Race
47
Lubrication-Steering Head
47
Front Wheel
48
Removal from Fork
48
Fitting Limits for Bearings
48
Front Wheel and Hub Assembly - Single Lead
49
Early Half with Hub
50
Rear Wheel
51
Removal of Wheel – Quickly-Detachable Type
51
Cush Drive
51
Removal and Re-Assembly of Rear Wheel Sprocket
51
Rear Wheel and Hub Assembly
52
Dismantling the Rear Brake Shoes
53
Removal of Bearing from Centre Hub and Re-Assembly
53
Re-Assembly of Brake Shoes
53
Operation of a Single Lead Shoe - Drum Brake
53
Adjustment of Drive Chain
54
Drive Chain Adjustment
54
Wheel Alignment
54
General
55
Wheel Rims
55
Spokes
55
Wheel Building and Truing
55
Tyres
56
Tyres - Removal and Replacement
57
Ignition and Lighting System
60
Alternator
60
Circuit Detail
61
Emergency Starting
61
Direct Operation
61
Rectifier
62
General View of Rectifier
62
Contact Breaker Unit/Contact Set
63
Cleaning Contact Breaker Points
63
Setting Contact Breaker Gap
63
Setting Ignition Timing
63
Lubrication (Every 5,000 Kms.)
64
Automatic Timing Control
64
Battery
67
Headlamp
67
Parking Lights
68
Speedometer Light
68
Stop and Tail Light
68
Horn
68
Carburetter
70
Dismantling
70
Tuning the Carburetter
71
Air Cleaner
71
Causes of High Petrol Consumption
71
Description of Bing Carburetter
74
Control of Fuel Feed
74
Main Control System
74
Idling System
75
Starting System
75
Servicing of the Carburetter
75
Function
78
Starting Jet System
78
Pilot Jet System
79
Main Jet System
79
Servicing
81
Setting Idling
81
Service Limits
82
Valve Spring Free Length
82
Trouble Shooting : Bullet Motor Cycles
83
Trouble Shooting: Engine Difficult/Does Not Start
84
Complaint: Low Idling Problem
86
Low Idling Problem
87
Loss of Power
88
Complaint: High Lube Oil Consumption
89
High Lube Oil Consumption
90
Method of Checking Oil Circulation
90
Method of Checking Return Pump Operation
90
Low Mileage
91
Engine over Heating
93
Complaint: Engine Noisy in Operation
94
Complaint: Premature Wear of Engine Components
95
Flame at the Carburettor (Back Fire)
95
Complaint: Flame at the Silencer (after Fire)
96
Complaint: Clutch Slippage
96
Complaint: Clutch Dragging
97
Complaint: Gears Difficult to Engage
97
Complaint: Premature Wear of Drive Chain and Sprocket
98
Complaint: Tyre / Tube Damages Prematurely
98
Complaint: Brake Less Effective
99
Complaint: Brake Binding
99
Complaint: Brake Squeaking
99
Complaint: Front Fork Hitting Noise
100
Wheel Wobbling
100
Complaint: Motorcycle Pulling to One Side
101
Complaint: Battery Discharges Fast
101
Complaint: DIM Head Light
102
Complaint: Frequent Bulb Fusing
102
Bullet 350 CC/500 CC - Torque Values
104
Special Tools List
106
350Cc and 500Cc
106
Metric Conversion Tables
112
5
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Royal Enfield 350 BULLET 1989 Specifications
General
Brand
Royal Enfield
Model
350 BULLET 1989
Category
Motorcycle
Language
English
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