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Royal Enfield
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Bullet RES 500
Royal Enfield Bullet RES 500 User Manual
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BULLET
by
Pete
Snidal
2
Table of Contents
Index
3
How this Manual Came to be
6
Four Stroke Engine Basics
8
Horsepower and Torque
8
Performance Boosting
9
Operation of the Motorcycle
10
Starting Drill
10
Breaking the Clutch Free
10
Actual Starting
10
Flooded Starting
11
Learning to Operate the Machine
11
Moving off and Coming to a Halt
12
The Stop Reflex
12
Throttle Control
12
Upshifting
12
The Ratchet Shift
13
Downshifting
13
Trouble Changing Gears
13
Coming to a Halt
13
Stay off that Clutch Lever!
14
Use of the Brakes
14
Putting the Machine Away
15
Troubleshooting - Starting
15
Push Starting
15
Ignition
16
Fuel
17
Cleaning the Fuel System
17
Here Are some Possible Problems and Their Cures
18
Basic Day-To-Day Maintenance: Lubrication, Cleaning, and Adjustments
20
Cleaning
20
Lubrication
20
Wet-Sumping
20
Preventing Wet-Sumping
21
Low Oil
21
Changing Oils
23
Engine
23
Checking the Quill-Style Oil Pressure Feed Bush
24
Oil Change Intervals
24
Verifying Oil Delivery
25
Nightmare Time: What about Stripped Drain Plugs?
25
Gearbox
26
Primary Case
27
General Chassis Lubrication
27
Second-Guessing the Dealer: New Motorcycle Pre-Delivery Preparation
28
Electrical System
28
Fuel Delivery Problems
29
Basic Day-To-Day Maintenance: Checking and Adjustments
30
Adjusting Pushrod End Play
30
Clutch Linkage Adjustment
30
Cable Adjustment
31
Correcting Slip or Drag - Properly Adjusted Clutch
31
Simple
31
The Long Way
31
Brake Adjustments
33
Rear Brake Adjustment
33
Front Brake Adjustment
33
The Single Leading Shoe Brake
34
The Twin Leading Shoe Brake
34
TLS Linkage Adjustment
34
Brake Improvement
35
Spoke Tuning
36
Spokes Can Get too Long!
36
Chains - Checking and Adjustments
36
The Rear Chain
36
Checking Adjustment
37
Moving the Wheel
38
Replacing a Chain
39
The Primary Chain
39
Chain Adjustment Slipper
40
Checking Condition of Primary Chain
40
Carburetor Adjustments
40
Carburetor Jetting
40
Checking and Adjusting
41
The Pilot Jet
41
Plug Checks
41
MID-Range Carburetion Check - the Plug Chop
41
The Midrange-Highrange Circuit
42
Float Level
42
Bad Flooding
43
Chassis Adjustments
43
Front Forks
43
Tire Pressure
44
Wheel Alignment
44
Controls
44
Fittings
44
Checking Your Ignition Timing
45
The Signs
45
Checking Point Gap
45
Chassis Electrics
46
Changing Light Bulbs
46
Power Testing
46
Wiring Considerations
47
Troubleshooting
47
Longs
47
A Typical Checking Strategy
48
Voltage Drops
49
Valve Adjustment
49
Description:the Valve Train
49
Checking Valve Train Clearance
49
Hot or Cold?
50
Checking While Engine Is Running
50
Checking with Engine Stopped
50
Checking - Do They Require Adjustment?
50
Inconsistency
51
Hot Vs Cold - a Reprise
51
General Chassis Work
52
Removing Wheels
52
Front Wheel
52
The Rear Wheel
52
The Regular Wheel
53
Replacing the Standard Wheel
53
Removing the QD Wheel
53
The Cush Drive Rubbers
54
Checking the Cush Drive Rubbers
54
Changing Tires
54
Replacing the QD Rear Wheel
54
Replacing the Tire
55
Replacing Control Cables
56
Inspection
56
Replacement
56
Throttle Cable
56
Clutch Cable
57
Front Brake
58
Replacing Brake Shoes
58
The Rear Brake Shoes
58
The Whole-Hog Method
59
The Simple~But-Trickier Method
59
A Note on Removing the Brake Actuator Shaft Lever
59
Re-Assembly of Brake Shoes
59
Checking the Arc
60
Added Brake Refinements
61
The Wheel Bearings
61
Re and Re Wheel Bearings
61
Examination and Packing
62
Re-Installation
62
Ensuring Proper Running Clearance (Bearings)
63
Checking for Adequate Bearing Clearance
63
The Front Wheel
63
Checking/Packing Wheel Bearings
64
Broken Stud Removal
64
Removing Screws with Heads Intact
64
Removing Broken Studs and Screws
64
Left-Hand Drill Bits
65
Oversizing
65
A Final - or First - Option
65
Disk Brake Maintenance
66
The Hydraulic System
66
Maintenance Tasks
66
Linkage Adjustment
66
Puck Examination/Replacement
67
Maintenance of the Hydraulics
68
Monitoring Fluid Level
68
Monitoring and Correcting Leaks
68
Correcting Air Problems
68
Bleeding the System
69
Preliminary Caution!
69
Reverse Bleeding
69
Forward Bleeding
71
Down and Dirty
72
Leaktrouble-Shooting
72
Repairing/Replacing Cylinders
72
Fluid Changing
73
Engine Work
74
Replacing the Big End Oil Feed Quill Bushing
74
Removing the Old Cork Bushing
75
Replacing the Bushing
75
Removing and Replacing the Timing Cover
75
Removing the Timing Cover
76
Inspection of Parts
76
Removal of the Timing Pinion/Pump Drive Nut
76
Replacing the Timing Cover
77
On Startup
77
Trouble Shooting
78
Oil Pump Operation
78
The Timing Chest
79
Contact Breaker and Drive Gear
79
The Gears
80
The Cover
80
Checking and Setting Ignition Timing
80
The Objective
81
Tools and Materials
81
Setting the Point Gap
81
Replacing the Point Set
82
What about the Condenser?
82
Checking Ignition Timing
83
Static Timing-In the Shop
83
The Timing Stick
83
Finding the Point of Spark Occurrence
83
Gadgets/Obsessive-Compulsive
84
Dynamic Timing - Running
85
Ping Timing
85
Checking for "Ping"
85
Top End Overhaul
87
Checking Compression
87
"Wet and Dry" Compression Testing
87
An Explanation of Clearances
88
Combustion Deposits
89
Doing the Job
89
Top End Overhaul - Removing the Cylinder Head
89
The Cylinder Head
90
Removing the Cylinder Head
90
The Valve Assemblies
91
Valve Spring Compressor
91
Examining Thevalves, Guides, and Springs
93
Refacing the Valves and Seats
93
Choosing a Machine Shop
93
"Lapping" the Valves
94
Removal and Replacement of Valve Guides
94
The Decompression Valve
94
Valve Spring Length
95
The Valve Train
95
Re-Fitting the Cylinder Head
95
Valves
95
Torquing Bolts Without a Torque Wrench
96
Re-Torquing the Head Gasket
96
Running in Your New Top End
97
Re-Torquing and Re-Setting
98
Removing the Cylinder Barrel
98
Pistonlcylinder Clearances
98
Connecting Rod Clearances
99
Examination of Piston and Rings
99
Checking Cylinder Wear
100
Interpreting Your Readings
100
Removing the Piston
101
Extracting the Piston Pin
101
Examining Big-End Clearance
102
Examining Piston-Cylinder Clearances
102
Visually
102
The Micrometers Method
102
Honing, or "De-Glazing" Cylinder Bores
103
The Cylinder Barrel: Re-Assembly
104
Replacing Piston Rings
104
Fitting the Piston
105
The Cylinder Barrel
105
Splitting the Crankcase
106
Timing Chest
106
Separating the Case Halves
107
Suggestions for Presses
107
Drive Side
107
Timing Side
107
Examination of Parts
108
Reassembly
108
Front Forks
110
The Front Forks Description and Operation
110
Damping
110
The Upper Fork Crown/Casquette/Steering Head
111
Adjusting Steering Head Bearings
111
Detecting Bearing Damage
112
Removal of the Fork Crownlcasquette Assembly
112
Removal of the Casquette Assembly
112
Replacing the Bearings and Fork Crown
112
The Front Stanchion/Main Tube Assemblies
113
Changing Fork Oil
113
Re-Centering the Spring Studs
113
Replacingthe Fork Oil
113
Dismantling the Fork Leg Assembly
114
Examination of Components
114
The Rear Suspension
116
The Rear Shocklspring Units
116
The Swingarm Bushes
116
Removing the Swingarm
116
De-Bushing the Swingarm
117
Centering the Bushes
117
Reinstalling the Swingarm
117
The Primary Drive
118
The Clutch
118
Clutch Servicing
118
Dismantling the Clutch
118
Replacing the Clutch
120
Assumptions
120
Removing the Alternator and Engine Sprocket
121
Replacing the Alternator
122
The es Starter Drive System
122
Possible Problems
122
Operation
122
Gearbox Exploded View
123
The Gearbox
124
Adjustment of the Neutral Finder
124
Removal and Replacement of Countershaft Sprocket
124
Removing the Outer Cover
125
The Right Side Shifter
126
Removing the Inner Cover
127
Both Shifters
127
Drawing Anomaly
127
Breaking the Joint
128
Mainshaft Bearing
128
Stripping the Gearbox
128
Examination of Gearbox Parts
129
Bushings and Bearings
129
Enrichment Exercise
130
Gears, Dogs, and Shafts
130
Forks and Sliders
130
Correcting Faulty Gearchanging
131
Test Riding
131
Sloppy LH Shift Linkage
131
Determining Faulty Detent Plunger Action
131
Excessive Movement against Stops
132
Overview of the Shifter Mechanism
132
The Detent Plunger
132
The Ratchet Shifter Mechanism
132
The Stop Pins and Plate
133
Summary: the Variables
134
The Cures
134
Testing
134
Adjusting the Detent Plunger
135
Side Trip - Checking the Bellcrank Positions
135
Replacing the Detent Plunger
135
The Shifter Adjustment Plate (56)
136
Checking the Stop Plate
137
Insufficient Movement
137
Excessive Movement
137
The Kickstart Pawl Mechanism
138
Slipping Kickstarter
138
Installing the Right Foot Shift Kit
139
The Right-Shift Kit
139
Should You or Shouldn't You?
142
The Procedure
142
Hot Tip
143
Another Hot Tip
143
Gearbox Vent
143
Mainshaft End Play
144
Switch-Hitter's Hint
146
The 5-Speed Gearbox - an Overview
147
Clutch Throwout
147
Clutch Cable Replacement
147
The Gearbox Itself
148
Description
148
Trouble-Shooting - Kickstarter
149
Faulty Gear Changing - Poor to no Selection
149
Faulty Gear Changing - Lncomplete Engagement
150
Faulty Gear Changing - Firing out of Gear
150
Dismantling
150
Outer Cover
150
Carrier Plate (2.)
152
Inspection of Gearbox Parts
153
Gearbox Re-Assembly
153
Assembling the Layshaft
154
Mainshaft Reassembly
155
The Carrier Plate Assembly
156
The Shifter Mechanism
157
Outer Cover Assembly
158
The VM24 Mikcarb Carburetor
159
The VM28 Mikcarb Carburetor
160
The Bing Carburetor Bing Type 53/1
161
The Amal Monobloc Carburetor
162
The Amal Concetric Carburetor
163
Adjustment
164
The Float Circuit
164
Flooding Caused by Sticking Float
164
Checking and Adjusting Mixture Ranges
164
Finding the Optimum Mixture
165
Changing Needle Position
165
Setting the Main Jet
165
The Pilot Jet Setting
166
Electrical Work
167
Sorting out Electrical Difficulties
167
The Principles
167
The Electrical Circuit: Current Flow
167
Testing for Power Supply
168
Verifying Voltage
168
The Diagrams
168
Home (Indian) Model
172
UK Version (Pre-ES)
173
Export Electric Start
174
Isolating Circuits
175
The Elements of Circuits
175
Going Around the Circuit -Test Light Method
175
Locating Circuit Elements
176
Navigating through Switches
177
Voltage Drop
177
A Final Example: Ignition Checking
178
"Jumping" to Test Conductors
179
The Headlight Circuitry
179
The Switches and Connections
180
Alternator
180
North American AC Lights Wiring
180
Rectifierlregulator
180
Brake Light Switches
181
Model Specifics
181
North American Models - Specifics
181
Handlebar Switch
182
The North American Export Model AC Light Wiring
182
The Old Way
182
The New Way
182
UK Version
184
Home Versions
185
Performance Modifications
187
Modifying for Higher Performance
187
Volumetric Efficiency
187
Thermal Efficiency
188
Mechanical Efficiency
189
Necessary Mechanical Compensations
189
Where Do I Get Performance Parts
190
Clean Air Additions
192
The Pulse-Air System
192
Performance Considerations
193
View of Catalytic Converter Bodge in Header Pipe
193
Possible Improvements
194
The Crankcase Breather Condenser Tank
194
Don't Discard It!
194
Excessive "Blow-By"
194
Appendix
196
350 And 500 Bullet Engine Torque Values
197
350 And 500 Bullet Chassis Torque Values
198
Service Limits and Clearances
199
Inch Metric Conversion Table
200
Tech Specs - 500 CC
202
Tech Specs - 350 CC
203
How Do I Know What Year My Royal Enfield Is?
205
VIN Method
205
Key to Model Year Vl N
205
Cheap Tricks
205
Troubleshooting
206
4
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Royal Enfield Bullet RES 500 Specifications
General
Brand
Royal Enfield
Model
Bullet RES 500
Category
Motorcycle
Language
English
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