Documents

Workshop Manual Royal Enfield

Description
05-1 16 th June 2009 001/2009 Service Bulletin Safety recall for replacements of 3 rd , 4 th gear and main shaft. Models: Bullet Electra EFI/ Bullet EFI / Bullet Classic EFI Purpose Royal Enfield has determined that a condition relating to motor vehicle safety exists on certain Bullet Electra EFI/ Bullet EFI / Bullet Classic EFI model motorcycles. These motorcycles may experience 3 rd gear galling on the clutch shaft due to sudden oil starvation, when the motorcycle is driven at speed
Categories
Published
of 41
All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
Related Documents
Share
Transcript
  05-1 16 th  June 2009 001/2009Service Bulletin Safety recall for replacements of 3 rd , 4 th  gear and main shaft.Models: Bullet Electra EFI/ Bullet EFI / Bullet Classic EFI Purpose Royal Enfield has determined that a condition relating to motor vehicle safety exists on certain BulletElectra EFI/ Bullet EFI / Bullet Classic EFI model motorcycles. These motorcycles may experience 3 rd  gear galling on the clutch shaft due to sudden oil starvation,when the motorcycle is driven at speeds above 100 KMPH (70 MPH) continuously in top gear. Thiscondition can possibly cause the 3 rd  gear to seize to the main shaft resulting in a rear wheel lock up.A squealing noise may occur prior to this failure. However there may be cases where there is nowarning. This could result in a crash which could cause serious injury or death to the rider. .In the interest of motor vehicle safety and customer satisfaction, Royal Enfield is initiating a voluntaryrecall, of certain affected motorcycles, to replace the 3 rd , 4 th  gear and main shaft.You are required to perform the recall service on all affected vehicles in your inventory prior to delivering,renting or leasing these motorcycles.As required by law, you may sell but not deliver  any affected motorcycles to your customers, dealersuntil the remedy is completed. Motorcycles Affected This recall applies to certain Bullet Electra EFI / Bullet EFI / Bullet Classic EFI model motorcycles.Customer Notification You will need to identify the individual customers to whom the motorcycles, as given in the list, hasbeen sold, either directly or through your dealer network and send them appropriate notice with directionto bring the motorcycle in for the recall service.To protect the safety of our riders, it is our mutual responsibility to ensure the recall service is performedon all affected motorcycles. Therefore, we strongly urge you to perform the recall service even if themotorcycle was not purchased from your dealership.A modification kit is available to perform the replacements on the affected motorcycle and these kitsare sent to you from the factory at no charge and transportation paid. The detail of the kit is enclosed(Annexure 1). If additional kits are required please inform by email and the same will be sent to you.RE recognizes that in some places, sufficient labor resources with the time and skills may not beavailable to expediently complete the repairs. We fully expect RE Authorized distributors and theirdealers to recruit additional local mechanics to effect this safety recall. Based on mutual agreementwith RE authorized distributors, experienced and trained personnel from the factory will be sent at ourexpense for handholding and providing “on the job training” to the local personnel to effect the recallservice effectively..  05-2 Once a month, we expect to collate information across all sources on the overall status of this recalland will appreciate if you can coordinate with your dealers and send us a consolidation of the recallsdone for the week in the format that is attached (Annexure 2).It is unfortunate that this recall campaign has become necessary. However, we believe that it is alsoan opportunity to demonstrate to our customers that their trust and faith in our motorcycles, ourbrand, and our company are soundly placed. If we execute this together with precision, it is possiblethat we will come out of it with our reputation actually enhanced. We know that you will communicatethis effectively with our dealers.FILING A WARRANTY CLAIM:After performing each replacement please use the existing claim form to provide details of themotorcycle on which the parts have been replaced and the requisite labor time and other consumablesetc at our agreed man hour rates.Please do not hesitate to get in touch with me for any further clarifications.Thank you again for working with us on this. We value your business and look forward to continuingour good partnership.Sincerely,V. VikramHead, International ServiceRoyal Enfield Chennai SERVICE PROCEDURE: ã Refer to the detailed step by step procedure specific to engine disassembly andreassembly procedure, attached to this bulletin. ã Wash the motorcycle thoroughly before performing a engine removal from the frame ã Disconnect the battery terminals and remove the battery to prevent an accidentalshort circuit with could cause serious injury or death and in addition damage to themotorcycle. ã Place the motorcycle on a suitable vehicle ramp for the convenience to attend to themotorcycle and secure the motorcycle properly so as to avoid it falling over whichcould cause serious injury or death and in addition damage to the motorcycle. ã Store the removed components carefully and in a sequence for ease of reassemblyand to minimize the labor time. ã Ensure cosmetic parts like painted components, fuel tank etc are stored carefully andaway from work area to avoid accidental damage to the same. Take special care whenremoving and reinstalling the extra accessories.  05-3 COMPONENTS COMPONENTS COMPONENTS COMPONENTS COMPONENTS THATHATHATHATHAT CAN BET CAN BET CAN BET CAN BET CAN BEREMOREMOREMOREMOREMOVED VED VED VED VED WITH WITH WITH WITH WITH THE ENGINETHE ENGINETHE ENGINETHE ENGINETHE ENGINEMOUNTED ON THE FRAME.MOUNTED ON THE FRAME.MOUNTED ON THE FRAME.MOUNTED ON THE FRAME.MOUNTED ON THE FRAME.  Cylinder head assembly  Cylinder barrel & Piston  Crank case Cover RH  Crank case Cover LH  Clutch assembly  Inlet and Exhaust Cam assembly  Oil pump Assembly NOTE :  Before starting to dismantle engine,crank gently & bring piston to TDC. DISMANTLING PROCEDUREDISMANTLING PROCEDUREDISMANTLING PROCEDUREDISMANTLING PROCEDUREDISMANTLING PROCEDURE  Disconnect fuel hose. Take care to ensurefuel does not spill.  Disconnect fuel pump module and low fuelsensor couplers.  Remove the front and rear flange nuts,washer at the front & rear mounting of thefuel tank.  Lift the tank from the seat side & remove. CAUTION :  Keep a cloth on the front end of the fueltank, (below the handle bar clamp) toavoid damage to the fuel tank whileremoving. ENGINE DISMANTLING ,ENGINE DISMANTLING ,ENGINE DISMANTLING ,ENGINE DISMANTLING ,ENGINE DISMANTLING , INSPECTION INSPECTION INSPECTION INSPECTION INSPECTION AND AND AND AND AND ASSEMBLASSEMBLASSEMBLASSEMBLASSEMBLYYYYY SEASEASEASEASEAT REMOT REMOT REMOT REMOT REMOVVVVVAL BAL BAL BAL BAL BULLETULLETULLETULLETULLETELECTRA EFI (E5/G5)ELECTRA EFI (E5/G5)ELECTRA EFI (E5/G5)ELECTRA EFI (E5/G5)ELECTRA EFI (E5/G5)  Remove 4 nos. flange bolts from both sidesof the seats.  05-4  Remove the mounting bolts as shown andremove the seat.  Manual Bi starter  Remove the 2 screws, at the bottom of theLH switch module and separate themodule from the handle bar.  Remove cable from the straps in theframe.  Remove the pillion holder, lift from the rearend and pull out the seat BBBBBULLET CLASSIC EFI (C5)ULLET CLASSIC EFI (C5)ULLET CLASSIC EFI (C5)ULLET CLASSIC EFI (C5)ULLET CLASSIC EFI (C5)  Disconnect the cable from the lever. CLCLCLCLCLUTUTUTUTUTCH CABLE REMOCH CABLE REMOCH CABLE REMOCH CABLE REMOCH CABLE REMOVVVVVALALALALAL  Slacken the adjuster at the clutch cover endand disconnect the cable from the lever.  Take out clutch cable from the cover.
We Need Your Support
Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

Thanks to everyone for your continued support.

No, Thanks
SAVE OUR EARTH

We need your sign to support Project to invent "SMART AND CONTROLLABLE REFLECTIVE BALLOONS" to cover the Sun and Save Our Earth.

More details...

Sign Now!

We are very appreciated for your Prompt Action!

x