Continental Gt Owners Manual
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1Foreword
The Royal Enfield Continental GT is our lightest, fastest, and most powerful motorcycle in production. Its a machine
with a story, a nod to motorcyclings finest hour, the best expression yet of a cultural phenomenon that has simply
refused to fade away - the cafe racer.
And now you have one of your own. Congratulations!
Your meticulously re-engineered Continental GT debuts a twin downtube cradle frame chassis developed by the
renowned Harris Performance from UK. A new engine displaces 535cc and dollops of torque, when you need it. With
gas-charged rear shock absorbers from Paoli and Brembo disc brakes, you stay in charge. With an aerodynamic
seating position, Pirelli Sports Demon tyres and a remapped ECU, the new Continental GT is part homage, part
engineering tour-de-force.
This manual will help you to operate your motorcycle and guide you to wholly maintain it. We have also provided tips
on safe riding and on minor adjustments for the care of your motorcycle. Please avail the four free services at the
nearest Authorised Service Point at the appropriate time to maintain your motorcycle in top riding condition. We
request you to carefully read the terms and conditions of warranty and other useful information given in this manual
before starting to use your Continental GT. Log on to the exciting world of Royal Enfield on www.royalenfield.com to
get to know more about the company, its products and news from time to time.
Welcome to the world of the Rockers, and enjoy your burn-ups atop this spectacular machine.
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2
All information in this manual is based on the latest product information available at t he time of publication. Due to
continuous improvements or other changes, there may be discrepancies between information in this manual and your
vehicle. Royal Enfield reserves the right to make production changes at any time without prior notice and without
incurring any obligation to make same or similar changes to vehicles previously built or sold.
All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical
specifications are subject to change without prior notice.
Copyright 2014 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this manual shall be copied,
distributed or otherwise dealt without the express permission in writing from Royal Enfield.
Notice
Part No. 585441/A / Revision 1.0 / Qty. 500 / Apr. 2014
Disclaimer
This model fitted with tubeless tyre is provided withan inner tube.
Failure to use an inner tube in a spoked wheel willcause def lat ion of the tyre resul t ing in loss of
motorcycle control. The approved tyres marked with TUBELESS are
suitable for use with inner tube.
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3
PERSONAL & VEHICLE INFORMATION.. .. .. . 6
FREE SERVICE RECORD .... .. . .. . .. . .. .. . .. . .. .. . . 7
SAFETY DEFINITIONS . .. .. .. .. .. .. .. .. .. .. .. .. .. . 8
TECHNICAL SPECIFICATIONS... .. . .. .. .. . .. . .. . . 9
Engine. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 9
Ignition System .... .. . .. . .. .. .. . .. .. . .. . .. .. .. .. . . 10
Transmission.. . .. .. .. . .. . .. .. .. . .. .. . .. .. .. . .. .. . . 10
Electricals. . .. .. . .. . .. .. .. .. . .. .. .. . .. .. . .. . .. . .. .. . . 11
Chassis.. .. . .. .. . .. .. . .. . .. . .. .. . .. . .. .. .. .. . .. . .. . .. 12
Dimensions.. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . 13
Weights.. .. . .. .. . .. .. . .. . .. . .. .. . .. . .. .. .. .. . .. . .. . .. 13
SAFE RIDING TIPS/GUIDELINES .... . .. .. . .. . .. . 14
SAFE & HAPPY RIDING ... . .. .. . .. .. . .. . .. . .. . .. .. . 18
RULES OF THE ROAD.... .. . .. . .. .. .. .. . .. . .. . .. .. . . 19
VEHICLE IDENTI. NUMBER-DETAILS ... . .. . .. . 21
KEY PARTS LOCATION.... .. . .. . .. . .. . .. .. . .. .. . .. . 22
Right Side View.... . .. .. . .. . .. . .. .. . .. .. . .. . .. . .. 22
Left Side View... .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. . 23
Top View ... . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. .. . .. .. . .. . 24
OPERATION OF CONTROLS . .. .. .. .. .. .. .. .. .. 25
Ignit ion Switch.. .. .. . .. . .. .. . .. .. . .. . .. . .. .. . .. . .. 25
Steering Lock .. .. . .. . .. . .. .. . .. . .. . .. .. . .. .. . .. . .. 26Steering Unlock .. .. . .. .. . .. . .. . .. . .. .. . .. .. . .. . .. 26
Fuel Tank Cap.. .. . .. .. . .. . .. .. . .. .. .. .. . .. .. . .. .. . . 27
Side Panel LH / Bat tery Cover . .. .. .. .. .. . 27
Uti li ty Box .. .. . .. .. . .. . .. . .. .. . .. . .. .. .. .. . .. . .. .. . . 27
Side PANEL RH . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 27
Alpha-Numer ic disp lay unit .... ..... .... ..... 28
Head Lamp Switch.. .. . .. .. . .. . .. . .. .. . .. .. .. . .. . 30
Head Lamp Day Flash.. .. . .. . .. .. .. . .. .. . .. .. . . 30
Dip Switch .. .. . .. . .. .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . 30
Engine Start Swi tch. . .. .. .. .. .. .. .. .. .. .. .. .. .. 31
Engine Stop Swi tch . .. .. .. .. .. .. .. .. .. .. .. .. .. . 31Turn S ignal Swi tch . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 31
Horn .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . 32
Contents
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4Contents
Manual B i Star ter (choke) . .. .. .. .. .. .. .. .. .. 32
PRE OPERATIONAL CHECKS .... .. . .. . .. . .. .. . .. 33
RUNNING IN PERIOD.................................. 34
ELECTRONIC FUEL INJECTION (EFI) . .. . .. . .. 35
EFI .. .. .. . .. .. . .. .. .. . .. .. . .. . .. . .. .. . .. .. .. . .. .. . .. . .. 35
The Advantages of EFI . .. .. .. .. .. .. .. .. .. .. .. 35
Mal function Indicator Lamp (MIL) . .. .. .. .. 35
ROLL OVER SENSOR .... . .. .. .. . .. .. . .. . .. . .. .. . .. . 36
STARTING... . .. . .. .. .. . .. .. .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . 37
GEAR SHIFTING .... . .. .. .. .. . .. . .. .. . .. .. . .. .. .. . .. . .. 40
PARKING ... . .. .. . .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. 41
Center Stand .. .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . 41
Side Stand ... . .. .. . .. . .. . .. .. . .. . .. .. . .. .. .. . .. .. . . 41
TOOLS & FIRST AID KIT............................... 42
RECOMMENDED LUBRICANTS.... . .. .. .. .. . .. . .. 43
PERIODICAL MAINTENANCE .... . .. .. . .. .. . .. . .. . 44
MINOR MAINTENANCE TIPS .... . .. .. . .. . .. .. . .. . . 48
Control Cables, Hand lever,
Center / S ide Stand Pivots . .. .. .. .. .. .. .. .. . 48
Oil Level Inspection .. .. .. . .. .. .. . .. .. .. .. . .. . .. 48
Engine oil change .. .. . .. .. . .. . .. .. . .. .. . .. . .. . .. 49
Spark Plug ... . .. .. . .. . .. . .. .. . .. . .. .. . .. .. . .. .. .. . . 50Brake f lu id (Front & Rear) . .. .. .. .. .. .. .. .. .. 51
Inspection of t yres and whee ls . ... .. .. .. 51
Tyre pressure.. .. . .. . .. . .. .. . .. . .. . .. .. . .. .. . .. . .. 52
Front Wheel removal . .. .. .. .. .. .. .. .. .. .. .. .. . 52
Front Wheel reassembly . .. .. .. .. .. .. .. .. .. .. 53
Rear wheel removal . .. .. .. .. .. .. .. .. .. .. .. .. .. 54
Rear wheel reassembly .. .. .. .. .. .. .. .. .. .. .. 55
Adjustment s-C lutc h lever free play .... 57
Rear brake l ight switch adjustment .. .. .. 57
Drive Chain free play.. . .. .. . .. .. . .. .. . .. .. . .. . 58
Chain lock f i tment . . .. . .. .. . .. . .. .. . .. .. . .. . .. . .. 59
Adj. of gas fil led shockabsor ber ..... .... 60
Removal of Battery from the Vehicle... . . 61
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5Contents
Bat tery Maintenance.. .. .. .. .. .. .. .. .. .. .. .. .. . 61
Reassembly of B att ery on Veh ic le . .. .. . 62
CHANGING ELECTRICAL COMPONENTS.... 64
Head Lamp Bulb Replacement . .. .. .. .. .. . 64
Tail Lamp bulb Replacement . .. .. .. .. .. .. .. . 65
Traf f icator bulb Replacement . . .. .. .. .. .. .. 65
Fuse .. .. .. . .. . .. . .. .. .. .. . .. . .. .. . .. .. . .. .. .. .. . .. .. . . 66
Blade fuse usage l is t . .. .. .. .. .. .. .. .. .. .. .. .. . 66
Air Filter Paper element.... ..... ..... ..... .... .. 67
WASHING PROCEDURE.... . .. . .. .. .. . .. . .. .. . .. .. . . 68
Precautions ... . .. . .. . .. . .. . .. . .. . .. . .. .. . .. .. . .. . .. 68
Af ter was hing.. ..... ..... ..... ..... ..... .... ..... . 68
STORAGE PRECAUTION .... . .. .. . .. . .. . .. .. . .. .. . . 70
P repar ing t he motorcyc le for re-use . . . 71
LONG TRIP PRECAUTIONS .... . .. . .. .. . .. . .. .. . .. 72
COMPLETE WIRING DIAGRAM (Domestic) . 73
TROUBLE SHOOTING ... . .. . .. . .. .. .. . .. . .. . .. . .. . .. 74
Engine fai ls to s tar t . .. .. .. .. .. .. .. .. .. .. .. .. .. . 74
Engine mis fi ring . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 75
Poor pickup . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 75
White / Blue smoke . .. .. .. .. .. .. .. .. .. .. .. .. .. . 76
Engine overheating . .. .. .. .. .. .. .. .. .. .. .. .. .. . 76
Excess ive fuel consumpt ion. .. .. .. .. .. .. .. . 76
Brakes Poor.. . .. .. .. .. . .. . .. . .. . .. .. . .. .. . .. . .. . .. . 77
Vehicle wobbles... . .. . .. . .. . .. .. . .. .. . .. . .. . .. .. . 77
Electricals . . .. . .. . .. .. . .. .. . .. . .. . .. . .. .. . .. .. . .. . .. 77
Electronic Fuel In jec tion (EFI ) . .. .. .. .. .. .. . 78
WARRANTY... .. . .. .. . .. . .. .. . .. . .. .. . .. . .. . .. . .. . .. . .. . 79
EMISSION WARRANTY.... . .. . .. .. . .. . .. .. . .. .. . .. . . 81
FREE SERVICE COUPONS.... . .. . .. . .. .. . .. .. . .. .. 86
PAID SERVICE/MAINTENANCE RECORD... . . 95
ALL INDIA ROAD SIGNS .... ..... .... ..... ..... .... 103
LOG BOOK............................................... 104
NOTES .................................................... 108
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6
Name
Door No./St.
Locality
City State Pin
Contact Nos.Res: Off: Mobile: Email:
Engine No. Battery No.
Frame No. Battery make
Reg. No. Licence No.
Date of Sale Valid till dt.
Model Key No.
Tyre make Colour
Sold by Dealer Code
Vehicle Installation Form (VIF) No.
Personal & Vehicle Information
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7
It is our endeavour to provide excellent service to your CONTINENTAL GT at all times. Towards this we provide 4 freeservices at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to youand as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, to the service outlet.
Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, grease etc.
used for all free services are chargeable to the customer.
NOTE :Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.
Date of Service
Kms Covered
Servicing ASP /
Dealers Name
Address
1stService 4thService2ndService 3rdService
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Free Service Record
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8
The information given under the titles: Warning, Caution and Note are for your safety and for the care and safety to
your motorcycle and others. Please read these carefully and if disregarded it may result in injury to yourself or others
and damages to the motorcycle
Statement in this manual preceded by the following words are with special significance.
Warning
Indicates a potentially hazardous situation, which if not avoided, could result in serious injury or damage.
CAUTION :
Indicates a potentially hazardous situation , if not avoided, may result in minor or moderate injury or damage.
NOTE :
Indicates important and useful messages for clear understanding.
Safety Definitions
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9Technical Specification
ENGINE
Engine ....................................................... 4 Stroke, air cooled, single cylinder, OHV, SI Engine
Capacity.................................................... 535 cc
Bore.......................................................... 87 mm
Stroke........................................................ 90 mm
Compression ratio ..................................... 8.5 : 1
Max. Power @ RPM ................................... 29.1 BHP (21.4 kw) @ 5100 rpm
Max. Torque @ RPM .................................. 44 Nm @ 4000 rpm
Air Filter Element ....................................... Paper Element Filter
Engine Oil Capacity (dry fill) ....................... 2.75 Litres.
Lubrication ................................................ Forced Lubrication, Wet Sump
Engine Oil Grade ........................................ Royal Enfield 15 W 50 API SL Grade Engine Oil (JASO MA)
Fuel System .............................................. Electronic Fuel Injection Programmed (PGM-EFI)
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10Technical Specification
IGNITION SYSTEM
Ignition system.......................................... Electronic Ignition
Spark plug Electrode gap.......................... 0.80 - 0.90 mm
Spark plug ................................................ WQR8DC (Bosch Super)
TRANSMISSION
Clutch ....................................................... Wet Multiplate (7 Plates)
Primary drive ............................................ Duplex Chain
Primary Drive Ratio................................... 2.15 : 1
Gear box .................................................. Constant Mesh 5 Speed
Gear shift pattern ..................................... 1 - N - 2 - 3 - 4 - 5
Gear Ratios .............................................. 1st-3.063:1, 2nd-2.013:1, 3rd-1.522:1, 4th-1.212:1, 5th-1.000:1
Secondary Drive (F.D. Sprocket) . .. .. .. .. .. .. 18 Teeth
Final Drive Ratio ....................................... 2.00:1
Drive Chain Links...................................... 100 Links
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11
ELECTRICALS
Generation................................................ Alternator
System ..................................................... 12V DC
Battery...................................................... 12V - 14 AH
Head lamp................................................. 12V, H4 - 60/55 W,
.......................................................... Halogen Bulb
Brake / Tail lamp ....................................... 21/5 W
Turn signal................................................ 12V, 10W - 4 nos.
Instrument Cluster .................................... Digital instrument Cluster with LCD
High beam indicator.................................. 12V, 0.2W (L.E.D.)
Neutral Telltale Bulb .................................. 12V, 1.12W
Horn (Dual) ............................................... 12V, 2.5A (dual tone - LT, HT)
Starter Motor ............................................ 12V, 0.9 KW
WARNING
Using bulbs / other electricalgadgets other than specified rating may
lead to over loading / erratic behaviour /premature failure of electrical system.
Modifications on the bike which are notapproved by Royal Enfield may not onlydisqualify for warranty, but also affectsperformance of the bike.
Technical Specification
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12
CHASSIS
Frame ....................................................... Tubular steel double cradle
Tyre size .................................................. Front:100/90-18 M/C 56H
.......................................................... Rear:130/70-18 M/C 63H
Tyre pressure........................................... Front- Solo: 1.41 Kg/cm2 (20 PSI).......................................................... Pillion:1.55 Kg/cm2 (22 PSI)
.......................................................... Rear- Solo:2.11 Kg/cm2 (30 PSI)
.......................................................... Pillion:2.25 Kg/cm2 (32 PSI)
Fuel tank capacity .................................... 13.5 Litres***
Low fuel warning..................................... 3.00 Litres***
Suspension .............................................. Front:Telescopic , Stroke 110mm
.......................................................... Rear: Gas Charged, Stroke 80 mm
Front fork oil capacity .............................. 430 ml per leg
Front fork oil ............................................. Gabriel Fork Oil 2W 35
Hydraulic Brakes ...................................... Front: 300 mm dia floating disc, twin piston floating caliper
.......................................................... Rear:240 mm dia disc, single piston floating caliper
Brake oil grade ......................................... DOT 3 or DOT 4Brake oil capacity ..................................... Front:50 ml
.......................................................... Rear:100 ml
Technical Specification
Note:
***Fuel tank capacity givenhere is approximate. It canvary marginally from thisspecified value.
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13
DIMENSIONS
Length ...................................................... 2060 mm
Width ........................................................ 760 mm
Height ....................................................... 1070 mmWheel base .............................................. 1360 mm
Saddle height ........................................... 800 mm
Ground clearance .................................... 140 mm
WEIGHTS
Kerb Weight (with 90% Fuel) ................... 185 Kg
Gross vehicle weight ............................... 365 Kg
NOTE :
1. Values / Dimensions given above are for your guidance only.
2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.
Technical Specification
NOTE: BS III
This vehicle meets Emission Norms -Bharat (Trem) Stage - III
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14Safe Riding Tips / Guidelines
Before operating your new motorcycle, we
request you to carefully read and follow theoperating and maintenance instructions detailed
in this manual for the safety of your own, your
motorcycle, and also that of others.
Know and respect the rules of the road. Pleasebe a safe rider for your own safety and for others
in road.
Before starting the motorcycle, check for proper
operation of brakes, clutc h, gear shifter, handle
bar controls, tyre pressures, fuel and oil levels.
Use only genuine Royal Enfield spare parts and
approved accessories. Use of othermanufacturers performance parts may affect
the performance of your motorcycle and render
the motorcycle void of warranty. See your RoyalEnfield dealer for details.
Whenever refuelling your motorcycle, pleaseexercise utmost caution and carefully observe
the following rules.
DO NOT smoke and please ensure that
there are no open flames or sparks near themotorcycle, when refuelling OR servicingthe fuel system.
Switch OFF mobile phones and other hand
held electronic devices. Open the fuel fillercap slowly.
Refuel in a well ventilated area with theengine turned off.
DO NOT fill the tank to its brim. Please fillfuel only till the bottom of the filler neckinsert, so as to leave air space in the fuel
tank to allow for fuel expansion.
Warning
Royal Enfield cautions you against the use of certainnonstandard parts such as aftermarket and custommade extended front forks or suspensions, which may
adversely affect performance and handling. Removingor altering original parts may adversely affect
performance and could result in to an accident.
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15Safe Riding Tips / Guidelines
A new motorcyc le must be operated according
to the special running-in-procedure. See
running-in-procedure mentioned in Page No. 34.
Operate motorcycle only at moderate speeds and
out of traffic until you have become thoroughly
famil iar with i ts operation and handl ingcharacteristics under all conditions.
DO NOT exceed the legal speed limit or drive too
fast for existing conditions. Always reduce speed
when poor driving conditions exist. High speed
increases the influence of any other condition
affecting stability and increases the possibility of
loss of control.
NOTE :
If you are an inexperienced rider we recommend that
you obtain formal training on correct motorcycle riding
techniques and become thoroughly familiar with the
operation of your particular motorcycle. New ridersshould gain experience under various conditions while
driving at moderate speeds.
Pay strict attention to road surfaces and wind
conditions. Any two wheeled vehicle may be subject
to the following upsetting forces:
Wind blasts from passing trucks.
Rough uneven road surfaces.
Slippery road surfaces.
These forces may affect the handl ing
characteristics of your motorcycle. If this happens,
reduce speed and guide the motorcycle relaxed to
a controlled condition. Do not brake abruptly.
Operate your motorcycle defensively.
Remember that, a motorcycle does not afford
the same protection as an automobile in an
accident. One of the most common accident
situations occurs when the driver of the other
vehicle fails to see or recognize a motorcycle
and turns into the oncoming motorcyclist.
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16Safe Riding Tips / Guidelines
Wear an approved helmet, clothing, and foot
gear suited for riding a motorcycle. Bright OR
light colours are best for greater visibility in
traffic, specially at night. Avoid loose, flowing
garments and scarves.
W hen carrying a pi l l ion rider, i t is yourresponsibility to instruct them on proper riding
procedures.
DO NOT allow other individuals, under any
circumstances, to operate your motorcycle
unless you know they are experienced, licensed
riders and are thoroughly familiar with the
operating conditions of your motorcycle.
Warning
Regularly inspect shock absorbers and front forksand look for leaks. Replace worn out parts. Worn
out parts can adversely affect stability and handling.
Warning
For your personal welfare, all the listed service and
maintenance recommendations should be
performed. Lack of regular maintenance at the
suggested intervals may affect the safe operationof your motorcycle.
Warning
Avoid any contact with the exhaust syst em. Wear
clothing that will completely cover the legs while
riding. The exhaust system gets very hot when the
engine is running and remains too hot, even after the
engine is turned off. Failure to wear proper or protective
clothing could result in serious injury.
Warning
Exhaust gases contains poisonous carbonmonoxide and chemicals, known to cause Cancer,
Birth defects or other reproductive defects.
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17Safe Riding Tips / Guidelines
Warning
Motorcycle batteries contain lead and lead
components, acids and chemicals known to cause
cancer, birth defects or other reproductive harm.
Exercise extreme caution while handling a battery.Wash hands thoroughly whenever a battery is
handled.
Warning
Consult your Royal Enfield Dealer regarding any
questions or problems that occur in the operation
of your motorcycle. Failure to do so may aggravate
an initial problem, cause costly repairs & jeopardize
your personal safety.
Warning
DO NOT tow a disabled motorcycle. The steering
and handling of the disabled motorcycle will be
impaired due to the force of the towline. If a disabled
motorcycle must be transported, use a truck or atrailer. Towing a motorcycle may cause loss of
control of the motorcycle in the front, leading to an
accident.
Warning
DO NOT pull a trailer behind a motorcycle. Towing
a trailer may cause reduced braking efficiency, tyre
overloading and unstable handling. Towing a trailer
may cause loss of control of the motorcycle in the
front, leading to an accident.
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18Safe & Happy Riding
RIDING DRESS
Please wear proper riding apparel.
A pair of riding boots or shoes.
Soft leather gloves.
Goggles or spectacles to safe guard eyes.An approved helmet . Affixed w ith light reflect ing
strips of radium stickers at the front and rear.
NOTE :
A li ght coloured shir t enables greater visibili ty to other
road users specially during nights.
CAUTION :
Loose clothing may get caught on moving parts of
your motorcycle.
SITTING POSTURE
Correct sitting posture is a pre-requisite for stable
and safe riding
Sit in lean forwarded position.
Keep your elbows close to your body
Hold the handle bar grips, close to its inner end
Look extensively ahead, including rear view
mirrors, without turning the head.
BRAKING
Ap pl y fr on t and rear br ak es gent ly and
simultaneously for maximum braking efficiency.
WARNING
Applying any one of the brakes suddenly may cause
the vehicle to skid. The hydraulic disc brakes fitted
on your motorcycle require very less effort. High effort
or sudden application may lock the wheel. Please use
utmost caution while applying the brakes.
While riding on wet or bad road conditions use
brakes cautiously.
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19Rules of the Road
Be sure your number plate is installed in the
position specified by law and it is clearly visible
at all times.
Ride at a safe speed that is consistent with the
type of road surface you are on. Pay strict
attention to whether the surface is :
Dry
Oily
Icy
Wet
Watch for loose debris, such as leaves, slippery
substances or loose gravel that c an hamper the
stability of your vehicle.
DO NOT exceed the legal speed limit or drive
too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High
speed increases the influence of any othercondition affecting stability and increases the
possibility of loss of control.
Keep to the correct side of the road center line
when meeting oncoming vehicle.
Actuate your turn signals and exercise caution
when passing other vehicles going in the same
direction. Never try to pass another vehicle
going in the same direction at streetintersections, on curves, or when going up/or
down a hill.
At st reet inter sect ion give the right -of -way to
the vehicle on your left or right. DO NOT
presume you have the right-of-way.
Always signal when preparing to stop, turn or
pass.
While turning either right or left, watch for
pedestrians, animals, as well as vehicles.
All tr affic signs, inclu ding manual cont rols at
intersections, should be obeyed promptly.SLOW DOWN at traffic signs near schools and
CAUTION signs at railroad crossings.
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20
When intending to turn, signal at least 100 feet
(30.5 meters) before reaching the turning. Beclose to the center line (unless local rulesrequire otherwise), slow down and then turncarefully.
Never jump a traffic light. When achange is imminent from GO toSTOP (or vice versa) atintersections, slow down and waitfor the light to change to green.Never run through a yellow or redtraffic light.
DO NOT leave the curb or parking area withoutsignalling. Be sure your way is clear to entermoving traffic. A moving line of traffic alwayshas the right-of -way.
When parking the motorcycle, park on a firmand flat surface to prevent it from falling over.
Protect your motorcycle against theft. Afterparking your motorcycle, ensure that steeringhead is locked and then remove the Ignition key.
Rules of the Road
NOTE :
To help you to establish the relative distance of
vehicles behind your motorcycle, adjust each mirror
in such a way, that a small portion of your shoulder isvisible and a large portion behind your motorcycle is
seen clearly.
SIDE VIEW MIRRORS
Your motorcycles is equipped with convex mirrors
and have a curved surface. This type of mirror is
designed to give a much wider view of the rear than
a normal flat mirror. However, cars and other
objects seen in this type of mirror will look smaller
and farther away than when seen in a flat mirror.
Use care when judging the size or distance of
objects seen in these mirrors.
Red
Yellow
Green
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21Vehicle Identification Number - Details
CHASSIS NUMBER
Punched on the steering head tube RH side
ENGINE NUMBER
Punched on top of the Engine LH side.
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22
1. RH Trafficator front
2 . Brake Pedal
3. Kick Start Lever
4 . Star ter Motor
5. Horn
6. RH Side Panel
7. RH Trafficator Rear
1
26
7
RIGHT SIDE VIEW
43
Key Parts Location
5
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23Key Parts Location
7
1
2
3
6
54
LEFT SIDE VIEW1. Trafficator front LH
2. Spark plug
3. Gear Change Pedal
4. Centre stand
5. Side Stand
6. Side Panel LH / Battery Cover
7. Trafficator rear LH
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24Key Parts Location
1. Turn signal switch
2 . Horn but ton
3. Clutch lever
4. Day flash switch5. Head lamp dip switch
TOP VIEW
6. Manual Bistarter / Choke
7 . Speedometer
8 . Ign it ion swi tch
9. Malfunction Indicator Lamp10. Tacho Meter
11. Engine Kill switch
12. Park / head light switch
13. Electric Start Switch
14. Fuel tank cap
1
2
3
4 8 11
1213
14
975 6 10
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25Operation of Controls
IGNITION SWITCH
Insert ignition key and turn clockwise direction
to ON. Once you turn on t he ignition key all the
indicating lights in instrument cluster starts
glowing on for few seconds and the engine will
get ready to start. The key cannot be removed
from ON possition.
Turn the ignition key in anticlockwise direction
to OFF. Once you turn off, all the electrical
systems goes off. Now the key can be
removed.
OFFON
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26
STEERING LOCK
Turn the handle bar to extreme left or right position.
Push the key inside in OFF position, pressand further turn to anticlockwise direction tolock the steering system.
The key can be removed from the lock in thisposition.
STEERING UNLOCK
CAUTION :
Do not lubricate barrel locks with petroleum based
lubricants or graphite. Inoperative locks may result in
damage to your vehicle.
Push the key in steering lock Position, and turn
clockwise direction to unlock the steering.
The key can be removed from the lock in thisposition.
Operation of Controls
CAUTION :
Protect your motorcycle against theft. After parkingyour Motorcycle and lock the steering, then remove
the key from combination switch.
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27Operation of Controls
FUEL TANK CAP
Turn key clockwise
to open. Press the
cap to lock with key
in position.
NOTE :
Key can be removedonly in locked position.
SIDE PANEL RH
Uti l i ty box is
provided at the
bottom area of
battery carrier.
It is covered with
side panel LH
SIDE PANEL LH / BATTERY COVER
Turn key clockwise tounlock the side panel.
Pull the side paneloutside for openingthe same.
Key cannot be
removed in thisposition.
Unscrew the indicated
screw and then pull
the side panel for
opening the same.
UTILITY BOX
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28
Warning
Do not attempt to change any setting while riding the
motorcycle. It may cause loss of control leading to an
accident.
Operation of Controls
ALPHA-NUMERIC DISPLAY UNIT
This unit in the
speedometer consists
of
1. Odometer
2. Trip A
3. Trip B
4. Fuel level indicator
ODOMETER MODE
Odometer mode is the
initial display mode of
this unit. It displays
odometer reading by
default.
NOTE :
Once you turn ON the ignition key, whatever was the
last selection mode will get displayed.
TRIP METER MODE
A light pus h for lessthan one second onthe PUSH buttonswitch will change thedisplay from odometer
to Trip meter (TRIP A)
NOTE :For resetting the Trip Meter
1. Set the display as TRIP A or B as a current mode.
2. Press the PUSH button for more than 3 Seconds.
3. Automatically the display will become zero.
Again another press on the PUSH button switch
will change the display from TRIP A to TRIP B.Push Button
Switch
Alpha Numeric Display
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29Operation of Controls
The display bars of the fuel meter disappears
towards the Empty (E) when the fuel level
decreases.
when last bar start blinking (less than 3 litres), refuel
the bike at the earliest.
NOTE :
If the last bar of the fuel meter is blinking continuously
after fueling, visit a Royal Enfield authorised dealer
and check the same.
FUEL LEVEL INDICATOR
The fuel level indicator
indicates the level of fuel
in the fuel tank.
If the battery voltage is less than 12 volts, the low
voltage indicator will start glowing continuously.
While the ignition is ON, low voltage indicator
symbol will glow until engine reaches 700 RPM.
In running condition if the battery voltage is below
12 Volts for more than 3 seconds continuously, the
low voltage indicator will start glowing.
BATTERY LOW VOLTAGE INDICATOR
Battery low voltage indicator
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30
DIP SWITCHHEAD LAMP DAY FLASH
PRESS FOR HEAD LIGHT FLASH LOW BEAM HIGH BEAM
Operation of Controls
HEAD LAMP SWITCH
HEAD LAMP ON POSITION LAMP HEAD LAMP OFF
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31Operation of Controls
ENGINE STOP SWITCH
ENGINE ON ENGINE OFF
TURN SIGNAL SWITCH
LEFT RIGHTOFF (PUSH TO OFF)
ENGINE START SWITCH
PRESS
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32
MANUAL BI STARTER (CHOKE)
Operation of Controls
HORN
PRESSApply choke in cold start cond ition while starting the Bike
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33Pre Operational Checks
A careful check of t he following must be carr ied out
every time before riding and specially after long periods
of storage to determine if any additional maintenance
is necessary.
1. Adequate fuel in the tank.
2. Tyres for correct pressure, abrasions or cuts.
3. Rear chain for proper tension and sufficient
lubrication.
4. Brakes, s teer ing and throt t le for proper
responsiveness.
5. Cable for fraying or crimping and free operation.
Warning
For your personal welfare and safety, all the points
mentioned above should be performed periodically.
Failure to do so may affect safe operation, damage
your motorcycle and could result in an accident
causing serious injury.
6. Engine oil level.
7. Wheel spokes for proper tightness and no
breakage.
8. Headlamp, tail lamp, brake lamp and indicator
lamps for proper functioning.
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34Running In Period
Proper running-In is very important for obtainingmaximum life and performance of a new motorcycle.The following guidelines explain proper running-inprocedures.
Since the engine is brand new, it should not be loadedexcessively for the first 2,000 kilometers. During thefirst few hundred kilometers, the mating parts in the
engine will wear and polish themselves to the correctoperating clearances. Driving with prolonged fullthrottle operation, or in any high speed conditionsmight result in excessive heating of the engine andcause abnormal wear of the moving parts and hencethe same must be avoided.
1. 0-500 Kms :
The recommended speeds for the f irst 500Kilometers is below 50 to 60 Kmph. During thisperiod avoid operating the motorcycle with fullthrottle opening. Stop the motorcycle for about 5to 10 minutes to let it cool down, after every hourof running. Vary the speed of the motorcycleregularly during running but avoid using themotorcycle above 1/2 throttle opening position.
2. 501-2000 Kms :
The recommended speed is below 80 90 kmph.Avo id dr ivi ng the mot orc ycl e wit h fu ll th rot tle
opening. Vary the speed of the motorcycleregularly but avoid using the motorcycle above3/4th throttle opening position.
3. 2001 Kms and above
Avo id pr ol onged fu ll -t hr ot tl e oper at ion. Varyspeed occasionally.
CAUTION :
After covering the f irst 500 ki lometers, Please replacethe engine oil and oil filter element.
Royal Enfield engines are air-cooled andconsequently require forced air cooling over thecylinder and head to maintain proper operatingtemperature. Extended periods of idling may overheat the engine, resulting in serious engine damage.
DO NOT run the engine at extremely high RPM withclutch disengaged or transmission in neutral as itcan cause serious engine damage.
An engine runn ing for long dist ances at high speed
must be given close attention to avoid overheatingand possible engine damage
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35Electronic Fuel Injection (EFI)
ELECTRONIC FUEL INJECTION (EFI)
An electr onic control unit (ECU ) monitors engine
performance and provides exact requirement of Air
/ Fuel mixture to the engine, through the fuel injector
by taking inputs from various sensors provided in
the motorcycle.
THE ADVANTAGES OF EFI ARE
Faster response of the engine to suit road/load
conditions.
Better power output
Lower emission
Better reliability
Excellent cold Startability
Engine Diagnostic capabilities
Maintenance free
MALFUNCTION INDICATOR LAMP (MIL)
A Ma lf un c ti on in gIndicator Lamp (MIL)is provided in theRPM meter which islocated on the right
side of the Clusterunit.
1. EFI Mal Function Indicator : When both theIgnition & Engine kill switch is 0N, the MIL willglow for few seconds and will go OFF. Thisindicates that all the functions of Electronic ControlUnit (ECU) and other sensors are working perfectlyand the motorcycle can be used.
In case of any malfunctioning of the ECU or othersensors etc., the MIL will glow continuously. In theevent of any such phenomenon, it is recommendedto take the vehicle to a nearest Royal Enfield
authorised service point for inspection and furthernecessary action.
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36Rollover Sensor
ROLLOVER SENSOR Your motorcycle is fitted with a unique Roll OverSensor under the seat. This is a safety feature.
In the event of an accident OR if the motorcycle
falls over on any side with the engine running
condition, The Roll Over Sensor will switch off
Ignition and cut off fuel supply to prevent the
motorcycle from moving suddenly, while it is in gear.
To re-activate the system after the motorcycle has
been made upright, please switch off both the
Ignition & Engine kill switch, wait for a few seconds
and switch ON again.
This will help to RESET the Roll Over Sensor and
the engine can be started/ run.
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37Starting
Warning
Before starting engine, always shift gears into neutral.
CAUTION :
Do not force the gear lever while attempting to shift to
neutral. Move the motorcycle back & forth andsimultaneously press gear lever to come to neutral.
Ensure neutral Indicator light glows in the Speedometer.
NOTE :
If the engine does not start on the first attemptin cold climate, release the starter button, waitfor 30 seconds before pressing the starterbutton again.
Press starter button and release starter switchonce the engine starts.
A clutc h swit ch is provided in the sys tem forthe safety of the rider. This is to prevent thevehicle from starting when the vehicle is in gear.To start the engine when it is in gear, pull clutch
lever, press the starter button and releaseslowly after the engine starts.
Turn ignition
switch ON
Ensure the side
and main stands
are in released
position
Ensure that gears
are in neutral and
neutral lamp is
glowing
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38
Ensure Engine
stop switch is in
RUN position
Starting
Press Clutch
Lever.
Press Starter
Button and
release as soon
as engine starts
CAUTION :
Never accelerate the engine immediately after a cold
start. The engine should be allowed to run slowly for
15-30 seconds. This will allow the engine to warm up
and let oil reach all surfaces needing lubrication.
Failure to adhere may result in damage to the Engine.
Manual bi
Starter (choke)
NOTE :
It may be necessary to operate and hold the manual
bi starter, when starting the engine for the first time in
cold mornings, temperatures below 10C or at high
altitudes, to prevent the stalling and to keep the idlingRPM steady.
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39Starting
As soon as the engine at ta ins the operat ing
temperature, the RPM will raise, at which time the
manual Bi Starter should be released.
Warm up engine for 2 minutes - till idling is
consistent.
CAUTION :
Please ensure the motorcycle is not used with the
low fuel indicator bar blinking c ontinuously. It may not
only result in the motorcycle running out of fuel. But
will also cause serious damage to the fuel pump.
Please ensure fuel is filled up as s oon as the low fuel,
last bar start blinking.
CAUTION :
Air cool ed eng ine requir es air moveme nt over the
cylinder head and exhaust pipe to maintain proper
operating temperature.
Never accelerate the engine abnormally in stand still
condition of the motorcycle. Failure to adhere this may
result in damage to exhaust pipe / silencer of the
engine due to over heating.
Prior to starting, check to see the fuel level from
the fuel gauge.
If the last bar is blinking refuel immediately.
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40Gear Shifting
CAUTION :
The clutch must be fully disengaged before attempting
a gear shift. Failure to fully disengage the clutch may
cause a jerky start OR stalling the engine besidescausing damage to transmission parts.
Warm up engine
for 2 minutes -
ti l l idl ing is
consistent/stable
GEAR SHIFT PATTERN
1 N 2 3 4 5Press clutch lever towards the hand grip.
Press gear pedal with toe towards down to
engage 1st gear.
Gently open throttle and release clutch
simultaneously. If clutch is released suddenly,
the engine may stall and cause a jerky start.
NOTE :
Always start motorcycle with gear in neutral position.
Always move t he motorcycle in firs t gear position only.
When engine speed decreases or while climbing a
gradient or running at a reduced speed, shift to the
appropriate lower gear to prevent the engine fromstalling or straining to pull.
Press the gear
pedal upwards
with toe to
engage 2nd
and gear.
Follow the same procedure for 3rd, 4th and 5th
gear.
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41Parking
PARKING VEHICLE ON CENTER STAND
Select a firm, flat surface
Hold handle bar straight
Lower center stand, and ensure that both thelegs of the stand are resting evenly on firm ground.
Appl y pres su re on the ful crum lever on thecenter stand and pull vehicle upwards, gently.
PARKING VEHICLE ON SIDE STAND
Select a firm, flat surface
Lower Side Stand and gently tilt motorcycle to
the left till it rests firmly on the side stand.
Warning
Always park the motor cycle on a firm and flat surf ace. Parking in a soft ground may cause stand to sink and themotorcycle to fall, causing injury to you or to others and damage to the motorcycle parts.
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42Tools & First Aid Kit
NOTE :
This Tool Kit is kept in Utility box. Refer Page No. 27.
S.No. Description Qty.
1. Tool Bag 12. Screw Driver O6 X 160 13. Tommy Bar 14. Box Spanner 21 X 24 15. Double End Spanner 14 X 15 16. Double End Spanner 10 X 13 27. Double End Spanner 8 X 10 18. Allen Key 5 MM 19. Allen Key 3 MM 110. Tyre Removal Lever 2
1
4
5 6 7
3
S.No. Description Qty.
1. Antiseptic cream 5 gms 1
2. Gauze bandage 5 cm x 2 cm 1
3. E last ic Gauze bandage 8 cm x 1 mt r. 1
4 . Wash proof plas ter 1.9 cm x 7.2 cm 2
5 . Ster il ized Gauze S wab 5 cm x 5 cm 2
6. Steril ized elastic plaster 7 cm x 6 cm 1
7. First aid kit pouch 1
2
1 2 3 4 5 6 7 8 9 10
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43Recommended Lubricants
ISO 14001 EMS
Operation Control Process
1. All customers are advised timely replacement of Engine Oil,
Fork Oil & Brake Oil at the dealership /ASP. In case done
privately, it is advise to reach old/used Oil to our authorised
vendor through RE Dealer/ASP
2. Similarly we advise for disposal of old/used Battery, Tube &
Tyres as mentioned in above point No.1.
Engine Oil
Grade Royal Enfield 15 W 50 API SL Grade
Engine Oil
(JASO MA)
Front Fork Oil
Grade Royal EnfieldFront Fork Oil(or Gabriel ForkOil 2W 35)
Capacity 430 ml / leg
Brake Fluid
Grade DOT 3 or DOT 4
Capacity 2.75 Ltrs. (for dry fill)
2.50 Ltrs. (during oil & filter elementreplacement)
Warning
DO NOT switch oil brands indiscriminately because some oil interact chemically when mixed.
Use of inferior oils or non-detergent oils can damage the engine.
DO NOT Mix DOT 3 & DOT 4 brake fluid together.
CapacityFront : 50 ml
Rear : 100 ml
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44Periodical Maintenance
The maintenance schedule detailed here will help you to maintain your Continental GT meticulously and to get a long
trouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileage
at which regular inspections, adjustments, replacements and lubrications must be carried out.
The frequency of the maintenance must be shortened depending upon the severity of the Riding condition OR if the
motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad r oads, stagnant water
etc., Contact a nearest Royal Enfield Authorised Dealer / Service Point for expert advice and to carry out the
periodical maintenance.
Warning
For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of
regular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the
motorcycle to malfunction and stall abruptly resulting in an accident and cause serious injury.
NOTE :
For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultation with a
Royal Enfield Authorised Dealer / Service Point.
Do not mix DOT 3 and DOT 4 brake fluid together.
*Carbo cleaner / Carbclik or Fuel Line Cleaner Spray. (Make - Wurth or ITW Chemin)
A : Adjust C : Clean D : De-carbo nise I : Inspect L : Lubricate R : Replace
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45Periodical Maintenance
DESCRIPTION PAID SERVICES.
No.
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Months 1.5 3 6 9
FREE SERVICEwhichever is earlier
1 Engine OilR R R R R R
Check level at every 1000 Kms or earlier as required
2 Engine oil filter element R C R R R R R
3 Engine sump filter (oil strainer) C C C C C C C
4Magnetic drain plug under gear box and secondary
C C C C C C Cdrain plug under cranksharft in crankcase RH
5 Spark plug C&A C&A C&A C&A C&A R C&A C&A C&A C&A R
6 HT lead for crack I I I I I I I I I I I
7 Fuel hose & clip / Injector O Ring / Seal Ring I I I I R I I I R I I
8 Fuel Pump Check for screw tightness in all services
9 Accelerator & Throttle pully cable free play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold I I I I R I I I R I I
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46
DESCRIPTIONS.
No.
Periodical Maintenance
PAID SERVICEFREE SERVICEwhichever is earlier
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Months 1.5 3 6 9
12 Air filter paper element C C C C R C C C R C C
13 Inlet / Exhaust valve seating I I
14 Cylinder head (Combustion chamber) D
15 Exhaust pipe D
16 Clutch lever free play Adjust every 1000 Kms or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L
18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet contact (below ECU Mounting) I I
21 Rear W heel Drive Chain Adjust every 1000 Kms or earlier as required
Lubricate every 3000 Kms or earlier as required
22 Front Fork oil / leak I I I R I I I R I I I
23 Steering ball races / play adjustment A L A R A L A R A L
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47Periodical Maintenance
DESCRIPTIONS.
No.PAID SERVICEFREE SERVICE
whichever is earlier
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Months 1.5 3 6 9
24 Spokes tightness / Wheel rim run out front & rear I I I I I I
25 Rear wheel cush rubbers I & R I & R
26 Tyre wear front & rear I I I I I I I I I
27 Hand levers & Kick starter pivot Lubricate every 1000 Kms or earlier as required
28 Brake Oil level check / Replacement I I I I I I I I R I I
29 Pivot-Side Stand / Center Stand pivot L L L L L L L L L L L
30 Rider & Pillion Foot rest pivot L L L L L L L L L L L
31 Swing arm needle bearings and spindle L L
32 Vent Pipe under air filter box I & C I & C I & C I & C I & C I & C I & C I & C I & C I & C
33 Throttle body - cleaning spray* C C C C C
34 PAV pipes & hose clip I I I I I I I I R I I
35 Front & Rear brake hose and Banjo Bolt I I I I I I I I I I R
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48Minor Maintenance Tips
OIL LEVEL INSPECTION
Lever Pivot
Main Stand Pivot
The following minor maintenance can be carried
out easily with simple tools. However, In case, if it
is felt that the adjustments are best done by an
expert, we recommend that the motorcycle be t aken
to a nearest Royal Enfield Authorised Dealer /
Service Point.
CONTROL CABLES, HANDLE BAR LEVER, PIVOTS,CENTER / SIDE STAND PIVOTS
Lubricate after using the motorcycle in rain,
after waterwash or if used in dusty conditions.
Wipe the area free of dirt / grease.
Apply a few d rops of oil on the pivots.
Place motorcycle on its center stand on a firmsurface.
Warm up engine for a few minutes & switch off.
The level is correct if the oil level is in the middle
of the oil level window.
Top up with recommended oil if required.
Side StandPivot
MAXMIN
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49Minor Maintenance Tips
ENGINE - OIL CHANGE
PrimaryFilter Cap
Remove the oil filter paper element on theCrankcase Cover RH.
Allow the oil t o drain by tilting the motorc ycle toboth sides.
Wash the primary and secondary drain plugs
along with suction filter thoroughly and refit onthe crankcase after all the oil is drained out.
(Refer Periodical Maintenance Chart for f requency)
Remove primary drain cap, to drain oil & cleansuction filter, magnet.
Then remove secondary drain plug to drain oil &clean the magnet.
Finally remove primary drain bolt to drain thecomplete oil.
PrimaryDrainPlug
SecondaryDrain Plug
TILT VEHICLE RH & LH
Place motorcycle on its centre stand on a firmflat surface.
Start engine and warm up for 2 minutes.
Keep a clean tray below the engine
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50Minor Maintenance Tips
Max
Min
Fill recommendedoil to engine till theoil level is upto
MAX level mark inthe oil window inCrankcase CoverRH.
SPARK PLUG
Cleaning and adjusting gap (Refer PeriodicalMaintenance Chart for frequency)
Remove HT Lead and the spark plug from thecylinder head using the plug spanner andTommy bar.
Clean the insulator tip and electrodes of the plugcarefully using a pointed scraper or spark plugcleaner.
Set the gap between 0.80 to 0.90 mm.
Refit the spark plug on the cylinder head andconnect H.T. Lead.
NOTE :
Replace oil filter paper element whenever oil is beingreplaced.
CAUTION :
Do not fill oil over MAX mark. It may cause the engineto smoke and result in loss of power. Do NOT use themotorcycle if the oil is below the MIN mark. Doing
so will cause serious damage to the moving partsinside the engine and result in an engine lock up.
Soak a new oil filter paper element in the oil andrefit on the Crankcase Cover RH.
Assemb ly 3 bolts and ti ghten t hem. Ens ure ORing and gaskets are taken seat properly.
Gap 0.80 to 0.90 mm.
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51
MIN
MAX
CAUTION :
Brake fluid is highly c orrosive and can cause damage
to painted parts. Please ensure that brake fluid does
not spill on any part of the motorcycle. In the event of
a spill, please clean the area immediately with a soft
cloth (preferably a wet cloth) to avoid damage.
Dont mix DOT 3 & DOT 4 Brake fluid together.
Minor Maintenance Tips
Check if oil is below MIN level. To top Up, remove
cover and diaphragm, then top up with DOT 3 or
DOT 4 as specified.
BRAKE FLUID INSPECTION OF TYRES AND WHEELS
Inspect the tyre periodically for
tread wear, cracks and cuts.
FRONT BRAKE REAR BRAKE
MIN
Check and remove stone, splinters, nails or otherparticles embedded in the t yre treads.
Bald spots / swelling may be caused by internaldamage. Replace the tyres, if defective.
Replace tyres when the tread depth has reachedthe minimum as specified.
Periodically inspect wheels for spokes breakageand wheel rim run out.
Check proper seating of the tyre beading on therim whenever the tyre is reassembled.
Whenever a new tyre is installed, ensure rim
and spokes do not get damaged on account ofwrong handling.
Minimum tread depth
Front tyre : 1.00 mm
Rear tyre : 2.00 mm
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52Minor Maintenance Tips
FRONT WHEEL REMOVALUse only standard tyres & tubes inflated tocorrect pressure.
TYRE PRESSURE
Front Rear
Solo 1. 41 kg/c m2 2. 11 kg/c m2(20 PSI) (30 PSI)
With Pillion 1. 55 k g/c m2 2. 25 k g/c m2
(22 PSI) (32 PSI)
Warning
Tyres, rims and air valves must be correctly matched
to wheel rims. See your Royal Enfield Dealer.
Mismatching tyre, tubes, rims and air valves may result
in damage to the tyre bead during mounting, allow
tyre slippage on the rim and cause tyre failure.
Place the vehicle on center stand
Place a wooden blockthe front end of
engine to support the
vehicle.
Loosen the pinch bolt
on the RH fork guide
by 6 mm allen key.
Hold the axle head by
double end spanner
while loosening the
axle nut.
Remove the axle nut
along with washer.
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53Minor Maintenance Tips
Place a 4 mm thick wooden piece or cardboard
sheet between the brake pads to avoid pads
activation in the event the front brake lever is
accidently pressed.
FRONT WHEEL REASSEMBLYTap and remove thefront wheel spindle.
Tilt the vehicle to RHSide and take out the
wheel along with
wheel speed sensor
and LH side spacer.
CAUTION :
Do not press the front brake lever when wheel is
removed as this will result in the brake pads coming
too far out of the brake caliper.
Place the wheel speedsensor in position.
Ensure slot on hub
and speedo sensor ismatched c orrectly.
Insert the wheelalong with wheelspeed sensor and LHspacer between thefront fork endsensuring the brakedisc is locatedbetween the brakepads.
Insert and tap thefront wheel axlegently inside.
Refit the washer andtighten the nut firmly.
Remove the wooden piece / card board sheet
placed between the brake pads
Locating
TAB
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54
REAR WHEEL REMOVAL
Minor Maintenance Tips
Tighten the pinch bolt on the RH fork guide.
Rotate the wheel and check for smooth rotation.
Ensure wheel speed sensor wire coupler is being
connected to cluster unit and then check for
proper working of speedo meter.
Press brake lever 2 or 3 times to check front
brake efficiency.
Place the vehicle oncenter stand on afirm and flat surface.
Observe and mark
the alignment index
marks in the both
sides of swing arm.
Remove axle nut on
the RH side.
Remove wheel spindle
from LH side along
with wheel collar and
LH side spacer.
Index mark
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55
Remove the caliper
assembly by pulling
out from the swing
arm slot.
CAUTION :
Do not press the rear brake pedal when wheel is
removed as this will result in the brake pads coming
too far out of the brake caliper.
Place a 4 mm thick wooden piece or cardboardsheet between the brake pads to avoid padsactivation in the event the rear brake pedal isaccidently pressed.
Minor Maintenance Tips
Remove the distance collar.
Tilt the motorcycle towards RH side and take out
the rear wheel assembly conveniently.
REAR WHEEL REASSEMBLY
Tilt vehicle to right andinsert wheel assemblybetween the swingarms.
Position the rearwheel with cushrubber on the reardriven flange /adaptor.
Fix the LH side spacerin rear wheel hub.
Remove the wooden
piece / card board
sheet placed between
the brake pads.
Ensure the four Cush rubbers are in positioninside the rear wheel hub.
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56Minor Maintenance Tips
Warning
Ensure the vehicle do not come out of center standwhile dismantl ing and assembling the wheelassembly.
Align t he caliper bracket, wheel and s wing armholes in-line and ensure distance collar is
placed in hub dust seal.
Insert the cal iperassembly by pushingin the projectiongiven inside theswing arm. Ensurethe brake disc islocated in betweenthe brake pads.
Ensure that swing armend plate is seated
properly and the
chain adjuster nutsare correctly tight-
ened and Locked.
Insert and tap the rear
wheel axle gently.
Index mark
CAUTION :Do not force the spindle into
the wheel as the threads
may get damaged. Tap it
through the wheel gently.
Ensure the index marks alignments on both sides
of the swing arm are in same position for proper
wheel alignment.
Tighten the axle nut
firmly.
Adjuster End Plate
Adjuster Lock nut
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57
ADJUSTMENTS - CLUTCH LEVER FREE PLAY
Clutch Lever (free play 2 - 3 mm)
Loosen the cable outer lock nut (A).
Turn the Nut (B) Clockwise to reduce the play
or Anticlockwise to increase the free play.
Check free play 2 to 3 mm at Clutch lever pivot
on handle bar end.
Tighten lock nut (A) after adjustment is done.
B
A
2 to 3 mm
REAR BRAKE LIGHT SWITCH ADJUSTMENT
If above are alright, then do the adjustment asmentioned below:
1. Turn the brake light switch adjustment nut whileholding the rear brake light switch body inposition.
2. If the brake light do not glows after pressingthe pedal for approximately 25mm,turn theadjusting nut in clockwise direction by 2 to 3threads and check for brake light function.
3. If the brake light continuously glows,turn theadjusting nut in anti clockwise direction by 2to 3 threads so as to get the positions in whichthe light goes off.
The brake light glows onceyou press the brake pedal.
If brake light is not glowing,check the brake light switchwire for proper connection
and the brake light Switchspring for any bend,breakage or disconnection.
Minor Maintenance Tips
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58
DRIVE CHAIN FREE PLAY (PLAY 20 - 25 MM)
Minor Maintenance Tips
Place motor-
cycle on i ts
center stand on
a firm & flat
surface.
Shift the gear
into the neutral
position
Measure the
drive chain free
play as shown.
The drive chain
free play is 20 to
25 mm
Drive chain slackadjusting nut
Swing Arm
reference mark
Index mark
Adjuster
Lock nut
1. If the drive chain free play is incorrect adjust
as follows:
a. Loosen the axle nut of the rear wheel axle.
b. L oos en th e Q D
sprocket spindle nut.
c. Loosen the locknut at
both end of the
swing arm.
d. To reduce the freeplay, turn the drive
chain slack adjusting
nut in clockwise
direction.
e. To increase the free
play, turn the drive
chain slack adjusting
nut in anticlockwise
direction and push
the rear wheel
forward.
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59
CHAIN LOCK FITMENT
Minor Maintenance Tips
The open end of the chain master link lock should
face opposite to normal direction of chain rotation.
Warning
The fitment of lock in wrong direction other than
shown above can lead to its falling off, and thus can
cause the sudden disconnection of the chain during
the drive.
f. Later adjust the nut on LH side by matching
the index mark with respect to RH side index.
g. Ensure that both the sides are in same index
marks.
h. Finally torque the spindle and axle nuts to 7
kgm.
i. Tighten the adjuster locknut by 13mm spanneragainst chain slack adjusting nut.
Warning
Chain slackness beyond 30mm will lead to chain
slippage.
Maintain drive chain slackness within the specified
limits at every 1000 kms interval.
Please Check the front and rear wheels are correctly
aligned, after the chain adjustment.
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60Minor Maintenance Tips
ADJUSTMENT OF GAS FILLED SHOCKABSORBER
The rear gas filled shock absorber is an
adjustable type.The spring tension can be
increased or decreased.
Reduce the spring tension for low load operation
by turning the adjuster nut in the direction as
shown above by using a suitable C - spanner.
Increase the spring tension for high load
operation by turning the adjuster nut in oposite
direction.
Adjust both the rear shock absorbers to the same
thread possitions.
Recommended = 10 mm height adjustment only
from factory setting.
Warning
Riding the motorcycle with the shock absorbers
adjusted in different positions can cause loss of
control.
Regularly inspect shock absorbers and front forks for
any leaks.
NOTE :
Ensure access ories, fitted if any, do not foul with
rear shock absorbers. Check for suff icient gap
between the shock absorbers and the attachments
in a condition that the rear end of the Motorcycle is
fully loaded and the shock absorbers are maximum
compressed.
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61Minor Maintenance Tips
REMOVAL OF BATTERY FROM THE VEHICLE
Unlock (turn the key clockwise) and remove
the Left side panel.
Disconnect both the terminal wires (negative
first and positive next respectively)
Remove the battery carrier bracket by
loosening the two screws
Take out the battery.
BATTERY MAINTENANCE
The Motorcycle is provided with 12V - 14 AHbattery.
The battery must be periodically checked for
Cleanliness and corrosion free terminals.
Electrolyte level.
If electrolyte level is low, top up withdistilled water only.
NOTE :
The poor contact or loose fitment of Battery terminals
may cause ECU failure.
Battery Carrier bracket screw
(-) (+)TERMINAL TERMINAL
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62Minor Maintenance Tips
REASSEMBLY OF BATTERY ON MOTORCYCLEPosition the battery in the battery carrier suchthat negative terminal of the battery is towardsthe fuel pump side.
Warning
Always di sc onn ec t the neg ati ve (- ) bat ter y cab le
f irst and then the Red posit ive (+) cable while
removing the battery connections.
NOTE :
For checking the battery voltage and electrolyte
specific gravity, contact authorised Royal Enfield
Dealer / service point or battery service centre.
CAUTION :
Do not use battery with low electrolyte level as
the battery internal cells will get damaged.
Do not overfill the battery electrolyte level as it
will spill out through the overflow pipe and cause
corrosion to vehicle parts.
Use only distilled water meant for use in batteries
to avoid damage to battery.
Smear the terminals with petroleum jelly. (Donot use grease in the battery terminals).
Place the terminal boot / cap properly.
Refit the carrier bracket.
Refit LH side panel & lock it.
Ensure ignition switch isin OFF condition.
Connect the positive
terminal (Red wire) firstConnect the negativeterminal (Black wire) next.
NOTE :Clean the wire terminals free of corrosion and keepthe terminals coated with petroleum jelly.
CAUTION :Keep the +ve and -ve cables firmly conneted to therespective battery terminals. Failure to do so mayresult in damage to the motorcycle electrical system.
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63
CHANGING ELECTRICAL COMPONENTS
HEADLAMP BULB REPLACEMENT
Minor Maintenance Tips
NOTE :
Never touch the bulb with your
fingers. Finger prints will etch
the glass and decrease bulb life.
Loosen the rim
holding screw on
top and take out
the head lampdome.
Disconnect electri-
cal connections.
Thumb push and
remove the bulb
holding clamp
gently.
Remove the bulb.
Position new bulbinside the reflectorsuch that the threeprojections on thebulb align with the sloton the reflector.
Refix the bulb holding
clamp.Connect the Electrical
connections.
Position head lamp doom onto the head lamp
shell and tighten the mounting screw on top.
Always hold the bulb with paper or clean dry clot h
during handling as shown in fig.
X
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64
TAIL LAMP BULB REPLACEMENT
Minor Maintenance Tips
Unlock the batterycover
Remove the seatassembly by pulling
seat lock cable.
Remove the tai l
l ight glass byunscrewing i ts
mounting screw
Replace the bulb 12V 21 / 5W.
A s s e m b l e
back the tail
light in the
r e v e r s e
order ofdismantling
process.
Hold the bulb, press inside and rotate
anticlockwise to remove the tail light bulb from
its holder.
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65
TRAFFICATOR BULB REPLACEMENT
Remove the screw
from the trafficator
housing back side.
Open the Indicator
housing.
Take out the bulb
holder with help of
is screw driver.
Take out the bulb
and replace the
same.
Refi t the holder
fi tt ing i ts lock inproper position.
Minor Maintenance Tips
Fix the rubber gasket
cover.
Assemble back the
indicator housing
cover.
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66Minor Maintenance Tips
FUSEFuse
No .Color
BLADE FUSE USAGE LIST
ApplicationAmps
1 Blue 15A RR Fuse
2 Blue 15A MAIN Fuse
3 Red 10A ECU Fuse
4 Red 10A General i l lumination/Tail/Trafficator
5 Red 10A Head Lamp Fuse
6 Red 10A Instrument Cluster / Horn
7 Blue 15A Spare Fuse
8 Red 10A Spare Fuse
Warning
Electronic Control Unit (ECU) may fail due to loose
electrical connections, loose battery terminals etc.
Hence, it is very important to keep all the Electrical
connections intact.
Warning
While doing Arc welding any where in motorcycle, the batteryterminals and the Electronic Control Unit (ECU) coupler are to becompletely disconnected. Failure to do so m any cause damage tothe Electrical system of the Motorcycle.
Warning
Please get the electrical system of your Motorcycle checkedthoroughly and get the faults corrected immediately afterexperiencing any fuse failure. Not doing this can result in torepeated fuse failures.Usage of fuses other than specified rating will damage the completeelectrical system.
8
7
1
3
2
4
6
5
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67Minor Maintenance Tips
AIR FILTER PAPER ELEMENT
CLEAN AND REFIX : EVERY 3000 KMS
Remove the screw f rom the side cover bottom
side and then take out RH side cover.
Takeout air filter paper element and check
for dirt. Gently tap it as shown in fig and fix it
back.
NOTE :It is adviceable to replace air f ilter paper element once
in 10,000 KMS. In case of vehicle running in dusty /
mud road condition it may be replaced as earlier as
required.
Usage of high pressure compressed air is not
recommended to clean air filter paper element.
Fitment of air filter paper element is reverse order of
removal process.
Remove the air filter
cover screws and
then takeout air filter
box cover.
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68Washing Procedure
PRECAUTIONS
Wash vehicle when the engine is cold.
Cover the silencer tail end and control switches
with suitable plastic bags and tie it firmly to prevent
water entry into them.
Remove ignition key and seal key hole using
adhesive tape.
Do not remove RH side cover (panel) while
washing to avoid water entry into air filter box
assembly.
Use a suitable engine degreaser, available with
your local parts store, to remove dirt or grease
from the engine external parts if required. Follow
the directions in the label carefully before using
the degreaser.
Use low pressure jet of water to clean the entire
vehicle.
Never spray water with great force on head lamp,
Meter/cluster unit, trafficator lights, front and rear
wheel hubs, electrical connections and wires,
control cables, EFI components, sparkplug,
battery,air f illter cover etc.
Use Luke warm water and mild detergent on the
painted components to remove dirt, etc.
Rinse vehicle thoroughly with plain water to
remove the detergent and wipe vehicle dry.
If possible, use compressed air and blow off
water particles from the obscure areas of
the vehicle, electrical connections, EFI
components etc.
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69
Warning
Observe warnings and cautions given on labels of
cleaning compounds before it is used.
When washing your motorcycle, be careful not to get
the brakes, engine, mufflers or air cleaner etc., too
wet. Wet brake pad and / or disc can affect braking
efficiency. Engine can be started after washing.Ensure brakes and engine are working properly before
riding in the traffic and / or in highways at high speeds.
AFTER WASHING
Ensure the vehicle is thoroughly dry by wiping
with a clean soft water absorbent cloth or
chamois leather.
Remove all plastic bags and adhesive tapes.
Lubricate control cables, pivots f or footrest, side
stand, centre stand, brake and gear shifter
linkages, rear chain etc.with lube oil.
Polish the painted and plated surfaces using
polishing wax.
Start the bike and allow engine to idle & warm up.
Drive the motorcycle slowly, applying both brakes
intermittently to dry up the brake pads.
Test brakes for full efficiency.
Washing Procedure
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70Storage Precautions
Incase your Motorcycle is not going to be used for
a month or more, we advise the fol lowing
precautions to be taken
Carryout required repair/adjustments on the
motorcycle.
Wash the motorcycle thoroughly and lubricate
as per the maintenance chart.Start the engine, warm up for a few minutes
and switch off.
Drain out the fuel completely from the fuel tank
and fuel lines.
Remove the spark plug. Pour in about 20ml of
clean engine oil through spark plug hole. Close
the hole and crank engine few times and refit
the sparkplug.
Clean the rear chain thoroughly and apply
lubrication oil on it.
Remove battery from the bike. Clean i ts
terminals and apply petroleum jelly on the
terminals to avoid corrosion.
Maintain electrolyte level between max and
min marks, by adding distilled water and wipe
the battery dry.
Store the battery in a cool, dry and well
ventilated place.Do not place the battery in direct sun light, near
open flame or where temperature is above
40C or below 0C
Cover the silencer with plastic bags to prevent
moisture entry. Set the motorcycle on its center
stand.
Apply anti rust solution on all chrome plated
parts. Take care not to apply this solution on
rubber or painted parts.
Store motorcycle in a clean covered area free
of moisture and keep it covered to prevent dust
settling on it.
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71
PREPARING THE MOTORCYCLE FOR REUSE
Remove anti rust solution from all chrome
plated parts and clean the motorcycle.
Inflate the tyres to the correct tyre pressure.
Ensure battery is fully charged and electrolyte
level is properly maintained.
Connect the battery.
Lubricate all control cables and pivots.
Check level of oil in engine and top up if
necessary.
Fill fuel tank with fresh petrol.
Check fuel line for any cracks or cuts.
Clean the air filter.
Remove plastic covering from the silencer.
Remove spark plug on cylinder head and pour
in a few drops of engine oil. Crank engine a
few times to lubricate cylinder walls and piston.
Clean spark plug and refit.
Switch ON the ignition switch.
Start vehicle and warm up engine for a few
minutes before riding the vehicle.
NOTE :
Do not raise the engine rpm the moment it is started,
but allow the engine to run at Idling speed.
CAUTION :
Proper long-term storage is important for the safe,
trouble-free operat ion of your Royal Enf ield
motorcycle.
Storage Precautions
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72
CHECKS PRIOR TO THE COMMENCEMENT OF LONG
JOURNEY
Service the motorcycle thoroughly at Royal
Enfield Authorised Dealer / Service Point as per
periodical maintenance chart. (Ref. Page No. 45
to 47)
Sufficient quantity of petrol in the fuel tank forthe planned journey.
Check and correct tyre pressure if necessary.
Correct the oil levels in Engine, brake master
cylinders.
Check for good battery condition and proper
electro lyte level.
Proper drive chain tension and correctly
adjusted rear brakes.
Check for proper f unctioning of all lights & horn
etc.,
CHECKS AFTER EVERY 1500 KMS OF RUN
Tightness of all fasteners.
Tyre treads condition and wear pattern of tyres.
Battery condition and electrolyte level.
Correct oil level in engine.
Working of all lights and horn.
Proper drive chain tension.
ITEMS TO BE CARRIED
Tool kit.
First aid kit.
Bulbs for Headlight, Trafficator light and mini
Blade Fuses (15 & 10 Amps).
Accelerator and Clutch cable.
Rear chain master link lock assembly.
Spare tubes.
Foot operated Air Pump.
Insulation tape.
Spark plug (M14).
Long Trip Precautions
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73Complete Wiring Diagram
NOTE :
Complete Wiring Diagram is attached on this page.
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74Trouble Shooting
Warning
The trouble shooting section of this Owners Manualis intended solely as a guide for diagnosing problems.Carefully read the appropriate sections of this manual
before performing any work. Repair and maintenanceoperations not listed in this Owners Manual shouldbe performed by your Royal Enfield Dealer only.Improper repair / maintenance could result in the
motorcycle not functioning properly or injury seriously.
I. ENGINE FAILS TO START
1) Stop swi tch in OFF Posit ion ... .. .. .. .. .. Push stop switch to ON posit ion.
2) Vent hole c logged in fuel tank cap .... Clean vent hole.
3) Spar k plug cap / lead not connec ted . Fix c ap / lead f ir mly
4) Spar k plug elec trode dir ty / fouled .... Clean s par k plug
5) Spark p lug insu lat ion c racked .. .. .. .. ... Replace spark plug
6) Clutch slipp ing.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . *Adjust c lutch cable f ree p lay
7) Main or EFI Fuse fai led.. .. .. .. .. .. .. .. .. . . . Replace with new fuse
CAUSES REMEDIES
* Contact Authorised Dealer / Service Point
Warning
Please get the electrical system of your Motorcycle
checked throughtly and get the faults corrected
immediatly after experiencing any fuse failure. Not
doing this can result in to repeted fuse failures.
Usage of fuses other than spcified rating will damage
the complete electrical system.
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75Trouble Shooting
II. ENGINE MISFIRING
1) Loose spark plug cap........................ Fix cap / lead firmly
2) Spark plug fouled .............................. Clean spark plug or non specified heat range plug.
3) Any sensor loose connections......... * Check MAP or EOT or TPS sensor wiring / coupler loose connections
4) Water in petrol tank ........................... * Clean petrol tank. Fill tank with fresh petrol.
III. POOR PICKUP
1) Brake pedal ad justed too t ight . .. .. .. . *Re-adjust proper ly
2) Choked air f il ter ............................... Clean / Replace air f il ter
3) Rear chain ad justed too tight. . .. .. .. .. *Re-adjust proper ly
4) Under inflated tyres ......................... *Inflate to correct pressure
5) Accelerator cable free play excessive Adjust cable free play
6) Clutch Sl ipping................................. *Adjust clutch cable free play
7) Faulty fuel supply............................. *Remove fuel pump & clean.
Fuel pump, filter / injector blocked
CAUSES REMEDIES
* Contact Authorised Dealer / Service Point
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76Trouble Shooting
IV. WHITE/BLUE SMOKE
1) Oil level in sump above the Top line. * Check and drain excess oil
in the oil level window .....................
V. ENGINE OVERHEATING1) Low engine oi l level ......................... Check and top-up i f necessary
2) Clutch slipping ................................. * Check and correct
3) Cylinder fins not clean..................... Clean the cylinder fins at regular intervals
VI. EXCESSIVE FUEL CONSUMPTION
1) Under inflated tyres ......................... Inflate to correct pressure
2) Choked air fi lter ............................... Clean / Replace
3) Fuel leakage..................................... *Check and rectify, tank float unit, drain pipe, breather pipe,
.......................................................... fuel line / pump.
CAUSES REMEDIES
* Contact Authorised Dealer / Service Point
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77Trouble Shooting
VII. BRAKES POOR
1) Brake pad worn / Uneven wear. . .. .. . *Replace Brake pads
2) Oil /grease on disc............................ *Clean and refit
3) spongy brake.................................... *fil l brake fluid & remove air from the system.
VIII. VEHICLE WOBBLES1) Under inflated tyres ......................... Inflate to correct pressure
2) Loose / Broken spokes.................... * Tighten / Replace spokes
3) Wheels misal igned .......................... * Ensure proper al ignment
4) Wheel r im runout . .. .. .. .. .. .. .. .. .. .. .. .. .. .. * Recti fy
5) Tyres not fitted correctly.................. * Refi t tyres correctly
IX. ELECTRICALS
Bulbs do not glow
1) Bulb fused ........................................ * Replace bulb
CAUSES REMEDIES
* Contact Authorised Dealer / Service Point
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78
2) Fuse blown....................................... * Check and Replace fuse.
3) Loose / improper connect ion... .. .. .. .. * Check and correct
Horn not working
1) Fuse blown....................................... Check and correct
2) Loose connections........................... Check and correct
Trafficators not working
1) Loose / improper connect ions... .. .. .. Check and correct
2) Bulb fused ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . Replace
Brake light remains on
(1) Switch not adjusted properly.......... * Adjust connecting links properly
(2) Switch sticky .................................... * Replace switch
X. ELECTRONIC FUEL INJECTION (EFI)
Malfunctioning Indicator Lamp (MIL) glowing continuously
(1) Sensor Coupler Loose Connection . * Check for any EFI sensor coupler loose connection and correct them
(2) Any EFI Sensor Failure ...................... * Check & replace the same
Trouble Shooting
CAUSES REMEDIES
* Contact Authorised De