uk bullet efi 02

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BULLET ELECTRA - EFI

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Page 1: Uk Bullet Efi 02

BU

LL

ET

EL

EC

TR

A -

EF

I

Page 2: Uk Bullet Efi 02

BU

LL

ET

EL

EC

TR

A E

FI S

ervi

ceP

reca

uti

on

s

Page 3: Uk Bullet Efi 02

EN

GIN

E S

PE

CIF

ICA

TIO

NS

MA

KE

:M

OD

EL

:

Type

4 S

troke

DE

TA

ILS

RO

YA

L E

NF

IEL

DU

CE

-500

E.F

.IE

NG

INE

:

84S

troke

Len

gth

(mm

)90

Eng

. Dis

plac

emen

t (C

C)

499

Bor

e D

ia. (

mm

)

Com

p. R

atio

8.5

:1E

ngin

e co

olin

gN

atur

al A

ir D

raft

Eng

ine

Alig

nmen

t V

ertic

alV

alve

trai

nO

HV

, PU

SH

RO

D a

ctua

ted

No.

of v

alve

s/cy

l. 2

No.

of c

ylin

ders

1Id

le s

peed

(rpm

) 10

00±1

00Ig

n. T

imin

g (D

eg. B

TDC

)5º

Sta

ticE

ngin

e Lu

bric

atin

g oi

l gra

de15

W50

AP

I SL

Gra

deE

ngin

e oi

l qua

ntity

(Lite

rs)

2.75

Spa

rk p

lug

Gra

deB

OS

CH

SU

PE

R W

R3C

CS

park

plu

g E

lect

rode

air

gap

(mm

) 0.

7

Page 4: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

CH

ASI

S SP

EC

IFIC

AT

ION

S

Fro

ntRe

ar

Fron

t- So

lo

Fron

t- W

ith P

illion

Re

ar- S

olo

Rear

- With

Pilli

on

CH

ASSI

S:TY

PE

Tubu

lar f

ram

e, E

ngin

e as

stre

ssed

mem

ber

Tyre

size

(W X

DIA

)"90

/90

100/

90

Tyre

Air

pres

sure

(Psi

)

18 20 28 30VE

HIC

LE:

MO

TOR

CYC

LE- C

RUIS

ERFu

el ta

nk c

apac

ity (L

iters

) 14

.5 ±

1.0

Kerb

Wt (

kgs)

18

0G

ross

Wt (

kgs)

365

Leng

th (m

m)

2200

Wid

th (m

m)

790

Heig

ht (m

m)

1100

Whe

el b

ase

(mm

) 13

70Sa

ddle

hei

ght (

mm

)82

0G

roun

d cle

aran

ce (m

m)

140

Page 5: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

EL

EC

TR

ICA

L S

PE

CIF

ICA

TIO

NS

For

Bat

tery

R

R u

nit

EC

U

FU

SE

ratti

ng15

A15

A15

A

Low

fuel

Indi

cato

r 1.

7 W

Alte

rnat

or c

apac

ity

220

Wat

ts a

t 500

0 rp

m

Sta

rter M

otor

0.

9 K

WM

al-fu

nctio

n In

dica

tor (

M.I.

L)

3.4

W

Neu

tral I

ndic

ator

12

V, 2

W- 1

no.

Hor

n 12

V, 2

.5 A

mp

(Max

.)

Hig

h be

am in

dica

tor

12V

, 2 W

- 1 n

o.Tu

rn s

igna

l 12

V, 1

0 W

- 2+2

nos

.

Spe

edom

eter

lam

p 12

V, 3

.4W

- 1 n

o.Tu

rn s

igna

l 12

V, 2

W- 1

no.

Tail

/ Bra

ke la

mp

12V

, 5/2

1 W

Pilo

t lam

p 12

V, 2

W- 3

nos

.

Bat

ter c

apac

ity

12V

, 14A

HH

ead

Lam

p 12

V, 6

0/55

W

ELE

CTR

ICA

L S

YSTE

M:

Sys

tem

spe

c.

12V

, DC

Page 6: Uk Bullet Efi 02

UN

IT C

ON

STR

UC

TIO

N E

NG

INE

– 5

00 c

c -

EF

I

Vie

w I

Page 7: Uk Bullet Efi 02

Vie

w I

I

Page 8: Uk Bullet Efi 02

ARC

HIT

ECTU

RE U

CE 5

00 E

FI E

NG

INE

(AS

COM

PARE

D T

O E

XIST

ING

LB

500)

#D

ES

CR

IPT

ION

LB

500

cc

EN

GIN

EU

CE

500

cc

EN

GIN

E1

Con

figur

atio

nE

ngin

e, g

ear

box

and

clut

ch a

re s

epar

ate

com

part

men

t.

Eng

ine,

gea

r bo

x an

d cl

utch

are

bei

ng

mad

e as

inte

gral

co

nstr

uctio

n.2

Oil

Sum

p sy

stem

Dry

sum

p lu

bric

atio

n sy

stem

Wet

su

mp

lu

bri

cati

on

sys

tem

Page 9: Uk Bullet Efi 02

3O

il pu

mp

Des

ign

Gea

r pu

mp

desi

gn.

Oil

flow

rat

e is

2.4

2 L/

mt

@ 5

500

engi

ne r

pm.

Ger

oto

r -

rota

ry

typ

e oi

l pum

p.

Flo

w

rate

: 9

.5 L

/ m

t @

55

00 e

ngin

e rp

m.

It

prov

ides

bet

ter

oil

flow

and

coo

ling

to

the

engi

ne.

4C

ombu

stio

n ch

ambe

r an

d po

rt d

esig

n

Wed

ge t

ype

com

bust

ion

cham

ber

with

hig

h tu

rbul

ence

.

Wed

ge t

ype

com

bust

ion

cham

ber

with

hig

h tu

rbul

ence

.

Page 10: Uk Bullet Efi 02

5P

isto

n d

esi

gn

So

lid s

kirt

pis

ton

with

fla

t cr

ow

n m

ade

up

of

hig

h

silic

on a

lum

Allo

y.

So

lid s

kirt

pis

ton

with

bo

wle

d

crow

n m

ade

up

of

hig

h s

ilico

n a

lum

Allo

y fo

r b

ett

er

com

bu

stio

n

6C

ylin

der

barr

elC

ylin

der

barr

el i

s m

ade

u

p o

f A

lum

iniu

m w

ith

cast

iron

lin

er

Cyl

ind

er

ba

rrel

is m

ade

up

of

Alu

min

ium

with

cas

t ir

on

line

r

7P

isto

n r

ing

pa

ckM

odu

lar,

ro

bus

t, t

hick

pis

ton r

ing p

ack

to

co

ntr

ol o

il co

nsu

mp

tion

Mod

ula

r, F

lexi

ble

th

in p

isto

n r

ing

p

ack

to

red

uce

frict

ion

an

d b

low

b

y th

ere

by

be

tte

r p

erf

orm

anc

e

Page 11: Uk Bullet Efi 02

8T

appe

t T

he t

appe

t is

sur

sulf

coat

ed a

fter

heat

tr

eatm

ent.

Hyd

raul

ic t

appe

t is

use

d.

It h

elps

to

mai

ntai

n ze

ro

clea

ranc

e of

pus

hrod

at

all e

ngin

e op

erat

ing

cond

ition

s en

ablin

g un

iform

val

ve t

imin

g

9ca

m g

ear

- in

let

Cam

gea

r ge

ts

asse

mbl

ed in

ecc

entr

ic

slee

ve w

ith

spin

dle

assy

. It

is t

o ad

just

the

ce

ntre

dis

tanc

e an

d he

nce

back

lash

get

s ad

just

ed.

An

ti b

ack

lash

gea

r sy

stem

is u

sed

to

arre

st

the

back

lash

bet

wee

n in

let

and

exha

ust

cam

ge

ars.

Page 12: Uk Bullet Efi 02

10E

ngin

e br

eath

ing

syst

em

Hig

her

engi

ne

cran

kcas

e pr

essu

re

and

henc

e se

para

te

brea

ther

box

is

prov

ided

to

colle

ct t

he

brea

ther

oil

Less

er c

rank

case

br

eath

er p

ress

ure

due

to

inte

grat

ion

of e

ngin

e w

ith

gear

box

and

clu

tch

com

part

men

t. O

il de

flect

or a

rran

gem

ent

has

been

pro

vide

d in

side

th

e en

gine

cov

er t

o pr

even

t oi

l mis

t co

min

g ou

t.

Page 13: Uk Bullet Efi 02

11

De

com

pre

sso

r d

esig

nA

ctu

ate

d t

hro

ug

h v

alv

e

train

lea

ds t

o

me

cha

nic

al lo

sse

s a

nd

hen

ce in

feri

or

fun

ction

ing

Auto

de

com

pre

ssor

de

sig

n a

ctivate

at

250

rp

m a

nd w

ill g

et

fully

de

activate

d a

t 35

0 r

pm

12

Prim

ary

cha

in

adju

ste

rM

ech

an

ical ty

pe c

hain

te

nsio

ne

r is

used

to

adju

st

the

pri

mary

ch

ain

.

Auto

cha

in t

ensio

ne

r

(

Ra

ck t

ype )

is u

sed

Page 14: Uk Bullet Efi 02

OIL

PO

UR

ING

ON

EN

GIN

E

OIL

FIL

LE

R C

AP

ON

RH

CO

VE

R

QT

Y O

F O

IL :

2.5

5 L

OIL

FIL

LE

R C

AP

ON

LH

CO

VE

R

QT

Y O

F O

IL :

0.2

L

EN

GIN

E O

IL Q

TY

: 2.

75 L

Page 15: Uk Bullet Efi 02

OIL

DR

AIN

PL

UG

WIT

HIN

BU

ILD

MA

GN

ET

OIL

DR

AIN

ING

Page 16: Uk Bullet Efi 02

OIL

LE

VE

L W

IND

OW

Pla

ce m

otor

cycl

e on

its

cent

er s

tand

on

a fi

rm s

urfa

ce.

War

m u

p en

gine

for

2-3

min

utes

& s

wit

ch o

ff b

efor

e ch

ecki

ng o

il le

vel.

The

leve

l is

corr

ecte

d if

the

oil l

evel

is in

the

mid

dle

of th

e oi

l lev

el w

indo

w.

Top

up

wit

h oi

l if

requ

ired

.

Page 17: Uk Bullet Efi 02

EFI

BLO

CK

DIA

GR

AM

Page 18: Uk Bullet Efi 02

The

mai

n s

yste

m in E

FI

is t

he

com

pute

rca

lled E

CU

(Engin

e Contr

ol U

nit).

This

monitors

engin

e oper

atin

g p

aram

eter

s by

taki

ng v

arious

inputs

lik

e en

gin

e sp

eed,

engin

e te

mp,

thro

ttle

posi

tion,

man

ifold

air

pre

ssure

, ex

hau

st o

xygen

fee

d b

ack

from

res

pec

tive

sen

sors

. Bas

ed o

n t

he

input

dat

a,

the

ECU

calc

ula

tes

the

idea

lam

ount

of

fuel

to b

e in

ject

ed t

o o

ptim

ize

the

air-

fuel

rat

io a

nd a

lso t

he

ignitio

ntim

ing f

or

the

spar

k plu

g.

FUN

CTI

ON

:

Page 19: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

INST

RU

CTI

ON

S (D

O’ ’’’S

& D

ON’ ’’’T

S)

•Ful

ly C

harg

ed B

atte

ry s

houl

d be

con

nect

ed

•Kee

p th

e ve

hicl

e on

cen

ter

stan

d or

rem

ove

the

stan

d an

d th

en s

tart

the

eng

ine

(NO

TE:

engi

ne w

ill s

witc

h O

FF if

par

ked

on s

ide

stan

d).

•Sw

itch

on t

he ig

nitio

n ke

y an

d w

ait

(for

app

. 3Se

c) u

ntil

the

MIL

(M

ALFU

NCT

ION

IN

DIC

ATO

RLA

MP)

glo

ws

off, t

hen

star

t th

e En

gine

. If

MIL

stil

lgl

ows

cont

act

the

deal

er.

Page 20: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

•Don

't re

mov

e an

y of

the

sen

sor

conn

ectio

ns o

rco

uple

rs

•Don

't to

uch

the

exha

ust

bend

, O2

sens

or a

ndsi

lenc

er w

ith b

are

hand

whe

n th

e en

gine

isru

nnin

g or

just

sw

itche

d of

f(N

OTE

: Ca

taly

tic C

onve

rter

pre

sent

insi

de, t

heex

haus

t sy

stem

will

be

very

hot

).

•Don

't re

mov

e th

e fu

el h

ose

(hig

h pr

essu

re)

from

the

fuel

pum

p to

fue

l inj

ecto

r, w

hile

rem

ove

prop

er c

are

shou

ld b

e ta

ken.

Page 21: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

PR

OB

LEM

MIL

BLI

NK

ING

CO

NTI

NU

OU

SLY

REM

EDY

:Ch

eck

for

all t

he s

enso

r co

nnec

tions

plu

gged

inpr

oper

ly a

nd t

hen

rese

t th

e sy

stem

by

the

follo

win

gpr

oced

ure

Switc

h on

bot

h th

e ig

nitio

n ke

y an

d ki

ll sw

itch

wai

t, f

or 1

0 se

c th

en c

ompl

etel

y op

en t

he t

hrot

tle f

or10

sec

, the

n re

leas

e th

e th

rott

le, a

fter

5 s

ec m

il w

illbl

ink

cont

inuo

usly

for

tw

ice,

res

et c

ompl

etes

. The

nsw

itch

off

the

igni

tion

and

switc

h th

e ig

nitio

n ke

yw

ait

for

3 se

c th

en s

tart

the

eng

ine.

(no

te d

urin

gre

set

proc

edur

e th

e en

gine

sho

uld

not

be s

tart

ed,

only

the

ign.

Key

and

kill

sw

itch

is t

o be

tur

ned

on.)

Page 22: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

ENG

INE

NO

T ST

AR

TIN

G:

Chec

k fo

r th

e si

de p

arki

ng s

tand

is o

n, if

so

rem

ove

the

side

par

king

sta

nd a

nd a

lso

chec

k fo

rth

e se

nsor

con

nect

ions

plu

gged

in p

rope

rly,

then

rese

t th

e sy

stem

by

the

abov

e p

roce

dure

Page 23: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

•Be

fore

att

empt

ing

to r

emov

e an

y pa

rt,

turn

the

igni

tion

switc

h “O

FF”

and

disc

onne

ct t

he b

atte

rygr

ound

cab

le.

•Al

way

s us

e a

12 v

olt

batt

ery

as a

pow

er s

ourc

e,ne

ver

use

a bo

oste

r or

hi

gh

volta

ge

char

ging

unit.

•D

o no

t di

scon

nect

the

bat

tery

cab

les

whe

n th

een

gine

is r

unni

ng.

•D

o no

t un

-plu

g an

y w

iring

con

nect

ors

with

the

engi

ne

runn

ing

or

the

igni

tion

“ON

” un

less

spec

ifica

lly in

stru

cted

to

do s

o.

GEN

ER

AL I

NS

TR

UC

TIO

NS

:

Page 24: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

•Ke

ep o

pen

flam

e ou

t of

wor

ksho

p ar

ea.

• U

se a

sho

p to

wel

to

hold

fue

l w

hen

open

ing

the

fuel

sys

tem

.

•Al

way

s ke

ep f

ire e

xtin

guis

her

in t

he w

orks

hop.

Alw

ays

use

eye

or

full

face

pr

otec

tion

whe

nw

orki

ng a

roun

d fu

el li

nes.

•D

o no

t re

v-up

th

e en

gine

im

med

iate

ly

afte

rst

artin

g or

just

prio

r to

shu

t do

wn.

•Ke

ep a

ll EC

U p

arts

and

har

ness

dry

dur

ing

serv

ice.

Prot

ect

the

ECU

an

d its

re

late

d so

lid-s

tate

com

pone

nts

from

ro

ugh

hand

ling

or

extr

eme

tem

pera

ture

.

Page 25: Uk Bullet Efi 02

LOCATIO

N O

F E

FI C

OM

PON

EN

TS

IN

TH

E V

EH

ICLE

Page 26: Uk Bullet Efi 02

EL

EC

TR

ON

IC C

ON

TR

OL

UN

IT

ELEC

TRO

NIC

CO

NTR

OL

UN

IT

Page 27: Uk Bullet Efi 02

FUEL

SY

STE

M

FU

EL

PU

MP

MO

DU

LE

LO

W L

EV

EL

SE

NSO

R

Page 28: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

INL

ET

MA

NIF

OL

D A

SSE

MB

LY

FU

EL

IN

JEC

TO

R

INL

ET

MA

NIF

OL

D

Page 29: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

TH

RO

TT

LE

BO

DY

ASS

EM

BL

Y

TH

RO

TT

LE

BO

DY

Page 30: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

EX

HA

UST

SY

STE

ML

AM

BD

A (

O2)

SE

NSO

R &

CA

TA

LY

TIC

CO

NV

ER

TO

R

CA

TA

LY

TIC

CO

NV

ER

TO

RL

AM

BD

A S

EN

SOR

Page 31: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

WA

RN

ING

SY

STEM

IN

DIC

ATO

R

SPE

ED

OM

ET

ER

LO

W F

UE

L W

AR

NIN

GM

AL

FU

NC

TIO

NW

AR

NIN

G

Page 32: Uk Bullet Efi 02

Gen

eral

Ser

vice

Pre

cau

tio

ns

IGN

ITIO

N K

EY

KIL

L S

WIT

CH

IG K

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