Owners Manual Continental GT

1Foreword

The Royal Enfield Continental GT is our lightest, fastest, and most powerful motorcycle in production. It’s a machinewith a story, a nod to motorcycling’s finest hour, the best expression yet of a cultural phenomenon that has simplyrefused 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 therenowned Harris Performance from UK. A new engine displaces 535cc and dollops of torque, when you need it. Withgas-charged rear shock absorbers from Paoli and Brembo disc brakes, you stay in charge. With an aerodynamicseating position, Pirelli Sports Demon tyres and a remapped ECU, the new Continental GT is part homage, partengineering tour-de-force.

This manual will help you to operate your motorcycle and guide you to wholly maintain it. We have also provided tipson safe riding and on minor adjustments for the care of your motorcycle. Please avail the four free services at thenearest Authorised Service Point at the appropriate time to maintain your motorcycle in top riding condition. Werequest you to carefully read the terms and conditions of warranty and other useful information given in this manualbefore starting to use your Continental GT. Log on to the exciting world of Royal Enfield on www.royalenfield.com toget 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.

2

All information in this manual is based on the latest product information available at the time of publication. Due tocontinuous improvements or other changes, there may be discrepancies between information in this manual and yourvehicle. Royal Enfield reserves the right to make production changes at any time without prior notice and withoutincurring 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. Technicalspecifications 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 with

an inner tube. Failure to use an inner tube in a spoked wheel will

cause deflat ion of the tyre result ing in l oss ofmotorcycle control.

The approved tyres marked with “TUBELESS” aresuitable for use with inner tube.

3

PERSONAL & VEHICLE INFORMATION ....... 6FREE SERVICE RECORD ........................... 7SAFETY DEFINITIONS ............................ 8TECHNICAL SPECIFICATIONS .................... 9

Engine ................................................ 9Ignition System ................................... 10Transmission ...................................... 10Electricals ........................................... 11Chassis .............................................. 12Dimensions ......................................... 13Weights .............................................. 13

SAFE RIDING TIPS/GUIDELINES ................ 14SAFE & HAPPY RIDING ............................ 18RULES OF THE ROAD ............................... 19VEHICLE IDENTI. NUMBER-DETAILS .......... 21KEY PARTS LOCATION ............................. 22

Right Side View .................................. 22

Left Side View.................................... 23Top View ............................................ 24

OPERATION OF CONTROLS ................... 25Ignition Switch .................................... 25Steering Lock ..................................... 26Steering Unlock .................................. 26Fuel Tank Cap...................................... 27Side Panel LH / Battery Cover ............ 27Utility Box .......................................... 27Side PANEL RH ................................. 27Alpha-Numeric display unit.................. 28Head Lamp Switch............................... 30Head Lamp Day Flash.......................... 30Dip Switch ......................................... 30Engine Start Switch ............................ 31Engine Stop Switch ............................ 31Turn Signal Switch ............................. 31Horn .................................................. 32

Contents

4Contents

Manual Bi Starter (choke) ................... 32PRE OPERATIONAL CHECKS .................... 33RUNNING IN PERIOD.................................. 34ELECTRONIC FUEL INJECTION (EFI) ......... 35

EFI .................................................... 35The Advantages of EFI ....................... 35Malfunction Indicator Lamp (MIL) ......... 35

ROLL OVER SENSOR ............................... 36STARTING ................................................ 37GEAR SHIFTING ....................................... 40PARKING .................................................. 41

Center Stand ...................................... 41Side Stand ......................................... 41

TOOLS & FIRST AID KIT............................... 42RECOMMENDED LUBRICANTS ................... 43PERIODICAL MAINTENANCE ..................... 44MINOR MAINTENANCE TIPS ...................... 48

Control Cables, Hand lever,Center / Side Stand Pivots .................. 48Oil Level Inspection ............................ 48Engine oil change ............................... 49Spark Plug ......................................... 50Brake fluid (Front & Rear) ................... 51Inspection of tyres and wheels .......... 51Tyre pressure..................................... 52Front W heel removal .......................... 52Front Wheel reassembly ..................... 53Rear wheel removal ........................... 54Rear wheel reassembly...................... 55Adjustments-Clutch lever free play .... 57Rear brake light switch adjustment...... 57Drive Chain free play .......................... 58Chain lock fitment ............................... 59Adj. of gas filled shockabsorber ......... 60Removal of Battery from the Vehicle..... 61

5Contents

Battery Maintenance........................... 61Reassembly of Battery on Vehicle ...... 62

CHANGING ELECTRICAL COMPONENTS.... 64Head Lamp Bulb Replacement ............ 64Tail Lamp bulb Replacement ................ 65Trafficator bulb Replacement .............. 65Fuse .................................................. 66Blade fuse usage list .......................... 66Air Filter Paper element......................... 67

WASHING PROCEDURE............................. 68Precautions ........................................ 68Af ter washing..................................... 68

STORAGE PRECAUTION ........................... 70Preparing the motorcycle for re-use ... 71

LONG TRIP PRECAUTIONS ....................... 72COMPLETE WIRING DIAGRAM (Domestic) . 73TROUBLE SHOOTING ............................... 74

Engine fails to start ............................ 74Engine misfiring ................................. 75Poor pickup ....................................... 75White / Blue smoke ............................ 76Engine overheating ............................ 76Excessive fuel consumption................ 76Brakes Poor ........................................ 77Vehicle wobbles.................................. 77Electricals .......................................... 77Electronic Fuel Injection (EFI) .............. 78

WARRANTY ............................................. 79EMISSION WARRANTY.............................. 81FREE SERVICE COUPONS ......................... 86PAID SERVICE/MAINTENANCE RECORD ..... 95ALL INDIA ROAD SIGNS ........................... 103LOG BOOK ............................................... 104NOTES .................................................... 108

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

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 ServiceKms CoveredServicing ASP /Dealer’s NameAddress

1st Service 4th Service2nd Service 3rd Service

Dealer / ASPRubber Stamp




Free Service Record

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The information given under the titles: Warning, Caution and Note are for your safety and for the care and safety toyour motorcycle and others. Please read these carefully and if disregarded it may result in injury to yourself or othersand 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

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)

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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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

WARNINGUsing bulbs / other e lec tr ical

gadgets other than specified rating maylead 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

12

CHASSIS

Frame ....................................................... Tubular steel double cradleTyre size .................................................. Front: 100/90-18 M/C 56H

.......................................................... Rear: 130/70-18 M/C 63HTyre 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 mmFront fork oil capacity .............................. 430 ml per legFront fork oil ............................................. Gabriel Fork Oil 2W 35Hydraulic Brakes ...................................... Front: 300 mm dia floating disc, twin piston floating caliper

.......................................................... Rear: 240 mm dia disc, single piston floating caliperBrake oil grade ......................................... DOT 3 or DOT 4Brake oil capacity ..................................... Front: 50 ml

.......................................................... Rear: 100 ml


Note:

***Fuel tank capacity givenhere is approximate. It canvary marginally from thisspecified value.

13

DIMENSIONS

Length ...................................................... 2060 mm

Width ........................................................ 760 mm

Height ....................................................... 1070 mm

Wheel base .............................................. 1360 mm

Saddle height ........................................... 800 mm

Ground clearance .................................... 140 mm

WEIGHTSKerb 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.


NOTE: BS IIIThis vehicle meets Emission Norms -Bharat (Trem) Stage - III

14Safe Riding Tips / Guidelines

Before operat ing your new motorcycle, werequest you to carefully read and follow theoperating and maintenance instructions detailedin this manual for the safety of your own, yourmotorcycle, and also that of others.

Know and respect the rules of the road. Pleasebe a safe rider for your own safety and for othersin road.

Before starting the motorcycle, check for properoperation of brakes, clutch, gear shifter, handlebar controls, tyre pressures, fuel and oil levels.

Use only genuine Royal Enfield spare parts andapproved accessor ies. Use of othermanufacturer ’s performance parts may affectthe performance of your motorcycle and renderthe motorcycle void of warranty. See your RoyalEnfield dealer for details.

Whenever refuelling your motorcycle, pleaseexercise utmost caution and carefully observethe following rules.

DO NOT smoke and please ensure thatthere are no open flames or sparks near themotorcycle, when refuelling OR servicingthe fuel system.

Switch OFF mobile phones and other handheld 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 fueltank 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 mayadversely affect performance and handling. Removingor altering or iginal parts may adversely affectperformance and could result in to an accident.


A new motorcycle must be operated accordingto the spec ial running- in-procedure. Seerunning-in-procedure mentioned in Page No. 34.

Operate motorcycle only at moderate speeds andout of traffic until you have become thoroughlyfamil iar with it s operat ion and handl ingcharacteristics under all conditions.

DO NOT exceed the legal speed limit or drive toofast for existing conditions. Always reduce speedwhen poor driving conditions exist. High speedincreases the influence of any other conditionaffecting stability and increases the possibility ofloss of control.

NOTE :If you are an inexperienced rider we recommend thatyou obtain formal training on correct motorcycle ridingtechniques and become thoroughly familiar with theoperation of your particular motorcycle. New ridersshould gain experience under various conditions whiledriving at moderate speeds.

Pay strict attention to road surfaces and windconditions. Any two wheeled vehicle may be subjectto the following upsetting forces:

Wind blasts from passing trucks.

Rough uneven road surfaces.

Slippery road surfaces.

These forces may affec t the handlingcharacteristics of your motorcycle. If this happens,reduce speed and guide the motorcycle relaxed toa controlled condition. Do not brake abruptly.

Operate your motorcycle defensively.Remember that, a motorcycle does not affordthe same protection as an automobile in anaccident. One of the most common accidentsituations occurs when the driver of the othervehicle fails to see or recognize a motorcycleand turns into the oncoming motorcyclist.


Wear an approved helmet, clothing, and footgear suited for riding a motorcycle. Bright ORlight colours are best for greater visibility intraffic, specially at night. Avoid loose, flowinggarments and scarves.

W hen carrying a p il lion r ider, i t is yourresponsibility to instruct them on proper ridingprocedures.

DO NOT allow other individuals, under anycircumstances, to operate your motorcycleunless you know they are experienced, licensedriders and are thoroughly familiar with theoperating conditions of your motorcycle.

Warning

Regularly inspect shock absorbers and front forksand look for leaks. Replace worn out parts. Wornout parts can adversely affect stability and handling.

Warning

For your personal welfare, all the listed service andmaintenance recommendations should beperformed. Lack of regular maintenance at thesuggested intervals may affect the safe operationof your motorcycle.

Warning

Avoid any contact with the exhaust system. Wearclothing that will completely cover the legs whileriding. The exhaust system gets very hot when theengine is running and remains too hot, even after theengine is turned off. Failure to wear proper or protectiveclothing could result in serious injury.

Warning

Exhaust gases contains poisonous carbonmonoxide and chemicals, known to cause Cancer,Birth defects or other reproductive defects.


Warning

Motorcycle bat ter ies contain lead and leadcomponents, acids and chemicals known to causecancer, birth defects or other reproductive harm.Exercise extreme caution while handling a battery.Wash hands thoroughly whenever a battery ishandled.

Warning

Consult your Royal Enfield Dealer regarding anyquestions or problems that occur in the operationof your motorcycle. Failure to do so may aggravatean initial problem, cause costly repairs & jeopardizeyour personal safety.

Warning

DO NOT tow a disabled motorcycle. The steeringand handling of the disabled motorcycle will beimpaired due to the force of the towline. If a disabledmotorcycle must be transported, use a truck or atrailer. Towing a motorcycle may cause loss ofcontrol of the motorcycle in the front, leading to anaccident.

Warning

DO NOT pull a trailer behind a motorcycle. Towinga trailer may cause reduced braking efficiency, tyreoverloading and unstable handling. Towing a trailermay cause loss of control of the motorcycle in thefront, leading to an accident.

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 with light reflectingstrips of radium stickers at the front and rear.

NOTE :A light coloured shirt enables greater visibility to otherroad users specially during nights.

CAUTION :Loose clothing may get caught on moving parts ofyour motorcycle.

SITTING POSTURECorrect sitting posture is a pre-requisite for stableand 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 viewmirrors, without turning the head.

BRAKINGApply front and rear brakes gently andsimultaneously for maximum braking efficiency.

WARNING

Applying any one of the brakes suddenly may causethe vehicle to skid. The hydraulic disc brakes fittedon your motorcycle require very less effort. High effortor sudden application may lock the wheel. Please useutmost caution while applying the brakes.

While riding on wet or bad road conditions usebrakes cautiously.

19Rules of the Road

Be sure your number plate is installed in theposition specified by law and it is clearly visibleat all times.

Ride at a safe speed that is consistent with thetype of road surface you are on. Pay str ictattention to whether the surface is :

DryOilyIcyWet

Watch for loose debris, such as leaves, slipperysubstances or loose gravel that can hamper thestability of your vehicle.

DO NOT exceed the legal speed limit or drivetoo fast for existing conditions. Always reducespeed when poor driving conditions exist. Highspeed increases the inf luence of any othercondition affecting stability and increases thepossibility of loss of control.

Keep to the correct side of the road center linewhen meeting oncoming vehicle.

Actuate your turn signals and exercise cautionwhen passing other vehicles going in the samedirection. Never try to pass another vehiclegoing in the same direct ion at s treetintersections, on curves, or when going up/ordown a hill.

At street intersection give the right-of-way tothe vehic le on your left or r ight . DO NOTpresume you have the right-of-way.

Always signal when preparing to stop, turn orpass.

While turning either right or left, watch forpedestrians, animals, as well as vehicles.

All traffic signs, including manual controls atintersect ions, should be obeyed promptly.SLOW DOWN at traffic signs near schools andCAUTION signs at railroad crossings.

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 v ice 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 dis tance ofvehicles behind your motorcycle, adjust each mirrorin such a way, that a small portion of your shoulder isvisible and a large portion behind your motorcycle isseen clearly.

SIDE VIEW MIRRORS

Your motorcycles is equipped with convex mirrorsand have a curved surface. This type of mirror isdesigned to give a much wider view of the rear thana normal f lat mirror. However, cars and otherobjects seen in this type of mirror will look smallerand farther away than when seen in a flat mirror.

Use care when judging the size or distance ofobjects seen in these mirrors.

Red

Yellow

Green

21Vehicle Identification Number - Details

CHASSIS NUMBER

Punched on the steering head tube RH side

ENGINE NUMBER

Punched on top of the Engine LH side.

22

1. RH Trafficator front

2. Brake Pedal

3. Kick Start Lever

4. Starter Motor5. Horn

6. RH Side Panel

7. RH Trafficator Rear1

26

7

RIGHT SIDE VIEW

43

Key Parts Location

5

23Key Parts Location

7

1

2 3

6

54

LEFT SIDE VIEW1. Trafficator front LH2. Spark plug3. Gear Change Pedal4. Centre stand5. Side Stand6. Side Panel LH / Battery Cover

7. Trafficator rear LH

24Key Parts Location

1. Turn signal switch2. Horn button3. Clutch lever4. Day flash switch5. Head lamp dip switch

TOP VIEW

6. Manual Bistarter / Choke7. Speedometer8. Ignition switch9. Malfunction Indicator Lamp10. Tacho Meter

11. Engine Kill switch12. Park / head light switch13. Electric Start Switch14. Fuel tank cap

1

2

3

4 8 11

1213

14

975 6 10

25Operation of Controls

IGNITION SWITCH

Insert ignition key and turn clockwise directionto “ON”. Once you turn on the ignition key all theindicating lights in instrument cluster startsglowing on for few seconds and the engine willget ready to start. The key cannot be removedfrom “ON” possition.

Turn the ignition key in anticlockwise directionto “OFF”. Once you turn off, all the electricalsys tems goes off . Now the key can beremoved.

OFFON

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 basedlubricants or graphite. Inoperative locks may result indamage to your vehicle.

Push the key in steering lock Position, and turnclockwise 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 removethe key from combination switch.


FUEL TANK CAP

Turn key clockwiseto open. Press thecap to lock with keyin position.

NOTE :Key can be removedonly in locked position.

SIDE PANEL RH

Uti li ty box isprovided at thebot tom area ofbattery carrier.

I t is covered withside panel LH

SIDE PANEL LH / BATTERY COVER

Turn key clockwise tounlock the side panel.

Pull the s ide paneloutside for openingthe same.

Key cannot beremoved in thisposition.

Unscrew the indicatedscrew and then pullthe s ide panel foropening the same.

UTILITY BOX

28

WarningDo not attempt to change any setting while riding themotorcycle. It may cause loss of control leading to anaccident.


ALPHA-NUMERIC DISPLAY UNITThis unit in thespeedometer consistsof

1. Odometer

2. Trip A

3. Trip B

4. Fuel level indicator

ODOMETER MODE

Odometer mode is theinitial display mode ofth is unit . It displaysodometer reading bydefault.

NOTE :Once you turn “ON” the ignition key, whatever was thelast selection mode will get displayed.

TRIP METER MODEA light push for lessthan one second onthe “PUSH” buttonswitch will change thedisplay from odometerto Trip meter (TRIP A)

NOTE :For resetting the Trip Meter1. 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 switchwill change the display from “TRIP A to “TRIP B”.

Push ButtonSwitch

Alpha Numeric Display


The display bars of the fuel meter disappearstowards the Empty (E) when the fuel leveldecreases.

when last bar start blinking (less than 3 litres), refuelthe bike at the earliest.

NOTE :

If the last bar of the fuel meter is blinking continuouslyafter fueling, visit a Royal Enfield authorised dealerand check the same.

FUEL LEVEL INDICATOR

The fuel level indicatorindicates the level of fuelin the fuel tank.

If the battery voltage is less than 12 volts, the lowvoltage indicator will start glowing continuously.

While the ignition is “ON”, low voltage indicatorsymbol will glow until engine reaches 700 RPM.

In running condition if the battery voltage is below12 Volts for more than 3 seconds continuously, thelow voltage indicator will start glowing.

BATTERY LOW VOLTAGE INDICATOR

Battery low voltage indicator

30

DIP SWITCHHEAD LAMP DAY FLASH

PRESS FOR HEAD LIGHT FLASH LOW BEAM HIGH BEAM

Operation of ControlsHEAD LAMP SWITCH

HEAD LAMP ON POSITION LAMP HEAD LAMP OFF


ENGINE STOP SWITCH

ENGINE ON ENGINE OFF

TURN SIGNAL SWITCH

LEFT RIGHTOFF (PUSH TO OFF)

ENGINE START SWITCH

PRESS

32

MANUAL BI STARTER (CHOKE)


HORN

PRESSApply choke in cold start condition while starting the Bike

33Pre Operational Checks

A careful check of the following must be carried outevery time before riding and specially after long periodsof 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 sufficientlubrication.

4. Brakes, s teer ing and throt t le for properresponsiveness.

5. Cable for fraying or crimping and free operation.

Warning

For your personal welfare and safety, all the pointsmentioned above should be performed periodically.Failure to do so may affect safe operation, damageyour motorcyc le and could result in an accidentcausing serious injury.

6. Engine oil level.

7. W heel spokes for proper t ightness and nobreakage.

8. Headlamp, tail lamp, brake lamp and indicator

lamps for proper functioning.

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 theengine 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 irs t 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 us ing themotorcycle above 1/2 throttle opening position.

2. 501-2000 Kms :The recommended speed is below 80 – 90 kmph.Avoid driving the motorcycle with full throttle

opening. Vary the s peed of the motorcyc leregularly but avoid using the motorcycle above3/4th throttle opening position.

3. 2001 Kms and aboveAvoid prolonged full-th rottle operation. Varyspeed occasionally.

CAUTION :After covering the first 500 kilometers, Please replacethe engine oil and oil filter element.Royal Enf ield 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 running for long distances at high speedmust be given close attention to avoid overheatingand possible engine damage

35Electronic Fuel Injection (EFI)

ELECTRONIC FUEL INJECTION (EFI)

An electronic control unit (ECU) monitors engineperformance and provides exact requirement of Air/ Fuel mixture to the engine, through the fuel injectorby taking inputs from various sensors provided inthe motorcycle.

THE ADVANTAGES OF EFI ARE

Faster response of the engine to suit road/loadconditions.

Better power output

Lower emission

Better reliability

Excellent cold Startability

Engine Diagnostic capabilities

Maintenance free

MALFUNCTION INDICATOR LAMP (MIL)A Malfunc t ioningIndicator Lamp (MIL)is provided in theRPM meter which islocated on the rightside of the Clusterunit.

1. EFI Mal Function Indicator : W hen 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 Enfieldauthorised service point for inspection and furthernecessary action.

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 motorcyclefalls over on any side with the engine runningcondition, The “Roll Over Sensor” will switch offIgnition and cut off fuel supply to prevent themotorcycle from moving suddenly, while it is in gear.

To re-activate the system after the motorcycle hasbeen made upright, please switch off both theIgnition & Engine kill switch, wait for a few secondsand switch “ON” again.

This will help to RESET the “Roll Over Sensor” andthe engine can be started/ run.

37Starting

Warning

Before starting engine, always shift gears into neutral.

CAUTION :Do not force the gear lever while attempting to shift toneutral . Move the motorcyc le back & for th 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 clutch switch is provided in the system 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 clutchlever, press the starter button and releaseslowly after the engine starts.

Turn ignit ionswitch ‘ON’

Ensure the sideand main standsare in releasedposition

Ensure that gearsare in neutral andneutral lamp isglowing

38

Ensure Enginestop switch is in“RUN” position

Starting

Press ClutchLever.

Press StarterButton andrelease as soonas engine starts

CAUTION :

Never accelerate the engine immediately after a coldstart. The engine should be allowed to run slowly for15-30 seconds. This will allow the engine to warm upand let oil reach all surfaces needing lubrication.Failure to adhere may result in damage to the Engine.

Manual biStarter (choke)

NOTE :It may be necessary to operate and hold the manualbi starter, when starting the engine for the first time incold mornings, temperatures below 10°C or at highaltitudes, to prevent the stalling and to keep the idlingRPM steady.

39Starting

As soon as the engine attains the operat ingtemperature, the RPM will raise, at which time themanual Bi Starter should be released.

Warm up engine for 2 minutes - till idling isconsistent.

CAUTION :

Please ensure the motorcycle is not used with thelow fuel indicator bar blinking continuously. It may notonly result in the motorcycle running out of fuel. Butwill also cause serious damage to the fuel pump.Please ensure fuel is filled up as soon as the low fuel,last bar start blinking.

CAUTION :

Air cooled engine requires air movement over thecylinder head and exhaust pipe to maintain properoperating temperature.

Never accelerate the engine abnormally in stand stillcondition of the motorcycle. Failure to adhere this mayresult in damage to exhaust pipe / silencer of theengine due to over heating.

Prior to starting, check to see the fuel level fromthe fuel gauge.

If the last bar is blinking refuel immediately.

40Gear Shifting

CAUTION :The clutch must be fully disengaged before attemptinga gear shift. Failure to fully disengage the clutch maycause a jerky start OR stalling the engine besidescausing damage to transmission parts.

Warm up enginefor 2 minutes -t il l id ling isconsistent/stable

GEAR SHIFT PATTERN1 N 2 3 4 5

Press clutch lever towards the hand grip.Press gear pedal with toe towards down toengage 1st gear.Gently open throt t le and release c lutchsimultaneously. 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 the motorcycle in first gear position only.

W hen engine speed decreases or while climbing agradient or running at a reduced speed, shift to theappropriate lower gear to prevent the engine fromstalling or straining to pull.

Press the gearpedal upwardswith toe toengage 2ndand gear.

Follow the same procedure for 3rd, 4th and 5thgear.

41Parking

PARKING VEHICLE ON CENTER STAND

Select a firm, flat surfaceHold handle bar straightLower center stand, and ensure that both thelegs of the stand are resting evenly on firm ground.Apply pressure on the fulcrum 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 tothe left till it rests firmly on the side stand.

Warning

Always park the motor cycle on a firm and flat surface. 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.

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

3S.No. Description Qty.

1. Antiseptic cream 5 gms 1 2. Gauze bandage 5 cm x 2 cm 1 3. Elastic Gauze bandage 8 cm x 1 mtr. 1 4. Wash proof plaster 1.9 cm x 7.2 cm 2 5. Sterilized Gauze Swab 5 cm x 5 cm 2 6. Sterilized 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

43Recommended Lubricants

ISO 14001 – EMSOperation Control Process

1. All customers are advised timely replacement of Engine Oil,Fork Oil & Brake Oil at the dealership /ASP. In case doneprivately, it is advise to reach old/used Oil to our authorisedvendor through RE Dealer/ASP

2. Similarly we advise for disposal of old/used Battery, Tube &Tyres as mentioned in above point No.1.

Engine OilGrade Royal Enfield 15 W 50 API SL Grade

Engine Oil(JASO MA)

Front Fork OilGrade Royal Enfield

Front 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 mlRear : 100 ml

44Periodical Maintenance

The maintenance schedule detailed here will help you to maintain your Continental GT meticulously and to get a longtrouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileageat 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 themotorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant wateretc., Contact a nearest Royal Enfield Authorised Dealer / Service Point for expert advice and to carry out theperiodical maintenance.

Warning

For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack ofregular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing themotorcycle 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 specif ied above, in consultation with aRoyal 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-carbonise I : Inspect L : Lubricate R : Replace


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 R3 Engine sump filter (oil strainer) C C C C C C C

4 Magnetic 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 R6 HT lead for crack I I I I I I I I I I I7 Fuel hose & clip / Injector ‘O’ Ring / Seal Ring I I I I R I I I R I I8 Fuel Pump Check for screw tightness in all services9 Accelerator & Throttle pully cable free play A A A A A A A A A A A10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I11 Rubber hose, Inlet manifold I I I I R I I I R I I

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 C13 Inlet / Exhaust valve seating I I14 Cylinder head (Combustion chamber) D15 Exhaust pipe D16 Clutch lever free play Adjust every 1000 Kms or earlier as required17 Rear brake pedal pivot L L L L L L L L L L L18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C19 Battery Electrolyte level I I I I I I I I I I I20 Earth wire eyelet contact (below ECU Mounting) I I

21 Rear Wheel 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 I23 Steering ball races / play adjustment A L A R A L A R A L


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

48Minor Maintenance Tips

OIL LEVEL INSPECTION

Lever Pivot

Main Stand Pivot

The following minor maintenance can be carriedout easily with simple tools. However, In case, if itis felt that the adjustments are best done by anexpert, we recommend that the motorcycle be takento 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 drops 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 middleof the oil level window.

Top up with recommended oil if required.

Side StandPivot

MAXMIN


ENGINE - OIL CHANGE

PrimaryFilter Cap

Remove the oil filter paper element on theCrankcase Cover RH.Allow the oil to drain by tilting the motorcycle toboth sides.Wash the primary and secondary drain plugsalong with suction filter thoroughly and refit onthe crankcase after all the oil is drained out.

(Refer Periodical Maintenance Chart for frequency)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


Max

Min

Fill recommendedoil to engine till theoil level is upto“MAX” level mark inthe oil window inCrankcase CoverRH.

SPARK PLUG

Cleaning and adjust ing 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. Doingso 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.Assembly 3 bolts and tighten them. Ensure ‘O’Ring and gaskets are taken seat properly.

Gap 0.80 to 0.90 mm.

51

MINMAX

CAUTION :Brake fluid is highly corrosive and can cause damageto painted parts. Please ensure that brake fluid doesnot spill on any part of the motorcycle. In the event ofa spill, please clean the area immediately with a softcloth (preferably a wet cloth) to avoid damage.Don’t mix DOT 3 & DOT 4 Brake fluid together.

Minor Maintenance Tips

Check if oil is below ‘MIN’ level. To top Up, removecover and diaphragm, then top up with DOT 3 orDOT 4 as specified.

BRAKE FLUID INSPECTION OF TYRES AND WHEELS

Inspect the tyre periodically fortread wear, cracks and cuts.

FRONT BRAKE REAR BRAKE

MIN

Check and remove stone, splinters, nails or otherparticles embedded in the tyre 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 rimand spokes do not get damaged on account ofwrong handling.

Minimum tread depthFront tyre : 1.00 mmRear tyre : 2.00 mm


FRONT WHEEL REMOVALUse only standard tyres & tubes inflated tocorrect pressure.

TYRE PRESSURE

Front Rear

Solo 1.41 kg/cm2 2.11 kg/cm2(20 PSI) (30 PSI)

With Pillion 1.55 kg/cm2 2.25 kg/cm2(22 PSI) (32 PSI)

Warning

Tyres, rims and air valves must be correctly matchedto wheel r ims. See your Royal Enf ield Dealer.Mismatching tyre, tubes, rims and air valves may resultin damage to the tyre bead during mounting, allowtyre slippage on the rim and cause tyre failure.

Place the vehicle on center stand

Place a wooden blockthe f ront end ofengine to support thevehicle.

Loosen the pinch bolton the RH fork guideby 6 mm allen key.

Hold the axle head bydouble end spannerwhile loosening theaxle nut.

Remove the axle nutalong with washer.


Place a 4 mm thick wooden piece or cardboardsheet between the brake pads to avoid padsactivation in the event the front brake lever isaccidently pressed.

FRONT WHEEL REASSEMBLYTap and remove thefront wheel spindle.

Tilt the vehicle to RHSide and take out thewheel along withwheel speed sensorand LH side spacer.

CAUTION :Do not press the front brake lever when wheel isremoved as this will result in the brake pads comingtoo far out of the brake caliper.

Place the wheel speedsensor in position.Ensure slot on huband speedo sensor ismatched correctly.Inser t the wheelalong with wheelspeed sensor and LHspacer between thefront fork endsensuring the brakedisc is locatedbetween the brakepads.Insert and tap thef ront wheel axlegently inside.Refit the washer andtighten the nut firmly.

Remove the wooden piece / card board sheetplaced between the brake pads

LocatingTAB

54

REAR WHEEL REMOVAL


Tighten the pinch bolt on the RH fork guide.

Rotate the wheel and check for smooth rotation.

Ensure wheel speed sensor wire coupler is beingconnected to cluster unit and then check forproper working of speedo meter.

Press brake lever 2 or 3 times to check frontbrake efficiency.

Place the vehicle oncenter stand on afirm and flat surface.Observe and markthe alignment indexmarks in the bothsides of swing arm.

Remove axle nut onthe RH side.

Remove wheel spindlefrom LH side alongwith wheel collar andLH side spacer.

Index mark

55

Remove the caliperassembly by pullingout f rom the swingarm slot.

CAUTION :

Do not press the rear brake pedal when wheel isremoved as this will result in the brake pads comingtoo 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.


Remove the distance collar.

Tilt the motorcycle towards RH side and take outthe rear wheel assembly conveniently.

REAR WHEEL REASSEMBLY

Tilt vehicle to right andinsert wheel assemblybetween the swingarms.

Posit ion the rearwheel wi th cushrubber on the reardr iven f lange /adaptor.

Fix the LH side spacerin rear wheel hub.

Remove the woodenpiece / card boardsheet placed betweenthe brake pads.

Ensure the four Cush rubbers are in positioninside the rear wheel hub.


Warning

Ensure the vehicle do not come out of center standwhile dis mant ling and as sembling the wheelassembly.

Align the caliper bracket, wheel and swing armholes in-line and ensure distance collar isplaced in hub dust seal.

Insert the caliperassembly by pushingin the project iongiven ins ide theswing arm. Ensurethe brake disc islocated in betweenthe brake pads.

Ensure that swing armend plate is seatedproperly and thechain adjuster nutsare correct ly t ight-ened and Locked.

Insert and tap the rearwheel axle gently.

Index mark

CAUTION :Do not force the spindle intothe wheel as the threadsmay get damaged. Tap itthrough the wheel gently.

Ensure the index marks alignments on both sidesof the swing arm are in same position for properwheel alignment.

Tighten the axle nutfirmly.

Adjuster End Plate

Adjuster Lock nut

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 playor Anticlockwise to increase the free play.

Check free play 2 to 3 mm at Clutch lever pivoton 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 while

holding 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 connectionand the brake light Switchspring for any bend,breakage or disconnection.


58

DRIVE CHAIN FREE PLAY (PLAY 20 - 25 MM)


Place motor -cyc le on it scenter stand ona f irm & f latsurface.Shif t the gearinto the neutralposition

Measure thedrive chain freeplay as shown.The drive chainfree play is 20 to25 mm

Drive chain slackadjusting nut

Swing Armreference mark

Index mark

Ad ju s t e rLock nut

1. If the drive chain free play is incorrect adjustas follows:

a. Loosen the axle nut of the rear wheel axle.

b. Loosen the QDsprocket spindle nut.

c. Loosen the locknut atboth end of theswing arm.

d. To reduce the freeplay, turn the drivechain slack adjustingnut in c lockwisedirection.

e. To increase the freeplay, turn the drivechain slack adjustingnut in anticlockwisedirection and pushthe rear wheelforward.

59

CHAIN LOCK FITMENT


The open end of the chain master link lock shouldface opposite to normal direction of chain rotation.

Warning

The f itment of lock in wrong direction other thanshown above can lead to its falling off, and thus cancause the sudden disconnection of the chain duringthe drive.

f. Later adjust the nut on LH side by matchingthe index mark with respect to RH side index.

g. Ensure that both the sides are in same indexmarks.

h. Finally torque the spindle and axle nuts to 7kgm.

i. Tighten the adjuster locknut by 13mm spanneragainst chain slack adjusting nut.

Warning

Chain slackness beyond 30mm will lead to chainslippage.Maintain drive chain slackness within the specif iedlimits at every 1000 kms interval.Please Check the front and rear wheels are correctlyaligned, after the chain adjustment.


ADJUSTMENT OF GAS FILLED SHOCKABSORBER

The rear gas f illed shock absorber is anadjustable type.The spring tension can beincreased or decreased.

Reduce the spring tension for low load operationby turning the adjuster nut in the direction asshown above by using a suitable C - spanner.

Increase the spr ing tension for high loadoperation by turning the adjuster nut in opositedirection.

Adjust both the rear shock absorbers to the samethread possitions.

Recommended = 10 mm height adjustment onlyfrom factory setting.

Warning

Riding the motorcycle with the shock absorbersadjusted in different positions can cause loss ofcontrol.

Regularly inspect shock absorbers and front forks forany leaks.

NOTE :

Ensure accessories, fitted if any, do not foul withrear shock absorbers. Check for suf f ic ient gapbetween the shock absorbers and the attachmentsin a condition that the rear end of the Motorcycle isfully loaded and the shock absorbers are maximumcompressed.


REMOVAL OF BATTERY FROM THE VEHICLE

Unlock (turn the key clockwise) and removethe Left side panel.

Disconnect both the terminal wires (negativefirst and positive next respectively)

Remove the battery car r ier bracket byloosening 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 with

distilled water only.

NOTE :The poor contact or loose fitment of Battery terminalsmay cause ECU failure.

Battery Carrier bracket screw

(-) (+)TERMINAL TERMINAL


REASSEMBLY OF BATTERY ON MOTORCYCLEPosition the battery in the battery carrier suchthat negative terminal of the battery is towardsthe fuel pump side.

Warning

Always disconnect the negative (-) battery cablef i rst and then the Red pos it i ve (+) c able whi leremoving the battery connections.

NOTE :

For checking the battery voltage and electrolytespecif ic gravity, contact authorised Royal Enf ieldDealer / service point or battery service centre.

CAUTION :Do not use battery with low electrolyte level asthe battery internal cells will get damaged.

Do not overfill the battery electrolyte level as itwill spill out through the overflow pipe and causecorrosion to vehicle parts.

Use only distilled water meant for use in batteriesto 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 pos it iveterminal (Red wire) firstConnect the negat iveterminal (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.

63

CHANGING ELECTRICAL COMPONENTS

HEADLAMP BULB REPLACEMENT


NOTE :Never touch the bulb with yourfingers. Finger prints will etchthe glass and decrease bulb life.

Loosen the rimholding screw ontop and take outthe head lampdome.

Disconnect electri-cal connections.

Thumb push andremove the bulbhold ing clampgently.

Remove the bulb.

Posit ion new bulbinside the ref lectorsuch that the threeproject ions on thebulb align with the sloton the reflector.Refix the bulb holdingclamp.Connect the Electricalconnections.

Position head lamp doom onto the head lampshell and tighten the mounting screw on top.

Always hold the bulb with paper or clean dry clothduring handling as shown in f ig.

X

64

TAIL LAMP BULB REPLACEMENT


Unlock the batterycover

Remove the seatassembly by pullingseat lock cable.

Remove the tai ll ight g lass byunscrewing it smounting screw

Replace the bulb 12V 21 / 5W.

A s s e m b l eback the taillight in ther e v e r s eorder ofdismantlingprocess.

Hold the bulb, press ins ide and rotateanticlockwise to remove the tail light bulb fromits holder.

65

TRAFFICATOR BULB REPLACEMENT

Remove the screwfrom the trafficatorhousing back side.

Open the Indicatorhousing.

Take out the bulbholder with help ofis screw driver.

Take out the bulband replace thesame.

Ref it the holderf i t t ing it s lock inproper position.


Fix the rubber gasketcover.

Assemble back theindicator housingcover.


FUSEFuseNo. Color

BLADE FUSE USAGE LIST

ApplicationAmps1 Blue 15A RR Fuse2 Blue 15A MAIN Fuse3 Red 10A ECU Fuse4 Red 10A General i llumination / Tail / Trafficator5 Red 10A Head Lamp Fuse6 Red 10A Instrument Cluster / Horn7 Blue 15A Spare Fuse8 Red 10A Spare Fuse

WarningElectronic Control Unit (ECU) may fail due to looseelectrical connections, loose battery terminals etc.Hence, it is very important to keep all the Electricalconnections intact.

WarningWhile doing Arc welding any where in motorcycle, the batteryterminals and the Electronic Control Unit (ECU) coupler are to becompletely disconnected. Failure to do so many cause damage tothe Electrical system of the Motorcycle.

WarningPlease 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


AIR FILTER PAPER ELEMENTCLEAN AND REFIX : EVERY 3000 KMS

Remove the screw from the side cover bottomside and then take out RH side cover.

Takeout air filter paper element and checkfor dirt. Gently tap it as shown in fig and fix itback.

NOTE :It is adviceable to replace air filter paper element oncein 10,000 KMS. In case of vehicle running in dusty /mud road condition it may be replaced as earlier asrequired.Usage of h igh pres sure compres sed air is notrecommended to clean air filter paper element.Fitment of air filter paper element is reverse order ofremoval process.

Remove the air filtercover screws andthen takeout air filterbox cover.

68Washing Procedure

PRECAUTIONS

Wash vehicle when the engine is cold.

Cover the silencer tail end and control switcheswith suitable plastic bags and tie it firmly to preventwater entry into them.

Remove ignition key and seal key hole usingadhesive tape.

Do not remove RH side cover (panel) whilewashing to avoid water entry into air filter boxassembly.

Use a suitable engine degreaser, available withyour local parts store, to remove dirt or greasefrom the engine external parts if required. Followthe directions in the label carefully before usingthe degreaser.Use low pressure jet of water to clean the entirevehicle.Never spray water with great force on head lamp,Meter/cluster unit, trafficator lights, front and rearwheel hubs, electrical connections and wires,control cables, EFI components, sparkplug,battery,air fillter cover etc.Use Luke warm water and mild detergent on thepainted components to remove dirt, etc.Rinse vehicle thoroughly with plain water toremove the detergent and wipe vehicle dry.If possible, use compressed air and blow offwater part ic les from the obscure areas ofthe vehic le, elect r ical connect ions , EFIcomponents etc.

X

69

Warning

Observe warnings and cautions given on labels ofcleaning compounds before it is used.

When washing your motorcycle, be careful not to getthe brakes, engine, muff lers or air cleaner etc., toowet. Wet brake pad and / or disc can affect brakingeff ic iency. Engine can be s tarted af ter washing.Ensure brakes and engine are working properly beforeriding in the traffic and / or in highways at high speeds.

AFTER WASHING

Ensure the vehicle is thoroughly dry by wipingwith a c lean soft water absorbent cloth orchamois leather.

Remove all plastic bags and adhesive tapes.

Lubricate control cables, pivots for footrest, sidestand, centre stand, brake and gear shifterlinkages, rear chain etc.with lube oil.

Polish the painted and plated surfaces usingpolishing wax.

Start the bike and allow engine to idle & warm up.

Drive the motorcycle slowly, applying both brakesintermittently to dry up the brake pads.

Test brakes for full efficiency.

Washing Procedure

70Storage Precautions

Incase your Motorcycle is not going to be used fora month or more, we advise the followingprecautions to be taken

Carryout required repair/adjustments on themotorcycle.

Wash the motorcycle thoroughly and lubricateas per the maintenance chart.

Start the engine, warm up for a few minutesand switch off.

Drain out the fuel completely from the fuel tankand fuel lines.

Remove the spark plug. Pour in about 20ml ofclean engine oil through spark plug hole. Closethe hole and crank engine few times and refitthe sparkplug.

Clean the rear chain thoroughly and applylubrication oil on it.

Remove battery from the bike. Clean i ts

terminals and apply petroleum jelly on theterminals to avoid corrosion.

Maintain electrolyte level between max andmin marks, by adding distilled water and wipethe battery dry.

Store the bat tery in a cool, dry and wellventilated place.

Do not place the battery in direct sun light, nearopen flame or where temperature is above40°C or below 0°C

Cover the silencer with plastic bags to preventmoisture entry. Set the motorcycle on its centerstand.

Apply anti rust solution on all chrome platedparts. Take care not to apply this solution onrubber or painted parts.

Store motorcycle in a clean covered area freeof moisture and keep it covered to prevent dustsettling on it.

71

PREPARING THE MOTORCYCLE FOR REUSE

Remove anti rust solut ion from all chromeplated parts and clean the motorcycle.

Inflate the tyres to the correct tyre pressure.

Ensure battery is fully charged and electrolytelevel is properly maintained.

Connect the battery.

Lubricate all control cables and pivots.

Check level of oil in engine and top up ifnecessary.

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 pourin a few drops of engine oil. Crank engine afew 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 fewminutes 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-f ree operation of your Royal Enf ieldmotorcycle.

Storage Precautions

72

CHECKS PRIOR TO THE COMMENCEMENT OF LONGJOURNEY

Service the motorcycle thoroughly at RoyalEnfield Authorised Dealer / Service Point as perperiodical maintenance chart. (Ref. Page No. 45to 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 mastercylinders.

Check for good battery condition and properelectro lyte level.

Proper dr ive chain tension and correct lyadjusted rear brakes.

Check for proper functioning of all lights & hornetc.,

CHECKS AFTER EVERY 1500 KMS OF RUNTightness 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 CARRIEDTool kit.First aid kit.Bulbs for Headlight, Trafficator light and miniBlade 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

73Complete Wiring Diagram

NOTE :

Complete Wiring Diagram is attached on this page.

74Trouble ShootingWarning

The trouble shooting section of this Owner’s Manualis intended solely as a guide for diagnosing problems.Carefully read the appropriate sections of this manualbefore performing any work. Repair and maintenanceoperations not listed in this Owner’s Manual shouldbe performed by your Royal Enf ield Dealer only.Improper repair / maintenance could result in themotorcycle not functioning properly or injury seriously.

I. ENGINE FAILS TO START1) Stop switch in ‘OFF’ Position ............. Push stop switch to ‘ON’ position.2) Vent hole clogged in fuel tank cap .... Clean vent hole.3) Spark plug cap / lead not connected . Fix cap / lead firmly4) Spark plug electrode dirty / fouled .... Clean spark plug5) Spark plug insulation cracked ........... Replace spark plug6) Clutch slipping ................................... *Adjust clutch cable free play7) Main or EFI Fuse failed................... .. Replace with new fuse

CAUSES REMEDIES

* Contact Authorised Dealer / Service Point

Warning

Please get the electrical system of your Motorcyclechecked throughtly and get the faults correctedimmediatly after experiencing any fuse failure. Notdoing this can result in to repeted fuse failures.

Usage of fuses other than spcified rating will damagethe complete electrical system.

75Trouble Shooting

II. ENGINE MISFIRING1) Loose spark plug cap ........................ Fix cap / lead firmly2) 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 connections4) Water in petrol tank ........................... * Clean petrol tank. Fill tank with fresh petrol.

III. POOR PICKUP1) Brake pedal adjusted too tight ........ *Re-adjust properly2) Choked air filter ............................... Clean / Replace air filter3) Rear chain adjusted too tight .......... *Re-adjust properly4) Under inflated tyres ......................... *Inflate to correct pressure5) Accelerator cable free play excessive Adjust cable free play6) Clutch Slipping ................................. *Adjust clutch cable free play7) Faulty fuel supply ............................. *Remove fuel pump & clean.

Fuel pump, filter / injector blocked

CAUSES REMEDIES


76Trouble Shooting

IV. WHITE/BLUE SMOKE

1) Oil level in sump above the Top line. * Check and drain excess oilin the oil level window .....................

V. ENGINE OVERHEATING1) Low engine oil level ......................... Check and top-up if necessary2) Clutch slipping ................................. * Check and correct3) Cylinder fins not clean ..................... Clean the cylinder fins at regular intervals

VI. EXCESSIVE FUEL CONSUMPTION1) Under inflated tyres ......................... Inflate to correct pressure2) Choked air filter ............................... Clean / Replace3) Fuel leakage..................................... *Check and rectify, tank float unit, drain pipe, breather pipe,

.......................................................... fuel line / pump.

CAUSES REMEDIES


77Trouble Shooting

VII. BRAKES POOR1) Brake pad worn / Uneven wear ....... *Replace Brake pads2) Oil/grease on disc. ........................... *Clean and refit3) spongy brake.................................... *fill brake fluid & remove air from the system.

VIII. VEHICLE WOBBLES1) Under inflated tyres ......................... Inflate to correct pressure2) Loose / Broken spokes .................... * Tighten / Replace spokes3) Wheels misaligned .......................... * Ensure proper alignment4) Wheel rim runout ............................. * Rectify5) Tyres not fitted correctly .................. * Refit tyres correctly

IX. ELECTRICALSBulbs do not glow1) Bulb fused ........................................ * Replace bulb

CAUSES REMEDIES


78

2) Fuse blown ....................................... * Check and Replace fuse.3) Loose / improper connection ........... * Check and correctHorn not working1) Fuse blown ....................................... Check and correct2) Loose connections ........................... Check and correctTrafficators not working1) Loose / improper connections ......... Check and correct2) Bulb fused ........................................ ReplaceBrake 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


Warning

Please get the electrical system of yourMotorcycle checked thoroughly and get thefaul ts corrected immediat ly afterexperiencing any fuse failure. Not doingthis can result in to repeated fuse failures.Usage of fuses other than specified ratingwill damage the complete electrical system.

79Warranty

Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material andworkmanship.Royal Enfield (RE) warrants CONTINENTAL GT EFI Motor Cycle to be free from manufacturing and material defectunder normal use subject to following conditions.1. RE will replace or repair defective part / parts at their Authorised Dealer / Service Point, free of charge within a

period of 12 months from the date of sale (date of Installation) or 10,000 kms whichever occurs earlier.2. The warranty is applicable only to first registered owner.3. The warranty shall be applicable only if all the free services are availed at the respective period / kilometer range

as per the schedule given in the owner’s manual from RE Authorised Dealer / Service Point.4. During the warranty period, RE’s obligations shall be limited to repairing / replacing free of charge such part or

parts of the vehicle, which on examination to have manufacturing defect. Such defective part / parts which havebeen replaced becomes property of RE.

5. Cost of oil, oil filter, fuel and other consumables are chargeable to the customer.6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken up with respective

manufacturer or their authorised agents in the area directly by customer. RE shall not be liable in any manner toreplace them though their Dealers will provide assistance in preferring such claims on their manufacturer.

7. Warranty shall not apply to:(a) Normal ageing, detoriation or rusting of plated parts paints coat, rubber parts, soft items, glass items, plastic

parts etc.

80Warranty

(b) Components like fuel filter, oil filter paper element, control cables, brake shoes / brake pads, clutch plates,drive chain & sprocket kit, which are subjected to normal wear and tear.

(c) Damages due to use of lubricant / oil / grease etc., other than specified by RE.(d) Damages due to use of non-genuine parts.(e) Damages due to lack of proper maintenance of the vehicle.( f ) Damages due to incorrect driving or riding habits.(g) Parts damaged due to accidents, collision, abuse etc.(h) Irregularities not recognized as affecting the quality or function of the vehicle such as slight vibration, oil

leakage, discoloration of exhaust bent pipe / silencer / soft or hard shock absorber etc.(i) Defects arising from fitment of unauthorised / additional Electrical loads.(j) Vehicle serviced / repaired at unauthorised service points.(k) Vehicle used for competition / racing.(l) Electrical component like bulbs, fuses etc. & Electronic components failure due to repairs by arc welding.(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine tune up and other

such adjustments8. RE reserves the right to finally decide on all warranty claims9. RE reserves the right to make changes in Design of the vehicle without any obligation to install these changes on

previously supplied vehicles.

81Emission Warranty

In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal Enfield certifies thatthe following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in itsrange of motorcycles, in normal use to which it may be subjected to.

This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000 Kms. or 36 months,whichever occurs earlier, from the date of sale to the first customer and is in addition to and parallel to the warrantypolicy, conditions and obligations laid down in the Owner’s Manual.

Royal Enfield further warranty that if on examination by its Authorised Dealer / Service Point, the motorcycle fail tomeet the specified emission standards, then the Authorised Dealer / Service Point shall take necessary correctivemeasures and shall at its sole discretion, repair or replace free of charge such components of the emission controlsystem to meet the required emission standards.

The method/s of examination to determine the warranty conditions of the emission warranty related components willbe at the sole discretion of Royal Enfield and / or our Authorised Dealer / Service Point and results of such examinationwill be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royal enfieldwill have the right to charge all, or part of the cost of such examination to the customer in addition to the cost of thecomponents.

In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge, thecomponent/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeable to thecustomer as per actual.

82Emission Warranty

In case any of the components covered under emission warranty or the associated parts, are not independentlyreplaceable. Royal Enfield will have the sole discretion to replace either the entire assembly or parts of the assembly,through suitable repairs.

Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace any part,in addition to the repair or replacement of the components covered under emission warranty, to establish complianceto in-use emission standards. Such repairs / replacements will be chargeable to the customer.All parts removed for replacement under warranty will become the property of Royal Enfield.Royal Enfield will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised Dealer/ Service Point OR for any loss due to non availability of the motorcycle during the period of examination and repairsby Royal Enfield and / or their Authorised Dealer / Service Point.Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on account offailure to comply with the in-use emission standards.That cost/s incurred to check emission of the motorcycle will have to be borne by the customer.Emission warranty will be applicable irrespective of the change of ownership of the vehicle provided all the conditionsas laid down in this document are met from the date of original sale of the motorcycle.

THE WARRANTY SHALL APPLY IF THE CUSTOMERObserves all the important instructions and any other precautions listed in the owner’s manual.

83Emission WarrantyUnder all circumstances uses lubricants and fuel as recommended by Royal Enfield.Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the detailsin the Log book.Immediately approaches the nearest Authorised Dealer / Service Point upon discovery of failure to comply withthe IN-USE emission standard inspite of having maintained and used the vehicle in accordance with the instructionsin the owner’s manual and having carried out such repairs and adjustments as may be required with a view toestablish such compliance.Produce the ‘Pollution Under Control’ certificate valid for the period immediately preceding the test during whichthe failure is discovered, the test having been carried out either for obtaining a new certificate or pursuant uponbeing directed by an officer as referred to in sub rule (2) of rule 116 of the Central Motor Vehicles Rules (CMVR).Produce the Owner’s Manual and Log book for verification details.Produce receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date oforiginal purchase of the vehicle.Produce valid certificate of Insurance and R.T.O. Registration Certificate (RC Book).

THE EMISSION WARRANTY SHALL NOT APPLY IF

A valid “Pollution under control” certificate is not produced.The motorcycle is not serviced by Authorised Dealer / Service Point as per the service schedule described in themaintenance chart.

84Emission WarrantyThe motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met withan accident.Replacement parts not specified and approved by Royal Enfield have been used.The motorcycle, or parts thereof, has been altered, tampered with or modified or replaced in an unauthorisedmanner.The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, so thatthe actual distance covered cannot be readily determined.The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records.On examination by Royal Enfield or its Authorised Dealer / Service Point, if the motorcycle shows that any of theconditions stipulated in the Owner’s manual with regard to use and maintenance have been violated.The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by Royal Enfieldin the Owner’s manual or any other document given to the customer at the time of sale of the motorcycle.The emission related components are tampered with.All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced.All maintenance activities carried out on the vehicle during the tenure of the emission warranty is not entered inthe log book.

TIPS TO BE ON THE RIGHT SIDE OF LAWAlways get your vehicle checked to meet the emission regulations through and authorised emission checking centre.

85Emission WarrantyAlways carry a valid ‘Pollution Under Control’ certificate with you at all times during the validity of the emissionwarranty (30,000 Kms / 3 years from the date of first sale)

TIPS TO REDUCE POLLUTION1. Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal Enfield

Authorised Dealer / Service Point.2. Use only Unleaded petrol (> 91 octane) from reputed fuel pumps.3. Ensure the fuel used is not adulterated.4. Use correct spark plug as recommended in the owner’s manual.5. Use lubricants as per recommendations given on grade / brand in the owner’s manual.

86Free Service Coupons

It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we providefour free services at specific Intervals.

Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearestto you and as a token of satisfactory service, kindly return the free service coupon duly filled in and signed, to theservice outlet.

Availing the free services in the specified time is a prerequisite to warranty consideration.

The cost of fuel, oil, oil filter element, grease etc. used for free service is chargeable to the customer.

871st Free Service

500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE

Customer Name : Dealer Code :

Address :

500 Kmsor45+8 dayswhichever isearlier from thedate of sale

Enter the Detailsin Free ServiceRecord

Received the above vehicle after the service having been done to my entire satisfaction.

Customer’s Signature : ................................. Date :

Contact Phone / Mobile No.:

Regn. No:

Sale Date:

Serviced Date:

Serviced by(Dealer’s/ASP Name & Address)

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

1ST

FREESERVICE

(Cost of oil,oil filter elementand otherconsumablesused arechargeable tothe customer)

881st Free Service Activities

1. Water wash the vehicle and dry it with a clean cloth2. Electrolyte ........................................................ Check level & top-up3. Battery terminals ............................................. Clean and apply petroleum jelly4. Drive chain free play........................................ Check, clean, lubricate & adjust5. Rear brake pedal pivot ..................................... Lubricate6. Front & Rear disc brakes ................................ Check & top up brake fluid level7. Wheel rim Front & Rear ................................... Check spokes tightness8. Front fork oil ..................................................... Inspect for leakage9. Air filter element ............................................... Clean10. Spark plug (M14) .............................................. Check, clean & adjust gap11. H.T. Lead .......................................................... Inspect for cracks12. Fuel pump ........................................................ Check mounting screws13. Fuel hose ......................................................... Inspect for cracks14. Rubber hose, Air filter to throttle body.............. Inspect for cracks15. Accelerator cable ............................................ Adjust play16. Clutch cable ..................................................... Adjust play17. Engine oil sump strainer ................................... Clean18. Engine oil .......................................................... Replace19. Engine oil filter paper element .......................... Replace20. Hand levers & kick starter pivot........................ Lubricate

CUSTOMER COPYJob Card No:

Date :

Odo Reading :

Name of Dealer/ASP with Code:....................................................

ASP / Dealer’sStamp & Signature

892nd Free Service



Address :

2ND

FREESERVICE3000 Kmsor90+15 dayswhichever isearlier from thedate of sale






Regn. No:

Sale Date:

Serviced Date:


Frame No:

Engine No:


ODO Reading :


902nd Free Service Activities

1. Water wash the vehicle and dry it with a clean cloth2. Electrolyte ........................................................ Check level & top-up3. Battery terminals .............................................. Clean and apply petroleum jelly4. Drive chain free play........................................ Check, clean, lubricate & adjust5. Rear brake pedal pivot ..................................... Lubricate6. Front & Rear disc brakes ................................ Check & top up brake fluid level7. Wheel rim Front & Rear ................................... Check spokes tightness8. Front fork oil ..................................................... Inspect for leakage9. Air filter element ............................................... Clean10. Spark plug (M14) ............................................. Check, clean & adjust gap11. H.T. Lead .......................................................... Inspect for cracks12. Fuel pump ........................................................ Check mounting screws13. Fuel hose ......................................................... Inspect for cracks14. Rubber hose, Air filter to throttle body.............. Inspect for cracks15. Accelerator cable ............................................ Adjust play16. Clutch cable ..................................................... Adjust play17. Engine oil .......................................................... Check level & top up18. Hand levers & kick starter pivot........................ Lubricate19. Steering free play ............................................ Check & Adjust20. Oil filter element, oil strainer & magnetic drain plugs.. Clean


Date :

Odo Reading :



913rd Free Service



Address :

3RD







Regn. No:

Sale Date:

Serviced Date:


Frame No:

Engine No:


ODO Reading :


923rd Free Service Activities

1. Water wash the vehicle and dry it with a clean cloth2. Electrolyte ...................................................... Check level & top-up3. Battery terminals ............................................. Clean and apply petroleum jelly4. Drive chain free play ....................................... Check, clean, lubricate & adjust5. Rear brake pedal pivot .................................... Lubricate6. Front & Rear disc brakes ................................ Check & top up brake fluid level7. Wheel rims front & rear.................................... Check spokes tightness8. Tyre front & rear ............................................ Check wear and tread depth9. Air filter element .............................................. Clean10. Spark plug (M14) .............................................. Check, clean & adjust gap11. H.T. Lead ......................................................... Inspect for cracks12. Fuel pump ........................................................ Check13. Fuel hose ......................................................... Inspect for cracks14. Rubber hose, Air filter to throttle body ............. Inspect for cracks15. Accelerator cable ............................................ Check & adjust play16. Clutch cable .................................................... Adjust play17. Engine oil sump strainer .................................. Clean18. Engine oil ......................................................... Replace19. Engine oil filter paper element .......................... Replace20. Hand levers & kick starter pivot ....................... Lubricate21. PAV System ................................................... Check & Clean22. Steering system ............................................... Check, Lub. steering balls & Adj. play


Date :

Odo Reading :



934th Free Service



Address :

4TH







Regn. No:

Sale Date:

Serviced Date:


Frame No:

Engine No:


ODO Reading :


944th Free Service Activities

1. Water wash the vehicle and dry it with a clean cloth2. Electrolyte ....................................................... Check level & top-up3. Battery terminals ............................................ Clean and apply petroleum jelly4. Drive chain free play ....................................... Check, clean, lubricate & adjust5. Rear brake pedal pivot .................................... Lubricate6. Front & Rear disc brakes ................................ Check & top up brake fluid level7. Wheel rims front & rear.................................... Check spokes tightness8. Front fork oil ..................................................... Replace oil9. Air filter element ............................................. Clean10. Spark plug (M14) ............................................. Check, clean & adjust gap11. H.T. Lead ......................................................... Inspect for cracks12. Fuel pump ........................................................ Check13. Fuel hose ......................................................... Inspect for cracks14. Rubber hose, Air filter to throttle body ............. Inspect for cracks15. Accelerator cable ............................................ Check & adjust play16. Clutch cable .................................................... Adjust play17. Engine oil ....................................................... Check & top-up18. Hand levers & kick starter pivot ....................... Lubricate19. Steering free play ............................................ Check & Adjust20. Tyres ................................................................ Check wear and tread depth


Date :

Odo Reading :



95Paid Service / Maintenance Record

CUSTOMER COPY12,000 + 250 Kms. Service

Job Card No :................. Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer’s Stamp & Signature

DEALER / ASP COPY12,000 + 250 Kms. Service

Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :


96


Brief Work Done :



Brief Work Done :



Brief Work Done :



Brief Work Done :


Paid Service / Maintenance Record

97


Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :


21,000 + 250 Kms. Service

Job Card No :................. Date : .........................


Brief Work Done :


DEALER / ASP COPY


98


Brief Work Done :



Brief Work Done :



Brief Work Done :



Brief Work Done :



99


Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



100


Brief Work Done :



Brief Work Done :



Brief Work Done :



Brief Work Done :



101


Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



Job Card No :................. Date : .........................


Brief Work Done :



102


Brief Work Done :



Brief Work Done :



Brief Work Done :



Brief Work Done :



103All India Road Signs

MANDATORY SIGNS

INFORMATION SIGNS

CAUTIONARY SIGNS

104

Sl.No.

Date Kms. Details IdlingCO%

Authorised Dealer / Service Point

Job Card No. Stamp &Signature

Log Book

105

Sl.No.




Log Book

106

Sl.No.




Log Book

107

Sl.No.




Log Book

108Notes

109Notes

110Notes

111Notes

112Notes

Telephone Residence

Invoice No.

Delivery Note / Advice No.

Have you visited Royal Enfield website? Yes No

Bike Regn. No.

Telephone Office

E

Sales Representative

or

PRE DELIVERY INSPECTION LIST - CONTINENTAL GTModel : Engine No :

Dealer's Name : Location :

Colour : Key Number :

Battery Number Tyre Number Front Rear :

Aggregate Area Defect Code MeasureDefect

#1

Defect

#2

Defect

#3Remarks

CHASSIS / ENGINE NUMBER 1 Engine / Vehicle Number Details DF Same

CONNECT BATTERY / Check

Voltage2 Battery Charging & Vent pipe connection D / NC / Weak Cell 12.6 V BATTERY

3Replace oil & oil filter / Check Oil level (Loose three

Drain Bolts)

EO - (Drained Oil

Level)

2.5 Litres (Capacity is 2.75

Litres) -Loose three Drain Bolts

to Drain Oil

4 Clean Oil Strainer - Clean

LOCK OPERATION 5Ignition Cum steering/ Side cover Lock / Cap Fuel

Tank LockH / LF / NW Same

PETROL 6 Fill Petrol - 3 Litres

7 Fuel Leak L No Leak (Tank, Pump, hose )

8 Fuel Tank Alignment M Straight

9 Tank Monogram LHS & RHS alignment check up M

10 Caliper Mtg BOLT LF 2.7 to 3 Kgm

11 Fr.Wheel Rotation W / T / LF / NFree (Check Spokes

Looseness & Runout

12 Front Mudguard Alignment M / RB Straight

13 Front Wheel Nut LF 7.0 to 7.7 Kgm

14 Front Tyre Condition ( Check Tyre Line Seating) WF Good

15 Front Tyre Pressure LESS 22PSI

16 Front Brake Light NW / F

17 Speedo sensor cable coupler connection & function WF / NW

18 Clutch Operation H / N Smooth

19 Clutch Lever Free Play EP / V / T 2 - 3 mm

20 Accelerator Operation T / SY Smooth

21 Lever Brackets Tightness LF Tight

22 Switch Modules Tightness LF Tight

23 Steering Movement T Free

24 Clip on Handle Bar fasteners LF

25 DOME Lock Nut T- Stem LF 4.5 to 5.5 Kgm

26 Brake / Tail Light NW /F No Defects

27 Electrical Switch Operation NW / F No Defects

28 Head lamp Low & High beam light NW / F No Defects

29 Parking light NW / F No Defects

30 Front / Rear brakes switch operation NW / F No Defects

31 Initial (ZPD) operation NW / F No Defects

32 Neutral Lamp NW / F No Defects

33 Speedo / odo working NW /F No Defects

34 Battery indication NW /F No Defects

35 Trip A Check up NW /F No Defects

36 Trip B Check up NW /F No Defects

37 Cluster Illumination check NW /F No Defects

38 High beam tell tale NW /F No Defects

39 Trafficator tell tale NW /F No Defects

40 Fuel level Indication NW /F No Defects

41 Seat Alignment M

42 Seat Lock Cable H / NW / LF

43 Seat Catcher Mounting Bolt LF

44 Seat Cover Fit and finish

ENGINE OIL

Battery Make :

Lock Number:

FUEL TANK

CLUTCH

FRONT WHEEL

HANDLE BAR CONTROLS &

ELECTRICAL SWITCH

OPERATIONS

SEAT ASSY

ELECTRICALS

INSTRUMENT CLUSTER

NoiseMisalignment LeakStarting

Trouble/Missing Less Wobbling LooseFitment

Discharing Tight Fused Scratch Pulling WrongFitment

Hard JerkingVibration

M N V L ST LESS W LF D T F SC P WF H J

Excess Play Different Sticky NotAvailable

Smoke AdjustmentNot

Working Paint Defect Rust Peel Off Dull

Dent

Excessive Oil Rubbing Not ChargingSpongy

EP DF SG SY NA SK AD NW PD R PO DU

DN

EO RB NC

INSTRUCTIONS

1. Check the vehicle thoroughly for any transit damages or

shortage of parts.

2. Carry out all jobs listed under Pre-delivery Inspection Schedule.

3. Thoroughly road - test the vehicle for performance.

4. Please ensure delivery of the vehicle in brand new condition.

5. Claim transit loss and damage through ‘TRANSIT’ insurance only.

6. Claim Parts replaced for Manufacturing defects only under

warranty.

Format No : F/14A/CS/02, Oct. 2013 DLR / CS COPY

45 Rr. Brake Pedal Free Play T / EP 10-15mm

46Brake Fluid maximum level check up in the rear

Master CylinderLow

47 Routings of brake hose, twist or routing of hose. WF

48 Drive Chain Tension / slackness T / EP 20 -25 mm

49 Rear Wheel Rotation W / T / LF / NFree (Check Spokes

Looseness & Runout

50 Rear Sprocket Mounting Screws LF

51 Chain Guard Position M /WF

52 Rear Mudguard Alignment M Straight

53 Rear Tyre Pressure LESS 32PSI

54 Rear Tyre Condition (Check Tyre Line Seating) WF Good

55 RR Shock Absorber Operation / Adjustment H / N / AD Smooth

56 Swing Arm Bolts Fitment LF

57 Rider Foot Rest Foldable Function LH / RH H / NW

58 Presence of Foot Rest Peg / circlip Missing

59 Mudguards - Paint Related SC / PD / R / DN No Defects

60 Fuel Tank - Paint Related SC / PD / R / DN No Defects

61 side panel - Paint Related SC / PD / R / DN No Defects

62 Powder Coated Parts (Scratch/ Rust / Chipped OFF) SC / PD / R No Defects

63 Plated Parts (Scratch/ Rusty) SC / R / PO No Defects

64 Indicators Alignment M No Defect

65 Nuts, bolts,fasteners (Torque) LF

Tight (RH,LH Cover / Engine

Foundation / Accessories/

Wheel Nut)

66 Owner's Manual & Tool Kit Content - -

67 Spare fuse in fuse carrier NA -

68 Starting (Kick Start / Self Start) ST / N Easy Start

69 Front / Rear Brakes Effectiveness/ Feel AD / SG Sharp

70 One side pulling P Straight

71 ExcessiveVibration V

72 Wobbling W No Defects

73 Fork / Chain Noise N No Defects

74 Engine Performance / Gear Shifting N / ST / J / H Smooth

75 Silencer Heat shield / Exhaust pipe guardLF / V / SC / DN /

R / PO No Defects

76 Any Rattling / Squeaking Noise NNil (Silencer / Accessories /

Body Parts / Suspension)

77 Easy Start (Hot condition) ST / NW

78 Leak LNo Leak (Oil/ Fuel/ Hydraulic/

Acid leakage)

79 Smoke SK / EO No Smoke

80 Cam Noise / Top End Noise N

Any OTHER

Note ** Please inform plant in case of any engine dismantling during the PDI stage

REAR WHEEL

TEST RIDE

STATIC CHECK (AFTER

TEST RIDE)

AESTHETICS

OTHERS

SWING ARM / FOOT REST

We congratulate you on becoming a proud owner of Royal Enfield bike. We requestyou to give this feedback after completion of the delivery process.

BIKE INSTALLATION CONFIRMATION BY CUSTOMER

1 Bike Documents explained (Invoice, Insurance, RC / Road Tax Receipt)2 Owner’s Manual received3 Recommended Lubricants explained4 Maintenance Schedule sheet in Owner’s Manual shown and explained5 Next Free Service due explained6 All Free / Paid Services explained7 Warranty Guidelines explained8 “Running in period” details shown in the manual explained9 Service Station Address given and Location explained

10 Service Incharge Name & Mobile No given11 Bike delivered in neat and clean condition12 Tool Kit & First Aid Kit received and explained

NOYES

Suggestions If Any:

CUSTOMERSIGNATURE

Model: Registration No.:

Chassis No.:

We thank you and request you to return this filled up form to the person whodid the bike installation for you

KEEP RIDINGP

13 Control Switches & Disc Brake System usage explained14 Fuse Box location shown and explained15 Recommended Tyre Pressure explained16 Bike starting & Gear shifting procedure explained17 Quantity of Fuel in Fuel Tank informed18 Bike orientation & short distance drive provided19 Date and Time of Installation20 Name of Person who did Installation

NOYES

FORM 22[See Rules 47(g), 115, 124 (2), 126A and 127 (1), 127 (2)]

INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETYSTANDARDS OF COMPONENTS AND ROAD WORTHINESS

Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and therules made there under, including the following mass emission norms:

Brand name of the vehicle :-

Chassis number :-

Engine number/motor number :-(in case of battery operated vehicles)

Sub-rule No. of rule :- 115(2)(i), 115(14)(F)

Emission norms :- Bharat Stage III[Bharat Stage-I/II/III/Bharat (Trem) Stage-III etc.]

Date :

Continental GT

For ROYAL ENFIELD

Quality Assurance

Owners Manual Continental GT

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Transcript of Owners Manual Continental GT