Continental GT Owners Manual

1
Foreword
The Royal Enfield Continental GT is our lightest, fastest, and most powerful motorcycle in production. Its a machine
with a story, a nod to motorcyclings finest hour, the best expression yet of a cultural phenomenon that has simply
refused to fade away - the cafe racer.
And now you have one of your own. Congratulations!
Your meticulously re-engineered Continental GT debuts a twin downtube cradle frame chassis developed by the
renowned Harris Performance from UK. A new engine displaces 535cc and dollops of torque, when you need it. With
gas-charged rear shock absorbers from Paoli and Brembo disc brakes, you stay in charge. With an aerodynamic
seating position, Pirelli Sports Demon tyres and a remapped ECU, the new Continental GT is part homage, part
engineering tour-de-force.
This manual will help you to operate your motorcycle and guide you to wholly maintain it. We have also provided tips
on safe riding and on minor adjustments for the care of your motorcycle. Please avail the four free services at the
nearest Authorised Service Point at the appropriate time to maintain your motorcycle in top riding condition. We
request you to carefully read the terms and conditions of warranty and other useful information given in this manual
before starting to use your Continental GT. Log on to the exciting world of Royal Enfield on www.royalenfield.com to
get to know more about the company, its products and news from time to time.
Welcome to the world of the Rockers, and enjoy your burn-ups atop this spectacular machine.
2
All information in this manual is based on the latest product information available at the time of publication. Due to
continuous improvements or other changes, there may be discrepancies between information in this manual and your
vehicle. Royal Enfield reserves the right to make production changes at any time without prior notice and without
incurring any obligation to make same or similar changes to vehicles previously built or sold.
All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical
specifications are subject to change without prior notice.
Copyright 2014 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this manual shall be copied,
distributed or otherwise dealt without the express permission in writing from Royal Enfield.
Notice
Part No. 585441/A / Revision 1.0 / Qty. 500 / Apr. 2014
Disclaimer
This model fitted with tubeless tyre is provided with
an inner tube.
Failure to use an inner tube in a spoked wheel will
cause def l at i on of the tyr e r esul t i ng i n l oss of
motorcycle control.
The approved tyres marked wi th TUBELESS are
suitable for use with inner tube.
3
PERSONAL & VEHICLE INFORMATION....... 6
FREE SERVICE RECORD ........................... 7
SAFETY DEFINITIONS ............................ 8
TECHNICAL SPECIFICATIONS .................... 9
Engine ................................................ 9
Ignition System ................................... 10
Transmission ...................................... 10
Electricals ........................................... 11
Chassis .............................................. 12
Dimensions ......................................... 13
Weights .............................................. 13
SAFE RIDING TIPS/GUIDELINES ................ 14
SAFE & HAPPY RIDING ............................ 18
RULES OF THE ROAD ............................... 19
VEHICLE IDENTI. NUMBER-DETAILS .......... 21
KEY PARTS LOCATION............................. 22
Right Side View.................................. 22
Left Side View.................................... 23
Top Vi ew ............................................ 24
OPERATION OF CONTROLS ................... 25
Ignition Switch.................................... 25
Steering Lock ..................................... 26
Steering Unlock .................................. 26
Fuel Tank Cap...................................... 27
Side Panel LH / Battery Cover ............ 27
Utility Box .......................................... 27
Side PANEL RH ................................. 27
Alpha-Numeric display unit.................. 28
Head Lamp Switch............................... 30
Head Lamp Day Flash.......................... 30
Dip Switch ......................................... 30
Engine Start Switch ............................ 31
Engine Stop Switch ............................ 31
Turn Signal Switch ............................. 31
Horn .................................................. 32
Contents
4
Contents
Manual Bi Starter (choke) ................... 32
PRE OPERATIONAL CHECKS .................... 33
RUNNING IN PERIOD.................................. 34
ELECTRONIC FUEL INJECTION (EFI) ......... 35
EFI .................................................... 35
The Advantages of EFI ....................... 35
Malfunction Indicator Lamp (MIL) ......... 35
ROLL OVER SENSOR ............................... 36
STARTING ................................................ 37
GEAR SHIFTING ....................................... 40
PARKING .................................................. 41
Center Stand ...................................... 41
Side Stand ......................................... 41
TOOLS & FIRST AID KIT............................... 42
RECOMMENDED LUBRICANTS................... 43
PERIODICAL MAINTENANCE ..................... 44
MINOR MAINTENANCE TIPS ...................... 48
Control Cables, Hand lever,
Center / Side Stand Pivots .................. 48
Oil Level Inspection ............................ 48
Engine oil change ............................... 49
Spark Plug ......................................... 50
Brake fluid (Front & Rear) ................... 51
Inspection of tyres and wheels .......... 51
Tyre pressure..................................... 52
Front Wheel removal .......................... 52
Front Wheel reassembly ..................... 53
Rear wheel removal ........................... 54
Rear wheel reassembly...................... 55
Adjustments-Clutch lever free play .... 57
Rear brake light switch adjustment...... 57
Drive Chain free play .......................... 58
Chain lock fitment ............................... 59
Adj. of gas filled shockabsorber ......... 60
Removal of Battery from the Vehicle..... 61
5
Contents
Battery Maintenance........................... 61
Reassembly of Battery on Vehicle ...... 62
CHANGING ELECTRICAL COMPONENTS.... 64
Head Lamp Bulb Replacement ............ 64
Tail Lamp bulb Replacement ................ 65
Traf ficator bulb Replacement .............. 65
Fuse .................................................. 66
Blade fuse usage list .......................... 66
Air Filter Paper element......................... 67
WASHING PROCEDURE............................. 68
Precautions ........................................ 68
Af ter washing..................................... 68
STORAGE PRECAUTION ........................... 70
Preparing the motorcycle for re-use ... 71
LONG TRIP PRECAUTIONS ....................... 72
COMPLETE WIRING DIAGRAM (Domestic) . 73
TROUBLE SHOOTING ............................... 74
Engine fails to start ............................ 74
Engine misfiring ................................. 75
Poor pickup ....................................... 75
White / Blue smoke ............................ 76
Engine overheating ............................ 76
Excessive f uel consumption................ 76
Brakes Poor ........................................ 77
Vehicl e wobbl es.................................. 77
Electricals .......................................... 77
Electronic Fuel Injection (EFI) .............. 78
WARRANTY ............................................. 79
EMISSION WARRANTY.............................. 81
FREE SERVICE COUPONS ......................... 86
PAID SERVICE/MAINTENANCE RECORD..... 95
ALL INDIA ROAD SIGNS ........................... 103
LOG BOOK ............................................... 104
NOTES .................................................... 108
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 free
services at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you
and as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, to the service outlet.
Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, grease etc.
used for all free services are chargeable to the customer.
NOTE : Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.
Date of Service
Kms Covered
Servicing ASP /
Dealers Name
Address
1
st
Service 4
th
Service 2
nd
Service 3
rd
Service
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Free Service Record
8
The information given under the titles: Warning, Caution and Note are for your safety and for the care and safety to
your motorcycle and others. Please read these carefully and if disregarded it may result in injury to yourself or others
and damages to the motorcycle
Statement in this manual preceded by the following words are with special significance.
Warning
Indicates a potentially hazardous situation, which if not avoided, could result in serious injury or damage.
CAUTION :
Indicates a potentially hazardous situation , if not avoided, may result in minor or moderate injury or damage.
NOTE :
Indicates important and useful messages for clear understanding.
Safety Definitions
9
Technical 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)
10
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
11
ELECTRICALS
Generation................................................ Alternator
System ..................................................... 12V DC
Battery...................................................... 12V - 14 AH
Head lamp................................................. 12V, H4 - 60/55 W,
.......................................................... Halogen Bulb
Brake / Tail lamp ....................................... 21/5 W
Turn signal ................................................ 12V, 10W - 4 nos.
Instrument Cluster .................................... Digital instrument Cluster with LCD
High beam indicator .................................. 12V, 0.2W (L.E.D.)
Neutral Telltale Bulb .................................. 12V, 1.12W
Horn (Dual) ............................................... 12V, 2.5A (dual tone - LT, HT)
Starter Motor ............................................ 12V, 0.9 KW
WARNING
Using bul bs / ot her elect r ical
gadgets other than specified rating may
lead to over loading / erratic behaviour /
premature failure of electrical system.
Modifications on the bike which are not
approved by Royal Enfield may not only
disqualify for warranty, but also affects
performance of the bike.
12
CHASSIS
Frame ....................................................... Tubular steel double cradle
Tyre size .................................................. Front: 100/90-18 M/C 56H
.......................................................... Rear: 130/70-18 M/C 63H
Tyre pressure........................................... Front- Solo: 1.41 Kg/cm2 (20 PSI)
.......................................................... Pillion: 1.55 Kg/cm2 (22 PSI)
.......................................................... Rear- Solo: 2.11 Kg/cm2 (30 PSI)
.......................................................... Pillion: 2.25 Kg/cm2 (32 PSI)
Fuel tank capacity .................................... 13.5 Litres***
Low fuel warning..................................... 3.00 Litres***
Suspension .............................................. Front: Telescopic, Stroke 110mm
.......................................................... Rear: Gas Charged, Stroke 80 mm
Front fork oil capacity .............................. 430 ml per leg
Front fork oil ............................................. Gabriel Fork Oil 2W 35
Hydraulic Brakes ...................................... Front: 300 mm dia floating disc, twin piston floating caliper
.......................................................... Rear: 240 mm dia disc, single piston floating caliper
Brake oil grade ......................................... DOT 3 or DOT 4
Brake oil capacity ..................................... Front: 50 ml
.......................................................... Rear: 100 ml
Note:
***Fuel tank capacity given
here is approximate. It can
vary margi nal l y fr om thi s
specified value.
13
DIMENSIONS
Length ...................................................... 2060 mm
Width ........................................................ 760 mm
Height ....................................................... 1070 mm
Wheel base .............................................. 1360 mm
Saddle height ........................................... 800 mm
Ground clearance .................................... 140 mm
WEIGHTS
Kerb Weight (with 90% Fuel) ................... 185 Kg
Gross vehicle weight ............................... 365 Kg
NOTE :
1. Values / Dimensions given above are for your guidance only.
2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.
NOTE: BS III
This vehicle meets Emission Norms -
Bharat (Trem) Stage - III
14
Safe Riding Tips / Guidelines
Before operat ing your new motorcycl e, we
request you to carefully read and follow the
operating and maintenance instructions detailed
in this manual for the safety of your own, your
motorcycle, and also that of others.
Know and respect the rules of the road. Please
be a safe rider for your own safety and for others
in road.
Before starting the motorcycle, check for proper
operation of brakes, clutch, gear shifter, handle
bar controls, tyre pressures, fuel and oil levels.
Use only genuine Royal Enfield spare parts and
approved accessor i es. Use of ot her
manufacturers performance parts may affect
the performance of your motorcycle and render
the motorcycle void of warranty. See your Royal
Enfield dealer for details.
Whenever refuelling your motorcycle, please
exercise utmost caution and carefully observe
the following rules.
DO NOT smoke and please ensure that
there are no open flames or sparks near the
motorcycle, when refuelling OR servicing
the fuel system.
Switch OFF mobile phones and other hand
held electronic devices. Open the fuel filler
cap slowly.
Ref uel in a well vent ilat ed area with the
engine turned off.
DO NOT fill the tank to its brim. Please fill
fuel only till the bottom of the filler neck
insert, so as to leave air space in the fuel
tank to allow for fuel expansion.
Warning
Royal Enfield cautions you against the use of certain
nonstandard parts such as aftermarket and custom
made extended front forks or suspensions, which may
adversely affect performance and handling. Removing
or al t eri ng or i gi nal part s may adversel y af f ect
performance and could result in to an accident.
15
A new motorcycle must be operated according
t o t he special r unni ng-i n- procedure. See
running-in-procedure mentioned in Page No. 34.
Operate motorcycle only at moderate speeds and
out of traffic until you have become thoroughly
f amil iar wi t h i t s oper at ion and handl ing
characteristics under all conditions.
DO NOT exceed the legal speed limit or drive too
fast for existing conditions. Always reduce speed
when poor driving conditions exist. High speed
increases the influence of any other condition
affecting stability and increases the possibility of
loss of control.
NOTE :
If you are an inexperienced rider we recommend that
you obtain formal training on correct motorcycle riding
techniques and become thoroughly familiar with the
operation of your particular motorcycle. New riders
should gain experience under various conditions while
driving at moderate speeds.
Pay strict att enti on to road surf aces and wind
conditions. Any two wheeled vehicle may be subject
to the following upsetting forces:
Wind blasts from passing trucks.
Rough uneven road surfaces.
Slippery road surfaces.
These f or ces may aff ect t he handl i ng
characteristics of your motorcycle. If this happens,
reduce speed and guide the motorcycle relaxed to
a controlled condition. Do not brake abruptly.
Operat e your mot or cycl e def ensi vely.
Remember that, a motorcycle does not afford
the same protection as an automobile in an
accident. One of the most common accident
situations occurs when the driver of the other
vehicle fails to see or recognize a motorcycle
and turns into the oncoming motorcyclist.
16
Wear an approved helmet, clothing, and foot
gear suited for riding a motorcycle. Bright OR
light colours are best for greater visibility in
traffic, specially at night. Avoid loose, flowing
garments and scarves.
When carr yi ng a pil li on ri der, i t i s your
responsibility to instruct them on proper riding
procedures.
DO NOT allow other individuals, under any
circumst ances, t o operate your motorcycl e
unless you know they are experienced, licensed
riders and are thoroughl y famil iar wit h the
operating conditions of your motorcycle.
Warning
Regularly inspect shock absorbers and front forks
and look for leaks. Replace worn out parts. Worn
out parts can adversely affect stability and handling.
Warning
For your personal welfare, all the listed service and
mai nt enance r ecommendat i ons should be
performed. Lack of regular maintenance at the
suggested intervals may affect the safe operation
of your motorcycle.
Warning
Avoid any contact with the exhaust system. Wear
clothing that will completely cover the legs while
riding. The exhaust system gets very hot when the
engine is running and remains too hot, even after the
engine is turned off. Failure to wear proper or protective
clothing could result in serious injury.
Warning
Exhaust gases cont ai ns poi sonous car bon
monoxide and chemicals, known to cause Cancer,
Birth defects or other reproductive defects.
17
Warning
Mot or cycl e bat t eri es cont ain l ead and l ead
components, acids and chemicals known to cause
cancer, birth defects or other reproductive harm.
Exercise extreme caution while handling a battery.
Wash hands thoroughly whenever a batt ery is
handled.
Warning
Consult your Royal Enfield Dealer regarding any
questions or problems that occur in the operation
of your motorcycle. Failure to do so may aggravate
an initial problem, cause costly repairs & jeopardize
your personal safety.
Warning
DO NOT tow a disabled motorcycle. The steering
and handling of the disabled motorcycle will be
impaired due to the force of the towline. If a disabled
motorcycle must be transported, use a truck or a
trailer. Towing a motorcycle may cause loss of
control of the motorcycle in the front, leading to an
accident.
Warning
DO NOT pull a trailer behind a motorcycle. Towing
a trailer may cause reduced braking efficiency, tyre
overloading and unstable handling. Towing a trailer
may cause loss of control of the motorcycle in the
front, leading to an accident.
18
Safe & 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 reflecting
strips of radium stickers at the front and rear.
NOTE :
A light coloured shirt enables greater visibility to other
road users specially during nights.
CAUTION :
Loose clothing may get caught on moving parts of
your mot orcycle.
SITTING POSTURE
Correct sitting posture is a pre-requisite for stable
and safe riding
Sit in lean forwarded position.
Keep your elbows close to your body
Hold the handle bar grips, close to its inner end
Look extensively ahead, including rear view
mirrors, without turning the head.
BRAKING
Appl y f r ont and r ear br akes gent l y and
simultaneously for maximum braking efficiency.
WARNING
Applying any one of the brakes suddenly may cause
the vehicle to skid. The hydraulic disc brakes fitted
on your motorcycle require very less effort. High effort
or sudden application may lock the wheel. Please use
utmost caution while applying the brakes.
While riding on wet or bad road conditions use
brakes cautiously.
19
Rules of the Road
Be sure your number plate is installed in the
position specified by law and it is clearly visible
at all times.
Ride at a safe speed that is consistent with the
type of road surface you are on. Pay strict
attention to whether the surface is :
Dry
Oily
Icy
Wet
Watch for loose debris, such as leaves, slippery
substances or loose gravel that can hamper the
stability of your vehicle.
DO NOT exceed the legal speed limit or drive
too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High
speed i ncreases the inf luence of any other
condition affecting stability and increases the
possibility of loss of control.
Keep to the correct side of the road center line
when meeting oncoming vehicle.
Actuate your turn signals and exercise caution
when passing other vehicles going in the same
direction. Never t ry to pass anot her vehicle
goi ng i n t he same di rect ion at st r eet
intersections, on curves, or when going up/or
down a hill.
At street intersection give the right-of-way to
t he vehicl e on your lef t or ri ght . DO NOT
presume you have the right-of-way.
Always signal when preparing to stop, turn or
pass.
While t urning eit her right or lef t, watch f or
pedestrians, animals, as well as vehicles.
All traffic signs, including manual controls at
i nt ersect ions, shoul d be obeyed prompt ly.
SLOW DOWN at traffic signs near schools and
CAUTION signs at railroad crossings.
20
When intending to turn, signal at least 100 feet
(30.5 meters) before reaching the turning. Be
close t o t he center line (unless l ocal rules
require otherwise), slow down and then turn
carefully.
Never jump a traffic light. When a
change is imminent f rom GO t o
STOP ( or vi ce versa) at
intersections, slow down and wait
for the light to change to green.
Never run through a yellow or red
traffic light.
DO NOT leave the curb or parking area without
signalling. Be sure your way is clear to enter
moving traffic. A moving line of traffic always
has the right-of -way.
When parking the motorcycle, park on a firm
and flat surface to prevent it from falling over.
Protect your mot orcycle against t heft . Af ter
parking your motorcycle, ensure that steering
head is locked and then remove the Ignition key.
Rules of the Road
NOTE :
To hel p you t o est abl i sh the rel ati ve di stance of
vehicles behind your motorcycle, adjust each mirror
in such a way, that a small portion of your shoulder is
visible and a large portion behind your motorcycle is
seen clearly.
SIDE VIEW MIRRORS
Your motorcycles is equipped with convex mirrors
and have a curved surface. This type of mirror is
designed to give a much wider view of the rear than
a normal f lat mi rror. However, cars and ot her
obj ects seen in this type of mirror will look smaller
and farther away than when seen in a flat mirror.
Use care when j udging t he size or distance of
obj ects seen in these mirrors.
Red
Yellow
Green
21
Vehicle 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 Motor
5. Horn
6. RH Side Panel
7. RH Trafficator Rear
1
2 6
7
RIGHT SIDE VIEW
4 3
Key Parts Location
5
23
Key Parts Location
7
1
2
3
6
5
4
LEFT SIDE VIEW
1. Trafficator front LH
2. Spark plug
3. Gear Change Pedal
4. Centre stand
5. Side Stand
6. Side Panel LH / Battery Cover
7. Trafficator rear LH
24
Key Parts Location
1. Turn signal switch
2. Horn button
3. Clutch lever
4. Day flash switch
5. Head lamp dip switch
TOP VIEW
6. Manual Bistarter / Choke
7. Speedometer
8. Ignition switch
9. Malfunction Indicator Lamp
10. Tacho Meter
11. Engine Kill switch
12. Park / head light switch
13. Electric Start Switch
14. Fuel tank cap
1
2
3
4 8 11
12
13
14
9 7 5 6 10
25
Operation of Controls
IGNITION SWITCH
Insert ignition key and turn clockwise direction
to ON. Once you turn on the ignition key all the
indicating lights in instrument cluster starts
glowing on for few seconds and the engine will
get ready to start. The key cannot be removed
from ON possition.
Turn the ignition key in anticlockwise direction
to OFF. Once you turn off, all the electrical
syst ems goes off . Now t he key can be
removed.
OFF ON
26
STEERING LOCK
Turn the handle bar to extreme left or right position.
Push the key inside in OFF position, press
and further turn to anticlockwise direction to
lock the steering system.
The key can be removed from the lock in this
position.
STEERING UNLOCK
CAUTION :
Do not lubricate barrel locks with petroleum based
lubricants or graphite. Inoperative locks may result in
damage to your vehicle.
Push the key in steering lock Position, and turn
clockwise direction to unlock the steering.
The key can be removed from the lock in this
position.
CAUTION :
Protect your motorcycle against theft. After parking
your Motorcycle and lock the steering, then remove
the key from combination switch.
27
FUEL TANK CAP
Turn key clockwise
to open. Press the
cap to lock with key
in position.
NOTE :
Key can be removed
only in locked position.
SIDE PANEL RH
Ut i l i t y box i s
pr ovi ded at t he
bot t om ar ea of
battery carrier.
I t i s cover ed wi t h
side panel LH
SIDE PANEL LH / BATTERY COVER
Turn key clockwise to
unlock the side panel.
Pull t he si de panel
out side f or opening
the same.
Key cannot be
removed i n t hi s
position.
Unscrew the indicated
screw and then pull
t he si de panel f or
opening the same.
UTILITY BOX
28
Warning
Do not attempt to change any setting while riding the
motorcycle. It may cause loss of control leading to an
accident.
ALPHA-NUMERIC DISPLAY UNIT
This unit in the
speedometer consists
of
1. Odometer
2. Trip A
3. Trip B
4. Fuel level indicator
ODOMETER MODE
Odometer mode is the
initial display mode of
t his uni t . It displays
odomet er readi ng by
default.
NOTE :
Once you turn ON the ignition key, whatever was the
last selection mode will get displayed.
TRIP METER MODE
A light push for less
t han one second on
t he PUSH but t on
switch will change the
display from odometer
to Trip meter (TRIP A)
NOTE :
For resetting the Trip Meter
1. Set the display as TRIP A or B as a current mode.
2. Press the PUSH button for more than 3 Seconds.
3. Automatically the display will become zero.
Again another press on the PUSH button switch
will change the display from TRIP A to TRIP B.
Push Button
Swi tch
Alpha Numeric Display
29
The display bars of t he fuel met er di sappears
t owar ds t he Empt y ( E) when t he f uel level
decreases.
when last bar start blinking (less than 3 litres), refuel
the bike at the earliest.
NOTE :
If the last bar of the fuel meter is blinking continuously
af ter fueling, visit a Royal Enfield authorised dealer
and check the same.
FUEL LEVEL INDICATOR
The fuel l evel indicator
indicates the level of fuel
in the fuel tank.
If the battery voltage is less than 12 volts, the low
voltage indicator will start glowing continuously.
While the ignition is ON, low voltage indicator
symbol will glow until engine reaches 700 RPM.
In running condition if the battery voltage is below
12 Volts for more than 3 seconds continuously, the
low voltage indicator will start glowing.
BATTERY LOW VOLTAGE INDICATOR
Battery low voltage indicator
30
DIP SWITCH HEAD LAMP DAY FLASH
PRESS FOR HEAD LIGHT FLASH LOW BEAM HIGH BEAM
HEAD LAMP SWITCH
HEAD LAMP ON
POSITION LAMP
HEAD LAMP OFF
31
ENGINE STOP SWITCH
ENGINE ON ENGINE OFF
TURN SIGNAL SWITCH
LEFT RIGHT OFF (PUSH TO OFF)
ENGINE START SWITCH
PRESS
32
MANUAL BI STARTER (CHOKE)
HORN
PRESS
Apply choke in cold start condition while starting the Bike
33
Pre Operational Checks
A careful check of the following must be carried out
every time before riding and specially after long periods
of storage to determine if any additional maintenance
is necessary.
1. Adequate fuel in the tank.
2. Tyres for correct pressure, abrasions or cuts.
3. Rear chain for proper tension and sufficient
lubrication.
4. Brakes, st eer i ng and t hr ot t le f or proper
responsiveness.
5. Cable for fraying or crimping and free operation.
Warning
For your personal welfare and saf ety, all the points
mentioned above should be performed periodically.
Failure to do so may affect safe operation, damage
your mot orcycl e and coul d resul t i n an acci dent
causing serious injury.
6. Engine oil level.
7. Wheel spokes for proper t ightness and no
breakage.
8. Headlamp, tail lamp, brake lamp and indicator
lamps for proper functioning.
34
Running In Period
Proper running-In is very i mportant f or obtaining
maximum lif e and performance of a new motorcycle.
The following guidelines explain proper running-in
procedures.
Since the engine is brand new, it should not be loaded
excessively for the first 2,000 kilometers. During the
first few hundred kilometers, the mating parts in the
engine will wear and polish themselves to the correct
operati ng cl earances. Dri ving wi t h prol onged f ul l
throttle operation, or in any high speed conditions
might result in excessive heating of the engine and
cause abnormal wear of the moving parts and hence
the same must be avoided.
1. 0-500 Kms :
The recommended speeds f or t he f i r st 500
Kilometers is below 50 to 60 Kmph. During this
period avoid operating the motorcycle with full
throttle opening. Stop the motorcycle for about 5
to 10 minutes to let it cool down, after every hour
of running. Vary the speed of the motorcycl e
regul arl y duri ng runni ng but avoid usi ng the
motorcycle above 1/2 throttle opening position.
2. 501-2000 Kms :
The recommended speed is below 80 90 kmph.
Avoid drivi ng the motorcycle wi th f ul l throttl e
openi ng. Vary t he speed of the motorcycl e
regularly but avoid using the motorcycle above
3/4
th
throttle opening position.
3. 2001 Kms and above
Avoi d prol onged f ul l -throttl e operati on. Vary
speed occasionally.
CAUTION :
After covering the first 500 kilometers, Please replace
the engine oil and oil filter element.
Royal Enf i el d engi nes are ai r- cool ed and
consequent ly require f orced air cool ing over the
cyl i nder and head to mai nt ai n pr oper oper ati ng
temperat ure. Extended periods of i dling may over
heat the engine, resulting in serious engine damage.
DO NOT run the engine at extremely high RPM with
clutch disengaged or transmission in neutral as it
can cause serious engine damage.
An engine running for long distances at high speed
must be given close attention to avoid overheating
and possible engine damage
35
Electronic Fuel Injection (EFI)
ELECTRONIC FUEL INJECTION (EFI)
An electronic control unit (ECU) monitors engine
performance and provides exact requirement of Air
/ Fuel mixture to the engine, through the fuel injector
by taking inputs from various sensors provided in
the motorcycle.
THE ADVANTAGES OF EFI ARE
Faster response of the engine to suit road/load
conditions.
Better power output
Lower emission
Better reliability
Excellent cold Startability
Engine Diagnostic capabilities
Maintenance free
MALFUNCTION INDICATOR LAMP (MIL)
A Mal f unct i oni ng
Indicator Lamp (MIL)
is provided in t he
RPM meter which is
located on the right
side of the Cluster
unit.
1. EFI Mal Functi on Indicator : When both the
Ignition & Engine kill switch is 0N, the MIL will
glow for few seconds and wi ll go OFF. This
indicates that all the functions of Electronic Control
Unit (ECU) and other sensors are working perfectly
and the motorcycle can be used.
In case of any malfunctioning of the ECU or other
sensors etc., the MIL will glow continuously. In the
event of any such phenomenon, it is recommended
t o take t he vehi cle to a nearest Royal Enfiel d
authorised service point for inspection and further
necessary action.
36
Rollover Sensor
ROLLOVER SENSOR Your motorcycle is fitted with a unique Roll Over
Sensor under the seat. This is a safety feature.
In the event of an accident OR if the motorcycle
falls over on any side wit h t he engine runni ng
condition, The Roll Over Sensor will switch off
Ignition and cut off f uel suppl y to prevent the
motorcycle from moving suddenly, while it is in gear.
To re-activate the system after the motorcycle has
been made upright, please switch off both t he
Ignition & Engine kill switch, wait for a few seconds
and switch ON again.
This will help to RESET the Roll Over Sensor and
the engine can be started/ run.
37
Starting
Warning
Before starting engine, always shift gears into neutral.
CAUTION :
Do not force the gear lever while attempting to shift to
neutral . Move t he mot or cycl e back & f or th and
simultaneously 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 attempt
in cold climate, release the starter button, wait
for 30 seconds bef ore pressing t he start er
button again.
Press starter button and release starter switch
once the engine starts.
A clutch switch is provided in the system for
the safety of the rider. This is to prevent the
vehicle from starting when the vehicle is in gear.
To start the engine when it is in gear, pull clutch
l ever, press t he st art er but t on and release
slowly after the engine starts.
Turn i gni t ion
switch ON
Ensure the side
and main stands
are in released
position
Ensure that gears
are in neutral and
neut ral lamp is
glowing
38
Ensure Engi ne
stop switch is in
RUN position
Starting
Press Clutch
Lever.
Press Starter
Button and
release as soon
as engine starts
CAUTION :
Never accelerate the engine immediately after a cold
start. The engine should be allowed to run slowly for
15-30 seconds. This will allow the engine to warm up
and let oil reach all surf aces needing lubri cati on.
Failure to adhere may result in damage to the Engine.
Manual bi
Starter (choke)
NOTE :
It may be necessary to operate and hold the manual
bi starter, when starting the engine for the first time in
cold mornings, temperatures below 10C or at high
altitudes, to prevent the stalling and to keep the idling
RPM steady.
39
Starting
As soon as t he engi ne at t ai ns t he operat i ng
temperature, the RPM will raise, at which time the
manual Bi Starter should be released.
Warm up engine for 2 minutes - till idling is
consistent.
CAUTION :
Please ensure the motorcycle is not used with the
low fuel indicator bar blinking continuously. It may not
only result in the motorcycle running out of fuel. But
will also cause seri ous 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 the
cylinder head and exhaust pipe to maintain proper
operating temperature.
Never accelerate the engine abnormally in stand still
condition of the motorcycle. Failure to adhere this may
result in damage to exhaust pipe / silencer of the
engine due to over heating.
Prior to starting, check to see the fuel level from
the fuel gauge.
If the last bar is blinking refuel immediately.
40
Gear Shifting
CAUTION :
The clutch must be fully disengaged before attempting
a gear shift. Failure to fully disengage the clutch may
cause a jerky start OR stalling the engine besides
causing damage to transmission parts.
Warm up engine
for 2 minutes -
t il l idli ng i s
consistent/stable
GEAR SHIFT PATTERN
1 N 2 3 4 5
Press clutch lever towards the hand grip.
Press gear pedal with toe towards down to
engage 1st gear.
Gent l y open t hr ot t l e and r el ease cl ut ch
simultaneously. If clutch is released suddenly,
the engine may stall and cause a jerky start.
NOTE :
Always start motorcycle with gear in neutral position.
Always move the motorcycle in first gear position only.
When engine speed decreases or while climbing a
gradient or running at a reduced speed, shift to the
appropriate lower gear to prevent the engine from
stalling or straining to pull.
Press the gear
pedal upwards
wi t h t oe t o
engage 2nd
and gear.
Follow the same procedure for 3rd, 4th and 5th
gear.
41
Parking
PARKING VEHICLE ON CENTER STAND
Select a firm, flat surface
Hold handle bar straight
Lower center stand, and ensure that both the
legs of the stand are resting evenly on firm ground.
Apply pressure on the fulcrum l ever on the
center stand and pull vehicle upwards, gently.
PARKING VEHICLE ON SIDE STAND
Select a firm, flat surface
Lower Side Stand and gently tilt motorcycle to
the left till it rests firmly on the side stand.
Warning
Always park the motor cycle on a firm and flat surface. Parking in a soft ground may cause stand to sink and the
motorcycle to fall, causing injury to you or to others and damage to the motorcycle parts.
42
Tools & First Aid Kit
NOTE :
This Tool Kit is kept in Utility box. Refer Page No. 27.
S.No. Description Qty.
1. Tool Bag 1
2. Screw Driver O6 X 160 1
3. Tommy Bar 1
4. Box Spanner 21 X 24 1
5. Double End Spanner 14 X 15 1
8. Allen Key 5 MM 1
9. Allen Key 3 MM 1
10. Tyre Removal Lever 2
1
4
5 6 7
3
S.No. Description Qty.
1. Antiseptic cream 5 gms 1
2. Gauze bandage 5 cm x 2 cm 1
3. 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
43
Recommended Lubricants
ISO 14001 EMS
Operation Control Process
1. All customers are advised timely replacement of Engine Oil,
Fork Oil & Brake Oil at the dealership /ASP. In case done
privately, it is advise to reach old/used Oil to our authorised
vendor through RE Dealer/ASP
2. Similarly we advise for disposal of old/used Battery, Tube &
Tyres as mentioned in above point No.1.
Engine Oil
Grade Royal Enfield 15 W 50 API SL Grade
Engine Oil
(JASO MA)
Front Fork Oil
Grade Royal Enfield
Front Fork Oil
(or Gabriel Fork
Oil 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 element
replacement)
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.
Capacity
Front : 50 ml
Rear : 100 ml
44
Periodical Maintenance
The maintenance schedule detailed here will help you to maintain your Continental GT meticulously and to get a long
trouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileage
at which regular inspections, adjustments, replacements and lubrications must be carried out.
The frequency of the maintenance must be shortened depending upon the severity of the Riding condition OR if the
motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water
etc., Contact a nearest Royal Enfield Authorised Dealer / Service Point for expert advice and to carry out the
periodical maintenance.
Warning
For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of
regular maintenance at the suggested i ntervals may aff ect t he safe operati on of your motorcycl e causing the
motorcycle to malfunction and stall abruptly resulting in an accident and cause serious injury.
NOTE :
For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultation with a
Royal Enfield Authorised Dealer / Service Point.
Do not mix DOT 3 and DOT 4 brake fluid together.
*Carbo cleaner / Carbclik or Fuel Line Cleaner Spray. (Make - Wurth or ITW Chemin)
A : Adj ust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace
45
DESCRIPTION PAID SERVICE
S.
No.
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Months 1.5 3 6 9
FREE SERVICE
whichever is earlier
1 Engine Oil
R R R R R R
Check level at every 1000 Kms or earlier as required
2 Engine oil filter element R C R R R R R
3 Engine sump filter (oil strainer) C C C C C C C
4
Magnetic drain plug under gear box and secondary
C C C C C C C
drain plug under cranksharft in crankcase RH
5 Spark plug C&A C&A C&A C&A C&A R C&A C&A C&A C&A R
6 HT lead for crack I I I I I I I I I I I
7 Fuel hose & clip / Injector O Ring / Seal Ring I I I I R I I I R I I
8 Fuel Pump Check for screw tightness in all services
9 Accelerator & Throttle pully cable free play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold I I I I R I I I R I I
46
DESCRIPTION
S.
No.
PAID SERVICE
FREE SERVICE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Months 1.5 3 6 9
12 Air filter paper element C C C C R C C C R C C
13 Inlet / Exhaust valve seating I I
14 Cylinder head (Combustion chamber) D
15 Exhaust pipe D
16 Clutch lever free play Adjust every 1000 Kms or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L
18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet contact (below ECU Mounting) I I
21 Rear 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 I
23 Steering ball races / play adjustment A L A R A L A R A L
47
DESCRIPTION
S.
No.
PAID SERVICE
FREE SERVICE
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
48
Minor Maintenance Tips
OIL LEVEL INSPECTION
Lever Pivot
Main Stand Pivot
The following minor maintenance can be carried
out easily with simple tools. However, In case, if it
is felt that the adj ustments are best done by an
expert, we recommend that the motorcycle be taken
to a nearest Royal Enfield Authorised Dealer /
Service Point.
CONTROL CABLES, HANDLE BAR LEVER, PIVOTS,
CENTER / SIDE STAND PIVOTS
Lubricate after using the motorcycle in rain,
after waterwash or if used in dusty conditions.
Wipe the area free of dirt / grease.
Apply a few drops of oil on the pivots.
Place motorcycle on its center stand on a firm
surface.
Warm up engine for a few minutes & switch off.
The level is correct if the oil level is in the middle
of the oil level window.
Top up with recommended oil if required.
Side Stand
Pivot
MAX
MIN
49
ENGINE - OIL CHANGE
Primary
Filter Cap
Remove the oil fi lter paper element on t he
Crankcase Cover RH.
Allow the oil to drain by tilting the motorcycle to
both sides.
Wash the primary and secondary drain plugs
along with suction filter thoroughly and refit on
the crankcase after all the oil is drained out.
(Refer Periodical Maintenance Chart for frequency)
Remove primary drain cap, to drain oil & clean
suction filter, magnet.
Then remove secondary drain plug to drain oil &
clean the magnet.
Finally remove primary drain bolt to drain the
complete oil.
Primary
Drain
Plug
Secondary
Drain Plug
TILT VEHICLE RH & LH
Place motorcycle on its centre stand on a firm
flat surface.
Start engine and warm up for 2 minutes.
Keep a clean tray below the engine
50
Max
Min
Fill recommended
oil to engine till the
oil l evel i s upt o
MAX level mark in
the oil window in
Crankcase Cover
RH.
SPARK PLUG
Cleaning and adj ust i ng gap (Ref er Peri odi cal
Maintenance Chart for frequency)
Remove HT Lead and the spark plug from the
cyl inder head using the pl ug spanner and
Tommy bar.
Clean the insulator tip and electrodes of the plug
carefully using a pointed scraper or spark plug
cleaner.
Set the gap between 0.80 to 0.90 mm.
Refit the spark plug on the cylinder head and
connect H.T. Lead.
NOTE :
Replace oil filter paper element whenever oil is being
replaced.
CAUTION :
Do not fill oil over MAX mark. It may cause the engine
to smoke and result in loss of power. Do NOT use the
motorcycle if the oil is below the MIN mark. Doing
so will cause serious damage to the moving parts
inside the engine and result in an engine lock up.
Soak a new oil filter paper element in the oil and
refit 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
MIN
MAX
CAUTION :
Brake fluid is highly corrosive and can cause damage
to painted parts. Please ensure that brake fluid does
not spill on any part of the motorcycle. In the event of
a spill, please clean the area immediately with a soft
cloth (preferably a wet cloth) to avoid damage.
Dont mix DOT 3 & DOT 4 Brake fluid together.
Check if oil is below MIN level. To top Up, remove
cover and diaphragm, then top up with DOT 3 or
DOT 4 as specified.
BRAKE FLUID INSPECTION OF TYRES AND WHEELS
Inspect the tyre periodically for
tread wear, cracks and cuts.
FRONT BRAKE REAR BRAKE
MIN
Check and remove stone, splinters, nails or other
particles embedded in the tyre treads.
Bald spots / swelling may be caused by internal
damage. Replace the tyres, if defective.
Replace tyres when the tread depth has reached
the minimum as specified.
Periodically inspect wheels for spokes breakage
and wheel rim run out.
Check proper seating of the tyre beading on the
rim whenever the tyre is reassembled.
Whenever a new tyre is installed, ensure rim
and spokes do not get damaged on account of
wrong handling.
Minimum tread depth
Front tyre : 1.00 mm
Rear tyre : 2.00 mm
52
FRONT WHEEL REMOVAL Use only standard tyres & tubes inflated to
correct 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 matched
to wheel ri ms. See your Royal Enf i el d Deal er.
Mismatching tyre, tubes, rims and air valves may result
in damage to the tyre bead during mounting, allow
tyre slippage on the rim and cause tyre failure.
Place the vehicle on center stand
Place a wooden block
t he f ront end of
engine to support the
vehicle.
Loosen the pinch bolt
on the RH fork guide
by 6 mm allen key.
Hold the axle head by
double end spanner
whil e looseni ng t he
axle nut.
Remove the axle nut
along with washer.
53
Place a 4 mm thick wooden piece or cardboard
sheet between the brake pads to avoid pads
activation in the event the front brake lever is
accidently pressed.
FRONT WHEEL REASSEMBLY Tap and remove the
front wheel spindle.
Tilt the vehicle to RH
Side and take out the
wheel along wit h
wheel speed sensor
and LH side spacer.
CAUTION :
Do not press the f ront brake lever when wheel is
removed as this will result in the brake pads coming
too far out of the brake caliper.
Place the wheel speed
sensor in position.
Ensure slot on hub
and speedo sensor is
matched correctly.
I nser t t he wheel
along wi t h wheel
speed sensor and LH
spacer between the
f r ont f ork ends
ensuring the brake
di sc i s l ocat ed
bet ween t he brake
pads.
Insert and t ap t he
f ront wheel axl e
gently inside.
Refit the washer and
tighten the nut firmly.
Remove the wooden piece / card board sheet
placed between the brake pads
Locating
TAB
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 being
connected to cluster unit and then check for
proper working of speedo meter.
Press brake lever 2 or 3 times to check front
brake efficiency.
Place the vehicle on
cent er st and on a
firm and flat surface.
Observe and mark
the alignment index
marks i n t he bot h
sides of swing arm.
Remove axle nut on
the RH side.
Remove wheel spindle
from LH side along
with wheel collar and
LH side spacer.
Index mark
55
Remove the caliper
assembly by pulling
out f rom t he swing
arm slot.
CAUTION :
Do not press the rear brake pedal when wheel is
removed as this will result in the brake pads coming
too far out of the brake caliper.
Place a 4 mm thick wooden piece or cardboard
sheet between the brake pads to avoid pads
activation in the event the rear brake pedal is
accidently pressed.
Remove the distance collar.
Tilt the motorcycle towards RH side and take out
the rear wheel assembly conveniently.
REAR WHEEL REASSEMBLY
Tilt vehicle to right and
insert wheel assembly
bet ween t he swing
arms.
Posi t i on t he r ear
wheel wi t h cush
rubber on t he r ear
dr i ven f l ange /
adaptor.
Fix the LH side spacer
in rear wheel hub.
Remove the wooden
piece / card board
sheet placed between
the brake pads.
Ensure the four Cush rubbers are in position
inside the rear wheel hub.
56
Warning
Ensure the vehicle do not come out of center stand
whi l e di smant l i ng and assembl i ng the wheel
assembly.
Align the caliper bracket, wheel and swing arm
holes in-l ine and ensure di st ance collar is
placed in hub dust seal.
Insert t he cali per
assembly by pushing
i n t he proj ect ion
given i nsi de t he
swing arm. Ensure
t he brake di sc i s
l ocat ed in bet ween
the brake pads.
Ensure that swing arm
end plate is seated
properl y and t he
chain adj uster nuts
are correct l y t i ght -
ened and Locked.
Insert and tap the rear
wheel axle gently.
Index mark
CAUTION :
Do not force the spindle into
the wheel as the threads
may get damaged. Tap it
through the wheel gently.
Ensure the index marks alignments on both sides
of the swing arm are in same position for proper
wheel alignment.
Tighten the axle nut
firmly.
Adjuster End Plate
Adjuster Lock nut
57
ADJUSTMENTS - CLUTCH LEVER FREE PLAY
Clutch Lever (free play 2 - 3 mm)
Loosen the cable outer lock nut (A).
Turn the Nut (B) Clockwise to reduce the play
or Anticlockwise to increase the free play.
Check free play 2 to 3 mm at Clutch lever pivot
on handle bar end.
Tighten lock nut (A) after adjustment is done.
B
A
2 to 3 mm
REAR BRAKE LIGHT SWITCH ADJUSTMENT
If above are alright, then do the adj ustment as
mentioned below:
1. Turn the brake light switch adj ustment nut while
holding the rear brake light switch body in
position.
2. If the brake light do not glows after pressing
the pedal for approximately 25mm,turn t he
adj usting nut in clockwise direction by 2 to 3
threads and check for brake light function.
3. If the brake light continuously glows,turn the
adj usting nut in anti clockwise direction by 2
to 3 threads so as to get the positions in which
the light goes off.
The brake light glows once
you press the brake pedal.
If brake light is not glowing,
check the brake light switch
wire for proper connection
and the brake light Switch
spring for any bend,
breakage or disconnection.
58
DRIVE CHAIN FREE PLAY (PLAY 20 - 25 MM)
Pl ace mot or -
cycle on it s
center stand on
a f i rm & f lat
surface.
Shif t t he gear
into the neutral
position
Measur e t he
drive chain free
play as shown.
The drive chain
free play is 20 to
25 mm
Drive chain slack
adjusting nut
Swing Arm
reference mark
Index mark
Adj ust er
Lock nut
1. If the drive chain free play is incorrect adjust
as follows:
a. Loosen the axle nut of the rear wheel axle.
b. Loosen t he QD
sprocket spindle nut.
c. Loosen the locknut at
bot h end of t he
swing arm.
d. To reduce the free
play, turn the drive
chain slack adjusting
nut i n cl ockwi se
direction.
e. To increase the free
play, turn the drive
chain slack adjusting
nut in anticlockwise
direction and push
t he r ear wheel
f orwar d.
59
CHAIN LOCK FITMENT
The open end of the chain master link lock should
face opposite to normal direction of chain rotation.
Warning
The f itment of lock i n wrong di rection other than
shown above can lead to its falling off, and thus can
cause the sudden disconnection of the chain during
the drive.
f. Later adjust the nut on LH side by matching
the index mark with respect to RH side index.
g. Ensure that both the sides are in same index
marks.
h. Finally torque the spindle and axle nuts to 7
kgm.
i. Tighten the adjuster locknut by 13mm spanner
against chain slack adjusting nut.
Warning
Chain sl ackness beyond 30mm wi ll lead to chain
slippage.
Maintain drive chain slackness within the specified
limits at every 1000 kms interval.
Please Check the front and rear wheels are correctly
aligned, after the chain adjustment.
60
ADJUSTMENT OF GAS FILLED SHOCKABSORBER
The r ear gas f il led shock absorber i s an
adj ust able type.The spri ng t ension can be
increased or decreased.
Reduce the spring tension for low load operation
by turning the adjuster nut in the direction as
shown above by using a suitable C - spanner.
Increase t he spring t ension f or hi gh load
operation by turning the adj uster nut in oposite
direction.
Adjust both the rear shock absorbers to the same
thread possitions.
Recommended = 10 mm height adj ustment only
from factory setting.
Warning
Ridi ng the motorcycl e wi th the shock absorbers
adjusted in di ff erent posi ti ons can cause l oss of
control.
Regularly inspect shock absorbers and front forks for
any leaks.
NOTE :
Ensure accessories, fitted if any, do not foul with
rear shock absorbers. Check f or suf f i ci ent gap
between the shock absorbers and the attachments
in a condition that the rear end of the Motorcycle is
fully loaded and the shock absorbers are maximum
compressed.
61
REMOVAL OF BATTERY FROM THE VEHICLE
Unlock (turn the key clockwise) and remove
the Left side panel.
Disconnect both the terminal wires (negative
first and positive next respectively)
Remove t he bat t er y car ri er bracket by
loosening the two screws
Take out the battery.
BATTERY MAINTENANCE
The Motorcycle is provided with 12V - 14 AH
battery.
The battery must be periodically checked for
Cleanliness and corrosion free terminals.
Electrolyte level.
If elect rol yte level is low, top up wit h
distilled water only.
NOTE :
The poor contact or loose fitment of Battery terminals
may cause ECU failure.
Battery Carrier bracket screw
(-) (+)
TERMINAL TERMINAL
62
REASSEMBLY OF BATTERY ON MOTORCYCLE
Position the battery in the battery carrier such
that negative terminal of the battery is towards
the fuel pump side.
Warning
Always disconnect the negati ve (-) battery cabl e
f i rst and then t he Red posi ti ve ( +) cabl e whi l e
removing the battery connections.
NOTE :
For checki ng the battery vol tage and electrolyte
specifi c gravity, cont act authori sed Royal Enf ield
Dealer / service point or battery service centre.
CAUTION :
Do not use battery with low electrolyte level as
the battery internal cells will get damaged.
Do not overfill the battery electrolyte level as it
will spill out through the overflow pipe and cause
corrosion to vehicle parts.
Use only distilled water meant for use in batteries
to avoid damage to battery.
Smear the terminals with petroleum jelly. (Do
not 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 is
in OFF condition.
Connect t he posit i ve
terminal (Red wire) first
Connect t he negat i ve
terminal (Black wire) next.
NOTE :
Clean the wire terminals free of corrosion and keep
the terminals coated with petroleum jelly.
CAUTION :
Keep the +ve and -ve cables firmly conneted to the
respective battery terminals. Failure to do so may
result in damage to the motorcycle electrical system.
63
CHANGING ELECTRICAL COMPONENTS
HEADLAMP BULB REPLACEMENT
NOTE :
Never touch the bulb with your
fi ngers. Finger prints wil l et ch
the glass and decrease bulb life.
Loosen t he ri m
holdi ng screw on
t op and t ake out
t he head l amp
dome.
Disconnect electri-
cal connections.
Thumb push and
remove t he bulb
hol ding cl amp
gently.
Remove the bulb.
Posi t i on new bul b
i nsi de t he ref l ect or
such t hat t he t hree
proj ect ions on t he
bulb align with the slot
on the reflector.
Refix the bulb holding
clamp.
Connect the Electrical
connections.
Position head lamp doom onto the head lamp
shell and tighten the mounting screw on top.
Always hold the bulb with paper or clean dry cloth
during handling as shown in f ig.
X
64
TAIL LAMP BULB REPLACEMENT
Unlock the battery
cover
Remove t he seat
assembly by pulling
seat lock cable.
Remove t he t ai l
l i ght gl ass by
unscr ewi ng i t s
mounting screw
Replace the bulb 12V 21 / 5W.
As s emb l e
back the tail
l ight i n the
r e v e r s e
order of
dismantling
process.
Hol d t he bul b, press i nsi de and r ot at e
anticlockwise to remove the tail light bulb from
its holder.
65
TRAFFICATOR BULB REPLACEMENT
Remove the screw
from the trafficator
housing back side.
Open the Indicator
housing.
Take out the bulb
holder with help of
is screw driver.
Take out the bulb
and repl ace t he
same.
Ref it t he hol der
f i t t i ng it s lock i n
proper position.
Fix the rubber gasket
cover.
Assemble back the
i ndicat or housi ng
cover.
66
FUSE
Fuse
No.
Color
BLADE FUSE USAGE LIST
Application
Amps
1 Blue 15A RR Fuse
2 Blue 15A MAIN Fuse
3 Red 10A ECU Fuse
4 Red 10A General i ll umi nat ion/ Tai l / Traffi cator
5 Red 10A Head Lamp Fuse
6 Red 10A Instrument Cluster / Horn
7 Blue 15A Spare Fuse
8 Red 10A Spare Fuse
Warning
Electronic Control Unit (ECU) may fail due to loose
electrical connections, loose battery terminals etc.
Hence, it is very important to keep all the Electrical
connections intact.
Warning
While doing Arc welding any where in motorcycle, the battery
terminals and the Electronic Control Unit (ECU) coupler are to be
completely disconnected. Failure to do so many cause damage to
the Electrical system of the Motorcycle.
Warning
Please get the electrical system of your Motorcycle checked
thoroughly and get the faults corrected immedi ately after
experiencing any fuse failure. Not doing this can result in to
repeated fuse failures.
Usage of fuses other than specified rating will damage the complete
electrical system.
8
7
1
3
2
4
6
5
67
AIR FILTER PAPER ELEMENT
CLEAN AND REFIX : EVERY 3000 KMS
Remove the screw from the side cover bottom
side and then take out RH side cover.
Takeout air fil ter paper el ement and check
for dirt. Gently tap it as shown in fig and fix it
back.
NOTE :
It is adviceable to replace air filter paper element once
in 10,000 KMS. In case of vehicle running in dusty /
mud road condition it may be replaced as earlier as
required.
Usage of hi gh pressure compressed ai r i s not
recommended to clean air filter paper element.
Fitment of air filter paper element is reverse order of
removal process.
Remove the air filter
cover screws and
then takeout air filter
box cover.
68
Washing Procedure
PRECAUTIONS
Wash vehicle when the engine is cold.
Cover the silencer tail end and control switches
with suitable plastic bags and tie it firmly to prevent
water entry into them.
Remove ignition key and seal key hole using
adhesive tape.
Do not remove RH side cover (panel) while
washing to avoid water entry into air filter box
assembly.
Use a suitable engine degreaser, available with
your local parts store, to remove dirt or grease
from the engine external parts if required. Follow
the directions in the label carefully before using
the degreaser.
Use low pressure j et of water to clean the entire
vehicle.
Never spray water with great force on head lamp,
Meter/cluster unit, trafficator lights, front and rear
wheel hubs, electrical connections and wires,
control cables, EFI components, sparkplug,
battery,air fillter cover etc.
Use Luke warm water and mild detergent on the
painted components to remove dirt, etc.
Rinse vehicle thoroughly with plain water to
remove the detergent and wipe vehicle dry.
If possible, use compressed air and blow off
wat er part icl es from t he obscure areas of
t he vehi cle, el ect ri cal connect i ons, EFI
components etc.
X
69
Warning
Observe warnings and cautions given on labels of
cleaning compounds before it is used.
When washing your motorcycle, be careful not to get
the brakes, engine, muff lers or air cleaner etc., too
wet. Wet brake pad and / or disc can affect braking
eff i ciency. Engi ne can be started af ter washi ng.
Ensure brakes and engine are working properly before
riding in the traffic and / or in highways at high speeds.
AFTER WASHING
Ensure the vehicle is thoroughly dry by wiping
wi th a clean soft water absorbent clot h or
chamois leather.
Remove all plastic bags and adhesive tapes.
Lubricate control cables, pivots for footrest, side
stand, centre stand, brake and gear shifter
linkages, rear chain etc.with lube oil.
Polish the painted and plated surfaces using
polishing wax.
Start the bike and allow engine to idle & warm up.
Drive the motorcycle slowly, applying both brakes
intermittently to dry up the brake pads.
Test brakes for full efficiency.
Washing Procedure
70
Storage Precautions
Incase your Motorcycle is not going to be used for
a mont h or mor e, we advi se t he f oll owi ng
precautions to be taken
Carryout required repair/adj ustments on the
motorcycle.
Wash the motorcycle thoroughly and lubricate
as per the maintenance chart.
Start the engine, warm up for a few minutes
and switch off.
Drain out the fuel completely from the fuel tank
and fuel lines.
Remove the spark plug. Pour in about 20ml of
clean engine oil through spark plug hole. Close
the hole and crank engine few times and refit
the sparkplug.
Cl ean t he rear chai n t horoughly and apply
lubrication oil on it.
Remove bat t ery f rom t he bike. Cl ean i t s
termi nals and apply petroleum j elly on t he
terminals to avoid corrosion.
Maintain electrolyte level between max and
min marks, by adding distilled water and wipe
the battery dry.
St ore t he bat t ery in a cool , dry and wel l
ventilated place.
Do not place the battery in direct sun light, near
open flame or where temperature is above
40C or below 0C
Cover the silencer with plastic bags to prevent
moisture entry. Set the motorcycle on its center
stand.
Apply anti rust solution on all chrome plated
parts. Take care not to apply this solution on
rubber or painted parts.
Store motorcycle in a clean covered area free
of moisture and keep it covered to prevent dust
settling on it.
71
PREPARING THE MOTORCYCLE FOR REUSE
Remove anti rust solut ion f rom all chrome
plated parts and clean the motorcycle.
Inflate the tyres to the correct tyre pressure.
Ensure battery is fully charged and electrolyte
level is properly maintained.
Connect the battery.
Lubricate all control cables and pivots.
Check level of oil in engi ne and top up if
necessary.
Fill fuel tank with fresh petrol.
Check fuel line for any cracks or cuts.
Clean the air filter.
Remove plastic covering from the silencer.
Remove spark plug on cylinder head and pour
in a few drops of engine oil. Crank engine a
few times to lubricate cylinder walls and piston.
Clean spark plug and refit.
Switch ON the ignition switch.
Start vehicle and warm up engine for a few
minutes before riding the vehicle.
NOTE :
Do not raise the engine rpm the moment it is started,
but allow the engine to run at Idling speed.
CAUTION :
Proper long-term storage is important for the safe,
tr oubl e-f r ee operati on of your Royal Enf i el d
motorcycle.
Storage Precautions
72
CHECKS PRIOR TO THE COMMENCEMENT OF LONG
JOURNEY
Service the motorcycle thoroughly at Royal
Enfield Authorised Dealer / Service Point as per
periodical maintenance chart. (Ref. Page No. 45
to 47)
Sufficient quantity of petrol in the fuel tank for
the planned journey.
Check and correct tyre pressure if necessary.
Correct the oil levels in Engine, brake master
cylinders.
Check for good battery condition and proper
electro lyte level.
Pr oper dr ive chain t ensi on and corr ect l y
adj usted rear brakes.
Check for proper functioning of all lights & horn
etc.,
CHECKS AFTER EVERY 1500 KMS OF RUN
Tightness of all fasteners.
Tyre treads condition and wear pattern of tyres.
Battery condition and electrolyte level.
Correct oil level in engine.
Working of all lights and horn.
Proper drive chain tension.
ITEMS TO BE CARRIED
Tool kit.
First aid kit.
Bulbs for Headlight, Trafficator light and mini
Blade Fuses (15 & 10 Amps).
Accelerator and Clutch cable.
Rear chain master link lock assembly.
Spare tubes.
Foot operated Air Pump.
Insulation tape.
Spark plug (M14).
Long Trip Precautions
73
Complete Wiring Diagram
NOTE :
Complete Wiring Diagram is attached on this page.
74
Trouble Shooting
Warning
The trouble shooting section of this Owners Manual
is intended solely as a guide for diagnosing problems.
Carefully read the appropriate sections of this manual
before performing any work. Repair and maintenance
operations not listed in this Owners Manual should
be perf ormed by your Royal Enf i el d Deal er only.
Improper repair / maintenance coul d result in the
motorcycle not functioning properly or injury seriously.
I. ENGINE FAILS TO START
1) 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 firmly
4) Spark plug electrode dirty / fouled .... Clean spark plug
5) Spark plug insulation cracked ........... Replace spark plug
6) Clutch slipping ................................... *Adj ust clutch cable free play
7) Main or EFI Fuse failed................... .. Replace with new fuse
CAUSES REMEDIES
* Contact Authorised Dealer / Service Point
Warning
Please get the electrical system of your Motorcycle
checked throughtl y and get the f aul t s corrected
immediatly after experiencing any fuse failure. Not
doing this can result in to repeted fuse failures.
Usage of fuses other than spcified rating will damage
the complete electrical system.
75
Trouble Shooting
II. ENGINE MISFIRING
1) Loose spark plug cap........................ Fix cap / lead firmly
2) Spark plug fouled .............................. Clean spark plug or non specified heat range plug.
3) Any sensor loose connections ......... * Check MAP or EOT or TPS sensor wiring / coupler loose connections
4) Water in petrol tank ........................... * Clean petrol tank. Fill tank with fresh petrol.
III. POOR PICKUP
1) Brake pedal adj usted too tight ........ *Re-adj ust properly
2) Choked air filter ............................... Clean / Replace air filter
3) Rear chain adj usted too tight .......... *Re-adj ust properly
4) Under inflated tyres ......................... *Inflate to correct pressure
5) Accelerator cable free play excessive Adjust cable free play
6) Clutch Slipping ................................. *Adj ust clutch cable free play
7) Faulty fuel supply ............................. *Remove fuel pump & clean.
Fuel pump, filter / injector blocked
CAUSES REMEDIES
76
Trouble Shooting
IV. WHITE/BLUE SMOKE
1) Oil level in sump above the Top line. * Check and drain excess oil
in the oil level window .....................
V. ENGINE OVERHEATING
1) Low engine oil level ......................... Check and top-up if necessary
2) Clutch slipping ................................. * Check and correct
3) Cylinder fins not clean ..................... Clean the cylinder fins at regular intervals
VI. EXCESSIVE FUEL CONSUMPTION
1) Under inflated tyres ......................... Inflate to correct pressure
2) Choked air filter ............................... Clean / Replace
3) Fuel leakage..................................... *Check and rectify, tank float unit, drain pipe, breather pipe,
.......................................................... fuel line / pump.
CAUSES REMEDIES
77
Trouble Shooting
VII. BRAKES POOR
1) Brake pad worn / Uneven wear ....... *Replace Brake pads
2) Oil/grease on disc. ........................... *Clean and refit
3) spongy brake.................................... *fill brake fluid & remove air from the system.
VIII. VEHICLE WOBBLES
1) Under inflated tyres ......................... Inflate to correct pressure
2) Loose / Broken spokes .................... * Tighten / Replace spokes
3) Wheels misaligned .......................... * Ensure proper alignment
4) Wheel rim runout ............................. * Rectify
5) Tyres not fitted correctly .................. * Refit tyres correctly
IX. ELECTRICALS
Bulbs do not glow
1) Bulb fused ........................................ * Replace bulb
CAUSES REMEDIES
78
2) Fuse blown ....................................... * Check and Replace fuse.
3) Loose / improper connection........... * Check and correct
Horn not working
1) Fuse blown ....................................... Check and correct
2) Loose connections ........................... Check and correct
Trafficators not working
1) Loose / improper connections ......... Check and correct
2) Bulb fused ........................................ Repl ace
Brake light remains on
(1) Switch not adjusted properly.......... * Adjust connecting links properly
(2) Switch sticky .................................... * Replace switch
X. ELECTRONIC FUEL INJECTION (EFI)
Malfunctioning Indicator Lamp (MIL) glowing continuously
(1) Sensor Coupler Loose Connection . * Check for any EFI sensor coupler loose connection and correct them
(2) Any EFI Sensor Failure ...................... * Check & replace the same
Trouble Shooting
CAUSES REMEDIES
Warning
Please get the electrical system of your
Motorcycle checked thoroughly and get the
f aul ts cor rect ed i mmedi at l y af t er
experiencing any fuse failure. Not doing
this can result in to repeated fuse failures.
Usage of fuses other than specified rating
will damage the complete electrical system.
79
Warranty
Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material and
workmanship.
Royal Enfield (RE) warrants CONTINENTAL GT EFI Motor Cycle to be free from manufacturing and material defect
under normal use subj ect 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 owners manual from RE Authorised Dealer / Service Point.
4. During the warranty period, REs 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 have
been 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 to
replace 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.
80
Warranty
(b) Components like fuel filter, oil filter paper element, control cables, brake shoes / brake pads, clutch plates,
drive chain & sprocket kit, which are subj ected 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 adjustments
8. RE reserves the right to finally decide on all warranty claims
9. RE reserves the right to make changes in Design of the vehicle without any obligation to install these changes on
previously supplied vehicles.
81
Emission Warranty
In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal Enfield certifies that
the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its
range of motorcycles, in normal use to which it may be subj ected 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 warranty
policy, conditions and obligations laid down in the Owners Manual.
Royal Enfield further warranty that if on examination by its Authorised Dealer / Service Point, the motorcycle fail to
meet the specified emission standards, then the Authorised Dealer / Service Point shall take necessary corrective
measures and shall at its sole discretion, repair or replace free of charge such components of the emission control
system to meet the required emission standards.
The method/s of examination to determine the warranty conditions of the emission warranty related components will
be at the sole discretion of Royal Enfield and / or our Authorised Dealer / Service Point and results of such examination
will be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royal enfield
will have the right to charge all, or part of the cost of such examination to the customer in addition to the cost of the
components.
In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge, the
component/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeable to the
customer as per actual.
82
Emission Warranty
In case any of the components covered under emission warranty or the associated parts, are not independently
replaceable. 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 compliance
to 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 repairs
by 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 of
failure 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 conditions
as laid down in this document are met from the date of original sale of the motorcycle.
THE WARRANTY SHALL APPLY IF THE CUSTOMER
Observes all the important instructions and any other precautions listed in the owners manual.
83
Emission Warranty
Under 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 details
in the Log book.
Immediately approaches the nearest Authorised Dealer / Service Point upon discovery of failure to comply with
the IN-USE emission standard inspite of having maintained and used the vehicle in accordance with the instructions
in the owners manual and having carried out such repairs and adj ustments as may be required with a view to
establish such compliance.
Produce the Pollution Under Control certificate valid for the period immediately preceding the test during which
the failure is discovered, the test having been carried out either for obtaining a new certificate or pursuant upon
being directed by an officer as referred to in sub rule (2) of rule 116 of the Central Motor Vehicles Rules (CMVR).
Produce the Owners Manual and Log book for verification details.
Produce receipts covering maintenance of the motorcycle is specified in the owners manual from the date of
original 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 the
maintenance chart.
84
Emission Warranty
The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met with
an 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 unauthorised
manner.
The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, so that
the 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 the
conditions stipulated in the Owners 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 Enfield
in the Owners 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 in
the log book.
TIPS TO BE ON THE RIGHT SIDE OF LAW
Always get your vehicle checked to meet the emission regulations through and authorised emission checking centre.
85
Emission Warranty
Always carry a valid Pollution Under Control certificate with you at all times during the validity of the emission
warranty (30,000 Kms / 3 years from the date of first sale)
TIPS TO REDUCE POLLUTION
1. Ensure that the periodical maintenance is carried out as stipulated in the owners 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 owners manual.
5. Use lubricants as per recommendations given on grade / brand in the owners manual.
86
Free Service Coupons
It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide
four free services at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest
to you and as a token of satisfactory service, 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 to warranty consideration.
The cost of fuel, oil, oil filter element, grease etc. used for free service is chargeable to the customer.
87
1st Free Service
500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE
Customer Name : Dealer Code :
Address :
500 Kms
or
45+8 days
whichever is
earlier from the
date of sale
Enter the Details
in Free Service
Record
Received the above vehicle after the service having been done to my entire satisfaction.
Customers Signature : ................................. Date :
Contact Phone / Mobile No.:
Regn. No:
Sale Date:
Serviced Date:
Servi ced by
(Dealers/ASP Name & Address)
Frame No:
Engine No:
Vehicle Installation Form No.
ODO Reading :
Sold by (Dealers Name & Address)
1
ST
FREE
SERVICE
(Cost of oil,
oil filter element
and other
consumables
used are
chargeable to
the customer)
88
1st Free Service Activities
1. Water wash the vehicle and dry it with a clean cloth
2. Electrolyte ........................................................ Check level & top-up
3. Battery terminals ............................................. Clean and apply petroleum jelly
4. Drive chain free play........................................ Check, clean, lubricate & adjust
5. Rear brake pedal pivot ..................................... Lubricate
6. Front & Rear disc brakes ................................ Check & top up brake fluid level
7. Wheel rim Front & Rear ................................... Check spokes tightness
8. Front fork oil ..................................................... Inspect for leakage
9. Air filter element ............................................... Clean
10. Spark plug (M14) .............................................. Check, clean & adjust gap
11. H.T. Lead.......................................................... Inspect for cracks
12. Fuel pump ........................................................ Check mounting screws
13. Fuel hose ......................................................... Inspect for cracks
14. Rubber hose, Air filter to throttle body.............. Inspect for cracks
15. Accelerator cable ............................................ Adjust play
16. Clutch cable ..................................................... Adjust play
17. Engine oil sump strainer ................................... Clean
18. Engine oil .......................................................... Replace
19. Engine oil filter paper element .......................... Replace
20. Hand levers & kick starter pivot........................ Lubricate
CUSTOMER COPY
Job Card No:
Date :
Odo Reading :
Name of Dealer/
ASP with Code:
..........................
..........................
ASP / Dealers
Stamp & Signature
89
2nd Free Service
Address :
2
ND
FREE
SERVICE
3000 Kms
or
90+15 days
whichever is
earlier from the
date of sale
Enter the Details
in Free Service
Record
(Cost of oil,
oil filter element
and other
consumables
used are
chargeable to
the customer)
Regn. No:
Sale Date:
Serviced Date:
Servi ced by
Frame No:
Engine No:
ODO Reading :
90
2nd Free Service Activities
2. Electrolyte ........................................................ Check level & top-up
3. Battery terminals .............................................. Clean and apply petroleum jelly
4. Drive chain free play........................................ Check, clean, lubricate & adjust
5. Rear brake pedal pivot ..................................... Lubricate
7. Wheel rim Front & Rear ................................... Check spokes tightness
8. Front fork oil ..................................................... Inspect for leakage
9. Air filter element ............................................... Clean
10. Spark plug (M14) ............................................. Check, clean & adjust gap
11. H.T. Lead.......................................................... Inspect for cracks
12. Fuel pump ........................................................ Check mounting screws
14. Rubber hose, Air filter to throttle body.............. Inspect for cracks
15. Accelerator cable ............................................ Adjust play
16. Clutch cable ..................................................... Adjust play
17. Engine oil .......................................................... Check level & top up
18. Hand levers & kick starter pivot........................ Lubricate
19. Steering free play ............................................ Check & Adjust
20. Oil filter element, oil strainer & magnetic drain plugs.. Clean
CUSTOMER COPY
Job Card No:
Date :
Odo Reading :
Name of Dealer/
ASP with Code:
..........................
..........................
ASP / Dealers
Stamp & Signature
91
3rd Free Service
Address :
3
RD
FREE
SERVICE
6000 Kms
or
180+15 days
whichever is
earlier from the
date of sale
Enter the Details
in Free Service
Record
(Cost of oil,
oil filter element
and other
consumables
used are
chargeable to
the customer)
Regn. No:
Sale Date:
Serviced Date:
Servi ced by
Frame No:
Engine No:
ODO Reading :
92
3rd Free Service Activities
2. Electrolyte ...................................................... Check level & top-up
3. Battery terminals ............................................. Clean and apply petroleum jelly
4. Drive chain free play ....................................... Check, clean, lubricate & adjust
5. Rear brake pedal pivot .................................... Lubricate
7. Wheel rims front & rear.................................... Check spokes tightness
8. Tyre front & rear ............................................ Check wear and tread depth
9. Air filter element .............................................. Clean
10. Spark plug (M14) .............................................. Check, clean & adjust gap
11. H.T. Lead ......................................................... Inspect for cracks
12. Fuel pump ........................................................ Check
14. Rubber hose, Air filter to throttle body............. Inspect for cracks
15. Accelerator cable ............................................ Check & adjust play
16. Clutch cable .................................................... Adjust play
17. Engine oil sump strainer .................................. Clean
18. Engine oil ......................................................... Replace
19. Engine oil filter paper element .......................... Replace
20. Hand levers & kick starter pivot ....................... Lubricate
21. PAV System ................................................... Check & Clean
22. Steering system ............................................... Check, Lub. steering balls & Adj. play
CUSTOMER COPY
Job Card No:
Date :
Odo Reading :
Name of Dealer/
ASP with Code:
..........................
..........................
ASP / Dealers
Stamp & Signature
93
4th Free Service
Address :
4
TH
FREE
SERVICE
9000 Kms
or
270+15 days
whichever is
earlier from the
date of sale
Enter the Details
in Free Service
Record
(Cost of oil,
oil filter element
and other
consumables
used are
chargeable to
the customer)
Regn. No:
Sale Date:
Serviced Date:
Servi ced by
Frame No:
Engine No:
ODO Reading :
94
4th Free Service Activities
2. Electrolyte ....................................................... Check level & top-up
3. Battery terminals ............................................ Clean and apply petroleum jelly
4. Drive chain free play ....................................... Check, clean, lubricate & adjust
5. Rear brake pedal pivot .................................... Lubricate
7. Wheel rims front & rear.................................... Check spokes tightness
8. Front fork oil ..................................................... Replace oil
9. Air filter element ............................................. Clean
10. Spark plug (M14) ............................................. Check, clean & adjust gap
11. H.T. Lead ......................................................... Inspect for cracks
12. Fuel pump ........................................................ Check
14. Rubber hose, Air filter to throttle body............. Inspect for cracks
15. Accelerator cable ............................................ Check & adjust play
16. Clutch cable .................................................... Adjust play
17. Engine oil ....................................................... Check & top-up
18. Hand levers & kick starter pivot ....................... Lubricate
19. Steering free play ............................................ Check & Adjust
20. Tyres ................................................................ Check wear and tread depth
CUSTOMER COPY
Job Card No:
Date :
Odo Reading :
Name of Dealer/
ASP with Code:
..........................
..........................
ASP / Dealers
Stamp & Signature
95 Paid Service / Maintenance Record
CUSTOMER COPY
12,000 + 250 Kms. Service
Job Card No :................. Date : .........................
Odo Reading : ................. Dealer Code : .............
Brief Work Done :
Dealers Stamp & Signature
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
96
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
Paid Service / Maintenance Record
97
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
98
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
99
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
100
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
101
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
CUSTOMER COPY
Job Card No :................. Date : .........................
Brief Work Done :
DEALER / ASP COPY
Job Card No :................. Date : .........................
Brief Work Done :
102
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
DEALER / ASP COPY
Brief Work Done :
CUSTOMER COPY
Brief Work Done :
103
All India Road Signs
MANDATORY SIGNS
INFORMATION SIGNS
CAUTIONARY SIGNS
104
Sl.
No.
Date Kms. Details
Idling
CO%
Authorised Dealer / Service Point
Job Card No.
Stamp &
Signature
Log Book
105
Sl.
No.
Date Kms. Details
Idling
CO%
Job Card No.
Stamp &
Signature
Log Book
106
Sl.
No.
Date Kms. Details
Idling
CO%
Job Card No.
Stamp &
Signature
Log Book
107
Sl.
No.
Date Kms. Details
Idling
CO%
Job Card No.
Stamp &
Signature
Log Book
108
Notes
109
Notes
110
Notes
111
Notes
112
Notes
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 GT
Model : Engine No :
Dealer's Name : Location :
Colour : Key Number :
Battery Number Tyre Number Front Rear :
Aggregate Area Defect Code Measure
Defect
#1
Defect
#2
Defect
#3
Remarks
CHASSIS / ENGINE NUMBER 1 Engine / Vehicle Number Details DF Same
CONNECT BATTERY / Check
Voltage
2 Battery Charging & Vent pipe connection D / NC / Weak Cell 12.6 V BATTERY
3
Replace 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 5
Ignition Cum steering/ Side cover Lock / Cap Fuel
Tank Lock
H / 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 / N
Free (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
Noise Misalignment Leak
Starting
Trouble/Missing
Less Wobbling
Loose
Fitment
Discharing Tight Fused Scratch Pulling
Wrong
Fitment
Hard Jerking Vibration
M N V L ST LESS W LF D T F SC P WF H J
Excess Play Different Sticky
Not
Available
Smoke Adjustment
Not
Working
Paint Defect Rust Peel Off Dull
Dent
Excessive Oil Rubbing Not Charging Spongy
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
46
Brake Fluid maximum level check up in the rear
Master Cylinder
Low
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 / N
Free (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 guard
LF / V / SC / DN /
R / PO
No Defects
76 Any Rattling / Squeaking Noise N
Nil (Silencer / Accessories /
Body Parts / Suspension)
77 Easy Start (Hot condition) ST / NW
78 Leak L
No 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 request
you 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 Owners Manual received
3 Recommended Lubricants explained
4 Maintenance Schedule sheet in Owners Manual shown and explained
5 Next Free Service due explained
6 All Free / Paid Services explained
7 Warranty Guidelines explained
8 Running in period details shown in the manual explained
9 Service Station Address given and Location explained
10 Service Incharge Name & Mobile No given
11 Bike delivered in neat and clean condition
12 Tool Kit & First Aid Kit received and explained
NO YES
Suggestions If Any:
CUSTOMER
SIGNATURE
Model: Registration No.:
Chassis No.:
We thank you and request you to return this filled up form to the person who
did the bike installation for you
KEEP RIDINGP
13 Control Switches & Disc Brake System usage explained
14 Fuse Box location shown and explained
15 Recommended Tyre Pressure explained
16 Bike starting & Gear shifting procedure explained
17 Quantity of Fuel in Fuel Tank informed
18 Bike orientation & short distance drive provided
19 Date and Time of Installation
20 Name of Person who did Installation
NO YES
FORM 22
[See Rules 47(g), 115, 124 (2), 126A and 127 (1), 127 (2)]
INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETY
STANDARDS OF COMPONENTS AND ROAD WORTHINESS
Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and the
rules 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

Continental GT Owners Manual

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