We all know that during mass production of Royal Enfield bikes. The company give priority to production volumes rather than quality and good workmanship. I am a victim of the same crime. But I knew this from the time I planned to buy the bully. Since day 1 it is a DIY treatment for my bully. Not even the first service was given to the RE ASC.
Now the problem faced by me was the front handle starts to wobble in very low speed 10-20 kms/h. So checked the bearing condition and found that the front wheel was shaking but was freely rotating. So this is the usual symptoms of a worn out bearing but at 25000 kms it is too early for such failures. The reason for this pre mature wear is explained in the below DIY.
1. 24 mm socket.
2. Adjustable spanner
3. Screw driver – flat
5. Nose or normal pliers
1. Front wheel bearing 2 nos - Rs. 90 each
2. Dust cap (Optional) 2 nos – Rs. 30 each
1. Remove the speedometer cable using a nose or normal pliers.
2. Loosen the front bolt using a 10mm spanner and a 12 mm socket.
3. Loosen the nut using a 24 mm socket and an adjustable spanner.
4. Tap gently using a soft hammer and remove the spindle.
5. Remove the wheel.
6. Remove the dust cap using a flat screw driver and replace if damaged.
7. Using a rod and hammer gentle tap the centre bush to remove the bearing.
8. Remove the other bearing.
9. Clean all the internals and lubricate sufficiently using grease.
10. Install the new bearings and the dust cap.
11. Now the re-assembly is the critical part. First install all the parts like we have removed them. First tighten the nut using a 24 mm socket to the required torque. Then only the smaller bolt has to be tightened using a 10 and 12 mm spanners. This is the mistake that was done during the initial assembly of the bike in the factory. They have tightened the smaller bolt which locks the front spindle first and then they tightened the 24mm nut. This has resulted in the right side front forks to bend slightly resulting in rubbing of fork guard and pre mature failure of the bearings.
12. Now after the correction. The front suspension is so soft now and the overall mileage of the bike has also increase from 42 Kms/litre to 48 Kms/Litre.
Disclaimer – Kindly take all the precautions necessary and please do it at your own risk. I am not responsible for any damage incurred by trying this process.