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1. Emission Warranty 79 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 subjected to This emission warranty comes into force from 0151 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 Owner s 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 co
2. manta ater Periodical Maintenance 4 FREE SERVICE 05 3 6 9 12 15 24 2 30 G o e eee 13 meUExwwevaveseaing J L 14 Cylinder head Combustion chamber 15 latch iever tro Adwetewry 1000 Kme or ener ae required _ 16 8 117 Rear brake pedal pv t t t t 16 Baten 66 6 6 6 6 66 6 6 6 19 Battery 20 wire eyelet behind battery carrier L giFewFokole 11111811 111 Adjust for every 1000 Kms Clean Lubricate amp adjust 24 1 111 fe Periodical Maintenance 45 TO oele ea 4215 D 25 Steering ballraces play adusiment 26 Spokes 1 1 27 Swing Armpivotbush amp spacer t ft t r v 29 Brake 1 Repacmet 111111 A Adjust C Clean D De carbonise Inspect L Lubricate R Replace NOTE For maintenance after 30 000 Kms please repeat the same frequency levels specified above in consultation with a Royal Enfield Authorised Dealer Servi
3. 26 Electricals rm 10 Side BOX 26 Chassis 11 e Battery 27 e DIMENSIONS 12 Utility BOX 27 MESI m 12 e Head lamp switch 28 SAFETY DEFINITIONS 13 e Head lamp Day flash 28 SAFE DRIVING TIPS GUIDELINES 14 e Dip ere ena seuss 28 SAFE amp HAPPY RIDING 18 e Engine Start Switch 29 RULES OF THE ROAD 19 e Engine Stop Switch 29 VEHICLE IDENTIFICATION 21 e Turn Signal Switch 29 e Chassis 21 rmm 30 e Engine 21 e Manual Bi Starter choke 30 KEY PARTS LOCATION 22 PRE OPERATIONAL CHECKS 31 e Right Side View 22 RUNNING IN PERIOD ee 32 Contents A A nm e The Advantages of EFI e Malfunction Indicator Lamp MIL ROLL OVER SENSOR STARTING GEAR SHIFTING PARKING e Center Stand e Side Stand TOOLS amp FIR
4. Bajaj 45 Champion BA 03 Bao LML Graptor Beamer 1 04 jen Bajaj Boxer amp CT BAO5 MAHINDRA Bajaj Caliber SM BA 06 NI Mahindra Stallio ma BA 07 m Mahindra Macho Bajaj Eliminator m Bajaj Cageva CRX 3 m Bajaj Avenger Bajaj Platina 110 125 Bajaj Discover 100 125 150 Bajaj Pulsar 135 m Bajaj Pulsar 200 220 Kinetic Boss BA 12 BAT HeroPuch TICK THE OPTION MOST SUITABLE Could be Not good Extremely better Bad Communication during waiting period F 14A CS 03 Sep 2012 DLR CS Copy Ease of booking and other formalities Bike delivery and information given Format No Dealer s Signature amp Rubber Stamp Seal ROYAL ENFIELD PRE DELIVERY INSPECTION LIST MODEL BULLET 350 ELECTRA CLASSIC 350 CLASSIC 500 BULLET 500 Defect 29 Defect Defect Code 1 2 3 Weak Battery Voltage 12V whereas Fill 2 5 Litres Capacity is Replace oil amp oil filter Check Oil level 3 Drain Drained 2 75 Litres Remove 3 Bolts system Hex 19mm 8mm X 2nos and Oil Level Drain Bolts to Drain the Hex 12mm head bolts complete Oil Ignition Side Air Filter Box Tool Box Lock Front Wheel Rotation Spokes Looseness amp Runout Aggregate CHASSIS ENGINE NUMBER CONNECT BATTERY CHECK VOLTAGE 2 3 ENGINE OIL LOCK OPERATION PETROL
5. PUMP RELAY 2 PIN WATER PROOF FUEL 2 PIN WATER PROOF a INJECTOR IGNITION SPARK PLUG 1 SPARK PLUG 2 a 2x2 8 COUPLER TRAFFICATOR REAR BRAKE SWITCH BLACK BLACK GREEN BLACK BLUE LOW FUEL SENSOR RED WHITE 2x2 3 COUPLER FUSE DETAILS MAIN FUSE ALL LOADS ECU FUSE ECU LOADS amp LIGHTING CIRCUIT FUSE SIGNALING CIRCUIT FUSE AS Gm SPARE FUSE SPARE FUSE CAUTION 1 DO NOT SHORT CIRCUIT THE FUSES 2 DO NOT USE OVER RATED FUSE 3 IF THE FUSES BLOW REPLACE WITH ORIGINAL VALUE NOTE SG SENSOR GROUND PG POWER GROUND LG LOGIC GROUND CG CHASSIS GROUND EG ENGINE GROUND Trouble Shooting 72 A Warning A Warning The trouble shooting section of this Owner s Manual is Electronic Control Unit ECU may failure due to the intended solely as a guide to diagnosing problems following reasons Carefully read the appropriate sections of this manual before performing any work Repair and maintenance operations not listed in this Owner s Manual should be a In case of loose electrical sensors wire connectors couplers or Battery terminals performed by your Royal Enfield Dealer only Improper b While doing Arc welding on Motorcycle its is repair and or maintenance could result in the motorcycle recommended to SWITCH OFF ignition not functioning properly serious injury disconnect the Battery terminals amp ECU from Main Wiring Har
6. Front M d Ali t T FRONT WHEEL ront udguard Alignment Cover Tube M RB Straight Rubbing CLUTCH 24 Fuel Tap Operation Smooth Reserve 11 11 11 2 FUEL SYSTEM 25 FuetLeak fue Leak No Leak Tank Tap REAR WHEEL 6 8 HANDLE BAR CONTROLS amp 2 9 ELECTRICAL SWITCH OPERATIONS 1 SI Rear Wheel Rotation W T LF N 21 11 11 2 Rear Tyre Condition Check Tyre Line Seating RR Shock Absorber Operation Adjustment Smooth 27 32 34 35 SC PD R No Defects Mudguards Mudguards Paint Plating Related Fuel Tank Tool Fuel Tank Paint Related idi No Defects Tool LH Air Filter Box Battery Cover SC PD R Paint Plating Related Head Lamp Casing Paint Related SC PD R No Defects EE Powder Coated Parts Scratch Rust AESTHETICS Chipped OFF Defects Mudguards Plated Parts Scratch Rusty SC R PO Fuel Tank Wheel Rim Indicator 42 Buffed components poor Buffing amp Scratches SC DU No Defects Seat Alignment M No Defects Indicators Alignment MFR Amber No Defect Colour Stickers Knee Pads M LF SC No Defects 36 8 41 43 45 Tight RH LH Cover 46 Nuts Bolts Fasteners Torque LF Engine Foundation OTHERS Ac
7. Twister HM 02 E Escort Yamaha RXZ EY 05 Honda CB Shine HM 03 Yamaha 135 55 06 Honda Stunner HM 04 Yamaha 07 HM07 Yamaha Libero EY 10 HM 08 Yamaha Gladiator EY 11 HM 09 Yamaha 110 125 EY 12 Honda CB Unicorn Dazzler Honda CBR 150R Honda CBR 250R Honda Above 500 cc Mopeds Esots O moor 75 wo TICK THE OPTION Definitely MOST SUITABLE Agree Disagree Definitely Disagree Because it is my dream bike since childhood There is no other 350cc bike This kind of styling is not available on any other bike Because this is a Royal Enfield am willing to wait Other Reasons Customer s Signature amp Date Motor Cycle MEN LYamahassis Bais Yamaha Fazer 18 TVS Suzuki Max 100 Yamaha YZF R15 EY 19 2 TVS Suzuki 100 Yamaha Enticer EY20 TVS Suzuki Samurai 500 fey21 TVS Suzuki Shogun KINETIC TVS Suzuki Shaolin 80 Keo TVS Suzuki ES Kinetic Challenger keo TVS Star City DLX 1508 E Kinetic GF Laser 125 150 TVSMa4R 7509 Br KEO7 TVSApache RTR 512 Kinetic Velocity TVSVicor GLX GS T 13 Kinetic Comet LI Bajaj M80 Major ar E Bajaj KB 100 RTZ BAO2 LML Freedom DX
8. CUSTOMER COPY 18 000 250 Kms Service Job Card No Job Card No DEALER ASP COPY 18 000 250 Kms Service Odo Reading Dealer Code Brief Work Done Odo Reading Dealer Code Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature CUSTOMER COPY DEALER ASP COPY 21 000 250 Kms Service 21 000 250 Kms Service Job Card No Job Card No Odo Reading Dealer Code Odo Reading Dealer Code Brief Work Done Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 96 DEALER ASP COPY 18 000 250 Kms Service Brief Work Done Brief Work Done CUSTOMER COPY 18 000 250 Kms Service Dealers Stamp amp Signature Dealers Stamp amp Signature DEALER ASP COPY 21 000 250 Kms Service Brief Work Done CUSTOMER COPY 21 000 250 Kms Service Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 97 M CUSTOMER COPY 24 000 250 Kms Service Job Card No Job Card No DEALER ASP COPY 24 000 250 Kms Service Odo Reading Dealer Code Brief Work Done Odo R
9. Fuel Consumption SP 06 Suggested by Friends SP 07 Suggested by Local Mechanics SP 08 mM To Cover Long Distance SP 09 E SP 04 Image Status SP 05 Vehicle Installation Form VIF No What Vehicle do you own now First Time Two Wheeler Buyer ROYAL ENFIELD HHCD100 CD 10055 RoyalEnfeldBullet350 C REO1 HHSlek Royal Enfield Bullet DLX REO2 HHSplendor Royal Enfield Bullet Campus REO3 HHStret DLX HH04 Royal Enfield Machismo REO4 CBZ Drum Disc ES HH 05 Royal Enfield Machismo A350 REOS HHPassion Royal Enfield Lightning REOS HH Ambition 125 135 07 Royal Enfield Lightning 535 REO HH Super splendor HH 08 Royal Enfield Electra 4S REOS HH Splendor Plus NXG HH 09 Royal Enfield Electra 55 09 HH Hunk Extreme HH 10 Royal Enfield Thunderbird LB RE10 Herolgnitor 1 Royal Enfield Bullet 350 UCE RE11 Herolmpulse 12 Royal Enfield Electra UCE 8 12 CD Dawn DLX HH 13 RE Thunderbird Twin Spark REI Hero Splendor Pro Royal Enfield Classis 350 RE 14 REI Hero Passion Pro HH 15 15 SUZUKI MOTORCYCLE Hero Achiever Suzuki GW 250 SM 01 E Hero CBZ Xtreme HH 18 Suzuki Slingshot SM 02 Hero Karizma ZMR 19 HONDA MOTORCYCLE Escort Yamaha RX 100 FEY 03 03 Honda Dream Yuga HM 01 Escort Yamaha 135 04 Honda
10. ROYAL lt ENFIELD OWNERS MANUAL Foreword We congratulate you on your choice of the legendary Bullet motorcycle and welcome you to the exciting world of motorcycling on a Royal Enfield This manual will help you to operate your Classic 500cc motorcycle the right way and guide you to maintain your motorcycle meticulously 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 Bullet motorcycle in top riding condition Log on to the exciting world of Royal Enfield website www royalenfield com to get to know more about the company its products and exciting news from time to time 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 Bullet Motorcycle Service Headquarters Royal Enfield A Unit of Eicher Motors Limited Tiruvottiyur High Road Tiruvottiyur Chennai 600 019 Phone 044 4223 0400 Fax 044 4201 1719 E mail customerservice Q royalenfield com Website www royalenfield com Notice All information in this manual is based on the latest product information available at the time of publication Due to continues improvements or other changes there may be discrepancies between information in this manual and your vehicle
11. Turn anticlockwise to take out the bulb Position the new bulb inside the holder ensuring that the pins in the bulb match with the slots in the holder Press the bulb and turn clockwise to lock the bulb in the holder Refit the trafficator cover cut slot mark facing downwards and tighten the 2 screws Minor Maintenance Tips 63 FUSE BLADE FUSE USAGE LIST Spare Fuse e Open the LH tool box Ref Page No 26 e Ihefuse holder is located inside with 4 2 fuses Electronic Control Unit ECU may fail due to a Loose electrical sensors wire connectors couplers e Replace the required fuse with the spare fuse or Battery terminals b While doing Arc welding on Motorcycle it is Please ensure to replace a spare fuse in the holder recommended to SWITCH OFF ignition and at the earliest opportunity disconnect the Battery terminals amp ECU coupler from Main Wiring Harness Minor Maintenance Tips 54 AIR FILTER PAPER ELEMENT e the air filter element to remove dust as CLEAN AND REFIX EVERY 3000 KMS shown clean ET e Insert key turn thoroughly before anti clokwise to assembly remove RH side air filter box lid Clean intake duct and inside filter box as shown in pic e Loosenthe filter box cover holding nut by 10mm spanner as shown in pic e Assemble the filter element top cover and filter box cover in the reverse order of dismantling proc
12. 64 e Vehicle wobbles 75 PILLION REAR SEAT REMOVAL amp REFITTING 65 e 1845 75 e Rear seat removal 65 e Electronic Fuel Injection EFI 76 e Pillion Rear seat refitting 66 WARRANIY 77 WASHING PROCEDURE 67 EMISSION WARRANTY 79 Precautions 67 ALL INDIA ROAD SIGNS 83 e After washing 67 FREE SERVICE COUPONS 84 STORAGE PRECAUTION 68 PAID SERVICE MAINTENANCE RECORD 93 e Preparing the motorcycle for re use 69 LOG 101 LONG TRIP PRECAUTIONS 70 NOTE G 103 COMPLETE WIRING DIAGRAM 71 ANNEXURES TROUBLE 72 e Vehicle Installation Form e Engine fails to start 72 e Pre Delivery Inspection Report e Engine misfiring 73 e Bike Installation Confirmation By Customer e Poor pickup 73 e Form 22 Personal amp Vehicle Information by 080 Res Off Mobile Email Contact Nos engine NO y Vehicle Installation Form VIF No N
13. Dealer s Hand levers amp kick starter pivot Lubricate Stamp amp Signature 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 3000 KMS OR 90 15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Dealer Code 111 Customer Address Frame No No TT TELE Vehicle Installation Form No TL Sold by Dealer s Name amp Address Serviced by Dealer s ASP Name amp Address Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date 2nd Free Service Activities s Water wash the vehicle and dry it with a clean cloth CUSTOMER COPY Electrolyte Check level amp top up 100 Na Battery terminals Clean and apply petroleum jelly Drive chain free play Check clean lubricate amp adjust 211111 Rear brake pedal pivot Lubricate Date 211111 Wheel front amp rear Check spokes tightness Front brake Check amp top up brake fluid level Odo Reading Front fork oil leak Check for leak 111111 Air filter element p lg o
14. cracks and cuts Minimum tread depth Front tyre 1mm Rear tyre 2 mm e Checkand remove stone splinters nails or other particles embedded in the tyre treads Check if oil 15 above min level To top up remove e Bald spots swelling may be caused by internal cover and diaphragm and top up with either DOT 3 damage Replace the tyres if defective or DOT 4 as specified CAUTION e Replace tyres when the tread depth has reached the minimum as specified Please take care that it does not spill over any other parts of the motorcycle Please wipe the spilled e Periodically inspect wheels for spokes breakage brake fluid immediately if there is any spill over and wheel rim run out using a soft cloth preferably a wet cloth to avoid damage to paint work or other parts Check proper seating of the tyre beading on the Don t mix DOT 3 amp DOT 4 Brake fluid together Minor Maintenance Tips Whenever a new tyre is installed ensure rim and spokes do not get damaged on account of using wrong levers e Use only standard tyres amp tubes inflated to correct pressure TYRE PRESSURE 1 41 kg cm2 2 11 kg cm2 20 PSI 30 PSI 1 55 kg cm2 2 25 kg cm2 32 PSI Tyres rims and air valves must be correctly matched to wheel rims See your Royal Enfield Dealer Mismatching tyre tubes rims andair valves may result in damage to the tyre bead during mounting allow tyre slippage on the rim an
15. Code 111 Customer Address Frame No No TT TELE Vehicle Installation Form No TL Sold by Dealer s Name amp Address Serviced by Dealer s ASP Name amp Address Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date 1st Free Service Activities s a Water wash the vehicle and dry with clean cloth CUSTOMER COPY Electrolyte Check level amp top up No Battery terminals Clean and apply petroleum jelly Drive chain free play Check clean lubricate amp adjust 211111 Hear brake pedal pivot Lubricate Date Hear brake Wheel rim front amp rear Check spokes tightness 211111 Check amp top up brake fluid level Odo Reading oO e Iw Front fork oil leak Check for leak Air filter element 211111 Spark plugs 2 Nos Check clean amp adjust gap Nameot Dealer H T Leads Inspect for cracks ASP with Code Fuel pump Check mounting screws Fuel hose Inspect for cracks Rubber hose Air filter to throttle body Inspect for cracks Accelerator cable Adjust play Clutch cable Adjust play Engine oil sump strainer Engine oil Replace Engine oil filter paper element Replace ASP
16. Job Card No Job Card No Odo Reading Dealer Code Odo Reading Dealer Code Brief Work Done Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 100 DEALER ASP COPY 30 000 250 Kms Service Brief Work Done Brief Work Done CUSTOMER COPY 30 000 250 Kms Service Dealers Stamp amp Signature Dealers Stamp amp Signature DEALER ASP COPY 33 000 250 Kms Service Brief Work Done CUSTOMER COPY 33 000 250 Kms Service Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Log Book 101 SI Idling Authorised Dealer Service Poin Stamp amp Log Book 102 D D Idling Authorised Authorised Dealer Service Point Service Point ate etails CO 20 Notes 103 Notes 104 ROYAL ENFIELD Dealer s Name Place of Dealership Engine No Chassis No Customer s Name Door No amp Street Village Town District Pin Code Telephone Office E mail address if any 18 20 Yrs 01 36 40 Yrs 05 1 2 Educational Qualification Diploma coo wes coo Post Graduate coa MBA coe Family Vehicle P26 To Commute Res College IP31 P27 a To carry load business p32 29 For long dista
17. Motor Cycle to be free from manufacturing and material defect under normal use subject to following conditions 1 B5 og 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 The warranty is applicable only to first registered owner The warranty shall be applicable only if all the free services are availed at the respective period kilometer range as per the schedule given in the owner s manual from RE Authorised Dealer Service Point During the warranty period RE s obligations shall be limited to repairing replacing free of charge such part or parts of the vehicle which on examination to have manufacturing defect Such defective part parts which have been replaced becomes property of RE Cost of oil oil filter fuel and other consumables are chargeable to the customer 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 Warranty shall not apply to a Normal ageing detoriation or rusting of plated parts paints coat rubber parts soft items glass items plastic pa
18. Shooting CAUSES IV WHITE BLUE SMOKE 1 Oil level in sump above the Top line in the oil level window V ENGINE OVERHEATING 1 Cylinder fins not clean 2 Clutch slipping 3 Low engine oil level VI EXCESSIVE FUEL CONSUMPTION 1 Fuel leakage 2 Choked air filter 3 Under inflated tyres 3 Sticky Choke Bi starter valve REMEDIES Check and drain excess oil Worn out valve stem oil seal Clean the cylinder fins at regular intervals Check and correct Check and top up if necessary Check and rectify Clean Replace Inflate to correct pressure Check and rectify Contact Authorised Dealer Service Point Trouble Shooting CAUSES VII BRAKES POOR 1 Not adjusted properly 2 on lining or drum or disc 3 Linings worn Uneven wear 4 Drums Disc scored Uneven wear VIII VEHICLE WOBBLES 1 Wheel rim runout 2 Loose Broken spokes 3 Tyres not fitted correctly 4 Wheels misaligned Under inflated IX ELECTRICALS Bulbs do not glow 1 Loose improper connection RE
19. corrosion free terminals Electrolyte level If electrolyte level is low top up with distilled water only e vehicle is provided with 12V 14 AH e Unlock turn the key clockwise and remove the battery cover e Remove the battery holding two rubber straps gently e Apply petroleum jelly over the battery terminals e Pull out the battery and turn then disconnect to avoid sulphation both the terminal wires negative and positive NOTE respectively Incase of poor contact or loose fitment of Battery e Take out the battery terminals may cause the failure of ECU Minor Maintenance Tips Warning Always disconnect the negative battery cable first and then the Red positive cable while removing the battery connections NOTE For checking the battery voltage and electrolyte specific gravity contact authorised Royal Enfield service or battery service centre CAUTION e not use battery with low electrolyte level as the battery internals cells will get damaged e Do not overfill the battery electrolyte level as it will spill out through the overflow pipe and cause corrosion to vehicle parts e Use only distilled water meant for use in batteries to avoid damage to battery e Electrolyte should not be filled when the level is between minimum amp maximum levels indicated in battery as MIN amp ASSEMBLY OF BATTERY ON VEHICLE e Position the battery in the batte
20. dry it with a clean cloth Electrolyte Check level amp top up Battery terminals Clean and apply petroleum jelly Drive chain free play Check clean lubricate amp adjust Hear brake pedal pivot Lubricate Hear brake Cam clean lubricate amp Adjust play Swing Arm bush amp spacer Lubricate Wheel rim front amp rear Check spokes tightness Front brake Check amp top up brake fluid level Tyres front amp rear Check wear and tread depth Air filter element Clean Spark plugs 2 Nos Check clean amp adjust gap Inspect for cracks Fuel pump Fuel hose Check Inspect for cracks Rubber hose Air filter to throttle body Inspect for cracks Accelerator cable Check amp adjust play Clutch cable Adjust play Engine oil sump strainer Clean Engine oil amp oil filter paper element Throttle body Injector Clean by carbo spray Hand levers amp kick starter pivot Lubricate PAV System Check amp Clean Steering System Check Lub steering balls amp adj play Recommended ITW Chemin or Wurth Odo Reading of Dealer ASP with Code ASP Dealer s Stamp amp Signature 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 9000 KMS OR 270 15 DAYS WHICHEVER IS EARLIER FROM DA
21. ede Spark plugs 2 Nos Check clean amp adjust gap Name of Dealer H T Leads Inspect for cracks ASP with Code Fuel pump Fuel hose Inspect for cracks Rubber hose Air filter to throttle body Inspect for cracks Accelerator Check amp adjust play Clutch cable Adjust play Steering free play Check amp Adjust Engine oil Check level amp top up Hand levers amp kick starter pivot Lubricate Oil filter element oil strainer amp magnetic drain plug Clean ASP Dealer s Stamp amp Signature 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 6000 KMS OR 180 15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Dealer Code 111 Customer Address Frame No C TET TTL ETL ren No see pate Vehicle Installation Form No 1 Sold by Dealer s Name amp Address Serviced by Dealer s ASP Name amp Address Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date 3rd Free Service Activities 2 CUSTOMER COPY Job Card No 211111 Date 211111 Water wash the vehicle and
22. fitted on your motorcycle requires very less effort High effort or sudden application may lock the wheel Please use utmost caution while applying the brakes e While riding on wet or bad road conditions use brakes cautiously e Avoid excessive banking otherwise footrest may touch the ground and cause instability Rules of the Road Be sure your number plate is installed in the position specified by law and 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 increases the influence 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 Always sound your horn actuate your turn signals and exercise caution when passing other vehicles going in the same direction Never try to pass another vehicle going in the same direction at street intersections on curves or when going up or down a hill At street intersection give the right of way to the vehicle on your left or right DO NOT presume you hav
23. i E UC 7 A Remove the oil filter element on the 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 Minor Maintenance Tips e Soaka new oil filter element in the oil and refit on the Crankcase Cover RH e Assembly 3 bolts and tighten them Ensure O Ring and gaskets are taken seat properly Fill recommended oil to engine till the oil level is upto MAX level mark in the oil window in Crank case Cover RH Max NOTE Min Replace oil filter element whenever oil is being replaced CAUTION Filing up oil over MAX mark may cause smoke and or loss of power Do NOT allow oil level to fall below MIN mark Doing so may result in engine internal damage or malfuncton SPARK PLUG Gap 0 70 to 0 80 mm Cleaning and adjusting gap Refer Periodical Maintenance Chart for frequency e Remove HT Lead and the spark plug from the cylinder head using the plug spanner and tommy bar e Clean the insulator tip and electrodes of the plug carefully using a pointed scraper or spark plug cleaner Set the gap between 0 70 to 0 80 mm e Refit the spark plug on the cylinder head and connect H T Lead Minor Maintenance Tips 49 BRAKE FLUID INSPECTION OF TYRES AND WHEELS e Inspect the tyre periodically for tread wear
24. injury to yourself or others and damages to the motorcycle A Warning Indicates a potentially hazardous situation Disregarding this message may result in injury to rider or other persons CAUTION This message if disregarded may result in damage to the vehicle NOTE Indicates important and useful messages for clear understanding Safe Riding Tips Guidelines 14 Before operating your new motorcycle it is your responsibility to carefully read and follow the operating and maintenance instructions detailed in this manual for your own safety your motorcycle and that of others Know and respect the rules of the road Be a safe rider for your own safety and for other road users 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 accessories Use of other manu facturer s 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
25. ARRARARERAREARRARARRRRARERRHARRARRRRRRARS 12V m 14 AH MF failure of electrical system ER 12V 60 55 W Halogen bike Position lamp 12V AW approved by Royal Enfield may not only disqualify for warranty but also affects Brake Tail lamp 12V 21 5 W performance of the bike I nE Junip 12V 10W 4 nos POL aN 12 2 W 2 nos amp 12V AW 1 no Speedometer lamp 12V 3 4 W 1 no Turn signal High beam indicator 12V 2W 2 nos Neutral 12V 2W 1 no DUAN 12V 2 5 Amp Max X2 Starter MOON 1 treten 12V 0 9 KW Technical Specification n CHASSIS gi Tubular Frame Tyre CPP Front 90 90 19 52 P Rear 120 80 18 62 P 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 Fuel tank is not a measuring instrument Low fuel warning 2 2 5 Litres approx The capacity of tank may vary slightly from specified value Dead stock of petrol unusable fuel 0 75 Litres approx SUS PENSION Front Teles
26. E HEADLAMP e Refix the new head lamp halogen bulb into reflector unit by locating the wide protrude on top side mounting e Fix bulb holding U clip into reflector body knotch then press the both ends of clip and lock in its slot e Fit the rubber grommet e Connect the wire couplers as mentioned below TOP SIDE GREEN COLOUR RIGHT SIDE BLUE COLOUR LEFT SIDE ORANGE COLOUR e Position the reflector ring bottom lug into head lamp casing slot and slide it then tighten the top mounting screw NOTE After connecting above said procedure turn ignition switch to ON condition and then check ensure that flash light working in HIGH BEAM mode If you use the bulb other than specified rating 12V 55 60W may result in over loading electrical system lead to premature failure or frequent battery discharge Minor Maintenance Tips TAIL LAMP BULB REPLACEMENT Remove the two nuts each from RH amp LH side of the rear number plate holder Pull out Tail Lamp assembly along with bracket and twist the bulb holder in anticlockwise to remove bulb holder assembly Turn old bulb to remove and replace with a new bulb Refit the bulb holder and turn clockwise to lock the bulb holder Hefit the tail lamp with bracket on the reverse order removal process TRAFFICATOR BULB REPLACEMENT Remove the 2 screws amp take out trafficator glass cover Press bulb gently amp
27. Free Service Record It is our endeavour to provide excellent service to your Classic 500 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 15 Service 279 Service 39 Service 4 Service Date of Service TI Kms Covered Servicing ASP Dealers Name Address NOTE Please ensure that the free service details are recorded in this sheet immediately after the service is carried out Technical Specification ENGINE NAG MOT 4 Stroke air cooled single cylinder OHV SI amp FI Engine 499 cc Displacement BOTO M 84 90 Compression ratio 8 5 1 Max Power 27 2 5250 rpm Torque 41 3 4000 Air Filter Element Corrugated Paper Eleme
28. MEDIES Adjust properly Clean and refit Replace linings Rectify or Replace drums disc Rectify Tighten Replace spokes Refit tyres correctly Ensure proper alignment Inflate to correct pressure Check and correct Contact Authorised Dealer Service Point Trouble Shooting 7e CAUSES REMEDIES 2 Bulb TUSOQ Replace bulb 9 Fuse blown Check and Replace fuse Horn not working 1 Loose connections Check and correct 2 Fuse blown Check and Replace fuse Trafficators not working 1 Loose improper connections Check and correct 2 Bulb fused Replace bulb 3 Fuse blown Check and Replace fuse Brake light remains on 1 Switch link not adjusted properly Adjust connecting links properly 2 SWICK SUCI uere nU 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 amp replace the same Contact Authorised Dealer Service Point Warranty Royal Enfield Motor Cycles are manufactured by following best Quality practices respect of the material and workmanship Royal Enfield RE warrants Classic 500 EFI
29. ND SUSTAINS WHICHEVER IS EARLIER EA ue 25 18 6 If engine doesn t start in the first attempt release the ES button and repeat the above procedure 7 It is advised not to apply excessive throttle during starting Complete Wiring Diagram SWITCH MODULE SWITCH 9x2 8 COUPLER PILOT LAMP C2 HEAD LIGHT 60 55W HALOGEN NEUTRAL SWITCH BROWN POSITION 2x6 3MM COUPLER MAGNETO WITH CRANK POSITION SENSOR GREENWHITE PIN NO 34 NLSW PIN NO 3 CRK P WHITE piN NO 9 CRK M mE 3 PIN WATER PROOF WATER COUPLER PROOF COUPLER NO 13 VCC XLI EAE PIN NO 5 TH PIN NO 24 SG 3 PIN WATER PROOF COUPLER 2 PIN WATER PROOF COUPLER 3 2 3 WATER PROOF COUPLER PIN NO 6 PM PIN NO 22 TE PIN NO 2 ROLL PIN NO SHOLO3NNOO NDA 1 IGP BLACK GREEN ORANGE PIN NO 11 FLPR PIN NO 10 K LINE FREY PIN NO 21 MIL PIN NO 20 PIN 35 PIN NO 36 PIN NO 8 LG TEST H BULLET BLACK PG1 PG2 3x6 3 COUPLER YELLOW 21 mcer YELLOW WHITE RED 2x6 3 COUPLER BLACK MAIN FUSE 15A BLACK umi 12V 14Ah BATTERY BLACK Classic 500 BLUE WHITE 2x2 3 WATER PROOF COUPLER NATURAL 0 9 KW STARTER TRAFFICATOR REAR RH BLACK GREEN 3x2 8 COUPLER m RED WHITE BLACK GREEN RED WHITE 2x6 3 L TYPE COUPLER LH FUSE 10A
30. R CS COPY ROYAL ENFIELD BIKE INSTALLATION CONFIRMATION BY CUSTOMER 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 Documents explained Invoice Insurance RC Road Tax Receipt Owner s Manual received Recommended Lubricants explained Maintenance Schedule sheet in Owner s Manual shown and explained a 2 Next Free Service due explained Free Paid Services explained Warranty Guidelines explained Running in period details shown in the manual explained service Station Address given and Location explained service Incharge Name amp Mobile No given 1 oo Bike delivered in neat and clean condition Tool Kit amp First Aid Kit received and explained Control Switches amp Disc Brake System usage explained Fuse Box location shown and explained Recommended Tyre Pressure explained Bike starting amp Gear shifting procedure explained Quantity of Fuel in Fuel Tank informed Bike orientation amp short distance drive provided Date and Time of Installation 0 Name of Person who did Installation 13 14 15 16 17 18 19 20 Suggestions If Any CUSTOMER SIGNATURE Model Registration No Chassis We thank you and request you to return this filled up form to the person who did the bike installation for yo
31. 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 specification 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 of Royal Enfield Applicable for Classic Desert Storm Model Disclaimer Care needs to be taken as instructed below in order to ensure a longer life for the paint 1 Do not polish your motorcycle as it increases gloss 2 Wash only with plain water 3 Scratches or marks cannot be removed Part No 591822 B Qty 800 Apr 14 No warranty for DESERT STORM Colour Contents 3 PERSONAL amp VEHICLE INFORMATION 6 e Left Side 23 FREE SERVICE RECORD 7 E 24 TECHNICAL SPECIFICATIONS 8 OPERATION OF CONTROLS 25 cet erm 8 e ignition 25 e Ignition System 9 Steering bero de 25 51 9 Fuel tank
32. ST AID KIT RECOMMENDED LUBRICANTS PERIODICAL MAINTENANCE MINOR MAINTENANCE TIPS e Control Cables Hand lever Pivots Center Side Stand Pivots Oil Level Inspection Engine oil change Spark Plug Brake fluid Inspection of tyres and wheels Tyre pressure Front Wheel removal Front Wheel assembly Rear wheel removal Rear wheel assembly Adjustments Clutch Drive Chain free play Checking Rear Brake Pedal Height Rear Brake free play adjustment Chain lock fitment Adjustment of gas shockabsorber Removal of Battery on Vehicle Battery Maintenance Assembly of Battery on Vehicle CHANGING ELECTRICAL COMPONENTS Head Lamp Bulb Replacement Assembling the Head Lamp Contents 5 e Tail Lamp bulb Replacement 62 e White Blue smoke 74 e Trafficator bulb Replacement 62 e Engine overheating 74 Hia prm 63 e Excessive fuel consumption 74 e Blade fuse usage list 63 Brakes POOL 75 AIR FILTER PAPER ELEMENT
33. T Sharp bend ahead Dead end ahead Side road ahead Side read ahead Lise of sound Speed Lmit Overtaking Drive dead towards left to to left signals prohibited slow main prohibited road ahead n m Hairpin bend ahead Hair pin bend ahead Harrow bridge Steep hill ahead INFORMATION SIGNS towards le ahead 7 End of Parking place No Parking speed limit zone Rough road ahead Guarded Unguarded Ferry crossing School lewel crossing level crossing ahead ahead ahead ahead Free Service Coupons 84 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 157 FREE SERVICE 500 Kms or 45 8 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 500 KMS OR 45 8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Dealer
34. TE OF SALE Dealer Code 111 Customer Address Frame No C TET TTL ETL ren No see pate Vehicle Installation Form No 1 Sold by Dealer s Name amp Address Serviced by Dealer s ASP Name amp Address Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date 4th Free Service Activities 2 J Water wash the vehicle and dry it with a clean cloth CUSTOMER COPY Electrolyte Check level amp top up Job Card No Battery terminals Clean and apply petroleum jelly Drive chain free play Check clean lubricate amp adjust 211111 Hear brake pedal pivot Lubricate Date Rear brake cam Lubricate amp Adjust Wheel rim front amp rear Check spokes tightness Front brake Check amp top up brake fluid level Odo Reading Front fork oil leak Check for leak amp replace oil Air filter element 211111 Spark plugs 2 Nos Check clean amp adjust gap Name of Dealer H T Leads Inspect for cracks ASP with Code Fuel pump Fuel hose Inspect for cracks Rubber hose Air filter to throttle body Inspect for cracks Accelerator cable Check amp adjust play Clutch cable Adjust play Engine oil Check amp top up Hand levers amp kick starter pivot Lu
35. ake lever is accidently pressed e Insert and tap the front wheel axle gently inside e Refit the washer and tighten the nut firmly Minor Maintenance Tips e Rotate the wheel and check for smooth rotation e Connect the speedo cable to speedo drive unit and rotate the wheel to check for proper working of speedo meter e Press brake lever 2 or 3 times to check front brake efficiency NOTE Ensure that the speedo drive is correctly located such that the cable can be connected without difficulty REAR WHEEL REMOVAL e Place the vehicle on center stand on a firm and flat surface e Note and mark the position of the chain adjuster butting with the stopper on the right side e Remove split pin and castle nut on the RH side Remove wheel spindle from LH side along with chain adjuster taking care not to drop the wheel collar and spacer from the LH side of the wheel e Tilt vehicle to RH side and slide out rear wheel Minor Maintenance Tips 53 REAR WHEEL ASSEMBLY m Ensure that the chain adjuster knotch butts with the stopper as appropriate when both the front m Ensure the four cush rubbers are in position amp rear wheels are aligned inside the rear wheel hub 8 m Tighten the castle nut firmly ensure that the hole on axle shaft and the slot on castle nut are aligned to enable split pin fitment m Tilt vehicle to right and insert wheel as
36. ansported 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 Safe amp Happy Riding RIDING DRESS Please wear a proper riding apparel A pair of riding boots or shoes Soft leather gloves Goggles or spectacles to safe guard eyes A certified helmet Affix light reflecting strips of 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 motorcycle SITTING POSTURE Correct sitting posture is a pre requisite for stable and safe riding e SitStraight with your shoulders completely relaxed e Keep your elbows close to your body Keep your toes in straight ahead direction Slightly grip the petrol tank with both knees Hold the handle bar grips close to its inner end Look extensively ahead including rear view mirrors without turning the head BRAKING e Apply front and rear brakes gently and simultaneously for maximum braking efficiency A WARNING Applying any one of the brakes suddenly may cause the vehicle to skid The hydraulic disc brake
37. ation which if not avoided could result in serious injury Minor Maintenance Tips ADJUSTMENT OF GAS SHOCKABSORBER e The rear gas shock absorber is of adjustable type i e the spring tension can be increased or reduced e Increase the spring tension for high load operation Reduce the spring tension for low load operation e The adjuster provided on the bottom of the spring has five notches e Insert special spanner on the bottom adjuster and rotate to change knotch position e Turnthe adjuster such that the adjuster moves up to increase the spring tension and vice versa to reduce the spring tension e Adjust both left hand and right hand shock absorbers so that the same notch rests on the pin in both sides Warning Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident Regularly inspect shock absorbers and front forks for leaks Replace worn parts Worn parts can adversely affect stability and handling NOTE Ensure no fouling of any accessories with rear shock absorber Check for sufficient gap availability between the shock absorber and the attachments when the rear end of the motorcycle is fully loaded and the shock absorbers are fully compressed Minor Maintenance Tips 58 REMOVAL BATTERY FROM THE VEHICLE BATTERY MAINTENANCE e The battery must be periodically checked for battery O Cleanliness and
38. bricate Steering System Check Lub steering balls amp adj play ASP Dealer s Check wear and tread depth Stamp amp Signature Paid Service Maintenance Record 93 CUSTOMER COPY 12 000 250 Kms Service Job Card No Job Card No DEALER ASP COPY 12 000 250 Kms Service Odo Reading Dealer Code Brief Work Done Odo Reading Dealer Code Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature CUSTOMER COPY DEALER ASP COPY 15 000 250 Kms Service 15 000 250 Kms Service Job Card No Job Card No Odo Reading Dealer Code Odo Reading Dealer Code Brief Work Done Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature eT Paid Service Maintenance Record 94 DEALER ASP COPY 12 000 250 Kms Service Brief Work Done Brief Work Done CUSTOMER COPY 12 000 250 Kms Service Dealers Stamp amp Signature Dealers Stamp amp Signature DEALER ASP COPY 15 000 250 Kms Service Brief Work Done CUSTOMER COPY 15 000 250 Kms Service Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 95
39. cap slowly Refuel in a well ventilated area with the engine turned off 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 A Warning 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 altering original parts may adversely affect performance and could result in an accident Safe Riding Tips Guidelines 15 e new motorcycle must be operated according to the special running in procedure See running in procedure mentioned in Page No 32 Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly familiar with its operation and handling 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 dr
40. ce Point Minor Maintenance Tips 46 The following minor maintenance can be carried out OIL LEVEL INSPECTION easily with simple tools However In case if it is felt that the adjustments are best done by an expert we recommend that the motorcycle be taken to a nearest Royal Enfield Authorised Dealer Service Point CONTROL CABLES HANDLE BAR LEVER PIVOTS CENTER SIDE STAND PIVOTS ME e Place motorcycle on its center stand on a firm 8 11 8 11 3 VES surface a e Lubricate after using the motorcycle in rain Wall Up engine tora Tew minutes secswITOnor after waterwash or if used in dusty conditions e The level is correct if the oil level is in the e Wipe the area free of dirt grease middle of the oil level window e Apply a few drops of oil on the pivots e Top up with recommended oil if required Minor Maintenance Tips ENGINE OIL CHANGE Secondary Primary Drain Plug Primary Drain Bolt Drain Cap Refer Periodical Maintenance Chart for frequency Place motorcycle on its center stand on a firm flat surface Start engine and warm up for 2 minutes Keep a clean tray below the engine Hemove primary drain cap to drain oil amp clean suction filter magnet Then remove secondary drain plug to drain oil amp clean the magnet Finally remove primay drain bolt to drain the complete oil rA a y e hr Me BT VEHICLE E
41. cessories Wheel Nut 47 Owner s Manual amp Tool Kit Content nM Availability 48 Spare Fuse Fuse Carrier INA Tubular Blade Fuse 50 56 TEST RIDE STATIC CHECK AFTER TEST RIDE z Front Fork Drive Chain Noise Engine Performance Gear Shifting N ST J H Smooth TPS Setting Easy Start Hot Condition ST NW 57 No Leak Oil Fuel e n Hydraulic Acid Leakage Lolo 4 ANY OTHER Any Abnormal Noise or Engine Open cases during PDI Inform to Plant Factory INSTRUCTIONS 1 Check the vehicle thoroughly for any transit damages or 4 Please ensure delivery of the vehicle in brand new condition shortage of parts 5 Claim transit loss and damage through TRANSIT insurance only 2 Carry out all jobs listed under Pre delivery Inspection Schedule 6 Claim Parts replaced for Manufacturing defects only under 3 Thoroughly road test the vehicle for performance warranty P Starti 5 5 i Misalignment Noise Vibration Leak Trouble Missing Less Wobbling Discharing Tight Fused Scratch Pulling Dent Hard Jerking M N V L ST LESS LF D T F DN WF H J 1 Excess Play Different Spongy Sticky Smoke Adjustment Working Paint Defect Rust Peel Off Dull Excessive Oil Rubbing Not Charging EP DF SG SY NA SK AD NW PD R PO DU EO RB NC Format No F 14A CS 02 Mar 2013 DL
42. copic Dia 35mm Hydraulic Damping Stroke 130mm Rear Swing arm with gas filled shock absorbers Stroke 80 mm Front fork oil capacity 195 ml per leg Front fork 1F Endurance or Royal Enfield fork oil 812 Coy A E Front Hydraulic 280 mm Ventilated Disc Rear Foot Operated 153mm Single Lead Internal expanding Brake oil capacity 60 ml Brake oil DOT 3 or DOT 4 Technical Specification DIMENSIONS NOTE BS III This vehicle meets Emission Norms 2170 Bharat Trem Stage III 2 800 nsa 1070 sks 1370 Saddle height 800 mm Ground clearance 135 WEIGHTS Kerb Weight with 90 Fuel 190 Kg Max pay c 175 1 Values Dimensions given above are for your guidelines only 2 n view of continuous improvements being done on our products the specifications are subject to change without notice Safety Definitions E 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 may result in
43. d cause tyre failure FRONT WHEEL REMOVAL e Place the vehicle on center stand Place a wooden block the front end of engine to support the vehicle Disconnect speedo cable Loosen the pinch bolt on the RH fork guide Hold front axle by spanner and loosen axle nut then remove nut along with washer Minor Maintenance Tips s e Tap and remove the front wheel spindle FRONT WHEEL ASSEMBLY e Tilt the vehicle to RH Side and take out the wheel e Remove the wooden piece card board sheet along with speedo drive with bush amp LH side spacer placed between the brake pads MARC 1 PI 3 1 e CEN D b c CN T _ xn ou 2 M L T E 5 r J 7 1 Li J E x3 Br e Place the speedo m drive bush position and place speedo drive over it e Insert the wheel along with speedo drive assembly and LH spacer between the front fork ends ensuring the brake disc is located between the brake pads y I e out Speedo Wi NE drive and bush on Bien the RH side as Ww D E A shown in pic 3 eae CAUTION Do not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper Place a 4mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the front br
44. dicator Lamp MIL is provided in the small meter located on the right side of the head lamp casing There are two indications in this unit Low fuel indication amp EFI Mal function Indicator Lamp MIL When both the Ignition amp Engine kill switch is ON the MIL will glow for few seconds and will 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 Incase 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 to take the vehicle to a nearest Royal Enfield authorised service point for inspection and further necessary action Rollover Sensor 34 ROLLOVER SENSOR Your motorcycle is fitted with a unique Roll Over Sensor under rider seat This is a safety feature CN In the event of an accident OR if the motorcycle falls over on its side with the engine running The Roll Over Sensor will switch off Ignition and cut off fuel supply to prevent the motorcycle from moving suddenly if it is in gear To re activate the system after the motorcycle has been made upright please switch off both the Ignition amp 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 Before starting engine always shift gears int
45. e the right of way Always signal when preparing to stop turn or pass While turning either right or left watch for pedestrians animals as well as vehicles All traffic signs including manual controls at intersections should be obeyed promptly SLOW DOWN at traffic signs near schools and CAUTION signs at railroad crossings Rules of the Road When intending to turn signal at least 100 feet 30 5 meters before reaching the turning Be close to the center line unless local rules require otherwise slow down and then turn carefully change is imminent from GO to STOP vice versa at 22 intersections slow down and wait for the light to change to green o Never run through a yellow or red traffic light Never jump a traffic light When a DO leave the curb or parking area without signaling Be sure your way is clear to enter moving traffic A moving line of traffic always has the right of way Park your motorcycle on a firm and flat surface to prevent it from falling over Protect your motorcycle against theft After parking your motorcycle remove Ignition key from switch and lock the steering head SIDE VIEW MIRRORS Your motorcycle is equipped with convex mirrors and have a curved surface This type of mirror is designed to give a much wider view to the rear than a flat mirror however cars and other objects seen in this type of mirror will look smaller and farther away than whe
46. eading Dealer Code Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature CUSTOMER COPY DEALER ASP COPY 27 000 250 Kms Service 27 000 250 Kms Service Job Card No Job Card No Odo Reading Dealer Code Odo Reading Dealer Code Brief Work Done Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 98 So M DEALER ASP COPY 24 000 250 Kms Service Brief Work Done Brief Work Done CUSTOMER COPY 24 000 250 Kms Service Dealers Stamp amp Signature Dealers Stamp amp Signature DEALER ASP COPY 27 000 250 Kms Service Brief Work Done CUSTOMER COPY 27 000 250 Kms Service Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature Paid Service Maintenance Record 99 CUSTOMER COPY 30 000 250 Kms Service Job Card No Job Card No DEALER ASP COPY 30 000 250 Kms Service Odo Reading Dealer Code Brief Work Done Odo Reading Dealer Code Brief Work Done Dealers Stamp amp Signature Dealers Stamp amp Signature CUSTOMER COPY DEALER ASP COPY 33 000 250 Kms Service 33 000 250 Kms Service
47. ed Gauze Swab 5 cm x 5 cm Sterilized elastic plaster 7 cm x 6 cm First aid kit pouch Tool bag Box spanner 21 X 24 Screw driver O6 X 160 Double end spanner 1 4 X 5 16 Double end spanner 10 X 12 Tool Spark plug Tommy bar Tubular spanner 12 X 13 Single end ring spanner 17 Extension tube NOTE This Tool Kit is kept in Utility box Refer Page No 27 cl IP ee Recommended Lubricants a Front Fork Oil Brake Fluid Royal Enfield 15 W 50 API SL Grade Engine Oil ront Fork Oi JASO MA 1 Grade DOT 3 or DOT 4 Endurance ISO 14001 5 Operation Control Process customers are advised timely replacement of Engine Oil Fork Oil amp Brake Oil at the dealership ASP In case done Capacity 2 75 Ltrs with oil filter privately it is advise to reach old used Oil to our authorised 2 50 Ltrs during oil amp filter element vendor through RE Dealer ASP replacement Similarly we advise for disposal of old used Battery Tube amp Tyres as mentioned in above point No 1 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 amp DOT 4 brake fluid together Periodical Maintenance 42 The maintenance schedule detailed here will help you to maintain your Cla
48. er Authorised Service Point as per periodical maintenance chart Ref Page No 43 44 amp 45 Sufficient quantity of petrol in the fuel tank for the journey planned Check and correct tyre pressure if necessary CHECKS AFTER EVERY 1500 KMS OF RUN Tightness of all fasteners Tyre tread condition and wear 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 e Toolkit e First aid kit e Bulbs for Headlight Trafficator light Rear Tail Lamp and Blade Fuse 10 amp 15 Amps Accelerator Choke Clutch and Speedo Cable Rear chain master link lock assembly Spare tube puncture repair kit cold vulcanising type Foot operated Air Pump Insulation tape Spark plugs M14 amp M10 Fuel hose Complete Wiring Diagram 4 VEHICLE STARTING PROCEDURE Basic Guidelines to be followed FOR ALL ELECTRIC START VEHICLES 1 When ignition key is switched ON please wait until the malfunction indicator lamp MIL goes off before attempting to start In cold condition of the engine or for initial start it is advised to use electric start ES only Apply choke in cold start condition ambient temperature 25 C DO NOT ATTEMPT HALF START BY CASUALLY PRESSING ELECTRIC START BUTTON PLEASE PRESS AND HOLD ELECTRIC START BUTTON FOR ATLEAST 3 SECONDS CONTINUOUSLY FOR THE CRANKING OR UNTIL THE ENGINE FIRES A
49. ess e Remove the nut washer and box cover top cover filter to take out air filter element e Please ensure proper sealing of cover against air filter element box Pillion Seat Removal amp PILLION REAR SEAT REMOVAL Loosen front mounting nut of the rear seat under the rider seat with 12mm tubular spanner Loosen both LH and RH shock absorber top mounting nuts by holding the bolt with 3 8 x 15 16 double end spanner and turning the doom nut with 17mm eyelet spanner Pull out the front mounting bolt of the rear seat from the bracket under the rider s seat D Pull the rear seat with its sub frame towards back so that it will become free from the shock absorber mounting bolts Take out the rear seat sub assembly Re tighten the shock absorber mounting bolts amp nuts before using the vehicle Pillion Seat Removal amp Refitting s PILLION REAR SEAT REFITTING J Loosen shock absorber upper mounting nuts and 4 D Tighten the front 2 mounting nut with 12mm tubular place the pillion seat in the position over the rear mudguard inserting the front end of its sub frame goes to its mounting under the rider s seat Ensure the slit of rear mounting brackets are seated properly in the LH amp RH shock absorber mounting bolts C Insert the front mounting bolt through the bracket under the rider seat spanner
50. holding the bolt with 13mm double end spanner from other side Tighten both LH amp RH rear shock absorber top mounting bolt and nuts Washing Procedure PRECAUTIONS e 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 e Use a suitable engine degreaser available with your local parts store to remove dirt or grease from the engine external parts if required Follow the directions in the label carefully before using the degreaser Use low pressure jet of water to clean the entire vehicle Never spray water with great force on head lamp speedometer trafficator lights front and rear wheel hubs electrical connections and wires control cables EFI components sparkplug battery etc Use luke warm water and mild detergent on the painted components to remove dirt etc e Rinse vehicle thoroughly with plain water to remove the detergent and wipe vehicle dry e 1 possible use compressed air and blow off water particles from the obscure areas of the vehicle electrical connections EFI components etc AFTER WASHING Ensure the vehicle is throughly dry by wiping with a clean soft absorbent cloth or chamois leather Hemove all plastic bags and adhesive tapes Lubricate control cables pivot and rear chain with lube oil Polish
51. iately to align both the wheels e Check and ensure that the knotches on the cam are resting on the pin in the swing arm on both sides Loosen the lock nut e Turn in or out the pdeal stop pin bolt till the brake pedal and front footrest are in the same height level as shown in above fig e Apply brake and tighten all nuts e Finally Torque the e Tighten the lock nut anchor Nut e Check for free rotation of rear wheel Minor Maintenance Tips REAR BRAKE FREE PLAY ADJUSTMENT 4 E The recommended brake pedal travel is 20 30 mm e Checkthat the brake is not binding and the rear wheel rotates freely A Warning Please ensure brakes are adjusted to their maximum efficiency Inefficient brakes can cause an accident Please ensure adequate caution while applying brakes Sudden application OR pressing the levers fully can caused the wheels to lock This may cause the motorcycle to skid with possible loss of control and result in an accident causing Brake shoes must be inspected for wear every 4000 Kms If you ride under adverse conditions steep hills heavy traffic etc a more frequent inspection at 1600 Kms or less is required CHAIN LOCK FITMENT The open end of the chain lock to face opposite to normal direction of chain rotation A Warning The fitment in wrong direction can lead to falling off of chain link thus disengaging the drive This will lead to potentially hazardous situ
52. indicator lamps for proper operation Warning For your personal welfare and safety all the points mentioned above should be performed periodically Failure to do so may affect safe operation and damage your motorcycle and could result in an accident causing serious injury 3 Brakes steering and throttle for responsiveness 4 Cable for fraying or crimping and free operation Running In Period Proper running in is very important for obtaining maximum life 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 kms During the first few hundred kms the various parts in the engine wear and polish themselves to the correct operating clearances Driving with prolonged full throttle operation or any high speed conditions might result in excessive heating of the engine and cause abnormal wear of the moving parts and hence must be avoided 1 0 500 Kms The recommended speeds for the first 500 Kms is below 50 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 motorcycle regularly during running but avoid using the motorcycle above 72 throttle opening position 501 2000 Kms The recommended speed is below 80 Kmph Avoid d
53. iving at moderate speeds Pay strict attention to road surfaces and wind conditions Any two wheeled vehicle may be subject to the following upsetting forces Wind blasts from passing trucks Rough uneven road surfaces Slippery road surfaces These forces may affect the handling characteristics of your motorcycle If this happens reduce speed and guide the motorcycle with a relaxed grip to a controlled condition Do not brake abruptly or force the handlebar Operate your motorcycle defensively Remember 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 Safe Riding Tips Guidelines 16 Wear an approved helmet clothing and foot gear suited for riding a motorcycle Bright OR light colors are best for greater visibility in traffic specially at night Avoid loose flowing garments and scarves When carrying a pillion rider it is your responsibility to instruct them on proper riding procedures DO NOT allow other individuals under any circumstances to operate your motorcycle unless you know they are experienced licensed riders and are thoroughly familiar with the operating conditions of your motorcycle A Warning Regularly inspect shock absorbers and front forks and look for leaks Replace worn parts Worn
54. n NOTE e Key be removed only in locked position e Use high quality unleaded high octane petrol 91 octane above for enhanced performance SIDE BOX ELAINE SIDE BOX LH AIR FILTER BOX RH Turn Key anti clockwise to open Turn Key anti clockwise to open NOTE e Key is common for ignition petrol tank cap steering lock side boxes and battery cover Key for fuel tank and tool boxes can be removed from the lock only in locked Operation of Controls 27 BATTERY CARRIER UTILITY BOX Battery Box Cover Turn Key clockwise amp lift the battery box cover To remove cover turn key anti clock wise and pull gently the oval cover by applying finger pressure Operation of Controls 28 HEAD LAMP SWITCH j 2 Z LOW HIGH BEAM Operation of Controls 29 ENGINE START SWITCH ENGINE STOP SWITCH gt RIGHT Operation of Controls HORN MANUAL STARTER CHOKE Apply choke in cold start condition while starting the Bike Pre Operational Checks s A careful check of the following must be carried out every time before riding and specially after long periods of storage to determine if additional maintenance is necessary 1 Tyres for correct pressure abrasions or cuts 5 Engine oil level 2 Rear chain for proper tension 6 Wheel spoke for proper tightness no breakage Chain 7 Headlamp tail lamp brake lamp and
55. n seen in a flat mirror Use care when judging the size or distance of objects seen in these mirrors NOTE To help you establish the relative distance 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 Vehicle Identification 21 CHASSIS NUMBER ENGINE NUMBER Punched on the steering head tube Punched on top of the engine LH side Key Parts Location RIGHT SIDE VIEW Key Parts Location 23 1 Trafficator front LH LEFT SIDE VIEW 3 Spark plug 4 Gear Change Pedal 5 Battery Cover 6 Side Stand 8 Trafficator rear LH sa Key Parts Location VIEW 53 456 7 8 9 10 i 8 Speedometer 13 Fuel tank cap 4 Dayflashswich 9 Malfuncton LowfuelIndictr o 5 Head lamp dip switch 10 Engine Kill With S Operation of Controls 25 IGNITION SWITCH STEERING LOCK Turn key clockwise to lock e Lock the steering when leaving bike parked CAUTION Protect your motorcycle against theft After parking your motorcycle remove the ignition key from switch and lock the steering head DO NOT lubricate barrel locks with petroleum based lubricants or graphite Inoperative locks may result in damage to your vehicle Operation of Controls 26 FUEL TANK CAP Turn key clockwise to open Press cap to lock with key in positio
56. nce leisure rides onl Pss P30 anyother P36 Usage Road Type Personal Vehicle To move around as part of work Business To go around with friends No Specific Purpose Commute Between Received as Gift Residence and Office To run Family Errands Hilly Road Plain Road Kutcha Road Highways Road RTO City Road Congested City Road Non Congested Mixed type of Road Have you visited Royal Enfield website For Office use only Monthly Household Income BelowRs 10 000 Rs 10 000 20 000 Rs 20 000 50 000 AboveRs 50 000 MEO4 Yes N VEHICLE INSTALLATION FORM me ewe Installation Date 11111111 STD Code Telephone Residence Bike Regn No Invoice No Delivery Note Advice No Expected Average KMs Per Day Lesser than 10 KMs IKMOl 11 30 5 13 15KMs Above 50 KMs 4 Private Company Employee CP 01 2 03 04 05 CP 06 Farmer Agriculturist CP 07 Small Trader Shopkeeper CP 10 Chartered Accountant CP 15 Mode of Purchase sh Organised Company Local Finance Loan from friends IMPOS wo Government Employee Sales Representative Bank Insurance Employee Software Engineer or IT ITeS Emps Public Sector Employee Others Please mention
57. ness CAUSES REMEDIES 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 Adjust clutch cable free play Contact Authorised Dealer Service Point Trouble Shooting 73 CAUSES REMEDIES Il ENGINE MISFIRING 1 Water in petrol tank Clean petrol tank Fill tank with fresh petrol 2 Loose spark plug cap Fix cap lead firmly 3 Spark plug fouled Clean spark plug or non specified heat range plug 4 Any sensor loose connections Check MAP or EOT or TPS sensor wiring coupler loose connections 11 POOR PICKUP 1 Accelerator cable free play excessive Adjust cable free play 2 Choked air filter Clean Replace air filter 3 Brakes adjusted too tight Re adjust properly 4 Rear chain adjusted too tight Re adjust properly 5 Clutch Slipping Adjust clutch cable free play 6 Under inflated tyres Inflate to correct pressure Contact Authorised Dealer Service Point Trouble
58. nfield in the Owner s manual or any other document given to the customer at the time of sale of the motorcycle e The emission related components are tampered with e All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced e 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 e Always get your vehicle checked to meet the emission regulations through and authorised emission checking centre e 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 owner s manual through a Royal Enfield Authorised Dealer Service Point Use only Unleaded petrol 91 octane from reputed fuel pumps Ensure the fuel used is not adulterated Use correct spark plug as recommended in the owner s manual Use lubricants as per recommendations given on grade brand in the owner s manual SM sco I All India Road Signs MANDATORY SIGNS CAUTIONARY SIGNS Road ahead zigzags Road ahead zigzaga Cross roads ahead Sharp bend ahead towards right towards lef towards right NO PARKING No parking One ne way Street Zone SPEED 40 T LIMI
59. nt Engine Oil Capacity 2 75 Litres Lubrication Forced Lubrication Wet Sump Engine Oil Grade Royal Enfield 15W50 SL Grade Engine Oil JASO MA Cooling system Natural Air Flow Fugl 1 Electronic Fuel Injection Programmed PGM EFI Technical Specification IGNITION SYSTEM Ignition system 1 Electronic Ignition ECU Variable Spark plug Electrode gap 0 70 to 0 80 mm ME WQRSDP Bosch Super M14 8 UR6DC Bosch Super M10 TRANSMISSION e Wet Multiplate 7 Plates Duplex Chain Primary Drive Ratio 2 15 1 Gear Ge Constant Mesh 5 Speed Gear shift pattern 1 N 2 3 4 5 Gear Ratios P 1 1 3 06 1 2nd 2 01 1 1 52 1 4th 1 21 1 5th 1 1 Secondary Drive F D Sprocket 18 Teeth Final ral m 2 11 1 Drive Chain 1 102 links Technical Specification r ELECTRICALS Alternator WARNING Using bulbs other electrical gadgets System Se eo eo 12V DC other than specified rating may lead to over loading erratic behaviour premature Battery RRRRAREEAERRARRRARRARR
60. o 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 e Observes all the important instructions and any other precautions listed in the owner s manual e Under all circumstances uses lubricants and fuel as recommended by Royal Enfield e 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 owner s manual and having carried out such repairs and adjustments as may be required with a view to establish such compliance Emission Warranty 1 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 Owner s Man
61. o neutral CAUTION Do not force the gear lever while attempting to shift to neutral Move the motorcycle back amp forth and simultaneously press gear lever to come to neutral Ensure neutral indicator light comes in the Speedometer NOTE e f the engine does not start on the first attempt in cold climate release the starter button wait for 30 seconds before pressing the starter button again e Press starter button and release starter switch once the engine starts 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 lever press starter button and release as soon as the engine starts Turn ignition switch ON Ensure the side and main stands are in released position Ensure that gears are in neutral and neutral lamp is glowing Ensure Engine stop switch is in position Press Clutch Lever Press Starter Button and release as soon as engine starts CAUTION Never accelerate the engine immediately after a cold start The engine should be allowed to run slowly for 15 30 seconds This will allow the engine to warm up and let oil reach all surfaces needing lubrication Failure to adhere may result in damage to the Engine e Manual bi choke Starter NOTE It may be necessary to operate and hold the manual bi star
62. parts can adversely affect stability and handling A Warning For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle A 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 A Warning Exhaust gases contains poisonous carbon monoxide and chemicals known to cause Cancer Birth Defects or other reproductive defects safe Riding Tips Guidelines 17 Warning Motorcycle batteries contain lead and lead components acids and chemicals known to cause cancer birth defects or other reproductive harm Exercise extreme caution while handling a battery Wash hands thoroughly whenever a battery is handled Warning Consult your Royal Enfield Dealer regarding any questions or problems that occur in the operation of your motorcycle Failure to do so may aggravate an initial problem cause costly repairs amp jeopardize your personal safety A 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 tr
63. re 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 Storage Precautions PREPARING THE MOTORCYCLE FOR REUSE Remove anti rust solution from all chrome plated parts and clean the motorcycle Inflate the tyres to the correct tyre pressure Ensure battery is fully charged and proper electrolyte level is maintained Connect the battery Lubricate all control cables and pivots Check proper level of oil in engine Fill fuel tank with fresh petrol Check fuel line for any cracks or cuts Clean the air filter Remove plastic covering from the silencer Hemove 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 e Switch ON ignition switch e Start vehicle and warm up engine for a few minutes before riding the vehicle NOTE Do not raise the engine rpm the moment it is started but allow the engine to run at idling speed CAUTION Proper long term storage is important for the safe trouble free operation of your Royal Enfield motorcycle Long Trip Precautions CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY Service the motorcycle thoroughly at Royal Enfield Deal
64. riving the motorcycle with full throttle opening the speed of the motorcycle regularly but avoid using the motorcycle above 3 4 throttle opening position 3 2 001 kms and above Avoid prolonged full throttle operation Vary speed occasionally CAUTION After covering the first 500 kms please replace the engine oil and oil filter element Enfield engines are air cooled and consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature Extended periods of idling 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 long distances at high speed must be given close attention to avoid over heating and possible engine damage Electronic Fuel Injection amp MIL 33 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 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 Malfunctioning In
65. rts etc Warranty 78 b Components like fuel filter oil filter paper element control cables brake shoes brake pads clutch plates drive chain amp sprocket kit which are subjected to normal wear and tear c Damages due to use of lubricant oil grease etc other than specified by RE d Damages due to use of non genuine parts e Damages due to lack of proper maintenance of the vehicle f Damages due to incorrect driving or riding habits g Parts damaged due to accidents collision abuse etc h Irregularities not recognized as affecting the quality or function of the vehicle such as slight vibration oil leakage discoloration of exhaust bent pipe silencer soft or hard shock absorber etc Defects arising from fitment of unauthorised additional Electrical loads Vehicle serviced repaired at unauthorised service points Vehicle used for competition racing Electrical component like bulbs fuses etc amp 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 RE reserves the right to finally decide on all warranty claims RE reserves the right to make changes in Design of the vehicle without any obligation to install these changes on previously supplied vehicles Note Scratches or marks cannot be removed No warranty for DESERT STORM Colour gt
66. ry carrier such that the negative terminal of the battery is towards fuel pump Ensure ignitiion switch is in OFF condition Connect the positive terminal Red wire first Connect the negative terminal Black wire next Smear the terminals with petroleum jelly Do not use grease e Refit the rubber strap bracket to hold the battery e Refit LH side panel NOTE Clean the wire terminals free of corrosion and keep the terminals coated with petroleum jelly CAUTION Connect the and ve cables to the respective battery terminals Failure to do so may result in damage to the motorcycle electrical system Minor Maintenance Tips 60 CHANGING ELECTRICAL COMPONENTS HEADLAMP BULB REPLACEMENT LAT Remove rubbergrommet from the reflector assembly Loosen the head lamp holding top screw Then pull out head lamp assembly Gently press the bulb holding U clip from both the sides downwards and release it from reflector slot as shown Pull out head lamp bulb and inspect its filament for fuse CAUTION Never touch the bulb with your fingers Finger prints will etch the wire connectors Green glass and decrease bulb life Orange and Blue Color 4 f Always hold the bulb with paper terminals or clean dry cloth during handling e Detach bottom lug from the head lamp housing body e Disconnect head lamp Minor Maintenance Tips ASSEMBLING TH
67. sembly between the swing arms mg Position the rear wheel with cush rubber on the rear chain sprocket m Fix the split pin Hold wheel collar 25 and spacer CAUTION position Do not force the spindle into the wheel as the threads w Assemble the wheel may get damaged Tap it through the wheel gently spindle along with A chain adjuster from Warning the LH side of vehicle Ensure the vehicle does not come off center stand while and gently tap it assembling disassembling the wheel assembly Failure through the wheel to adhere could result in damage or serious injury Minor Maintenance Tips 54 ADJUSTMENTS DRIVE CHAIN FREE PLAY PLAY 25 30 Remove rear wheel split pin Loosen castle nut spindle nut anchor nut and brake rod nut Clutch Lever free play 2 to 3 mm Clutch Free Play Adjustment e Loosen the cable outer lock nut A Turn the RH adjuster cam appro priately till 25 to 30 mm slackness is achieved on the top run of the chain e Turn the Nut B Clockwise to reduce the play or Anticlockwise to increase the free play e Check free play 2 to 3 mm at Clutch lever pivot on handle bar end e Tighten lock nut A after adjustment is done Minor Maintenance Tips 55 e Check brake pedal free play necessary CHECKING REAR BRAKE PEDAL HEIGHT e Check that the front and rear wheels are correctly aligned e Turn the LH adjuster appropr
68. ssic 500cc 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 driving 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 A Warning For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the motorcycle to malfunction and stall abruptly resulting in an accident and cause serious injury Periodical Maintenance 43 05 3189 153189 Check level at every 1000 Kms or earlier as required 3 3 3 ele el Tel drain plug under crankshaft in crankcase RH 7 Fuelnose amp cip ietor o Ring Sea Ring 111118 11111 81111 S FwePump undertang OCheckforscrewighinessimalisevices SE ESERIES
69. st 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 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 Emission Warranty 80 Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace 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 t
70. ter when starting the engine for the first time in cold mornings or at high altitudes to prevent the stalling and to keep the idling RPM steady Starting As soon as the engine attains the operating temperature the RPM will raise at which time the manual Bi Starter should be released e Warm up engine for 2 minutes till idling is consistent Prior to starting check to see if the low fuel indicator is glowing continuously ROYAL ENFIELD i This will glow i continuously if the fuel level in tank is below 2 5 litres approx CAUTION Please ensure the motorcycle is not used with the low fuel indicator lamp ON continuously It may not only result in the motorcycle running out of fuel But will also cause serious damage to the fuel pump Please ensure fuel is filled up as soon as the low fuel lamp comes USING KICK START e Slightly crank the engine further till compression eases over e Start the motorcycle with a powerful swinging kick e Release the choke if applied Gear Shifting Warm up engine for 2 minutes till idling is consistent stable GEAR SHIFT PATTERN 1 N 2 3 4 5 e Press clutch lever towards the hand grip e Press gear pedal with toe to engage 1st gear e Gently open throttle and release clutch simultaneously If clutch is released suddenly the engine may stall and cause a jerky start CAUTION The clutch must be f
71. the painted surfaces using polishing wax Start the bike allow engine to idle and warm up Drive the motorcycle slowly applying both brakes intermittently to dry up the brake shoes Test brakes for full efficiency A Warning Observe warnings and cautions given on labels of cleaning compounds When washing your motorcycle be careful not to get the brakes engine mufflers or air cleaner etc too wet Storage Precautions Incase your Motorcycle is not going to be used for a month or more we advise the following precautions to the taken Carryout required repair adjustments on the motorcycle Wash the motorcycle thoroughly and lubricate as per the maintenance chart Start the engine warm up for a few minutes and switch off Drain out the fuel completely from the fuel tank and fuel lines Remove spark plug Pour in about 25ml of clean engine oil through spark plug hole Close the hole and crank engine several times and refit sparkplug Clean rear chain thoroughly and apply a thin film of lube oil Hemove battery from the bike Clean the terminals free of corrosion Maintain electrolyte level between max or min mark by adding distilled water and wipe the battery dry Store the battery in a cool dry and well ventilated place Do not place the battery in direct sun light near open or where temperature is above 40 or below 0 Cover the silencer with plastic bags to prevent moistu
72. u KEEP RIDING 22 See Rules 47 0 115 124 2 126A 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 Classic 500 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 Ill Bharat Trem Stage lll etc For ROYAL ENFIELD Date CK AA Quality Assurance P ROYAL ENFIELD ROYALENFIELD COM
73. ual and Log book for verification details Produce receipts covering maintenance of the motorcycle is specified in the owner s manual from the date of original purchase of the vehicle Produce valid certificate of Insurance and 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 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 Emission Warranty 52 e Onexamination by Royal Enfield or its Authorised Dealer Service Point if the motorcycle shows that any of the conditions stipulated in the Owner s manual with regard to use and maintenance have been violated e The motorcycle has been run on adulterated leaded fuel or lubricant other than those specified by Royal E
74. ully disengaged before attempting a gear shift Failure to fully disengage the clutch may cause a jerky start and OR stalling the engine besides causing damage to transmission parts e Press the gear e Follow the same pedal with heel to procedure for engage 2nd and 3rd 4th and 5th higher gear gear NOTE Always start motorcycle with gear in neutral position Always move the motorcycle in first gear position only When engine speed decreases 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 39 PARKING VEHICLE ON CENTER STAND e Select a firm flat surface e Select a firm flat surface e Hold handle bar straight e Lower center stand and ensure that both the legs of the stand are resting evenly on firm ground e Apply pressure on the fulcrum lever on the center stand and pull vehicle backwards gently 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 e Lower Side Stand and gently tilt motorcycle to the left till it rests firmly Tools amp First Aid Kit 40 5 2 o Description Antiseptic cream 5 gms Gauze bandage 5 cm x 2 cm Elastic Gauze bandage 8 cm x 1 mtr Wash proof plaster 1 9 cm x 7 2 cm Steriliz

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