Royal Enfield Classic 350 Owner's Manual

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Person al and vehicle information .................... 4

Free s ervice record ............................................ 5

Specifications ..................................................... 6

Safety Definitions .............................................. 9

Safe and happy riding ....................................... 10

Vehicle identification numbers ........................ 11

Location of key par ts ........................................ 12

Operation of con trols ........................................ 15

Pre-Operational Checks ..................................... 20

Running in P eriod ............................................. 22

Starting ............................................................... 23

Starting & Gear Shifting .................................. 24

Riding, Stopping & Parking ............................. 25

Park ing ............................................................... 26

Tools & First aid kit .......................................... 27

Periodical maintenance ..................................... 28

Recommended lubricants .................................. 31

Do it yourself ..................................................... 32

Washing procedure ............................................ 49

Storage precautions .......................................... 50

Long trip precautions ....................................... 52

Complete Wiring diagram ................................. 53

Trouble shooting ................................................ 54

Warranty terms and cond itions ....................... 62

Emission Warr anty ........................................... 64

Log Book ............................................................ 69

Free Service coupo ns ......................................... 70

Paid Service / Maintenance Record

All Indi a Road Signs

Notes

Anne xures

Vehicle Installation Form

Pre-Deliver y Inspection Rep ort

Bike Installation Confirmation By Customer

Form 22

Contents

Personal & Vehicle Information

Vehicle Installation Form (VIF) No.

Name

Door No./Street

Loc ali ty

City State Pin

Contact Nos. R es: Off: Mobile : Email :

Engine No. Battery No.

Frame No. Battery make

Reg. No. Licence No.

Date of Sale Valid till dt.

Mode l Key No. :

Tyre make Col our

Sold by Dealer Co de

It is our endeavour to provide excellent service to your Classic 350 at all times. Towards this we provide 4 free services at specific Intervals.

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

Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, grease etc. used for all free services are chargeable to the customer.

NOTE : Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.

Date o f Service Kms Covered Servicing Dealer’s Name Address

Service 4th Serv ice2nd Service 3rd Serv ice

Free Service Record

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

ENGINE

Engine Type ................... 4 Stroke, OHV, Dual

........................................ Spark Ignition, air

........................................ cooled, single Cylinder

Bore ................................ 70mm

Stroke ............................. 90mm

Swept volume ................. 346cc

Compression ratio ......... 8.5:1

Max Power @ rpm ......... 19.8 BHP @ 5250 rpm

Max Torque @ rpm ........ 28 Nm @ 4000 rpm

Idle rpm .......................... 1050±200 rpm

Starting .......................... E’Start / Kick Start

Air filter element ........... Paper element

Carburettor .................... Ucal - BS 29

Lubrication .................... Wet Sump

........................................ Forced lubrication

Engine oil capacity ....... 2.75 lits

Engine oil grade ............ Royal Enfield 15W50 API

........................................ SL Engine Oil (JASOMA)

FD Sprocket ................... 16 Teeth

Rear Wheel Sprocket ..... 38 Teeth

Cooling ........................... Natural air flow

TRANSMISSION

Clutch ............................. Wet multiplate (6plates)

Primary drive ................. 3/8” Duplex chain

........................................ & sprocket

Primary ratio ................. 2.15 : 1

Gear box ......................... Constant mesh 5 Speed

Gear ratio ....................... 1

- 3.06 : 1

........................................ 2

- 2.01 : 1

........................................ 3

- 1.52 : 1

........................................ 4

- 1.21 : 1

........................................ 5

- 1 : 1

Secondary drive ............. 5/8” Chain & Sprocket

Secondary ratio ............. 2.375 : 1

Drive Chain links .......... 100 links

Specifications

CHASSIS

Frame ............................. Tubular

Suspension : Front ........ Telesco pic , hydraulic

........................................ damping 130mm

Rear ........... Swing arm with gas

........................................ filled shockabsorbers

Fr. Fork oil capacity ..... 195 ml per leg

Front fork oil ................ 1F (Endurance Fork Oil)

Brakes : Front ........ Hydraulic 280 mm

........................................ ventilated disc

Rear ......... Foot operated 153 mm

........................................ single lead, internal

........................................ expanding (drum)

Brake Oil Capacity ........ 60ml

Brake Oil Grade ............. DOT 3 or DOT 4

Tyre size : Front ....... .. 90/90 X 19” - 52P

Rear .......... 110/90 X 18” - 61P

TYRE PRESSURE

Solo : Front ...... 20 psi/1.41kg/cm

Rear ........ 30 psi/2.11kg/cm

With Pillion : Front ....... 22 psi/1.55kg/cm

Rear ........ 32 psi/2.20kg/cm

Fuel tank capacity ......... 13.5 litres***

Reserve ........................... 2 litres approx.

ELECTRICALS

Generation ..................... Alternator/magneto

System ............................ 12V - DC

Ignitio n .......................... D igi tal D ual Spar k

........................................ Ignition, TCI System

Batter y ........................... 12V - 14AH, MF

Spark plug ..................... Mico / W5DC (M14)

........................................ Super Bosch / UR5DC

........................................ (M10)

Spark plug gap .............. 0.70 to 0.80 mm

Head lamp ...................... 12V, 60 / 55W

Halogen

Specifications

Position Lamp ................ 12V, 4W

Brake / Tail lamp ........... 12V, 21 / 5 W

Speedometer lamp .......... 12V, 3.4W

Neutral lamp Tell tale ... 12V, 2W

Turn Signal Tell Tale .... 12V, 2W

Turn signal .................... 12V, 10W - 4 nos

Horn ............................... 12V DC

Starter Motor ................. 12V, 0.7KW

WEIGHTS

Kerb weight ................... 187 Kgs.

Max. pay load ................. 163 Kgs.

DIMENSIONS

Length ............................ 2160 mm

Width .............................. 800 mm

Height ............................ 1050 mm

Wheel base ..................... 1370 mm +

20 mm

Ground clearance .......... 135 mm

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

Rear Chain Slackness ...... 25-30 mm

NOTE :

 Values / Dimensions given above are for your guidance only.

 In view of continuous improvements being done on our products, the specifications are likely to

change without prior notice.

Specifications

***Fuel tank is not a meas uring i nstrument. The c apacity of tank may vary slightly from spe cified value.

WARNING

Us in g bul bs / oth er e le ctr ic al gadg et s othe r th an spe cifi ed rat ing ma y lea d to over loa ding / e rra tic be havio ur / p rema ture failure o f e lec trica l s yst em.

Modi fica tions on the bike w hich are not app rove d by R oyal Enfie ld may not only dis qual ify for warr anty, but also affects per forma nce of the bike .

The infor mation giv en unde r the titles : Warning, Caution and Note are for y our sa fety and for the care and safety to your motorcycle and other s. Plea se read these carefully and if disregarded may result in injury to yourself or others and damage s to the mo torcycle.

WARNING

Indicates a potentially hazar dous situation. Disre garding this mess age 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 un derstan ding.

Safety Definitions

NOT E: BS I II This vehi cle meets Emissio n N orms Bhara t (Tr em) St age - III

RIDING DRESS

 A proper riding appar el

NOTE :

A ligh t coloured shirt enables gre ater visibility to other road users specially during nights.

CAUTION :

Loose clothing may get caught on moving parts of your motor-cycle.

 A pair of riding boots or shoes.  Soft leather gloves.  Goggles or spectacles to safe guard eyes.  An IS I ce rtified helmet. Affix light reflecting

strips of sticke rs at the front and rea r.

SITTING POSTURE

Correc t sitting posture is a pre-requisite for stable and safe riding :

 Sit Straight with your sh oulders completely

relaxe d.

 Keep you r elbo ws close to your body.

 Keep y our toes in straight ahe ad d irection.

 Sligh tly press the knee pad of petrol tank with

the knees.

 Hold the handle grip clos e to its inner end.

 Look extensively, including rear view mirror,

without turning the head.

BRAK ING

 Us e both front and rear brakes together for

maximum braking efficiency.

WARNING

Applying an y on e of the brakes sudde nly may cause the vehicle to skid.

The hydraulic disc brake, fitted on your Classic 350 requires ver y less effort and high effort or sudden application may lock the wheel. Please use utmost ca ution while applying the hydraulic disc brake .

 While riding on wet or bad roa d c onditions

use brakes cautiously.

Safe and Happy riding

FRAME NUMBER

Punched on steering head tube RH side.

ENGINE NUMBER

Punched o n top o f t he engine LH side.

Vehicle Identification Numbers

Location of Key Parts

11. Rear Mudgaurd Reflector

12. Pilot Lamp RH

13. Shock Absorber (gas filled)

14. E-Start Motor

1. Rear Trafficator RH

2. Air filter box

3. Carburetor

4. Head Light

5. Front Number Plate

6. Front Trafficator RH

7. Steering lock

8. Brake Pedal

9. Kick Start Lever

10. Silencer

RIGHT SIDE VIEW

1. Front Trafficator LH

2. Fuel Tank

3. Fuel Tap

4. Battery Box Cover

5. Seat - Rider

11. Gear Change Lever

12. Horn

13. Pilot Lamp LH

6. Seat - Pillion Rider

7. Rear Trafficator LH

8. Number Plate Rear

9. Side Stand

10. Center Stand

Location of Key Parts

LEFT SIDE VIEW

4 5

Location of Key Parts

1. Turn Signal Switch

2. Hor n Button

3. Head Lamp Dip Switch

4. Cluth Lever

5. Ignition Switch

6. Speedo Meter

7. Ammeter

8. Engine Kill Switch

9. Brake Lever

10. Pilot & Head Lamp Switch

11. E-Start Switch Button

12. Petrol Tank Cap

TOP VIEW

Turn Key Clockwise to open

NOTE :

 During fuel tank

cap lift position key will not come out.

Gently press Lid to close.

OFF

Operation of Controls

IGNITION SWITCH

FUEL TANK CAP

Tool Box LH

Turn Key anticlockwise to open

Air Filter Box RH

Turn Key anticlockwise to open

Operation of Controls

SIDE BOX STEERING LOCK

NOTE :

 Key is common for ignition, petrol tank cap,

steering lock, side boxes and battery cover.

 Ke y for fue l tank and too l bo xes can be

re m ov e d f rom th e lo c k o n ly in l oc k ed condition.

Turn Key clockwise to lock

Turn Key anticlockwise to unlock

NOTE :

 T u rn ha nd l e bar to extr em e left , be fo r e

attempting to lock the steering.

BATTERY BOX COVER

Turn Key clockwise & lift the battery box cover gently

FUSE LOCATION

Open LH side box cover to check fuse condition

E-START BUTTON

ENGINE STOP SWITCH

OFF

Operation of Controls

BATTERY CARRIER

ELECTRIC START SWITCH

Operation of Controls

HEAD LIGHTS SWITCH DIMMER SWITCH

OFF

Pilot ON

Head Lamp ON

High Beam

Low Beam

Flash button

CAUTION :

 Chok e should be used o nly to start a cold

engine. Riding the motorcycle with the choke ‘ON’ will increase pollution and result in high fuel consumption and loss of power.

OFF

Pull Out

Press

Operation of Controls

TURN SIGNAL SWITCH

HORN

Left turn signal ON

OFF (Push top off)

Right turn signal ON

Press

Choke

OFF

Turn knob to horizontal position

Main ON

Turn knob downward position

Reserve ON

Turn knob upward position

Front Brake

Rear Brake

Operation of Controls / Pre Operational Checks

FUEL TAP CHECK FOR :

1. Petrol level in the tank and leaks.

2. Oper ate and free play of f ront and rear brakes.

Br ake Ped al

3. Free play and s moothness of all o per ating cables .

4. Free movement of s teering

5. Battery electrolyte level.

6. Any cuts, cracks in the tyre and correct tyre pressure.

8. Lub oil level should be in between “MAX “ & “MIN” Le vel. Top u p if n ec es sary . Do not overfill above maximum level.

NOTE :

Start engine, run for 2 minutes before che cking oil level

9. Operation of all electrical par ts.

Pre Operational Checks

MIN

7. Brake fluid is above the ‘min’ level in the master cylinder.

MIN

MAX

The Classic 350, as you would be experiencing, is capable of c onsistent high speeds. However as wi th any new motorc yc le, a “r un nin g-in procedure” is essential during the first 2000 kms to achieve optimum performance subsquently.

The following tips will help in proper bedding of a new motorcycle.

1. During the first 2000 Kms of run, do n ot

Vehicle

Speed

Gear

First 500 kms 501 - 2000 kms

1 15 KMPH 20 KMPH

2 25 KMPH 30 KMPH

3 30 KMPH 40 KMPH

4 45 KMPH 55 KMPH

5 60 KMPH 70 KMPH

Running in Period

exceed the following speed limits.

2. Do not exceed maximum pay load as specified.

3. Warm up the engine for a few minutes to allow oil for all engine parts before riding the bike.

4. Do not ride in con st an t throttl e for long distances. Vary the speed by 10%.

5. Avoid sudden revving and racing starts.

 Turn fuel tap to

‘ON’

 Use choke if required

(E.g.. When starting a cold engine in winter season).

 Switch on ignition.

 Ensure gear is in neutral position.

NOTE :

 Neutral position is indicated by neutral light

on the cockpit.

 To s hift into neutral, move the motorc yc le

back and forth gently, while shifting the gear.

CAUTION :

1. Attempting to shift gears without moving the motorcycle back and forth, may damage gears.

2. Slightly crank engine further till compr ession eases over.

 Star t the motorcycle

wi th a pow e r fu l swinging kick.

 Re lease the choke, if

applied.

Starting

USING KICK START

 Pr es s t he clutch lever and press starter

button and release once th e engine starts.

NOTE :

If the engine does not start, wait for 30 seconds before pr essing the starter button again.

CAUTION :



Please ensure that the gears are in neutral before starting the motorcycle.



Press S tar ter b utton and re lea se starter switch once the engine starts.



A Clutch switch is provided in the system for the safety of the rider. When the v ehicle is gear, the vehicle cannot be started - To start in gear operate the clutch lev er, pre ss Starter button and re lease starter switch once the engine starts.



Warm up engine for 2 minutes - till idling is co nsistent.



Operate clutch lever.



Press gear pedal with toe to engage 1

gear.

Starting & Gear Shifting

USING THE ELECTRIC START



Ge ntly ope n t hrottle and r eal ea s e cl ut ch simultaneously. If clutch is released sudd enly, the engine may stall and cause the motorcycle to move with a jerk.



To shift to 2nd and higher gears, close throttle, oper ate the clutch lever a nd press the gear pedal with heel.

NOTE :

Ge a r sh ift ped a l is on th e le f t s ide o f the motorcycle.

To s t op t h e veh i cle , cl o s e t h rot t le , app ly fron t brake with right hand a nd rea r bra ke s wi th ri ght leg si mu lt ane o us ly . Shift gears into neutral before th e mo to r c ycl e ju st co m e s to a com p le t e stop.



Tu r n the igni tio n sw i tc h to ‘ OFF ’ position .



Turn fuel tap ‘OFF’

Riding, Stopping & Parking

 Select a firm, flat surface.

 Extend sid e s tand. Tilt th e mo torcycle to

the left, till it is s upported firmly.

 Select a firm, flat surface.

 Hold handle bar straight.

 Lower center stand, su ch that, both the legs

of the stand are resting on firm gr ound.

 Apply pressure on the fulcrum lever on the

center stand and pull vehicle backward.

WARNING

Ensure both the stands are retracted fully b efore riding the motor cycle.

Please exer cise extreme c are while parking and ensure it is parked firmly to avoid the motorcyc le from falling ove r and causing injury to you or to others and damage to the motorcyc le parts.

PARKING VEHICLE ON CENTER STAND PARKING VEHICLE ON SIDE STAND

Parking

Tools & First Aid Kit

1. Tool bag 1

2. Box spanner 21 X 24 1

3. Screw driver O6 X 160 1

4. Double end sp anner 1/4 X 5/16 1

5. Double end sp anner 10 X 12 2

6. Tool- Spar k plug 1

7. Tommy bar 1

8. Tubular span ner 12 X 13 1

9. Single end ring spanner - 17 1

10. Ex tension tube 1

1. Antiseptic cream 5 gms 1

2. Wash proof p laster 1.9 cm x 7 .2 cm 2

3. Gauze bandage 5 cm x 2 cm 1

4. Sterilized Gauze Swab 5 cm x 5 cm 2

5. Sterilized elastic plaster 7 cm x 6 cm 1

6. Elastic Gauze bandage 8 cm x 1 mtr. 1

7. First aid kit pouch 1

1 2 3 4 5 6 7 8 9 10

S.No. Description Qty.

The maintena nce schedule detailed he re will he lp you maintain your Classic 350 meticulously and to get a long troub le fre e se rvice. The sched ule provided herein is base d upon average ridin g conditions and indicates the Kms at which regular inspection s, adjustments, replacements and lubrications are to be carried out. The frequency of the maintenance must be shortened depending upon the se verity of the drivi ng condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Au tho rised Deale r / Se rv ice Point for exper t advice an d to carry o ut the required mainte nance .

No.

DESCRIPTION

FREE SERVICE

whichever is earlier

PAID SERVICE

Periodical Maintenance

Kms (x 1 000) 0.5 3 6 9 1 2 1 5 1 8 2 1 2 4 2 7 3 0

Month s 1 .5 3 6 9

1 E ngine Oil R I R I R I R I R I R

Check level at every 1000 Kms or earlier as required

2 E ngin e oil filter elemen t R C R R R R R 3 E ngin e sump filt er (oil st rai ner ) C C C C C C C

Magne tic drain plug under gear box and secondary

C C C C C C C

drai n plug under crankshaft in crankc ase RH

5 Spark plug - 2nos. A A A A A R A A A A R

6 HT leads for crack I I I I I I I I I I I

7 A ir filter paper elemen t C C C C R C C C R C C

8 Carburet or (C.V. Type) *Clean, Inspect and Tune

No.

DESCRIPTION

FREE SERVICE

whichever is earlier

PAID SERVICE

Kms (x 1 000) 0.5 3 6 9 1 2 15 1 8 2 1 2 4 2 7 3 0

Month s 1 .5 3 6 9

Periodical Maintenance

9 Fuel Tap C C C C C C C C C C C

1 0 Fuel tank C C C C C

1 1 Fuel hose / Pipe I I I R I I I R I I

1 2 Accel erat or and car bureto r cable play Adju stme nt A A A A A A A A A A A

1 3 Rubber hose, Air filter to Carb uretor I I I I R I I I R I I

1 4 Rubber hose, Inlet manifold I I I I R I I I R I I

1 5 Inlet / Exhaust valve se ating I I

1 6 Cylinde r head (Combu stion chamber) D

1 7 Exhaust system D

1 8 Clutch lever fre e play Adjust every 1000 Kms or ear lier as re quired

1 9 Rear brake pedal pivot L L L L L L L L L L

2 0 Batter y terminals (apply pet roleum jelly) C C C C C C C C C C C

2 1 Batte ry Elect rolyte level I I I I I I I I I I

2 2 Earth wire eyelet (behind battery car rier ) I I

2 3 Rear Chain

Adjust every 1000 Kms or ea rlier as required

Lubric ate every 1000 Kms or earlie r as requi red

No.

DESCRIPTION

FREE SERVICE

whichever is earlier

PAID SERVICE

Kms (x 1 000) 0.5 3 6 9 1 2 15 1 8 2 1 2 4 2 7 3 0

Month s 1 .5 3 6 9

Note : For Mainte nance after 30,000 Kms, Please repea t the same frequency specified above, in consultation with a Ro yal Enfield Authorised Dealer / Service Point.

* Refer Service Manua l.

A : Adjust C : Cle an D : De-carbonise I : Inspect L : L ubricate R : Re place

Periodical Maintenance

2 4 Front Fork oil / leak

I R I R I

Check level every 1000 Kms or earlier as required

2 5 Hand levers & kick start er pivot Lubric ate every 1000 Kms or earli er as requi red

2 6 Rear brake play Adjust eve ry 1000 Kms or earlier as required

2 7 Rear bra ke cam L L L L L

2 8 Steering ball races / Play Adjustment A L A R A L A R A L

2 9 Spokes tightness & Whee l r im run out front / rear I I I I I I I

3 0 Rear wheel cus h rubbe rs I& R I& R

3 1 Swing Arm spacer & piv ot L L L R

3 2 Tyre wear Front / Rear I I I I I I I I I

3 3 Brake Oil level check / Replacem ent I I I I I I I I I I I

3 4 Pivot-Side stand, Center stand, Pillion foot rest L L L L L L L L L L L

Recommended Lubricants

CAUTION :

Use of Wrong grade oil can reduce the life of the moving pa rts and seriously affect performance

ISO 14001 – EMS

Operation C ontrol Process

1. All customers are advised timely replacement of Engine Oil, Fork Oil & Brake Oil at the dealersh ip /ASP. In case done privately, it is advise to rea ch old/used Oil to our authorised vendor through RE Dealer/ASP

2. Si mila rl y we adv is e for dis pos al of old /us ed Battery, Tube & Tyres as mentioned in above point No.1.

Engine Oil

Grade Royal Enfield 15 W 50 API SL

Engine Oil (JASO MA)

NOTE : Recommendation subject to change withou t n otice. * Common oil for Engine, Gear box & Clutch. DO NOT Mix DOT 3 & DOT 4 brake fluid together.

Capa city 2.75 Ltrs. (with oil filter)

2.50 Ltrs. (during oil & filter element replacement)

Brake Fluid

Grade DOT 3 or DOT 4

Capa city 60ml

Front Fork Oil

Grade Royal Enfield

Front Fork Oil (or 1F Grade Endura nce)

Capa city 195 ml/leg

The following simple m aintenance activities will help in maintaining your motorcycle. However for an elaborate maintenance, we recomme nd you to get it done at a R oyal Enfield Authorised Dealer / Service Point.

CONTROL CABLES

Lubricate after using the motorcycle in rain, after waterwash or if use d in dusty conditions.

HAND LEVER & KICK STARTER PIVOTS

Wipe the area free of dirt / greas e.

Apply a few d rops of oil on the pivots.

CENTER / SIDE STAND PIVOTS

Apply a few drops of oil on the pivots after cle aning the area of dirt.

Do it yourself

Check if oil is below ‘min’ level. To top up, remove cover and diaphragm and top up with DOT 3 or DOT 4 as specified.

 Place motorcy cle on its center stand on a firm

surface.

 Warm up engine for a few minutes & switch

off before checkin g oil level.

 The le vel is cor rect if the oil level is in the

middle of the oil level window.

 Top up with rec ommended oil if requ ired.

Do it yourself

OIL LEVEL INSPECTION

BRAKE FLUID

MI N

M AX

CAUTION :

Use of wrong grade or spurious oil can seriously affect motorcycle performance & damage to moving parts

CAUTION :

Don’t mix DOT 3 & DOT 4 Br ake fluid tog ether.

ENGINE - OIL CHANGE

Secondary Drain Plug

Prim ary Drain Cap

(Re fe r Peri odi cal Mainte nanc e Char t for fre que ncy )

 Place motorc ycle on its cent er stand on a fir m flat

sur fac e.

 Start engine and warm up for 2 minutes.  Keep a cle an tray below the e ngine  Re move primar y drain cap, to drain oil & cle an

suction filter, magnet.

 Then remove secondar y drain plug to dra in oil &

clean the magnet.

 Fin ally remove primar y drain bolt to drain the

com ple te oil.

Prim ary Drain Bolt

 R emov e the oil filte r elem ent on the Crankc ase

Cover RH.

 Allow th e oil to drain by tilting the motorcycle to

both sides.

 W as h th e drai n p l ug and th e su cti on f il t e r

thoroughly and re fit on the crankcase afte r all the oil is drained out.

 Soak a new oil filter e lement in the oil and ref it on

the Crankcase Cover RH.

 A sse mbl y 3 bol ts an d tight en them. Ensu re ‘O ’

Ring and gas kets ar e taken seat properly.

NOTE :

Re p la ce oi l fil t er el e me nt wh en e ve r oil is be in g re pl ac ed .

CAUTION :

Filling up oil over “MAX” m ark may c ause smoke and / or loss of power. Do NOT allow oil le vel to fall below “MIN” mark. Doing so may resu lt in e ngine internal damage or malfuncton.



Fi ll r e c om me n de d o il t o engine till the oil level is upto “MAX ” level mark in the oil windo w in Crank- case Cover RH.

Max

Min

Do it yourself

Cleaning and adjusting Plug gap

 In spect the tyres pe rio dic ally for

tread wear, cracks and cuts.

 Check and remove stone, s plinters,

nails or other particles embed ded in the tyre treads.

 Bald spots / swelling may be caused by internal

damage. Replace the tyres , if defective.

 Replace tyres when the tread depth has reached

the minimum as specified.

 P e rio d ic a l ly i nsp e c t w h e els f or spo k es

breaka ge and wheel rim run out.

 Check proper seating of the tyre beading on

the ri m when ever the tyre is reassembled.

 Whenever a new tyre is in stalled, e nsure rim

and spokes do not get damaged on account of using wrong levers.

 Us e only standard tyres & tubes inflated to

correct pressur e.

Minimum tread depth :

Front tyre : 1mm Rear tyre : 2 mm

Do it yourself

SPARK PLUG

INSPE CTION OF TYRES & WHEELS

 Re peat the above proce dure for the seconda ry

sparkplug.

 Set the g ap between 0.70 to 0.80 mm.

Tyre Pressure

 Two spark plugs are provided

in your vehic le

 Re move sp ark plug using the

plug spanner and tommy ba r.

 C lean th e ins ulato r tip and

el e c tr o d es of t he p l ug ca r e fu l ly u sin g a po int e d scraper or spark plug cleaner.

 Refit the spark p lug on t he

cylinder head.

Front Rear

Solo 1.41 kg/cm

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

With Pillion 1.55 kg/cm

(22 PSI) 2.20kg/cm2 (32 PSI)

Gap 0.70 to 0.80 mm.

 Remove the axle nut along with washer.

 Tap and remo ve the front wheel spindle

 Tilt the vehicle to RH Side and take out the

whee l along with speedo drive and RH side spacer.

 Tak e ou t Sp eedo drive and bu sh on the RH

side.

FRONT WHEEL REMOVAL

 Place the vehicle on center stand

 P la ce a woo den blo ck the fro nt end of

engine to support the vehicle.

 Disconnect spee do cable.

 Loosen the pinch bolt on the RH fork guide.

Do it yourself

 Place a 4 mm thick wooden piece or cardboard

sheet between the brak e shoes to avoid brake shoes getting locked.

CAUTION :

Do not press the front brake lever when wheel is removed as this will result in brake shoes getting locked.

FRONT WHEEL REASSEMBLY

 Remove the wooden piece / card bo ard sheet

placed between the brake shoe s.

 Place the speedo drive bush in p osition and

place speedo drive ove r it.

 Inser t the whee l along with spee do drive and

RH sp a c er be t wee n the fr o n t fo r k ends ensuring that the brake disc is located between the brake shoe s.

 Ins er t and tap the front wh eel axle ge ntly

inside .

 Re fit the wa sher and tighten the nut fir mly.

NOTE :

Ensure that the speedo drive is correctly located such that the cab le ca n be conn ected w ith out difficulty.

 Tighten the pinch bolt on the RH fork guide.

Do it yourself

REAR WHEEL REMOVAL

 P lace vehicle on center stand on a firm an d

flat surface .

 N o te and mar k the p o si ti on of the ch ain

adjuster butting with the stopper on the right side.

 R e mo v e split pin an d

ca s tle nu t on th e RH side.

 R emove w he el spind le

from LH side along with chain a djuster, taking ca r e n o t t o d rop th e wheel colla r and spacer from the LH side of the wheel.

 T ilt v eh icle to RH side

and slide out rear wheel.

 R ota te th e whe e l a n d che c k for sm o oth

rotation.

 Conne ct t he speedo cable to speedo drive and

check for proper working of spee do meter.

Do it yourself

REAR WHEEL REASSEMBLY

 Ensure the four cus h rubbers are in position

inside the rear wheel hub.

 Ti lt vehicle to right and insert wheel assembly

be t wee n the s wi n g arms.

 Po sition the rear wheel

with cus h rubb er on th e r e a r ch a in sprocket.

 Hold whee l collar and

spacer in position.

 A s s emb l e th e wh ee l

spindle a long with chain adjuster from the LH side of vehicle and gently tap it thr ough the wheel.

 E nsu re tha t the chain a djuster notch butts

with the s toppe r as a ppro priate w hen both the front & real wheels are aligne d.

Do it yourself

 Ti ghten the castle nut firmly and ensure that

the hole on axle sha ft an d the slot on castle nut are aligned to enable split pin fitment.

 Fi t th e s plit pin.

REAR BRAKE PEDAL HEIGHT

 Lo osen the lock nut

 Tu rn in o r out the pedal stop pin till the brake

pedal and front footrest are in the same height as shown in fig.

WARNING

Pl eas e ensu re br a ke s are ad ju s ted to th eir maximum efficien cy. Inefficient brakes can cause an acc ident.

Drive Chain tension (play 25 - 30 mm)

 Re move rear wheel split pin.

 Loosen castle nut, spindle nut, an chor nut

and brake ro d nut.

 Turn the adjuster cams on both sides, till 25

to 30 mm slackness is achieved.

 Ti ghten the lock n ut

 Ch eck for free rotation of rear whee l.

REAR BRAKE

 Tu rn in or out the adjuster nut at the bra ke

rod end. The rec ommande d br ake pedal travel is 20 - 30 mm.

 C heck that the brake

is not binding a nd the re a r w h e e l r ota tes freely.

Do it yourself

20 to 30mm

 Check and ensure that the number of notches

from the punch mark on the cam to the notch resting on the pin a re equal on both sides.

 Apply brake and tighten all nuts.

ADJUSTMENT OF REAR GAS SHOCK ABSORBER

 The rear gas shock absorber is of adjustable

type i.e., the spring tension can be increased or red uced.

 Increase the spring

te n sio n fo r h igh load o peration.

 Reduce the spring

te n sio n fo r lo w load o peration.

 T h e adj u st e r

pr o v id e d on the bottom of the spring has five notches.

- InsertSpecial ‘C’ S pann er on the bottom adjus te r and r otate to c ha ng e kno tch position

- Turn the adjuster such that the adjuster moves up to increase the spring tension an d vic e ver s a t o r ed u ce th e sp r in g tens ion.

Do it yourself

REMOVAL O F BATTERY FROM THE VEHICLE

 Re move the side box cove r.

 Disconnect b oth the terminal wir es (negative

first and then positive).

- A djus t b oth left hand and ri ght hand shock absorbers to same position.

WARNING

Riding the motorcycle with the notches adjusted in different po sitions can ca use loss of control and may lead to on acciden t.

 Re move br acket.

 Take out battery.

 Visually check for

- Electroly te level

BATTERY MAINTENANCE

 The vehicle is provided with 12 V - 14 AH

Do it yourself

 The battery must be pe riodically checked for

- Cleanliness and corrosion free terminals.

- Electroly te level

- I f elec tro ly te level is low, top up with

distilled water.

NOTE :

For checking the battery voltage and electrolyte specific gravity, contact authorised battery service centre.

REASSEMBLY OF BATTERY ON VEHICLE

 Position the battery in the battery carrier such

that the negative termina l of the battery i s towards fuel tap.

 Connect the positive terminal (Red wire ).

 Connect the negative terminal (Black wire).

 Smear the terminals with p etroleum jelly. (Do

not use grease ).

 Refit the bracke t to h old the ba ttery.

 Refit battery carrier cover and lock the same.

CAUTION :



Do not use battery with low electrolyte level as the battery inte rnals will get damaged.



Do not overfill the battery electrolyte as it will spill ot thr ough the over flow pipe and cause corrosion to vehicle p arts.



Us e only distille d water me ant for u se i n batteries to avoid damage to battery.



Clean the wire terminals free of corrosion and keep the terminals coated with petroleum jelly.

Do it yourself

 Di sconne ct the electrical connections.  R emov e the rubber gro mmet and the sealed

beam.

 T hu mb pu sh a nd r emo ve the bulp h old ing

clamp.

 Re move he adlight bulb.

REASSEMBLING THE HEAD LAMP

1 Refix the new halogen bulb into r eflector unit

of the headlamp.

2 G ent ly p r e ss

th e bu l b ho l din g cl ip and lock in its slot.

3 F it th e

r u b b e r grommet.

4. Co n nec t th e e l e c t r i c a l c o n ne ct i o n s carefully .

CHANGING ELECTRICAL COMPONENTS

Head Lamp bulb

CAUTION :

Never touch the bul b with y our finger. Finger prints will etch the glass and decrease b ulb life. Hence, it is recommended to gr ab the bulb with paper or clean dry cloth during handling.

REMOVING THE HEADLAMP

 Lo osen the rim holding screws - 1 on top and 2

at the sid e s a n d ta k e ou t th e hea d lam p assembly.

Do it yourself

 P osition the head lamp d oom assembly in to

th e c a si ng an d tigh te n all the mou n ting scre ws.

TAIL LAMP BULB

 Re move the two nuts holding the rear number

plate of RH & LH side.

 Re move the three sc rews ho lding the tail lamp

to the br acket.

 T w is t the bu lb ho ld e r a n ti c lo ckw i se an d

remove.

 Re move the old bulb and replace with a new

bulb .

 Re fit the bulb holder and turn clockwise to

lock the bulb ho lder.

 Re fit the tail lamp on the bracket and rear

number plate in the reverse order of removal.

NOTE :

Plea se ensure to re pla ce a spare f use in th e holder at the earliest opp ortunity.



Open the LH tool b ox

 Replace the required fuse with the spar e fuse

available in the fuse carrier.

Fuse No. Color Remar ks

1 B lue Main F us e (15A)

2 Red Ig nitio n Fus e (10 A)

3 Red Spare Fuse (1 0A)

4 B lue Sp are Fus e (15 A)

FUSE

BLADE FUSE USAGE LIST

Do it yourself

(D) Pull the rear seat wi th its su b fra m e towards back so that it will b ecome fr ee from th e sh o ckab s o rb e r mounting bolts.

(E) Ta ke out the rear seat

Rear Seat Removal

(A) Lo o sen fr o n t mounting nut of the rear seat under the rider seat wi th 1 2 mm t u bul ar spann er.

(B) Loosen b oth LH an d RH shoc k -a b s or b er to p mounting nuts by holding the bolt with 3/8” x 15/16” double end spanner a nd tu r nin g the d o o m nut with 17mm eyelet spanner.

(D)

(E)

REAR SEAT REMOVAL & REFI TTING

Do it yourself

(B)

(C)

(A)

Rear Seat Ref itting

(A) Place the rear seat in th e po sition ove r the re a r m u d gua r d , inserting the front end of its sub frame goes to its mo unting under the rider’s seat.

(B) E ns u r e the r e a r mounting br ackets are sea ted p rop erl y in the LH & RH s hoc k ab s o rbe r m o u nt i ng bolts.

(D) T ig ht en the fr on t mo u nti ng nu t wit h 12mm tubular spanner ho ld in g t he bol t wit h 13 m m d ou b l e e n d sp a n ner f r om o t her side.

(E) Tighten both LH & RH rear shock-ab sorber top foundation bolt a nd nuts.

(D)

(E)

Do it yourself

(A)

(B)

(C)

 Rinse vehicle thoro ughly with plain water to

remove the detergent and wipe vehicle dr y.

 If p ossible, use compressed air and blow off

water particles from the obscure areas of the vehicle, electrical connections, etc.

After washing

 En sur e, the ve hicle is thoro ughly dry b y

wiping with a clean soft water absorbent cloth or cha mois leathe r.

 Remove all plastic b ags and adhesive tapes.

 Lubricate control cables, pivot and rear chain

with lube oil

 Polish the painted and plated surfaces using

polishing wax.

 Start engine and allow to run at idling spee d

for a few minutes to warm up engine.

 Drive the mo torcycle slowly, apply ing both

brake s inter mit ten tly to d ry u p the brake shoes.

 Test brakes for full efficiency.

PRECAUTIONS

 Was h vehicle when the en gine is cold.

 Cover the silencer, tail pipe, ca rburettor and

control s witches with suitable plastic bags and tie it firmly to prevent water entry to the m.

 Re move ignition key and seal key hole using

adhesive tape.

 Brush engine area with ke rose ne / diesel to

remove dirt or grease.

 Use low pres sure jet of water to clean t he

vehicle or engine.

 Never spray water with great force on head

lamp, speedometer, flasher lights, front and rear wheel hubs, electrica l co nnec tions an d wires, control cables, carburetor, sparkplug, battery etc.

 Do no t apply kerose ne or die sel on painted

parts or rubber parts.

 Us e luke war m water an d mild detergent on

the painted components to remove dirt, etc.

Washing Proceedure

Incase you r Motorcy cle is not going to be used for a mo nth or more, we advice the following precau tions to the taken.

 Carryout req uired repair / adjustments on the

motorcycle.

 Was h the motorcycle thoroughly and lubricate

as per the maintenance chart.

 Dr ain fuel tank, fuel line and carbu retor.

 Keep the fuel tap in closed po sition and spray

mo tor oil i ns ide t he fuel tan k to pre ven t rusting.

 Remove s park plug. Pour in abo ut 3 0ml of

cle an en gin e oil t hro ug h spar k plug hole . Close the hole and crank e ngine several times and refit spark plug.

 Clean rear chain thorough ly and apply a thin

film of lub oil >90 grade.

 R em ove batt er y from the bike . C le an the

terminals free of corrosion.

 Maintain electrolyte level between max. or min.

mark, by adding distilled water and wipe the battery dr y.

 S to re the ba tt er y in a c ool, dry and well

ventilate d place.

 Do not place the battery in direct sun light,

near open flame or where temperature is above 40

C or below 0oC

 Cover the silencer with plastic bags to prevent

moisture entry. Set the motorcycle on its center stand.

 Apply a thin film of oil on the engine barrel

fins , cylin de r head fi ns an d other painted parts.

 Apply anti-rust solutions on all plated parts.

Take care not to apply this solution on rubber or painted parts.

 Stor e motorcycle in a clean covered area free

of m oistur e a nd dus t. K ee p it c ov er e d to preven t d ust settling on it.

Storage Precautions

Preparing the motorcycle for reuse

 Re move the a nti-rust solution fro m all plated

parts and clean the motorcycle well.

 Inflate the tyres to the cor rect tyre pressure.

 Ensure battery is fully charge d and pr oper

electroly te level is ma intained.

 Connect the battery.

 Lubricate all control cables and pivots.

 Check proper level of oil in engin e.

 Clean and remove the motor oil from tank and

fill tank with fresh petrol.

 Clean carburettor and air filter.

 Re move plastic cove ring from the silence r.

 Re move spark plug on cylinder head and pour

in a few drops of engine oil. Crank engine a

few times to lubricat e cy lin der w all s and piston. Clean spark plug a nd refit.

 Switch on ignition s witch.

 Star t vehicle and warm up engine for a few

minutes before riding the vehicle.

NOTE :

Do not raise the e ngine rpm the m ome nt it is started, allow the engine to run at idling speed.

Storage Precautions

Check s pri or to the commenc em ent of long journey

 Service the motor cyc le thoroughly a Ro yal

En f ie l d auth ori s e d ser v ice po i nt as pe r periodical maintenance chart.

 Sufficient quant ity of petrol in the fuel tank

for the journey planne d.

 Correct tyre pressur e.

Checks af ter every 1500 kms of run

 Tightness of all fasteners.

 Tyre tread condition and we ar of tyres.

 Battery cond ition and electrolyte leve l.

 Correct level of oil level in engine, clutch, gear

box and front fork.

 Working of all lights and horn.

 Pr oper chain ten sion.

Items to be carried

 Tool kit

 First aid kit.

 Bulbs for headlight, trafficator light, re ar

tail lamp and fuse (15Amps & 10Amps).

 Ac celerator, clutch, front brake.

 Re ar chain link lock assembly.

 Spare tube, tyre punctu re repair kit - cold

vulcanising type.

 Foot ope rated air pump.

 Insulation tape.

 Spark plug, spark plug cap, fuel hose.

Long Trip Precautions

Wiring Diagram

Basic Guidelines to be followed “FOR ALL ELECTRIC START VEHICLES”

1. In cold condition of the engine or for initial star t, it is advis ed to use electric star t (ES) only.

2. Apply choke in cold start condition. (a mbient temperatur e <25° C)

3. D O NOT ATTEMPT – “HAL F S TART” BY CASUALLY PR ESSING E LEC TRIC START BUTTON.

4. PL EASE PRESS AND HOLD ELECTRIC START BUTTON FOR ATLEAST 3 SECONDS CONTINUOUSLY FOR THE CRANKING OR UNTIL THE ENGINE FIRES AND SUSTAINS, WHICHEVER IS EARLIER.

5. If engine d oesn’t start in the first attempt, re lease the ES button and repeat the above Procedure.

6. It is adv ised not to a pply excessive throttle during starting.

Vehicle Starting Procedure

SWITCH MODULE RH

FRONT

BRAKE

SWITCH

9x2.8

COUPLER

PARK

KILL

H.LAMP

E START

RED/WHITE

GREEN

GREY

YELLOW

PILOT LAMP

GREEN

LIGHT GREEN

NEUTRAL SWITCH

BROWN

IGNITION

SWITCH

OFF

POSITION

2x6.3MM

COUPLER

CLUTCH SWITCH

9x2.8 COUPLER

SPEEDOMETER ASSY

BLACK

BLUE

GREEN

GREY

BLUE

GREY

BLACK

YELLOW/WHTE

BLACK

GREEN

GREY

BLACK

BLACK/GREEN

BLACK

BROWN

PILOT

LAMP

BLACK

GREY

HEAD LIGHT

60/55W

HALOGEN BULB

YELLOW/RED

RED/WHITE

12V 14Ah

BATTERY

MAX

MIN

B/W

B/G

RED/WHITE

BLACK

GREY

RED

BLACK/WHITE

BLACK/GREEN

10W FRONT

TRAFFICATORS

RED

BLACK

GREY

HORN LT

HORN HT

RED/WHITE

BLACK/RED

BLACK/GREEN

BLACK/WHITE

SWITCH

MODULE LH

WHITE

TRAFFIC

HORN

HB/LB

9x2.8

COUPLER

AMMETER

ASSEMBLY

TRAFFICATOR

REAR RH 10W

TRAFFICATOR

REAR LH 10W

STOP/TAIL

LIGHT

21/5W

THREE

PHASE

MAGNETO

PULSER

COIL

RED

RED/YELLOW

BLUE/WHITE

GREEN/WHITE

LIGHT GREEN

4x6.3 COUPLER

RED

YELLOW

RED

2x6.3 COUPLER

3x6.3 COUPLER

RECTIFIER

REGULATOR UNIT

(THREE PHASE)

RED

BROWN

BLACK

2x2.3 WATER PROOF

COUPLER NATURAL

3x2.8 COUPLER

2x2.8

COUPLER

2x2.3

WATER PROOF

COUPLER

4x2.3

WATER PROOF

COUPLER

RELAY STARTER

0.7 KW STARTER

MOTOR

THROTTLE

SWITCH

TCI UNIT

GREEN

WHITE

SPARK

PLUG (M14)

BROWN

WHITE/RED

RED

FUSE-1

10A

BLACK

GREEN

RED/WHITE

RED

BLACK

FUSE -2

15A

BROWN

WHITE/RED

IGNITION

COIL 1

SPARK

PLUG (M10)

IGNITION

COIL 2

2x2.3

WATER PROOF

COUPLER

2x2.8

COUPLER

6x2.8 COUPLER

2x6.3

‘L’ TYPE

COUPLER

FLASHER

REAR BRAKE

SWITCH

BLACK

BLACK/WHITE

GREY

POSITION

LAMP 4W

GREY

WHITE

LIGHT GREEN

BLADE FUSE LIST

TCI FUSE

IGNITION LOADS

Fuse 1

Fuse 2

Fuse 3

Fuse 4

Complete Wiring Diagram - Classic 350

I. ENGINE FAILS TO START

1) Ignition switch in ‘OFF’ Position ............................. Switch on ignition.

2) Stop switch in ‘OFF’ Position .................................... Push stop switch to ‘ON’ position.

3) Clogged fuel line / tap ................................................ Clean the fuel line / tap.

4) Vent hole clogg ed in fuel tank cap .......................... Clean vent hole.

5) Carburetor passage & jets b locked ......................... * Dismantle car buretor & clea n jets

...................................................................................... / passages

6) Carburetor float stuck in closed position ............... Ensure correct move ment of float

7) Spark plug cap / lead n ot con nected ......................... Fix cap / lead firmly

8) Loose HT connections ................................................ Fix connections firmly

9) HT Lea d Damag ed .................................................... * Replace HT Lead

10) Spark plug electrode dirty / fouled ........................... Clean spark plug & Reset gap.

11) Spark plug in sulation cracked ................................. Replace spark plug

* Contact Authorised Dealer / Service Point

Trouble Shooting

CAUSES REMEDIES

CAUSES RE MEDIES

12) Poor c ompres sion :

- Auto Decompressor not working ......................... * Ensur e fr ee motion of flyweight in exhaust

...................................................................................... ca m gear assembly

- Loos e spark plug .................................................... * Tighten spark plug.

13) Clutch slipping .......................................................... * Adjust clutch cable fre e play

II. ENGINE MISFIRING

1) Water in petrol tank/carburetor ............................. * Clean car buretor / petrol tank. Fill tank

...................................................................................... with fresh petrol.

2) Leak thro ugh intake hose ......................................... Tighten rubber hose suitably.

...................................................................................... Re place if necessary

3) Loose spark plug cap ................................................. Fix cap / lead firmly

4) Spark plu g fouled/insulation broken ....................... Clean / reset gap or, replac e.

5) Poor Compr ession ..................................................... * Auto deco mpress or sticky or

...................................................................................... no t working

Trouble Shooting

* Contact Authorised Dealer / Service Point

Trouble Shooting

CAUSES RE MEDIES

* Contact Authorised Dealer / Service Point

III. ENGINE STARTS, BUT RUNS IRREGULARLY & STOPS

1) Faulty fuel supply ..................................................... Clean the fuel line / tap / vent ho le

2) Very low idling spe ed ................................................. Increase idling speed

IV. POOR PICKUP

1) Accelerator cable free play excessive ....................... Adjust cable free play

2) Faulty fuel supply ...................................................... Clean the fuel line / tap / vent ho le

3) Choked air filter ......................................................... Clean / Replace air filter

4) Loose carburetor mounting ...................................... Tighten clamps firmly

5) Brakes adjusted too tight ........................................ * Re-adjust properly

6) Rear chain adjusted too tight ................................. * Re-adjust properly

7) Clutch Slipping ......................................................... * Adjust clutch cable free play

8) Under inflated tyres ................................................. * Inflate to corr ect pressu re

9) TPS setting ................................................................ * Retar d setting

* Contact Authorised Dealer / Service Point

V. WHITE/BLUE SMOKE

1) Oil level in tank above the middle line in the ....... * Check and drain excess oil

oil le vel window

VI. ENGINE OVERHEATING

1) Cylinder fins not clean .............................................. Clean the cylinder fins at

...................................................................................... re gular interva ls

2) Clutch slipping .......................................................... * Check and correct

3) Suction leakage ........................................................ * Check and corre ct

4) Incorrect carburetor adjustments .......................... * Check and correct

5) TPS setting ................................................................ * Advance setting

VII. EXCESSIVE FUEL CONSUMPTION

1) Fuel leakage .............................................................. * Check and rectify

2) Worn out carburetor jets ......................................... * Change the defective jets

Trouble Shooting

CAUSES RE MEDIES

* Contact Authorised Dealer / Service Point

3) Incorrect carburetor adjustments .......................... * Check and adjust correctly

4) Choked air filter ......................................................... Clean / Replace

5) Poor c ompression ..................................................... * Auto decompr essor sticky or

...................................................................................... no t work ing properly

6) Under inflated tyres ................................................... Inflate to correct pressure

7) TPS setting ................................................................ * Over advance se tting

VIII. IGNITION KNOCK

1) Carbur etor adjusted too lean .................................. * Check and readjust

2) Suction leakage ........................................................ * Check and corre ct

IX. BRAKES POOR

1) Not ad justed proper ly .............................................. * Adjust properly

2) Oil / grease on lining or drum or disc ................... * Clean and refit

Trouble Shooting

CAUSES RE MEDIES

* Contact Authorised Dealer / Service Point

3) Linings worn / Uneve n we ar ................................... * Replace linings

4) Drum scored / Uneven wear .................................... * Rectify or Replace drums

X. VEHICLE WOBBLES

1) Wheel rim runout ..................................................... * Rectify

2) Loose / Broken spok es ............................................. * Tighten / Replace spokes

3) Tyres not fitted cor rectly ........................................ * Refit tyres correctly

4) Wheels misaligned .................................................... * Ensure proper alignment

5) Under inflated tyres ................................................... Inflate to correct pressure

XI. Electricals

Bu l b s do no t lig h t

1) Loose / improper connection ................................... * Check and correct

2) Bulb fused ................................................................. * Replace bu lb

3) Fuse blown ................................................................ * Replace fuse

Trouble Shooting

CAUSES RE MEDIES

* Contact Authorised Dealer / Service Point

4) Switch defective ........................................................ * Replace switch

Horn not working

1) Loose connections .................................................... * Check and correct

2) Requires tuning ........................................................ * Tune horn

3) Switch Defective ........................................................ * Replace

Trafficators no t working

1) Loose / improper connections ................................... Check and correct

2) Bulb fused ................................................................... Rep lace

3) Switch defective ........................................................ * Replace

4) I.C. Flasher defective ............................................... * Replace

Brake light remains on

(1) Switch no t adjusted proper ly .................................. * Adjust switch proper ly

(2) Switch s ticky ............................................................. * Replace switch

Trouble Shooting

CAUSES RE MEDIES

XII. ELECTRIC START

Ve h i c l e n ot s ta r t i ng

(1) Neutral indicator no t glowing ................................. Bring the vehicle in neutral

(2) If vehicle is without neutral indicator .................... Press the clutch lever & start switch together

(3) Loose Conn ection ...................................................... * Check & C orrect

(4) Starter relay not working ....................................... * Check & R eplace

(5) Malfunctioning of c lutch s witch ............................ * Check & Replace

(6) Malfunctioning of S tarter switch........................... * Check & Replace

(7) Battery discharge ..................................................... * Check & Recharge

(8) Motor not working .................................................. * Check & Replace

(9) Battery not fully charged ........................................ * Check & charge

(10)Failure of sprag clutch ............................................ * Check & repla ce

Trouble Shooting

CAUSES RE MEDIES

* Contact Authorised Dealer / Service Point

Royal Enfield Motor Cycles are manu factured by following best Quality pr actices in respec t of the material and workmanship.

Royal Enfield (RE) warrants Classic 350 motorcycle to be fre e from manufacturing and material defect under normal use subject to following conditions.

1. RE will replace or repair defective part / parts at their Author ised Dealer / Service Po int, free of

charge within a period of 12 months from the date of sale (date of Installation) or 10,000 k ms whichever occurs earlier.

2. The warranty is applicable only to first registered owner.

3. The warranty shall be applicable only i f a ll the free services are av ailed at the respective per iod /

kilometer range a s per the sche dule given in the owner’s manual from RE Authorised Dealer / Service Point.

4. During the warranty period, RE’s obligations shall be limited to repa iring / replacing free of charge

such part or parts of the vehicle, which on examination to have manufactur ing defect. Such defective part / parts which have been r eplaced become proper ty of RE.

5. Cost of oil, oil filter, fuel and other consumables are c hargeab le to the cus tomer.

6. Claims on proprietary item s like tyres, tubes , spa rk plug, ba ttery etc. shou ld be taken up with

respec tive ma nufacturer or the ir auth orised agents in the area dire ctly by customer. RE shall not be liable in any ma nner to re place them though their Dea lers will provide as sistance in p referring such claims on their manufacturer.

7. Warran ty shall not apply to:

(a) Norma l ag eing, detoriation or rusting of plated parts paints coat, rubber parts, soft items ,

glass items, pla stic parts etc.

Warranty Terms & Conditions

(b) Components like fuel filter, oil filter pap er element, control cables, brake shoes / brake pads,

clutch plates, drive chain & sprocket kit, which are subjected to normal wear and tear.

(d) Da mages due to use of non-ge nuine parts.

(e) Damag es due to lack of proper maintena nce of the vehicle.

(f) Damages d ue to incorrect driving or riding habits.

(g) Parts dam aged due to ac cidents, collision, abuse etc.

(h) Irregu larities not reco gnized as affecting the quality or function of the vehicle such as slight

vibration , oil leakage, discoloration of exhaus t bent pipe / silencer / soft, hard sh ock absorber etc.

(i) Defects arising from fitment of unauthorised / additional Electrical load s.

(j) Vehicle s erviced / repaired at unauthorised ser vice points.

(k) Vehicle used for competition / racing.

(l) Electrical comp onent likes bulbs, fuses etc.

(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine tune

up and other such adjustments

8. RE reserves the right to finally decide on all warran ty claims

9. RE reserves the right to make changes in De sign of the v ehicle without any obligation to install these changes on previo usly su pplied vehicles.

Warranty Terms & Conditions

In c ompliance with the pro visio ns of Rule 115(2) of the Central Motor Vehicle Rules, 1 989, Royal Enfield ce rtifies that the followin g warranty is applicable to those compone nts liable to affec t th e emission of the gaseou s pollutants in its ran ge o f motorcycles, in nor mal use to which it may be subjected to.

This emission warranty comes into force from 01 st 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 ad dition to and parallel to the war ranty policy, con ditions and obligations laid down in the Owner’s Manual.

Royal Enfield further warranty tha t if on examination by its Autho rised Dealer / Service Point, the motorcycle fail to mee t the s pecified emission standards, then the Autho rised Dealer / Service Point shall tak e ne cessary correc tive measures and shall at its sole discretion, repair or replace fre e o f charge such components of the emission control system to me et the req uired emission s tandards.

The method/s of examination to deter mine the warr anty c onditions of the emission warr anty 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 c onditions of the part/s is/are not established. R oyal enfield will have the righ t to charge a ll, or part of the c ost 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 replac e free of char ge, the componen t/s as re quire d. However , the consumab les like fuel, lubricants, s olvents, etc shall be chargeable to the custo mer as per actuals.

In c ase any of the compon ents covere d under emission w arra nty or the as sociated parts, are n ot

Emission Warranty

independently replaceable. Royal Enfield will have the sole discretion to replace either the entire assembly or parts of the assembly, through suitable repairs.

Royal Enfield re serv es the right to carry ou t necessary co nsequential repairs to the motorcy cle or replace any part, in addition to the repair or replacement o f the compone nts covered under em ission warranty, to establish co mpliance to in-use emission standards. S uch repairs / replacements will be chargeable to the customer.

All parts removed for replacement under wa rranty will become the prop erty of Ro yal Enfield.

Royal Enfield will not be respo nsible for the cos t of transportation of the motorcycle to the nearest Authorise d Dealer / Service P oint OR for any loss due to non availability of the motorcycle during the period of examination and repairs b y Royal Enfield and / or their Au thorised Dealer / Service Poin t.

Royal Enfield will not be res ponsible for any penalties that may be charged by statuatory authorities on accoun t of failure to comp ly with the in-use emission standard s.

That cost/s incurred to check emission of the motorcycle will have to be borne by the cus tomer.

Emission warranty will be applica ble irrespective of the change of ownership of the vehicle provided all the co nditions as laid down in this doc ument are met from the date of original sale of the motorcycle.

The wa rranty shall apply i f the customer :

 Observes all the impor tant instructions and any other precautions listed in the owner’s manual.

Emission Warranty

 Under all circumstances uses lubricants and fuel as recommended by Royal Enfield.

 Regularly obtains and carries out maintenan ce in accordance with Royal Enfield guidelines and

enters the details in the Log book.

 Immediately approaches the neare st Authorised Dealer / Se rvice Point upon discove ry 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 adjustmen ts as may be required with a v iew to establish such compliance.

 Produces the ‘Pollution Under Control ’ certificate valid for the period immediately prec eding the

test d uring which the failure is discovered, the test having been carr ied out either for obtaining a new certificate or purs uant upon being directed by an office r as re ferred to in sub rule (2) of rule 116 of the Central Motor Vehicles Rules (CMVR).

 Produces the owner’s manua l an d Log book for ve rification de tails.

 Produces receipts covering maintenance of the motorcycle is spe cified in the owner’s manual from

the date of original purchase of the ve hicle.

 Produces valid certificate of Insurance and R. T. O. Registration Certificate (R.C. Book).

The Emission warranty shall not apply IF :

 A valid “Pollution under control” certificate is not produced.

Emission Warranty

 The motorc ycle is not serviced by Authorised Dealer / Se rvice Point as per the se rvice sche dule

described in the maintenance char t.

 The mo torcycle h as been subjected to abnormal use, abuse, neglect and improper ma intenance or

has met with an accident.

 Re placement parts not specified and appr oved by Royal Enfield ha ve b een used.

 The motorcycle, or parts thereof, has been altered, tampered with or modified or replaced in an

unauthor ised ma nner.

 The odome ter is not functioning or the odometer and / or its reading has been change d / ta mpered

with, so that the actual distance cover ed cannot be readily de termined.

 The motorcyc le has been used for competitions, races, and rallies or for the purpose of establishing

records.

 On examin ation by Royal Enfield or its Authorised Dealer / Service Point, if the motorcycle shows

that any of the con ditions stipu lated in the Owner’s manual with regard to use and ma intenance have been violate d.

 The motorcycle has bee n run on adulterated / leaded fuel or lubricant other than those specified by

Royal Enfield in the Owner’s manual or any other docume nt g iven to the customer at the time of sale of the motorcycle.

 The emiss ion related components are tampe red with.

Emission Warranty

 All service and parts related bills and vouchers incurred during the tenure of the emission warranty

is not produced.

 All maintenance activities carried out on the vehicle during the tenure o f the emission warranty is

not entered in the log book.

Tips to be on the right side of Law

 Always get your vehicle checked to meet the emission regulations through and authorised emission

checking center.

 Always ca rry a v alid ‘Pollution Unde r Control’ certificate with you at all times during the validity

of the emission warranty (30,000 Kms / 3 ye ars 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 Roy al Enfield Authorise d Dealer / Service Point.

2. Use only Unleaded petrol (> 87 Octane) from reputed fuel pump s.

3. Ensur e the fuel used is not adulterated.

4. Use corre ct spark plug as reco mmended in the ow ner’s manual.

5. Use lubricants a s per r ecommen dations given on grade / brand in the owner’s manua l.

Emission Warranty

Sl.

No.

Date Km s. Details

Idling

Co%

Authorised Dealer /Service Point

Job Card N o.

Stamp &

Signature

Log Book

It is our endeavour to pro vide excellent se rvice to your Royal Enfield Motor C ycle at all times. Towards this we provide four free services at specific Intervals.

Plea se avail these se rvices at the specified tim e, in any o f the R oya l En field Authorise d D eale r / Serv ice Point ne ares t to you and as a toke n o f satisfacto ry service , kindly return the fre e service coupon du ly filled in and signed, to the servic e o utlet.

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

The cost of fuel, oil, grease etc . used for free service is c hargeable to the customer.

Free Service Coupons

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

Customer Name : Dealer Code :

Addre ss :

Free

Service

500 Kms

45+

8 days

which ever is

earlier from the

date of sale

Enter the Details in

Free Service

Re co rd

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

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

Contact Phone / Mobile No.:

REGN No:

SALE DATE :

SERVICE DATE :

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

FRAME NO :

ENGINE NO :

Vehicle Installation Form No.

ODO READING :

Sold by (De aler’s Name & Address)

(Cost of oil,

oil filter element

and other

cons umables

used are

chargeabl e to

the customer)

1st Free Service

1. Water wash the vehicle and dry it with a clean cloth

2. E lec tr olyt e ..................................................... Check level & top-up

3. B attery terminals ......................................... Cl ean and apply petroleum jelly

4. Dr ive chain fr ee play ................................... Check, clean, lubricate & adjust

5. Re ar brake pedal pivot ................................ Lubri cate

6. R ear brake .................................................... Ad just

7. Wheel rims front & rear ............................. Che ck spokes tightness

8. Front brake .................................................... Che ck & top up brake fluid level

9. Front fork oil leak ........................................ Check for leakage

10. Air fil ter element.......................................... Cl ean

11. Spark plugs (2 Nos) ..................................... Che ck, clean & adjust gap

12. H.T. Leads ....................................................... Inspect for cracks

13. Carbur etor ...................................................... Clean & tune

14. Fuel filter........................................................ C lean

15. Fuel hose......................................................... Inspect for cracks

16. Rubber hose, Air filter to carburetor........ Ins pect for cra cks

17. Accelerator / TPS cable................................ Check & adjust play

18. Clutch cable .................................................... Adju st play

19. Engine oil sump strainer ............................ Cle an

20. Engine oil ....................................................... R ep lace

21. Engine oil filter element.............................. R ep lace

22. Hand levers & kick starter pivot................ Lubric ate

I Free Service : Activities

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp & Signature

Customer Copy

3000 KMS OR 90+15 DAYS WHICHEVER IS EARLIER FROM THE DATE OF SALE

Customer Name : Dealer Code :

Addre ss :

Free

Service

3000 Kms

90+

15 days

which ever is

earlier from the

date of sale

Enter the Details in

Free Service

Re co rd

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

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

Contact Phone / Mobile No.:

REGN No:

SALE DATE :

SERVICE DATE :

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

FRAME NO :

ENGINE NO :

Vehicle Installation Form No.

ODO READING :

Sold by (De aler’s Name & Address)

(Cost of oil,

oil filter element

and other

cons umables

used are

chargeabl e to

the customer)

2nd Free Service

1. Water wash the vehicle and dry it with a clean cloth

2. E lec tr olyt e ................................................... Check level & top-up

3. B attery terminals......................................... Clean and ap ply petroleum jelly

4. Dr ive chain fr ee play ................................. Chec k, clean, lubricate & adjust

5. Re ar brake pedal pivot............................... Lubri cate

6. R ear brake.................................................... Ad jus t

7. Wheel rims front & rear............................. Check spokes tightnes s

8. Front brake................................................... Check & top up brake fluid level

9. Front fork oil leak........................................ Check for leakage

10. Air fil ter element........................................ Cle an

11. Spark plugs (2 Nos).................................... Check, clean & adjust gap

12. H.T. Leads ..................................................... Inspect for crac ks

13. Carbur etor ................................................... Clean & tune

14. Fuel filter...................................................... Cl ean

15. Fuel hose....................................................... Inspect for cracks

16. Rubber hose, Air filter to carburetor ..... Inspec t for cracks

17. Accelerator / TPS cable.............................. Che ck & adjust play

18. Clutch cable .................................................. A djust play

19. Steering free play........................................ Check & Adjust

20. Engine oil...................................................... Check level & top-up

21. Hand levers & kick starter pivot.............. Lu bricate

22.

Oil filter element, oil strainer & magnetic drain plug

.. Cle an

II Free Service : Activities

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp & Signature

Customer Copy

6000 KMS OR 180+15 DAYS WHICHEVER IS EARLIER FROM THE DATE OF SALE

Customer Name : Dealer Code :

Addre ss :

Free

Service

6000 Kms

180+

15 days

which ever is

earlier from the

date of sale

Enter the Details in

Free Service

Re co rd

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

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

Contact Phone / Mobile No.:

REGN No:

SALE DATE :

SERVICE DATE :

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

FRAME NO :

ENGINE NO :

Vehicle Installation Form No.

ODO READING :

Sold by (De aler’s Name & Address)

(Cost of oil,

oil filter element

and other

cons umables

used are

chargeabl e to

the customer)

3rd Free Service

1. Water wash the vehicle and dry it with a clean cloth

2. El ec tro lyte .................................................... Check level & top-up

3. Bat tery terminals ........................................ Clean and apply petroleum jelly

4. Dr ive chain free play .................................. Check, clean, lubricate & adjust

5. Re ar brake pedal pivot................................ Lubr icat e

6. Re ar brake..................................................... Cam clean, lubricate & Adjust play

7. Wheel rims front & rear.............................. Check spokes tightness

8. Front brake ................................................... Check & top up brake fluid level

9. Tyres front & rear........................................ Check wear and tread depth

10. Air filter element ........................................ Clean

11. Spark plug s (2 Nos) .................................... Check, clean & adjust gap

12. H.T. Leads...................................................... Inspect for cracks

13. Carbure tor ..................................................... Clean & tune

14. Fuel filter....................................................... Cle an

15. Fuel hose ....................................................... Ins pect for cracks

16. Rubber hose, Air filter to carburetor....... Inspect for cra cks

17. Accelerator / T PS cable................................ Check & adjust play

18. Clutch cable................................................... A djust play

19. Engine oil sump strainer............................ Clean

20. Engine oil ..................................................... Re pl ac e

21. Engine oil filter element............................. Re pl ac e

22. Hand levers & kick starter pivot.............. Lu bric ate

23. Steering syst em ........................................... Check, Lub. steering balls & adj. play

III Free Service : Activities

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp & Signature

Customer Copy

9000 KMS OR 270+15 DAYS WHICHEVER IS EARLIER FROM THE DATE OF SALE

Customer Name : Dealer Code :

Addre ss :

Free

Service

9000 Kms

270+

15 days

which ever is

earlier from the

date of sale

Enter the Details in

Free Service

Re co rd

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

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

Contact Phone / Mobile No.:

REGN No:

SALE DATE :

SERVICE DATE :

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

FRAME NO :

ENGINE NO :

Vehicle Installation Form No.

ODO READING :

Sold by (De aler’s Name & Address)

(Cost of oil,

oil filter element

and other

cons umables

used are

chargeabl e to

the customer)

4th Free Service

1. Water wash the vehicle and dry it with a clean cloth

2. E lec tr olyt e..................................................... Check level & top-up

3. B attery terminals ......................................... Clean and apply petroleum jelly

4. Dr ive chain fr ee play................................... Check, clean, lubricate & adjust

5. Re ar brake pedal pivot................................ Lubr icat e

6. R ear brake..................................................... A dju st

7. Wheel rims front & rear.............................. Che ck spokes tightness

8. Front brake .................................................... Check & top up brake fluid level

9. Front fork oil ................................................. Check level & top-up / replace

10. Air filter eleme nt ........................................ Cl ean

11. Spark plugs (2 Nos) ..................................... Check, clean & adjust gap

12. H.T. Leads ...................................................... Ins pect for cracks

13. Carbur etor .................................................... Clean & tune

14. Fuel filter ....................................................... Cl ean

15. Fuel hose ........................................................ Inspect for cracks

16. Rubber hose, Air filter to carburetor ...... Ins pect for cr acks

17. Accelerator / TPS cable................................ Check & adjust play

18. Clutch cable ................................................... Adjust play

19. Engine oil strainer....................................... Cl ean

20. Engine oil....................................................... Che ck level & top-up

21. Hand levers & kick starter pivot............... L ubricate

22. Steering free play......................................... Check & Adjust

23. Tyres................................................................ Check wear and tread depth

IV Free Service : Activities

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp & Signature

Customer Copy

Cust ome r Copy

12,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

12,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Cust ome r Copy

15,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

15,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

Cust ome r Copy

12,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

15,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

12,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

15,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

Cust ome r Copy

18,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

18,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Cust ome r Copy

21,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

21,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

Cust ome r Copy

18,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

21,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

18,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

21,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

24,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

24,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Cust ome r Copy

27,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

27,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

Cust ome r Copy

24,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

27,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

24,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

27,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

30,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

30,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Cust ome r Copy

33,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

33,000 + 250 Kms. Service

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

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

Brief Work Done : Reg. No.:

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

Cust ome r Copy

30,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Cust ome r Copy

33,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

30,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Dealer / ASP Copy

33,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

All India Road Signs

Notes

Telephone Residence

Bike Regn. No.

Telephone Office

Invoice No.

Delivery Note / Advice No.

Sales Representative

Have you visited Royal Enfield website? Yes No

PRE DELIVERY INSPECTION LIST

MODEL: BULLET 350 / ELECTRA / CLASSIC 350 / CLASSIC 500 / BULLET 500

Model : Engine No:

Dealer's Name : Location:

Colour : Key Number :

Area

Battery Make :

Defect

Code

D / NC / Weak Cell

EO - (Drained Oil Level)

H / LF / NW Same

M / RB Straight

WF Good

Battery Voltage 12V-whereas

13.5 V

Fill 2.5 Litres (Capacity is

2.75 Litres) - Remove 3 Drain Bolts to Drain the complete Oil

Free ( Check Spokes Looseness & Runout

No Leak ( Tank, Tap, Carburetor)

Free (Check Spokes Looseness & Runout)

Measure

(Max. online voltage)

Defect #1Defect #2Defect

Battery Number : Tyre Number : Front : Rear :

Aggregate

CHASSIS / ENGINE NUMBER

CONNECT BATTERY / CHECK VOLTAGE

ENGINE OIL

LOCK OPERATION 5

PETROL 6

FRONT WHEEL

CLUTCH

HANDLE BAR CONTROLS & ELECTRICAL SWITCH OPERATIONS

FUEL SYSTEM

REAR WHEEL

Engine / Vehicle Number Details DF Same

Battery Charging

Replace oil & oil filter / Check Oil level (3 Drain Bolts system Hex 19mm, 8mm X 2nos and

Hex 12mm head bolts)

Clean Primary Oil Strainer screen - Clean

Ignition / Side Air Filter Box / Tool Box Lock / Fuel Tank Lock

Fill Petrol - 5 Litres

Brake Lever Free Play EP / T 2-3 mm / (STD)

Caliper Mounting Bolts LF 2.7 to 3.0 Kgm

Front Wheel Rotation W / T / LF / N

Front Mudguard Alignment / Cover Tube

Rubbing

Front Wheel Nut LF 7.0 to 7.7 Kgm

Front Tyre Condition (Check Tyre Line Seating)

Front Tyre Pressure LESS 22 PSI

Clutch Operation H / N Smooth

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

Accelerator Operation T / SY Smooth

Lever Brackets Tightness LF Tight

Switch Modules Tightness LF Tight

Steering Movement T Free

Handle Bar Positioning WF W.r.to Dot Punch

Lock Nut T- Stem LF 4.5 to 5.5 Kgm

Electrical Switch Operation NW / F No Defects

Neutral Lamp NW / F No Defects

Fuel Tap Operation H / NW Smooth / Main / Reserve

Fuel Leak L

Fuel Tank Alignment M Straight

Rear Brake Pedal Free Play T / EP 20 - 30 mm

Pedal Position w.r.t foot rest DF Same Level

Chain Tension T / EP 20 - 25 mm

Rear Wheel Rotation W / T / LF / N

Anchor Pin Nut LF 4.5 Kgm

Rear Mudguard Alignment M Straight

Rear Tyre Pressure LESS 32 PSI

Rear Tyre Condition (Check Tyre Line Seating) WF Good

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

Remarks

AESTHETICS

OTHERS

TEST RIDE

STATIC CHECK (AFTER TEST RIDE)

36 Mudguards - Paint / Plating Related

37 Fuel Tank - Paint Related

Tool Box LH, Air Filter Box, Battery Cover -

Paint / Plating Related

39 Head Lamp Casing - Paint Related SC / PD / R / No Defects

Powder Coated Parts (Scratch / Rust /

Chipped OFF)

41 Plated Parts (Scratch / Rusty) SC / R / PO

42 Buffed components poor Buffing & Scratches SC / DU No Defects

43 Seat Alignment M No Defects

44 Indicators Alignment (MFR / Amber) M No Defect / Colour Lens Colour Check

45 Stickers / Knee Pads M / LF / SC No Defects

46 Nuts, Bolts, Fasteners (Torque) LF

47 Owner's Manual & Tool Kit Content - Availability

48 Spare Fuse in Fuse Carrier NA Tubular / Blade Fuse

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

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

51 Pulling P Straight

52 Vibration V Smooth

53 Wobbling W No Defects

54 Front Fork / Drive Chain Noise N No Defects

Engine Performance / Gear Shifting /

TPS Setting

56 Any Rattling / Squeaking Noise N

57 Easy Start (Hot Condition) ST / NW Smooth

58 Leak L

59 Smoke / Oil Droplets in Silencer SK / EO No Smoke

60 Cam Noise / Top End Noise N Smooth

SC / PD / R / DNNo Defects (Mudguards /

SC / PD / R / DN

SC / PD / R No Defects

N / ST / J / H Smooth

Fuel Tank / Tool Box

No Defects

No Defects (Mudguards / Fuel Tank / Wheel Rim / Indicator

Tight (RH, LH Cover / Engine Foundation / Accessories / Wheel Nut)

Nil (Silencer / Accessories / Body Parts / Suspension)

No Leak (Oil / Fuel / Hydraulic / Acid Leakage)

ANY OTHER

Note **

Any Abnormal Noise or Engine Open cases during PDI Inform to Plant / Factory

1. Check the vehicle thoroughly for any transit damages or shortage of parts.

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

3. Thoroughly road - test the vehicle for performance.

Misalignment

Excess Play

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

Noise

Vibration

Leak

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

Different

Spongy

L ST LESS

Sticky

Starting

Trouble/Missing

Not

Available

Less

Smoke

INSTRUCTIONS

Wobbling

Adjustment

Loose

Fitment

LF D T F SC P

Not

Working

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

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

6. Claim Parts replaced for Manufacturing defects only under warranty.

Discharing Tight

Paint Defect

Fused Scratch

Rust

Peel Off

Pulling

Excessive Oil

Dull

Wrong

Dent

EO RB NC

Hard

Fitment

Rubbing Not Charging

Jerking

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.

1 Bike Documents explained (Invoice, Insurance, RC / Road Tax Receipt) 2 Owner’s Manual received

3 Recommended Lubricants explained

4 Maintenance Schedule sheet in Owner’s Manual shown and explained

5 Next Free Service due explained

6 All Free / Paid Services explained

7 Warranty Guidelines explained

8 “Running in period” details shown in the manual explained

9 Service Station Address given and Location explained

10 Service Incharge Name & Mobile No given

11 Bike delivered in neat and clean condition

12 Tool Kit & First Aid Kit received and explained

YES

13 Control Switches & Disc Brake System usage explained

14 Fuse Box location shown and explained

15 Recommended Tyre Pressure explained

16 Bike starting & Gear shifting procedure explained

17 Quantity of Fuel in Fuel Tank informed

18 Bike orientation & short distance drive provided

19 Date and Time of Installation 20 Name of Person who did Installation

Suggestions If Any:

CUSTOMER SIGNATURE

Model: Registration No.:

Chassis No.:

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

KEEP RIDINGP

FORM 22

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

INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETY

STANDARDS OF COMPONENTS AND ROAD WORTHINESS

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

Brand name of the vehicle :- Classic 350

Chassis number :-

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

Sub-rule No. of rule :-

115(2)(i), 115(14)(F)

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

Date :

For ROYAL ENFIELD

Quality Assurance

Royal Enfield Classic 350 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual