Royal Enfield Classic 500 2009, Classic 350 2009 Service Manual

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Service Manual

Classic 500 & 350

INTRODUCTION

SECTION

ONE 01

01-2

PREPARATION FOR SERVICE

Good preparation is very important for carrying out correct service job. The motorcycle should be cleaned well before starting a repair job. Cleaning will occasionally uncover sources of trouble. Availability of tools, measuring instruments and parts should be ensured before commensing an overhaul, since Interruption to locate tools or parts can cause distraction and needless delay. Use of special tools will ensure a quality service.

USE OF GENUINE SPARE PARTS

Use only genuine Royal Enfield spares whenever replacing parts. Use of non genuine parts can seriously affect motorcycle performance and may result in costly rework, vehicle down time and above all customer dissatisfaction.

NOTE :

Proper service and repair is important for the safe and reliable operation of all mechanical products. The service procedures recommended and detailed in this manual will help to carry out correct repairs.

SAFETY

Every care is taken to ensure that the information given in this manual is correct at the time of going to print. However, Royal Enfield does not assume responsibility for any damage, loss or injury caused to the vehicle or to the person carrying out repairs, due to errors or omissions in this manual.

IMPORTANT NOTICE

All images shown are only for reference to explain and may not be exactly the same on the motorcycle. Technical specifications are subject to change without prior notice.

Because of changes that may occur in the manufacturing process, since this manual was printed, it is possible some instructions or illustrations found within this manual may differ from those found on the vehicle. However the technical information found within this manual is correct at the time, when it was approved for printing.

Future modifications, improvements etc will be communicated to our Authorised Distributors / Importers as and when changes are done to the motorcycle.

Foreword

“ © Copyright 2009 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Sevice technical manual shall be copied, distributed or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of this manual .”

01-3

HOW TO USE YOUR SERVICE MANUAL

Pictorial presentation of various activities, make this manual easy to understand and user friendly.

This service manual is divided into 10 Sections 01 to 10. Page numbers for each section starts with 01. Thus, page 05-10 indicates 10th page of section 5.

The sections are subdivided into subjects and presented in the following order.

SECTION ONE O1 INTRODUCTION

The manual and its arrangements

SECTION TWO 02 GENERAL

Salient features of the Unit construction engine & engine management system

Four stroke cycle operation

Basic terminology of IC Engine

Technical specifications

Identification of Chassis & Engine No.

List of special tools & its applications

Control cables and wiring harness routing.

SECTION THREE 03 SERVICE DATA

Service limits of components

Periodical maintenance chart

SECTION FOUR 04 ENGINE

Engine Lubrication system

Lubrication system

Hydraulic Tappets (RHVL)

Auto decompressor

Electric starting system & sprag mech.

Auto Chain Tensioner Assembly

Engine breather System

Inlet manifold & Throttle body

Blow up Charts

SECTION FIVE 05 ENGINE DISMANTLING INSPECTION & ASSEMBLY

Engine dismantling procedure

- Vital parts - Description

- Unidirectional fittings list

- Torque Specification - Engine

SECTION SIX 06 ENGINE MANAGEMENT SYSTEM (EMS)

Components description

Function of components

Identification of a malfunction identification of EMS

Instruction Do’s & Dont’s on EMS

Trouble shooting - EMS

SECTION SIX 07 CV CARBURETOR

Exploded View

Function of Carburetor

Dismantling procedure of Carburetor

Assembling procedure of Carburetor

Carburetor maintenance

Trouble Shooting

Contents

01-4

SECTION EIGHT 08 CHASSIS, WHEELS & BRAKES

Torque Specification - Chassis

Front wheel removal & reassembly

Disc brake

- General instruction

- Overhauling caliper & master Cyl.

- Bleeding procedure

- Dis assembly of master cylinder

- Reassembly of master cylinder

- Dis assembly of Wheel caliper

- Caliper Assembly

- Wheel Disc inspection

- Brake Drum assembly

SECTION NINE 09 SUSPENSION AND STEERING

Front fork working principle

Front fork - disassembly

Steering stem removal & reassembly

Gas filled shock absorber

- Working principle

- Removal and assy. of shock absorber

- Recharging of shock absorber

Swing Arm

- Removal

- Assemblyly

Centre Stand Disassembly

SECTION TEN 10 ELECTRICALS

Electrical symbols

Battery

- Precautions

- Charging

- Maintenance

Spark plug maintenance & Inspecton

Checking procedure of electrical components:

- Starter coil

- Pulsar coil

- Ignition coil

- Suppressor Cap

- Battery

- Horn

- Relay starter

- E-Starter motor

- IC Flasher

- RR Unit

Electrical parts Inspection

- Clutch switch

- Starter switch

Do’s and Dont’s

Complete Wiring diagram - Classic 500

Complete Wiring diagram - Classic 350

Trouble shooting - Electricals

SECTION ELEVEN 11 TROUBLE SHOOTING

SAFETY DEFINITIONSSAFETY DEFINITIONS

SAFETY DEFINITIONS Important aspects to be noted are given as follows in the manual.

NOTE :

Provides important information that will have to be adhered to while carrying out repairs.

CAUTION :

Indicates activities that are important to be noted. Non-adherance may result in breakage and or functional failures of the assembly.

SPECIAL TOOLS

Contains details of the special tools and its usage, These tools have been specially designed for a specific purpose.

Contents

GENERAL

SECTION

TWO 02

02-2

• HIGH TORQUE ENGINE

• ENHANCED POWER DELIVERY

• HYDRAULIC TAPPETS

• AUTO DECOMPRESSOR

• AUTO CHAIN TENSIONER FOR PRIMARY CHAIN

• HIGH CAPACITY TRACHOIDAL OIL PUMP FOR BETTER LUBRICATION

• IMPROVED ACCELERATION & HIGH SPEED CRUISING

• EXCELLENT COLD STARTING ABILITY

• ACCURATELY CONTROLLED, AIR FUEL MIXTURE & IGNITION TIMING BY THE ENGINE CONTROL UNIT

• IMPROVED PERFORMANCE AND FUEL EFFICIENCY THRO FUEL INJECTION SYSTEM.

FOUR STROKE CYCLE OPERATION

SUCTION COMPRESSION POWER EXHAUST STROKE STROKE STROKE STROKE

Inlet Valve Open Closed Closed Closed

Exhaust Valve Closed Closed Closed Open

Piston Movement TDC to BDC BDC to TDC TDC to BDC BDC to TDC

Gas Flow Air Petrol Air Petrol Air petrol mix. Exhaust gas

mixture is mixture gets burns, gas flows out. drawn into compressed. expands. cylinder Piston is

Few degrees before pushed down. BTDC, spark plug produces spark.

Salient Features of the Unit Construction Engine & Engine Management System

UNIT CONSTRUCTION ENGINE ELECTRONIC FUEL INJECTION

SYSTEM

02-3

Fuel

Air

Power

CUBIC CAPACITY / DISPLACEMENT :

It is a volume generated by piston when it travels from TDC to BDC. It is measured as Cubic Centimeter (CC). It can be mathematically arrived at with the radious of the piston and the stroke of the engine. (pr²× l, when ‘r’ is the radius of the piston and ‘l’ is the length of the stroke, & p is a constant equal to 3.14). It is also known as Swept Volume or Displacement volume of the engine.

CLEARANCE VOLUME :

It is the nominal volume or the space available above the piston when the piston is at the topmost position (TDC).

ENGINE :

The Engine converts Chemical energy availbale in petrol into heat energy then to mechanical energy for motion. It is the powerplant of the vehicle where the power is generated for moving the vehicle.

BORE :

Bore is the inside diameter of the cyclinder block in which Piston moves up and down.

TDC :

TDC stands for Top Dead Center. It is the top most position to which the piston can travel in the cylinder barrel.

BDC :

BDC stands for Bottom Dead Center. It is the bottom most position to which the piston can travel in the cylinder barrel.

STROKE :

It is a distance travelled by piston from TDC to BDC or Vice Versa.

Basic Terminology of IC Engines

02-4

TOTAL VOLUME :

It is the sum of the swept voume (Displacement volume) and Clearance volume.

Total Volume = Swept volume + Clerance volume.

COMPRESSION RATIO :

It is a ratio between total volume in the engine to the clearance volume available at the end

of compression stroke.

Compression ratio = Total volume of air fuel mixture

Clearance volume

VOLUMETRIC EFFICIENCY :VOLUMETRIC EFFICIENCY :

VOLUMETRIC EFFICIENCY :

Volumetric efficiency is the ratio between the volume of air fuel mixture that actually

enters the cylinder and Swept volume.

Volumetric Efficiency

= Volume of air fuel mixture inhaled during suction stroke

Swept volume

HORSE POWER (HP OR PS) :

HP : Horse Power

PS : PFERDESTARKE is German unit of power. Horse Power is the ability of the engine

to do a certain amount of work in a given time.

One Horse power is the power required for lifting a weight of 75 Kg. through vertical

distance of one meter in one second.

Conversion :

1PS = 0.986 HP = 0.735 KW

1 HP = 1.014 PS = 0.744 KW

1KW = 1.360 PS = 1.340 HP

Basic Terminology of IC Engines

02-5

IHP :

IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed inside the engine cylinder by combustion process. It is utilised to drive the piston.

FHP :

FHP stands for Frictionl Horse Power.

It is the amount of horse power used or lost to overcome the friction between various moving components of the engine.

BHP :

BHP stands for Brake Horse Power

Brake Horse Power is the amount of Power actually available at the crankshaft or output shaft. It is calculated by using dynamometer.

BHP = IHP - FHP

Mechanical Efficiency :

Mechanical Efficiency is the ratio between Brake horsepower and Indicated horse power.

Brake horsepower

BHP

Indicated Horse power

IHP

TORQUE :

Torque is a twisting or turning force or effort. It is the product of a distance and force in circular motion.

In the picture shown the torque-applied is the product of distance (distance between the center of the bolt and point where force is acting) and the amount of force applied.

With the same force, if the distance is increased, the torque will also increase and if distance is reduced, torque applied will also be reduced.

CONVERSION :

1kg-m = 7.23 lb.ft = 9.81 N-m.

1lb.ft = 0.138 Kg-m = 1.356 N-m.

1 N-m = 0.102 Kg-m = 0.737 lb.ft

1HP (Horse

Power Available

after explosion)

FHP (Frictional

Losses)

BHP (Horse

Power Avaiable at

Crankshaft)

Basic Terminology of IC Engines

02-6

IGNITION TIMING :

Ignition timing is the timing in degrees of rotation of crank shaft at which spark commences so that the spark from the spark plug can ignite the mixture in the combusion chamber at the end of TDC during compression stroke.

If spark occurs earlier than specified ignition timing, it is called “Advance” timing.

If spark occurs after the specified ignition timing, it is called “Retard” timing.

IDLING SPEED :

It is the speed of the crankshaft (i.e. RPM) of the engine when the throttle is in closed position.

Gear ratio :

The relative rotation between “Driven Gear” and “Driving Gear” is known as the “Gear Ratio”. It is determined by number of teeth on the respective gears.

Gear Ratio =

No. of teeth of Driven Gear

No. of teeth of Driving Gear

In Fig. 1, the Gear ratio is 20 ¸ 10 = 2 : 1

In Fig. 2, the Gear ratio is 20 ¸ 20 = 1 : 1

Gear ratios multiply the engine torque to fulfil various demands for pulling the vehicle like.

- More effort is required during initial movement of the vehicle.

- More effort is required to climb an elevation.

- More effort is required while driving in muddy or sandy surfaces etc.

FINAL DRIVE RATIO :

It is a relative rotation between the engine sprocket and the sprocket on the rear wheel. Both the sprockets are connected through drive chain.

Final drive ratio further multiplies the torque available at the output shaft of the gear box.

Basic Terminology of IC Engines

TDC Position

Ignition Timing

02-7

A. ENGINE AND ENGINE SYSTEMS

CLASSIC 500 CLASSIC 350

1. Engine Type 4 Stroke Single Cyl., Air cooled 4 Stroke Single Cyl. Air cooled

2. Bore 84mm 70mm

3. Stroke 90mm 90mm

4. Displacement 499cc 346cc

5. Compression ratio 8.5:1 8.5:1

6. Max Power @ rpm 27.2 HP @ 5250 rpm 19.6 HP @ 5250 rpm

7. Max Torque @ rpm 41.3 Nm @ 4500 rpm 28 Nm @ 4000 rpm

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

9. Starting Kick & Electric Start Kick & Electric Start

10. Air filter element Paper element Paper element

11. Lubrication Forced Lubrication, Wet Sump Forced Lub., Wet Sump

12. Engine oil tank capacity 2.75 litres 2.75 litres

13. Engine oil grade

MOTUL 3000 4T Plus 15W50 MOTUL 3000 4T Plus 15W50 API SL JASO MA API SL JASO MA

14. Cooling Natural air flow Natural air flow

B. TRANSMISSION

1. Clutch Wet multiplate (7 Friction Plates Wet multiplate(6 Friction Plates

& 6 Steel Plates) & 5 Steel Plates)

2. Primary drive 3/8” Duplex chain & sprocket 3/8” Duplex chain & sprocket

3. Primary ratio 2.15 : 1 2.15 : 1

4. Gear box 5 Speed Constant Mesh 5 Speed Constant Mesh

5. Overall Ratio

3.063 : 1 3.063 : 1

2.013 : 1 2.013 : 1

1.522 : 1 1.522 : 1

1.212 : 1 1.212 : 1

1:1 1:1

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

7. Secondary ratio 2.235 : 1 2.375 : 1

8. Drive Chain links 102 Links 100 Links

Technical Specifications

02-8

C. CHASSIS

CLASSIC 500 CLASSIC 350

1. Frame Tubular Tubular

2. Front Suspension Telescopic, hydraulic damping, Telescopic, hyd. damping, Stroke 130 mm Stroke 130 mm

3. Rear Suspension Swing arm with gas Swing arm with gas shock absorbers shock absorbers

4. Fr. Fork oil capacity 195 cc per leg 195 cc per leg

5. Front fork oil 1F Endurance Fork Oil 1F Endurance Fork Oil

6. Front Brake Hydraulic, Hand operated, Hydraulic, Hand operated, 280 mm dia ventilated disc 280 mm dia ventilated disc

7. Rear Brake Mechanical, Foot operated, Mechanical, Foot operated, 153 mm internal expanding 153 mm internal expanding

8. Brake Oil Capacity 60 ml 60 ml

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

10. Tyre size : Front 90/90 - 18” - 51 P Front 3.25X19 - 4PR/6PR

Rear 110/90 - 18” - 61 P Rear 110/90 - 18” - 61 P

D. TYRE PRESSURE

1. Solo : Front 20 PSI (1.41 kg. / cm2) Front 20 PSI (1.41 kg. / cm2)

Rear 30 PSI (2.11 kg. / cm2) Rear 30 PSI (2.11 kg. / cm2)

2. With Pillion : Front 22 PSI (1.55 kg. / cm2) Front 22 PSI (1.55 kg. / cm2)

Rear 32 PSI (2.25 kg. / cm2) Rear 32 PSI (2.25 kg. / cm2)

3. Fuel tank capacity 13.5 litres 13.5 litres

4. Reserve / Low Fuel 2.5 litres 2 litres approx.

Warning

5. Dead Stock of Petrol 0.75 litres Not applicable

(Unusable petrol)

E. ELECTRICALS

1. Generation Alternator Alternator

2. System 12V - DC 12V - DC

3. Battery 12V - 14 AH MF 12V - 14 AH MF

Technical Specifications

02-9

4. Spark plug - primary Mico - WR7 DDC 4 Mico - WR5DC

5. Spark plug - secondary Super Bosch UR5DC Super Bosch UR5DC

6. Spark plug gap 0.7 to 0.8 mm 0.7 to 0.8 mm

7. Head lamp 12V, 60/55w 12V, 60/55w

8. Tail / Brake Lamp 12V 5 / 21W 12V 5 / 21W

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

10. Hi beam indicator 12V, 2W 12V, 2W

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

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

13. Turn signal 12V, 10W 12V, 10W

14. Horn 12V DC 12V DC

15. Starter Motor 12V, 0.9 KW 12V, 0.7 KW

F. WEIGHTS

1. Kerb Weight 187 Kg. 182 Kg

2. Max pay load 178 Kg 168 Kg

G. DIMENSIONS

1. Length 2160 mm 2160 mm

2. Width 800 mm 800 mm

3. Height 1050 mm 1050 mm

4. Wheel base 1370 + 20 mm 1370 + 20 mm

5. Ground clearance 135 mm 135 mm

6. Saddle height 800 mm 800 mm

NOTE :

1. Values given above are for your guidelines only

2. In view of continuous improvements, specifications are likely to change without notice

Technical Specifications

02-10

Identification of Chassis & Engine No.

ENGINENO.

CHASSIS NO.

The engine number is punched on the left hand side Crankcase - below the

Cylinder barrel. It is the means of identification of the Engine and its

production details. Please do not tamper with the number as it is prohibited

by law.

Type of Engine

Swept Volume

Type of Start

Type of Transmission

Type of Fuel Feed

Dummy No

Year of Manufacturing

Month Manufacturing

Production Sl. No.

U 3 S 5 C O 9 A 00001

ENGINE NUMBER - DETAILS

The VIN is a 17 digit number punched on the right

side steering head tube.

Manufacture’s Code

Type of Engine

Swept Volume

Type of Start

Type of Transmission

Type of Fuel Feed

Dummy No

Year of Manufacturing

Month Manufacturing

Production Sl. No.

M E 3 X X X X X O 9 A 00001

VEHICLE IDENTIFICATION NUMBER -

02-11

1 ST-25118 - 4 Cylinder head nut tightening tool

To remove and tightening of cylinder head nut.

2 ST-25123 - 1 Valve spring compressor

To compress the valve spring for removal and fitting of valve.

3 ST-25612-4 Rotor tightening & loosening tool To hold magneto rotor while loosening

magneto nut.

4 ST-25128 - 2 Puller for magneto rotor

Removal of magneto rotor assy.

5 ST-25592-4 Connecting rod locking tool To hold connecting rod in its top position.

6 ST-25151-4 Puller for chain case outer

To remove Crankcase LH cover.

7 ST-25591-4 Sprocket & Clutch tightening tool To hold the clutch housing and sprag

sprocket while dismantling & assembly.

8 ST-25594-4 Clutch plate tightening tool To compress clutch springs while

dismantling & reassembling of clutch plates.

ST-25153 - 4 Extractor for gear box rocker

Removal of rocker shaft spring top

pivot pin

pivot pin and camplate pivot pin.

10 ST-25835-2 Front drive sprocket removing To remove FD sprocket on the sleeve

tool gear.

ST-25834-2 Front fork dismantling tool

To hold pipe seat of front fork while dismantling main tube with bottom case (fork end assy.)

12 ST-25114-4 Extractor for fork oil seal

To remove oil seal from front fork end assy. (bottom case)

13 ST-25113 - 4 Mandrel for oil seal

Fitment of oil seal in front fork end assy.

14 ST-25112-4 Expander for front fork Oil seal

Expanding the oil seal lip while inserting main tube into bottom case of front fork.

ST-25110-3 Gauge plate for tightening

Alignment of swing arm while

chain stay

mounting / tightening into chassis.

ST-25244 - 4 Special spanner adjuster To adjust gas filled shock absorber

spring load.

SL.

PART NO. DESCRIPTION APPLICATION

NO.

List of Special Tools & Its Application

02-12

ST-25118-4

Cylinder head nut tightening tool

Application : To remove and tightening of

cylinder head nut.

List of Special Tools & Its Application

Application : To compress the valve spring for

removal and fitting of valve.

ST-25123-1

Valve spring compressor

Rotor tightening & loosening Tool

Application: To hold magneto rotor while

loosening of magneto nut.

ST-25612-4

ST-25128-2

Puller Magneto (Rotor Extractor)

Application : Removal of magneto rotor assy.

02-13

List of Special Tools & Its Application

Application : To hold the connecting

rod in its top position.

ST-25592-4

Connecting rod locking tool

Puller for chain case outer

Application :To remove Crank case LH cover.

ST-25151-4

Application : To hold Clutch housing & sprag sprocket

while dismantling / tightening the Clutch & Sprag Sprocket bolt.

Sprocket & clutch tightening tool

ST-25591-4

ST-25594-4

Clutch plate tightening tool

Application : To compress clutch springs while

dismantling & reassembling of clutch plates.

02-14

List of Special Tools & Its Application

Application : To remove gear rocker shaft spring top

pivot pin and gear cam plate pivot pin.

ST-25153-4

Extractor for Gear box rocker pivot pin

FD sprocket removing tool

Application : To remove front drive sprocket

from Sleeve Gear.

ST-25835-2

Application : To hold pipe seat of front fork while

dismantling & tightening of front fork main tube with

bottom case (fork end assy.).

Front fork Dismantling tool

ST-25834-2

ST-25114-4

Extractor for Fork oil seal

Application : To remove oil seal in front fork bottom case.

02-15

List of Special Tools & Its Application

Application : Fitment of oil seal into front fork

bottom case.

ST-25113-4

Mandrel for oil seal

Expander for front fork oil seal

Application : Expanding the oil seal lip while

inserting main tube into bottom case of front fork

ST-25112-4

Application : Alignment of Swing Arm while

mounting / tightening into chassis.

Gauge plate for tightening chain stay

ST-25110-3

ST-25244-4

Application :To adjust gas filled shock

absorber spring load.

Special spanner adjuster

02-16

UNDER TANK AND SEAT TOP VIEW

UNDER TANK LH VIEW

CONTROL CABLES AND WIRING HARNESS ROUTING

Control Cables & Wiring Harness Routing

UNDER TANK RH VIEW

02-17

HARNESS ROUTING STEERING RH

MAGNETO WIRES ROUTING

PLUG WIRE ROUTING

STARTER RELAY CABLE ROUTING

General Vehicle Information

02-18

HORN WIRE ROUTING

FUSE CARRIERS ARRANGEMENT (CLASSIC 500)

General Vehicle Information

FUSE CARRIERS ARRANGEMENT (CLASSIC 350)

HANDLE BAR INSTRUMENT PANEL & CABLE ROUTING

02-19

TAIL LAMP & TRAFFICATOR WIRES ROUTING

ECU MOUNTING (CLASSIC 500)

TCI UNIT MOUNTING (CLASSIC 350)

General Vehicle Information

THROTTLE BODY MOUNTING

SERVICE DATA

SECTION

THREE 03

03-2

WEAR LIMITS

Wear limits are given as new min, new max and service limits.

New components must be within the limits specified. Components within service limits may be reused after careful inspection. Use of parts beyond service limit can reduce the operating life of the component and may affect the motorcycle performance seriously.

Ring to groove clearance : Comp. Top rings

Service Limits of Components (All units in mm unless specified)

New Min.

New Max.

Service Limit

Cylinder bore

Cylinder bore :

Point of measurement

84.045 70.00

84.075 70.03

84.190 70.10

Classic 500

Classic 350

New Min.

New Max.

Service Limit

0.03 0.04

0.07 0.08

0.11 0.12

Classic 500

Classic 350

New Min.

New Max.

Service Limit

83.940 69.94

83.970 69.97

83.890 69.87

Classic 500

Classic 350

New Min.

New Max.

Service Limit

0.03 0.04

0.07 0.18

0.15 0.12

Classic 500

Classic 350

New Min.

New Max.

Service Limit

0.095 0.05

0.115 0.07

0.30 0.20

Classic 500

Classic 350

New Min.

New Max.

Service Limit

0.06 0.06

0.15 0.15

0.21 0.21

Classic 500

Classic 350

Piston

Ring to groove clearance comp rings - Middle

Piston to bore clearance

Ring to groove clearance : oil ring

03-3

New Min.

New Max.

Service Limit

Piston ring end gap : compression

Piston Pin diameter

19.992 19.992

19.997 19.997

19.982 19.982

From top 1st 2nd 1 st 2nd

New Min. 0.20 0.35 0.15 0.20

New Max. 0.35 0.50 0.3 0.4

Service Limit 0.70 0.85 0.6 0.7

Piston ring end gap - Oil Ring Big end axial play

Crank shaft : Run out

Small end bore inner diameter

Service Limits of Components (All units in mm unless specified)

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.20 0.20

0.70 0.70

0.90 0.90

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.20 0.20

0.55 0.55

0.65 0.65

Classic 500 Classic 350

New Min.

New Max.

Service Limit

20.007 20.007

20.016 20.016

20.046 20.046

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.00 0.00

0.04 0.04

0.08 0.08

Classic 500 Classic 350

03-4

Service Limits of Components (All units in mm unless specified)

New Min.

New Max.

Service Limit

6.965 6.965

6.980 6.980

6.955 6.955

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.00 0.00

0.05 0.05

0.07 0.07

Classic 500 Classic 350

New Min.

New Max.

Service Limit

7.00 7.00

7.015 7.015

7.25 7.25

Classic 500 Classic 350

New Min.

New Max.

Service Limit

6.945 6.945

6.960 6.960

6.935 6.935

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.00 0.00

0.05 0.05

0.08 0.08

Classic 500 Classic 350

Connecting rod bend

Valve stem OD (Inlet)

Valve to guide (inlet) clearance

Cylinder Head warpage

Valve guide bore

Valve stem OD

(Exhaust)

New Min.

New Max.

Service Limit

0.02 0.02

0.05 0.05

0.08 0.08

Classic 500 Classic 350

03-5

Service Limits of Components (All units in mm unless specified)

New Min.

New Max.

Service Limit

21.387

21.405

21.380

Classic 500 Classic 350

New Min.

New Max.

Service Limit

42.80

44.80

41.50

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.04 0.04

0.07 0.07

1.00 1.00

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

Valve to guide (Exhaust) Clearance

Hydraulic Tappet OD

Valve Spring : length

21.417

21.438

21.450

Hydraulic Tappet guide bore

Push rod run out

0.00

0.02

0.05

0.012

0.051

0.060

Hydraulic tappet to guide clearance

21.387

21.405

21.380

42.80

44.80

41.50

21.417

21.438

21.450

0.00

0.02

0.05

0.012

0.051

0.060

03-6

Service Limits of Components (All units in mm unless specified)

Location

New Min.

New Max.

Service Limit

Classic 500 Classic 350

A B

19.99 23.93

20.00 23.95

19.97 23.90

A B

19.99 23.93

20.00 23.95

19.97 23.90

Main shaft Outer diameter

Selector fork shaft outer diameter

New Min.

New Max.

Service Limit

9.96

9.98

9.94

Classic 500 Classic 350

9.96

9.98

9.94

Location

New Min.

New Max.

Service Limit

Classic 500 Classic 350

X Y

17.99 23.95

18.00 23.97

17.97 23.93

X Y

17.99 23.95

18.00 23.97

17.97 23.93

Lay shaft Outer diameter

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

10.00

10.03

9.98

Selector fork inner diameter

3.90

3.95

3.88

Selector fork lug thikness

10.00

10.03

9.98

3.90

3.95

3.88

New Min.

New Max.

Service Limit

Classic 500 Classic 350

Cam plate inner diameter

13.01

13.03

13.06

13.01

13.03

13.06

03-7

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

18.03

18.06

18.09

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

Service Limits of Components (All units in mm unless specified)

Lay shaft 1st gear inner diameter

12.98

13.00

12.96

64.5

65.5

60.0

2.95

3.05

2.60

64.5

65.5

60.0

2.95

3.05

2.60

24.00

24.03

24.06

24.00

24.03

24.06

24.00

24.03

24.06

24.00

24.03

24.06

18.03

18.06

18.09

Pivot cam plate outside diameter

12.98

13.00

12.96

Lay shaft 2nd gear inner diameter

Clutch spring Length

Main shaft 3rd&4th gear inner diameter

Friction plate with insert : thickness

MS 3

MS 4

03-8

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.00

0.05

0.10

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

1 mm

2 mm

20.00

30.00

5.00

20.00

30.00

5.00

2 mm

4 mm

2 mm

4 mm

190.00

191.00

195.00

190.00

191.00

195.00

0.00

0.05

0.10

Service Limits of Components (All units in mm unless specified)

Clutch steel plate : Distortion

Throttle cable free play

1 mm

2 mm

Drive chain : slackness

Duplex Chain - Length across 21 pins

Clutch cable -Free play

Rear Sprocket chain pull off

03-9

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

152.40

152.50

153.50

1.0 mm

2.00 mm

0.00

0.01

0.02

1.0 mm

2.00 mm

0.00

0.01

0.02

3.80

4.06

2.00

3.80

4.06

2.00

320

322

328

320

322

328

Service Limits of Components (All units in mm unless specified)

152.40

152.50

153.50

Brake drum rear : Internal dia.

Sprocket

GOOD

REPLACE

Sharp, bend

broken teeth

Drive chain length across 21 pins

Wheel rim: Face out / Run out

Brake lining thickness

Axle shaft : run out

03-10

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

0.00

0.04

Classic 500 Classic 350

New Min.

New Max.

Service Limit

Classic 500 Classic 350

25.31mm

12.64 mm

12.76 mm

12.64 mm

12.76 mm

25.46 mm

538

544

527

538

544

527

0.00

0.04

Service Limits of Components (All units in mm unless specified)

25.31mm

Caliper Piston Outer Diameter

Main tube - run out

Front fork assembly spring : length

Master Cylinder piston OD

Caliper Bore Inner Diameter

Master Cylinder Bore

03-11

New Min.

New Max.

Service Limit

Classic 500 Classic 350

New Min.

New Max.

Service Limit

1.00 mm

Classic 500 Classic 350

0.7

0.8

0.7

0.8

1.00 mm

Service Limits of Components (All units in mm unless specified)

Tyre tread : Depth

Spark Plug Gap

Location

New Min.

New Max.

Service Limit

Classic 500 Classic 350

Bush

after

reaming

I.D.

Swing Arm bush & spacer

O.D. I.D.

SPACER

Spacer

I.D

18.9

19.0

19.5

18.7

18.8

18.5

Bush

after

reaming

I.D.

Spacer

I.D

18.9

19.0

19.5

18.7

18.8

18.5

03-12

The maintenance schedule detailed here will help you maintain your Classic Motorcycles meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the Kms at which regular inspections, adjustments, replacements and lubrications are to 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 cold, extreme heat, bad roads, standing water etc., Contact the nearest Royal Enfield Dealer for expert advice and to carry out the required maintenance.

No.

DESCRIPTION

FREE SERVICE

Whichever is earlier

PAID SERVICE

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace

Note : For Maintenance after 30,000 Kms, Please repeat the same frequency specified

above, in consultation with a Royal Enfield Authorised Service Centre.

Periodical Maintenance

Kms (x 1000)Kms (x 1000)

Kms (x 1000)

0.50.5

0.5

1212

1515

1818

2121

2424

2727

3030

MonthsMonths

Months

1.51.5

1.5

1 Engine Oil R I R I R I R I R I R

Check level at every 500 Kms or earlier as required

2 Engine oil filter element R R R R R R

3 Engine suction filter and Secondary drain magnetic plug C C C C C C

4 Spark plug - 2nos. C& A C&A C&A C&A C&A R C& A C&A C &A C&A R

5 HT leads for crack I I I I I IIII I I

6 Air filter element C C C C R C C C R C C

7 Carburettor

Clean, Inspect and Tune

as required

8 Fuel Tap C C C C R C C C R C C

9 Fuel tank C C C C C

10 Fuel hose I I I I R I I I R I I

11 Accelerator and carburetor cable play Adjustment A A A A A A A A A A A

12 Rubber hose, Air filter to Carburettor I I I I R I I I R I I

13 Rubber hose, Inlet manifold I I I I R I I I R I I

14 Inlet / Exhaust valve seating I I

15 Cylinder head D

16 Exhaust system D

17 Clutch free play

Adjust every 1000 Kms or earlier as required

18 Rear brake pedal pivot L L L L L L L L L L L

19 Battery terminals (apply petroleum jelly) C C C C C C C C C C C

20 Battery Electrolyte level I I I I IIII I I

21 Earth wire eyelet (behind battery carrier) I I

Adjust for every 1000 Kms

22 Rear Wheel Drive Chain

Clean, Lubricate & adjust every 3000 Kms or earlier as required

23 Front Fork oil I R I R I

24 Hand levers & kick starter pivot

Lubricate every 1000 Kms or earlier as required

25 Rear brake play

Adjust every 1000 Kms or earlier as required

26 Rear brake cam L L L L L

27 Steering ball races / Play Adjustment A L A L A

28 Spokes tightness I I I I I I

29 Wheel rim run out front & rear I I I I I

30 Tyre wear I I I I IIIII I

03-13

✰ Check and set electrode gap to 0.7

to 0.8 mm.

✰ Refit the spark plug and connect the

H.T. lead

NOTE :

A serviceable spark plug produces thick light blue spark across the electrode. If spark plug produces yellow / red, side sparks, replace it with new.

AIRFILTER CLEANING

✰ Blow compressed air from outside to

inside.

✰ Check for cracks, holes, clogging etc.

✰ Replace, if defective

✰ Assemble in the reverse order of

dismantling.

SPARK PLUG CLEANING

✰ Disconnect suppressor cap and remove

spark plug using spark plug spanner.

✰ Clean insulator tip and electrodes using

a pointed scrapper or plug cleaner.

✰ Open filter box cover RH

✰ Remove centre mounting nut

✰ Take out the air filter element

✰ Tap off the dirt

Periodical Maintenance

ENGINE OIL

OIL LEVEL CHECK

✰ Place the motorcycle on the centre

stand Before checking the oil level start and warm the engine for few minutes. Switch “OFF” the ignition, wait for two minutes and then check oil level at the inspection window on the RH Crankcase cover

03-14

✰ After the oil drains out, remove

vehicle from centre stand and tilt the vehicle to both LH and RH sides 3 to 4 times to drain out maximum oil.

✰ Quantity of oil that can be drained

in 2.35 Litres approximately.

✰ Two level marks are provided on

the Oil level window in Cover RH Max. & Min.

✰ If oil level is below the Min mark top

up, till the level in between Max and Min mark. Do not overfill.

NOTE :

Oil capacity Min to Max mark is approx 350 ml.

OIL CHANGE :

Refer Periodical Maintenance chart (page No. 03-12) for frequency.

✰ Keep vehicle on level ground.

✰ Start the engine and warm up

sufficiently so that the oil drains faster.

Max

Min

DRAINING PROCEDURE :

✰ Keep a clean tray under the engine

✰ Remove the two Hex Flange Bolts M5

X 16, Sump drain Cap, “O” ring and Suction filter Assy.

✰ Remove the Magnetic Plug assy

along with its washer.

Primary Drain Cap

Secondary Drain Plug

TILT VEHICLE

RH & LH

Periodical Maintenance

NOTE :

Replace oil filter element whenever engine oil is changed.

✰ Remove the old oil filter as shown in

Fig.

FITTING PROCEDURE

✰ Soak the new oil filter in engine oil

for 15 minutes.

✰ Refit the oil filter, “O’’rings and

plate washer.

✰ After cleaning secondary oil drain

magnet bolt assemble the same to crankcase with washer.

03-15

✰ Assemble cleaned suction filter

element in to Crank case and fix suction filter cap with “O” ring.

✰ Fill up with 15W50 API, SL grade,

MOTUL 3000 4T Plus engine oil.

✰ Refil oil quantity 2.40 Litres.

✰ Check the oil level.

✰ Oil level should be up to “MAX” level.

Periodical Maintenance

REAR WHEEL CHAIN

SLACKNESS ADJUSTMENT :

✰ Check slackness, It should be in

between

25 to 30 mm

✰ If more or less adjust as follows -

✰ Initially clean then lubricate chain

> EP90 oil and rotate rear wheel.

✰ Remove split pin and Hex castle nut

on the RH side.

✰ Loosen anchor nut.

✰ Loosen the brake rod nut

03-16

✰ Turn the adjuster cams on both sides

till 25 to 30 mm chain slackness is achieved

✰ Check and ensure that the number

of notches from the punch mark on the cam to the notch resting on the pin are equal on both sides.

✰ Rotate the wheel and apply brake and

tighten all the nuts and lock the split pin.

BRAKE CAM GREASING

(EVERY 6,000 KMS)

✰ Remove the brake cover plate.

✰ Clean the brake cam and apply

grease.

✰ Refit the cover plate.

BRAKE PEDAL PLAY ADJUSTMENT

PEDAL FREE PLAY 20 TO 30 MM

✰ Turn in/out the adjuster nut for

correct pedal play

REAR BRAKE SWITCH ADJUSTMENT

✰ Loosen bottom nut and tighten top

nut till the brake light comes on when brake pedal is pressed.

✰ Tighten the bottom nut duly

ensuring that the brake lamp is not glowing continously.

✰ In case brake light is continously

glowing then readjust till correct position in achieved.

Periodical Maintenance

03-17

NOTE :

Always re-check after adjustment of brake pedal level and free play.

CAUTION

Adjust both left and right shock absorbers to the same notch.

REAR SHOCK ABSORBERS ADJUSTMENT

✰ The rear shock absorber spring

preload can be increased or reduced according to road and load conditions.

✰ Increase the spring preload for high

load operation.

✰ Reduce the spring preload for low

load operation.

✰ The adjuster provided on the bottom

of the spring has five notches.

✰ To carry out the adjustment proceed

as follows :

✰ Using special tool, place it on the slot

provided on the adjuster.

✰ Turn the adjuster such that the

adjuster moves up to increase the spring preload and vice versa to reduce the spring preload.

FRONT FORK

A. OIL LEVEL CHECK (EVERY 6000 KMS)

✰ Take out front fork from the vehicle.

Remove bolt cap.

✰ Check oil level with a 5 mm dia rod.

✰ The level height must be 370 to 380

mm.

Periodical Maintenance

03-18

✰ Top up, with 1F Endurance Fork Oil

or equivalent, if required

B. OIL CHANGE

(EVERY 12,000 KMS)

✰ Remove the fork ends from the

vehicle.

✰ Check as detailed in the Section 8

DISC BRAKE FLUID LEVEL CHECK

✰ Check brake fluid is above the ‘Min’

level in master cylinder.

✰ Fill 195 ml of 1F Endurance Fork

Oil in each leg .

✰ Bump the fork several times and

then assemble bolt cap with “O” ring (to release air lock if any).

✰ Assemble back all removed parts.

MAX

MIN

✰ Top up if level is below ‘Min’ mark.

✰ To Top up the fluid, remove the

master cylinder top cover 2 screws and take out cover, plate & diaphragm.

✰ Top up brake Fluid DOT 3 or DOT 4

upto “MAX” level.

CAUTION :

As the brake fluid is highly corrosive, take care that it does not spill over other parts. It is suggested to wipe brake fluid immediately, if there is any spill over in other parts,using a soft cloth (preferably a wet cloth).

STEERING PLAY ADJUSTMENT

(EVERY 6,000 KMS)

✰ Keep a wooden plank under the

stand.

✰ Rock the front end and feel the play

at stem top end as shown in fig.

Periodical Maintenance

✰ If felt, adjust as follows :

✰ Loosen crown plate bolts as shown

picture ‘A’

03-19

Periodical Maintenance

✰ Tighten stem lock nut as shown

picture ‘B’

✰ Check play.

✰ Steering to be free with out any play.

✰ Tighten all the screws in reverse

order.

STEERING BALL RACE LUBRICATION (EVERY 12,000 KMS)

✰ Remove steering stem assembly.

✰ Clean and check the balls and races

thoroughly for damages / pittings / discolouration.

✰ Change them if found defective.

✰ Pack grease and balls (Lithium

Calcium based) on the bottom ball race as shown in Fig.

✰ Pack grease in the top ball race.

✰ Assemble the steering stem.

CLUTCH CABLE FREE PLAY : (2-3MM)

LEVER END

✰ Check clutch cable button seating

position inside lever and condition of the cable.

✰ Screw in or out the cable adjuster

for setting the required play at lever end (2 to 3 mm).

03-20

Periodical Maintenance

✰ After adjustment refix cable boot.

PRIMARY CHAIN TENSION ADJUSTMENT

✰ This vehicle is fitted with Auto chain

tensioner. Hence there is no need for periodic manual adjustment.

Auto Chain T ensioner

THROTTLE CABLE PLAY ADJUSTMENT (CLASSIC 500)

Throttle rotor free play 2-3 mm.

There are two adjuster provided - one at the top near the throttle grip and the other on the throttle body. Minor adjustments can be carried out at the top.

(A ) ADJUSTMENT AT HANDLE BAR END (CLASSIC 500)

✰ Slide the rubber boot, use 10 mm

spanner to adjust cable outer and lock the nut. Move the rubber boot over the lock nuts.

THROTTLE CABLE ASSY REPLACEMENT (CLASSIC 500)

✰ While replacing throttle cable

following procedure is recommended

- (A) Connect throttle cable to Rotor / throttle grip assembly

- (B) Connect cable to throttle body and ensure the recommended free play.

- (C) Route and strap the cable properly.

(B ) ADJUSTMENT AT THROTTLE BODY END (CLASSIC 500)

✰ Loosen the lock nuts on both the

cables.

✰ Adjust both cables unitform and

tighten the lock nuts.

THROTTLE CABLE PLAY ADJUSTMENT (CLASSIC 350)

(A ) ADJUSTMENT OF FREE PLAY AT ROTOR(THROTTLE) GRIP

FREE PLAY : 2 TO 3 MM

✰ Check throttle radial free play 2-3

mm. If excess play then adjust throttle cable as shown Fig.

03-21

Periodical Maintenance

(B) CHECKING PROCEDURE OF THROTTLE POSITION SENSOR (TPS) CABLE

To achieve response from TPS ignition timing

change over after 40% operation of rotor grip following adjustment and placement is recommended.

✰ After adjustment of throttle grip

free play, raise the throttle grip to “ FULL” position and observe TPS push rod free movement.

NOTE:

Ensure following position of A, B, C TPS cable outer nuts & bracket mounting X, Y screws.

 Slide the rubber boot, use 10 mm spanner

to adjust cable outer and lock the nut. Move the rubber boot over the lock nuts.

2 to 3 mm

Step 1:

✰ Two nuts (A & B) shall assemble

outside the throttle guide bracktet as showm in Fig.

Step 2:

✰ One nut (C) shall assemble inside the

throttle guide bracket at extreme left position as shown in Fig.

Step 3:

✰ Throttle guide bracket screws (X &

Y) shall assemble with the throttle switch body bracket at extreme right position of the slots as shown in Fig.

While replacing TPS assy. following steps are important to achive ignition timing changing shall take place at 40% of throttle opening to obtain more mileage and reduced emissions.

03-22

CAUTION :

After adjustment of free play, please ensure that throttle pully being rested on the idling screw. Other wise engine speed increases erratically.

(D) ADJUSTMENT OF INNER CABLE FREE PLAY AT CARBURETOR

✰ Loosen the lock nut in throttle cable

to adjust free play up to 1 mm.

✰ Screw out the cable adjuster will

reduce the play, where as screw in result increase the play.

✰ After adjustment of inner cable free

play, retighten the lock nut as shown in Fig.

SLOT POSITION

NOTE :

After TPS cable / switch fitment, please ensure that cable lock nuts (A, B, C) & mounting screws (X, Y) are being tightened.

THROTTLE CABLE ASSY REPLACEMENT (CLASSIC 350)

✰ While replacing throttle cable

following procedure is recommended.

(A) Connect throttle cable to Rotor /

throttle grip assembly.

(B) Connect cable to TPS switch as

illustrated in step no.1 & 2 at Page No. 03-20.

pully and ensure that recommended free play.

(D) Route and strap the cable properly

as shown in Fig.

NOTE :

Ensure that outer cable is being seated inside the cable junction box as showni n Fig.

JUNCTION BOX

Periodical Maintenance

03-23

CV CARBURETOR DRAIN AND TUNING PROCEDURE

✰ Drain the carburetor before tuning

process.

✰ Set the carburetor pilot screw to 3

full turns out from fully closed position.

✰ Now, start and warm up the engine

for 2 minutes.

FLOAT HEIGHT ADJUSTMENT

✰ Remove the float chamber body and

“O” ring.

✰ Hold the mixing chamber body in

inverted position as shown in Fig.

✰ Hold the float so that its tongue just

contacts the spring loaded plunger of the float needle valve.

✰ With a Vernier Caliper, measure the

height from the mixing chamber body face to top of the float is 17.1 mm(as shown in Fig.)

✰ If the float height is incorrect,

correct it by bending the float assembly tongue.

✰ Check the float height again.

NOTE :

After adjustment of float height, please ensure free movement of float in its pivot pin.

✰ Check for the smooth running of the

Engine.

✰ If erratic turn pilot screw in or out

upto one turn.

✰ Adjust the idling screw until the

engine is smoothly ticking over 1050 + 200 rpm

✰ Refit the boot to the pilot screw.

ENGINE COMPRESSION TEST

STEP-A

✰ Start and warmup the engine to

normal running temperature.

✰ Remove the spark plug & connect

compression gauge.

Periodical Maintenance

03-24

✰ Hold the throttle open fully and kick

several times (5 to 6 times).

✰ Note down the reading and repeat

the above process 3 times. Take to average mean reading in 100 ± 10 PSI which is the correct compression pressure. Specified engine compression pressure.

STEP-B

✰

In case compression pressure is less

than 80 PSI, then refit spark plug & start again to warmup the engine.

✰ Switch “OFF” Ignition and engine

stop switch condition.

a) Remove spark plug & put few drops

of engine oil into the combustion chamber.

b) Connect compression gauge &

repeat the procedure as explained in the step-A.

✰ If compression pressure does not

increase, then check for

- blown out cylinder head gasket

- improper torque of Rocker bearing bolts or cylinder head nuts.

- valve seat - damage / leakage

- valvestem bend

- cylinder head warpage

- improper valve timing

✰ If compression pressure reading

increases, then check for

- Improper alignment of piston ring (end gap position)

- piston ring jamed in groove.

- scoring / seizure of cylinder barrel / piston

- worn out piston/rings

- worn out cylinder barrel

NOTE :

In case compression pressure is more than 110 PSI then engine requires Decarbonisation of cylinder head / piston (combustion chamber).

DECARBONISING

(EVERY 30,000 KMS)

CYLINDER HEAD

✰ Remove carbon from the valves, ports

and combustion chamber by scrapping. Take care not to cause any damage to the valve faces or valve seat inserts. Scrape gently to avoid scoring the cylinder head.

Periodical Maintenance

03-25

✰ Remove the piston rings carefully.

For cleaning the groove in the piston, a piece of broken piston ring thrust into a wooden handle and filed to a chisel point can be used.

CYLINDER HEAD AND VALVES

VALVE SEAT INSPECTION

✰ Clean both Inlet & Exhaust valves

and thoroughly remove the carbon deposits

✰ Apply light coating of Prussian blue

to the valve seats.

NOTE :

Ensure proper valve seat contact by taping the valve in the valve seat without rotating.

✰ Remove the valve and inspect the

width of each seat.

✰ The seat contact should be within the

specified width and should be even all around the circumference

Standard : 0.9 - 1.1 mm

Service Limit : 1.5 mm

✰ Valve seat width is not within

specification, reface the valve seat.

CAUTION :

If a valve face is burnt or badly wornout or if it contacts the seat unevenly, replace the valve.

INSPECT THE VALVE SEAT FACE FOR :

✰ Damage of the face :

Replace the valve and re-face the valve seat.

✰ Uneven seat width :

Bent or collapsed valve stem. Replace the valve and re-face the valve seat.

Periodical Maintenance

03-26

VALVE SEAT REFACING

✰ Valve Seat cutters, a grinder or

equivalent valve seat refacing equipment are recommended to correct worn valve seat.

✰ If the contact area is too high on the

valve, the seat must be lowered using a 32 degree flat cutter.

✰ If the contact area is too low on the

valve, the seat must be raised using a 60 degree inner cutter.

NOTE :

Reface the valve seat with a 45 degree cutter when a valve guide is replaced.

✰ Contact area is too high or too low.

re-face the valve seat.

Periodical Maintenance

✰ Use a 45 degree cutter to remove the

roughness or irregularities from the seat.

✰ Using 32 degree cutter, remove top

1/4 of the existing valve seat material.

✰ Using 60 degree cutter, remove the

bottom 1/4 of the old seat.

✰ Remove the cutter and inspect the

area.

✰ Install a 45 degree finish cutter and

cut the seat to proper width.

✰ Make sure that all printing and

irregularities are removed. Refinish if necessary.

Standard seat width : 0.9 - 1.1 mm

03-27

NOTE :

To avoid damage to the seating face, turn the valve slowly while inserting.

✰ After cutting the seat, apply lapping

compound to the valve face and lap the valve applying light pressure.

NOTE :

Excessive lapping pressure may deform or damage the seat.

Change the angle of lapping tool frequently to prevent uneven seat wear.

Lapping compound can cause damage if it enters between the valve stem and guide.

✰ After lapping, wash any residual

compound off the cylinder head and valve.

✰ Recheck the seat contact after

lapping.

✰ Clean the cylinder head assembly

with solvent and blow through all oil passages with compressed air.

✰ Install the valve spring seats and

new valve stem seals.

✰ Lubricate each valve stem with clean

engine oil.

✰ Insert the intake and exhaust valve

into the valve guides.

1. CYLINDER HEAD

2. SPLIT COLLAR

3. RETAINER, SPRING

4. VALVE SPRING

5. VALVE STEM SEAL

6. SEAT, SPRING

7. VALVE GUIDE

8. PLUG OR EOT SENSOR for 500cc

9. VALVE SEAT INSERT, EXHAUST

10. VALVE EXHAUST

11. VALVE INLET

12. VALVE SEAT INSERT, INLET

THE PARTS DETAIL OF CYLINDER HEAD ASSEMBLY

Periodical Maintenance

03-28

Similarly check position of the inlet cam single punch mark align with the single punch mark on the exhaust cam.

ECCENTRIC CAM SPINDLE ADJUSTMENT

✰ The center distance adjustment of

gears is achieved by rotating the eccentric sleeve and locking it on the spindle by using M 10 lock nut once the desired backlash is arrived.

✰ Ensure to hold the eccentric sleeve

by spanner while tightening the lock nut which prevent the rotation of the sleeve during tightening the lock nut.

✰ The backlash is first adjusted

between pinion to exhaust gear and then exhaust to inlet gear to get effective backlash adjustment.

✰ The tightening torque for M10 lock

nut is 2 KG-M. This must be ensured.

Periodical Maintenance

VALVE TIMING CUM ECCENTRIC CAM SPINDLE

Bring piston to TDC so that the key way in the Rotor assembly is at 12 O’ Clock position.

Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear.

03-29

Periodical Maintenance

✰ Over size Cam Spindle (For Spares)

570040 : 0.1 mm Over size Spindle

570041 : 0.2 mm Over Size Spindle

CAUTION :

- During first service, the backlash between the cam gears must be checked. If not with in the desirable limit and if a slight cam noise is observed, then further adjustment of the eccentric sleeve has to be carried out as mentioned above.

- After adjustment to the required backlash, both the Inlet & Exhaust lock nut in the spindle must be tightened to the specified torque.

BATTERY

ELECTROLYTE LEVEL CHECKING :

✰ Electrolyte level can be seen

through the casing.

✰ Electrolyte to be filled upto “MAX”

Mark.

NOTE :

When electrolyte level drops to “MIN” Level, then top up distilled water upto “MAX” Level.

✰ Specific Gravity -

Fully charged 1.24 to 1.26.

Needs to be recharged 1.15 or less than that

TERMINAL CLEANING :

✰ Clean terminal with warm water and

apply petroleum jelly.

✰ In case of sulphation clean by zero

base emary paper.

✰ If required, top up with distilled

water.

SPECIFIC GRAVITY CHECKING :

✰ Check specific gravity (SG) with a

hydrometer.

ENGINE

SECTION

FOUR 04

04-2

Engine Lubrication System

04-3

LUBRICATION SYSTEM :

Oil from the oil tank is circulated to various parts through a powerful oil pump. The oil in the sump gets filtered through an oill strainer located in the crankcase and then pumped into the oil filter element located in the RH Cover. From here oil is circulated to 3 main areas. The first branch goes to flywheel to lubricate crank shaft as well as barrel piston assembly. The second branch goes to hydraulic tappet to maintain the oil pressure constantly. The third branch goes to rocker assembly and drains down to RH cover chamber through the push rod tunnel.

LUBRICATION OIL :

✰ Specification: MOTUL 3000 4T PLUS 15W50 API, JASO MA SL - GRADE ESTER-Semi

Synthetic

✰ Oil capacity: 2.75 l - Initial oil filling: through Oil filler Cap = 2.5 l, through Crankcse

LH Cover: 0.25 l

Lubrication System

ROCKER

PUSH ROD

OIL PUMP

HYDRAULIC

CAM

FLY

CRANK

OIL SUMP

STRAINER

04-4

Lubrication System

OIL PUMP : TROCHOID TYPE

Trichoidal high flow oil pump delivers oil with a pressure of 4.5 Bar. This provides good lubrication to all the moving parts and enhances the life of the moving parts in the engine.

CLASSIC 350

Output : 4.5 Litre per minute at 2750 RPM

CLASSIC 500

Output : 9 Litre per minute at 2750 RPM

04-5

Hydraulic Tappets (Roller Hydaulic Valve Lifter (RHVL)

WHAT IS HYDRAULIC TAPPET :

Hydraulic tappet (also called RHVL Roller Hydraulic Valve Lifter) is the element connects between cam profile to push rod and it operates with aid of the hydraulic pressure to eliminate the clearance and noise between valve train parts.

BENEFIT OF HYDRAULIC TAPPET :

1. Roller follower on cam with hydraulic tappet avoid sliding motion and friction, provides improved tappet and cam life.

2. Control of valve train lash adjustment. The RHVL compensates for changes in the length of valve train components by wear or variations in engine temperature.

ESCAPING OIL

(D) PUSHROD

SEAT

(B) OVER HEAD

OIL FLOW P A TH

(C)DISC VALVE

OIL INLET

OIL HEAD, OIL DELIVERY CONTROL

VAL VE, LOCKING ACTION

CHECK BALL

(A) HIGH PRESSURE CHAMBER OIL

FLOW PA TH

(H) HIGH PRESURE CHAMBER

(F) TRAPPED AIR VOLUME

AIR ESCAPE P ATH THROUGH

PLUNGER CLEARANCE

CHECK BALL

SEAT

PLUNGER

OIL TRANSFER ANULUS

OUTER BODY

ROLLER

PUSH ROD OIL

(E) LOW

PRESSURE

CHAMBER

CUT SECTION VIEW OF RHVL

RHVL

CAM

ROLLER

04-6

WORKING PRINCIPLE :

Engine oil enters the lifter through the body feed hole, and flows into the inside of the plunger through the plunger feed hole, filling the “low pressure chamber” (E, in Figure)

The oil flow continues around the check ball and through the slots of the ball retainer to fill the cavity below the plunger, called the “high pressure chamber” (A, in Figure). Oil is forced down into this area by momentary low pressure which occurs once during each valve event (cam revolution), which the RHVL roller bearing in on the cam base circle.

As the RHVL rises up the nose of the cam and the full load of the valve train is applied on the lifter, a predetermined and closely held clearance of .0002/.0003 inch (.0051/.0076 mm)between the outer diameter of the plunger and the inner diameter of the body permits a controlled amount of oil to escape up from the high pressure chamber.

This controlled oil leakage compresses the plunger spring and allows a small relative movement of the plunger with respect to the body. This movement is called LEAKDOWN (see Figure 04-4) and occurs once during each valve lift event.

As the RHVL rides back down the flank of the cam and returns to the base circle, the plunger spring provides the force to maintain zero back lash and forces the plunger back to its original position relative to the body. This allows engine oil to once again fill the high pressure chamber so the cycle can be repeated.

The volume of oil that enters the high pressure chamber during each base circle event is equal to the volume of oil that is lost through the plunger-to-body diametral clearance during the valve lift event (Leakdown).

The overhead oil supply is accurately metered from the “low pressure chamber”,

which is at engine oil pressure, by using a flat metal disk (metering valve C, in Figure), which wobbles against a cylindrical radius curved surface on the bottom of the push rod seat (D, in Figure). Oil then flows up through the hole in the push rod seat to lubricate the overhead valve train components (oil flow path B, in Figure).

The metering valve moves sufficiently to keep the push rod seat hole free and unclogged. When the engine is shut down, the valve seats on the shoulder of the plunger to minimize drain back of oil.

If the engine structure or valve train expands or contracts with changes in engine temperature or other differentials, the RHVL will automatically adjust its own internal length to compensate for these changes.

PRECAUTIONARY MEASURES :

The hydraulic tappets have minute holes for the oil to circulate and to also act at the hydraulic media. Hence oil contamination must be as less as possible. For this, all the filters ( oil filter on cover RH, sump drain filter with magnet and second drain plug with magnet ) must be cleaned periodically as mentioned in this Service manual.

Whenever the RHVL is removed for service / replacement or stored in spare parts, they must be kept upright (the rollar side surface pointing downwards and the push rod seating surface at top side as shown in fig. below) to prevent the oil

from drian off.

Hydraulic Tappets (Roller Hydaulic Valve Lifter (RHVL)

✓

04-7

Auto Decompressor

AUTO DECOMPRESSOR - WORKING PRINCIPLE

a. The Flyweight type decompressor

consists of a flyweight mechanism mounted on the cam gear exhaust.

b. When the engine is cranking below

a certain speed (350 rpm approx.), a pin rotates to protrude above the base circle of the exhaust cam.

c. The pin momentorily open the

exhaust valve on the compression stroke, lowering the pressure in the cylinder head combustion chamber thus leading to freeness when starting engine.

BENEFITS OF AUTO DECOMPRESSOR :

- Easy for kick or self start system.

- Avoids back kick and hence life of the sprag clutch system enhanced.

04-8

WORKING PRINCIPLE

The sprag is located in the primary sprocket on the crankcase drive side. This provides better rigidity of the sprag mechanism during initial cranking.

The auto decompressor mechanism further helps in reducing the load on the sprag during intitial cranking and also prevents reversal phenomenon of the crank shaft.

Electric Starting System & Sprag Mechanism

04-9

WORKING PRINCIPLE

The auto chain tensioner has a spring loaded plunger mechanism with a ratchet arrangement. It eliminates need for manual adjustment of the primary chain tension.

It is assembled on the crankcase LH below the chain tensioner pad. The spring loaded plunger applies force on the chain tensioner pad thereby lifting it and holding aginst the primary chain to the required tension.

The oneway rachet mechanism in the auto chain tensioner ensures that the plunger does not drop down due to the downward force of the chain tensioner pad.

It normally does not require any maintenance or service.

Auto Chain Tensioner Assembly

04-10

WORKING PRINCIPLE

The engine breather system is located on the RH cover of the crankcase. A connecting hole directs the engine breathing into a chamber in the RH cover which has an inbuilt deflector to deflect the oil that may come along with the fumes from the crankcase. This oil gets drained through a small hole provided at the bottom of the breather chamber.

The emission passes through the deflector chamber and goes to the air filter housing and passes through the inlet manifold back into the cylinder head.

Engine Breather System

Breather arrangement inside the RH cover

04-11

The inlet manifold has the fuel injector located on top portion and the throttle body attach to it.

The throttle body has a butterfly valve attached which is operated by the throttle cables attached to a small drum on the right side.

A manual Bi starter is located on the left side and is operated with spring and plunger type arrangement.

An idle air bypass screw is provided on the throttle body. It is the large brass coloured screw that is accessed from the top of the throttle body. The clamps on the throttle body may be loosened and the throttle body rotated outwards from the top to access the screw without removing the fuel tank and to adjust the idle speed with the bike running. Turn the screw CLOCKWISE (in) to DECREASE the idle speed. Turn the screw ANTICLOCKWISE (out) to increase the idle speed. Remember that this is an AIR BYPASS screw – not a throttle stop screw. Turning the screw about ¼ turn will result in an approximate 200 RPM change in the idle speed. DO NOT adjust the throttle stop screw on the side of the throttle body unless you are using the factory supplied software to recalibrate the base throttle opening.

Inlet Manifold & Throttle Body

04-12

Crankcase RH - Coverside View

Key No’s

22,23,24,25,26,27

Key No’s

7,8,9,10,1 1

Key No’s

22,23,26,63,64,65

Key No’s

50,51,52

04-13

A1 CAM GEAR ASSEMBLY-EXHAUST

WITH DECOMPRESSOR ASSY. 1 A2 OIL PUMP ASSEMBLY - 500CC 1 A3 OIL PUMP ASSEMBLY - 350CC 1 A4 GEAR CHANGER ASSEMBLY 1

1 CAM STEADY PLATE 1 2 DOWEL 6 MM 2 3 HEX. SOCKET HEAD CAP SCREW,

M6 X 30 2

4 HEX. SOCKET HEAD CAP SCREW,

M6 X 25 1

5 NUT - CAM SPINDLE 2 6 SHIM, CAM GEAR 2 7 PIVOT 1 8 FLY WEIGHT 1

9 TORSION SPRING 1 10 PIN ASSEMBLY 1 11 CAM GEAR AUB ASSEMBLY - EXHAUST 1 12 CAM SLEEVE 2

CAM SPINDLE ADJUSTABLE 2

13 CAM SPINDLE ADJUSTABLE

( 0.1 OVERSIZE ) 2 CAM SPINDLE ADJUSTABLE

( 0.2 OVERSIZE ) 2 14 CAM, GEAR - INLET 1 15 COVER, KICK START SHAFT 1 16 HEX SOCKET PAN HEAD SCREW

M5 X 12 4 17 NUT, SLEEVE GEAR 1 18 TAB WASHER 1 19 FD SPROCKET 18 TEETH

FOR 500CC & 16 TEETH FOR 350CC 1 20 DISTANCE PIECE 1 21 OIL SEAL 1 22 CIRCLIP 1 23 PUMP DRIVE PINION 1 24 CSK SOCKET HEAD SCREW M6 X 30 3 25 GASKET, OIL PUMP 1 26 'O' RING, OIL PUMP OUTLET 1 27 HEX. SOCKET HEAD CAP SCREW

M6 X 25 2 28 'O'- RING 1 29 CAP, PIVOT PIN 1 30 COPPER WASHER 1

Key No. Description Qty.

Crankcase RH - Coverside View

31 HEX FLANGE BOLT M5 X 12 1 32 HEX SOCKET HEAD CAP SCREW

M6 X 60 2 33 STARTER MOTOR ASSEMBLY 1 34 COVER STARTER MOTOR 1 35 HEX SOCKET, BUTTON HEAD SCREW,

M5 X 12 1 36 DOWEL PIN 2 37 TAPPET DOOR 1 38 CSK SOCKET HEAD SCREW M5 X 12 4 39 FLY WHEEL MAGNETO ASSEMBLY 1 40 MAGNETO KEY 1 41 PLAIN WASHER, 42 HEX. NUT M12 X 1.25 1 43 ASSEMBLY, GEAR LEVER SHAFT 1 44 SPACER - SHAFT, GEAR LEVER 1 45 HEX. SOCKET HEAD CAP SCREW,

M5 X 40 2 46 PIVOT BEARING, ROCKER SHAFT

BOTTOM 1 47 DOWEL, LOWER PIVOT BEARING 1 48 STOP PIN 1 49 'O' RING 1 50 ROCKER SHAFT ASSEMBLY 1 51 STRIKER, GEAR CHANGE 1 52 PIN, PIVOT 1 53 SPRING, GEAR CHANGE STRIKER 1 54 HEX. SOCKET HEAD CAP SCREW,

M6 X 12 2 55 PIVOT BEARING, ROCKER SHAFT

UPPER 1 56 'O' RING BLACK NITRILE RUBBER 1 57 SPACER 1 58 SPRING 1 59 PIVOT, CAMPLATE 1 60 ‘O’ RING 1 61 SPRING KICK 1 62 HEX SCREW M6X16 1 63 ‘O’ RING - OIL PUMP 1 64 ‘O’ RING 1 65 HEX. SOCKET HD. CAP SCREW, M4X30 4 66 PLUG 4 67 STATOR AND PULSAR COIL ASSEMBLY 1 68 ROTOR AND RELUCTOR ASSEMBLY 1

04-14

Crankcase LH - Inside View

04-15

CRANK CASE LH

Crankcase LH - Inside View

A1 CAM GEAR ASSEMBLY-EXHAUST

WITH DECOMPRESSOR ASSY. 1

1 FLANGE HEX NUT - M8 X 1.25 3

2 STUD, M8 X 128 3

3 JACK SHAFT 1

4 CIRCLIP 2

5 BALL BEARING 6305 C3 (25 X 62 X17) 1

6 BEARING SPACER CRANKCASE LH 1

7 ROLLER BEARING NU 305 C4 (25 X 62 X 17) 1

8 WASHER, THRUST 1

9 NEEDLE BEARING 1

10 HEX SOCKET HEAD CAP SCREW, M5 X 16 2

11 RETAINER PLATE, MAINSHAFT BEARING 1

12 STUD M6 X 133 2

13 BALL BEARING 6006, C3 (G/B MAIN SHAFT) 1

14 BEARING SPACER - LH CRANKSHAFT 1

Key No. Description Qty.

04-16

Crankcase RH - Inside View

04-17

CRANK CASE RH - INSIDE VIEW

1 HYDRAULIC VALVE LIFTER

ROLLER 2

2 BEARING NRB 1

3 DEEP GROOVE BALL BEARING-

SLEEVE GEAR 1

4 CIRCLIP 6.2 X 2N 1

5 NEEDLE BEARING 1

6 WASHER, THRUST 1

7 CRANK SHAFT ASSEMBLY 1

8 OIL DRAIN BOLT WITH MAGNET 1

9 SLEEVE GEAR 1

10 NEEDLE BEARING 1

11 NEEDLE BEARING 1

12 NEEDLE ROLLER 2

13 BRACKET - PIN - HYDRAULIC -

TAPPET 1

14 HEX. SOCKET HEAD CAP SCREW,

M6 X12 1

15 BOLT, PAWL 1

16 SPRING 1

17 PAWL, CAMPLATE 1

18 MACHINED WASHER 6.4 1

19 NUT M6 X 1, FLANGE NYLOC TYPE 1

20 STOP PLATE 1

21 HEX SCREW M8 X 23 1

Key No. Description Qty.

Crankcase RH - Inside View

22 OIL THROWER 1

23 HEX SOCKET HEAD CAP SCREW

M5 X 35 3

24 SUCTION FILTER ASY 1

25 O RING-DRAIN CAP 1

26 SUMP DRAIN CAP 1

27 HEX. FLANGE BOLT M5X16 2

28 WASHER DRAIN PLUG 1

29 DRAIN PLUG 1

30 MAGNET 1

31 DOWEL - HOLLOW 2

32 STUD, M8 X 128 3

33 FLANGE NUT-M8 3

34 KICK START SHAFT 1

35 SPRING 1

36 PLUNGER 1

37 PAWL 1

38 WASHER THRUST 2

39 ASSY., KICK START GEAR 1

40 BUSH 1

41 CIRCLIP 18N 1

42 LOCATING PIN,(PIVOT)-NRB 3X21.8 1

04-18

Engine Cover RH

04-19

Engine Cover RH

Key No. Description Qty.

A1 RH COVER SUB ASSEMBLY 1

1 COVER RH 1

2 GASKET, COVER PLATE 1

3 COVER PLATE, BREATHER

CHAMBER 1

4 HEX. SCREW, M5 X 12 6

5 GASKET - COVER RH 1

6 ALLEN SCREW M6 X 30 3

7 HEX SOCKET HEAD CAP SCREW

M5X16 2

8 CIRCLIP 24N 1

9 OIL SEAL, CRANK FEED 1

10 JET, CRANKSHAFT RH 1

11 HEX FLANGE BOLT M6 X 1 X 20 3

12 CAP, OIL FILTER 1

13 ‘O’ - RING, FILTER CAP 1

14 SPRING 1

15 WASHER 1

16 ‘O’ - RING 1

17 SPRING CAP 1

18 ‘O’ - RING 1

19 ELEMENT - OIL FILTER 1

20 HEX. FLANGE BOLT, M6 X 1 X 45 2

21 HEX. FLANGE BOLT, M6 X 1 X 70 7

22 HEX. FLANGE BOLT, M6 X 1 X 85 2

23 OIL LEVEL WINDOW 1

24 WASHER, INSPECTION SCREW 1

25 INSPECTION SCREW, IGNITION

TIMING 1

26 ‘O’ - RING 1

27 OIL FILLER CAP, METAL 1

28 SEALING WASHER 1

29 BOLT BREATHER 1

30 CLIP BREATHR PIPE 1

31 BREATHER PIPE 1

32 OIL SEAL KICK START 2

33 KICK START CRANK ASSEMBLY 1

34 SPRING 1

35 BOSS, KICK START CRANK 1

36 BALL DIA 6.35 1

37 LEVER KICK START 1

38 SLEEVE KICK START LEVER 1

39 PIN 1

40 CIRCLIP 10 1

41 HEX BOLT M8X40 1

42 HEX NUT M8 1

43 SCREW SPRING CAP 1

04-20

Crankcase LH - Coverside View

04-21

Crankcase LH - Coverside View

Key No. Description Qty.

A1 SPRAG CLUTCH ASSEMBLY 1

1 HEX. HEAD SCREW 1

2 WASHER 1

3 ENGINE SPROCKET 1

4 NEEDLE BEARING 1

5 DISTANCE WASHER, SPRAG

CLUTCH 1

6 CIRCLIP 1

7 KEY - JACK SHAFT 1

8 GEAR, - JACK SHAFT 1

9 SHAFT, DOUBLE GEAR 1

10 DOUBLE GEAR - STARTER DRIVE 1

11 HEX. SOCKET HEAD CAP

SCREW, M5 X 25 1

12 HEX. SOCKET HEAD CAP SCREW,

M5 X 45 3

13 HOUSING STARTER DRIVE 1

14 DOWEL (6MM) 2

15 NEUTRAL SWITCH WITH PACKING 1

16 COLLAR, MAINSHAFT 1

17 CLUTCH ASSEMBLY COMPLETE 1

18 PLAIN WASHER 1

19 NYLOCK NUT 1

20 BALL BEARING 6001 1

21 CLUTCH PUSH PAD 1

22 STUD M6 X 106 1

23 NUT M6X1, FLANGE NYLOC TYPE 20

24 STUD M6 X 168 1

25 STUD M6 X 196 2

26 PRIMARY CHAIN 1

27 HEX. SOCKET HEAD CAP SCREW,

M6X20 2

28 AUTO CHAIN TENSIONER

ASSEMBLY 1

29 ‘O’ RING, CHAIN TENSIONER

ASSEMBLY 1

30 CHAIN TENSIONER PAD 1

31 BUSH, CHAIN TENSIONER PAD 1

32 PLAIN WASHER 1

33 STUD, CHAIN TENSIONER PAD 1

34 STUD M6 X 226 2

35 HEX. SOCKET HEAD CAP SCREW,

M6 X 50 2

36 STUD M6 X 80 1

37 HEX. SOCKET HEAD CAP SCREW,

M6X85 1

38 SPRAG CLUTCH BEARING 1

39 COPPER WASHER 1

40 NUT - TENSIONER PAD 1

41 HEX. SOCKET HEAD CAP SCREW,

M6 X 90 4

04-22

Engine Cover LH

04-23

Engine Cover LH

A1 LH COVER SUB ASSEMBLY 1

A2 CLUTCH OPERATING LEVER 1

1 COVER, LH 1

2 HEX. FLANGE BOLT , M6 X 1 X 30 11

3 HEX SCREW M6 X 30 1

4 GEAR PEDAL ASSEMBLY 1

5 SLEEVE, GEAR LEVER 1

6 OIL SEAL 14 X 20 X 3 1

7 OIL FILLER PLUG 1

8 ‘O’ - RING (PLUG) 1

9 CLUTCH CABLE ASSEMBLY 1

10 CLUTCH OPERATING LEVER ASSEMBLY 1

11 PIN, CLUTCH OPERATING LEVER 1

12 CABLE CLEVIS, CLUTCH OPERATING LEVER 1

13 SPRING, CLUTCH OPERATING LEVER 1

14 LOCK PIN SPRING, CLUTCH OPERATING MECH. 1

15 OIL SEAL INA G 12 X 18 X 5 1

16 BUSH 1

Key No. Description Qty.

04-24

Gear Train Assembly

04-25

Gear Train Assembly

Key No. Description Qty.

A1 LAY SHAFT SUB ASSEMBLY 1

A2 MAIN SHAFT SUB ASSEMBLY 1

1 MAIN SHAFT 1

2 MAIN SHAFT 2ND GEAR 1

3 WASHER, THRUST 3

4 MAIN SHAFT 4TH GEAR ASSEMBLY 1

5 CIRCLIP 1

6 MAIN SHAFT 3RD GEAR ASSEMBLY 1

7 MAIN SHAFT 1ST GEAR 1

8 LAY SHAFT 1

9 LAY SHAFT 2ND GEAR ASSY. WITH BUSH 1

10 LAY SHAFT HIGH GEAR 1

11 LAY SHAFT 3RD GEAR / 4TH DOUBLE GEAR 1

12 LAY SHAFT 1ST GEAR ASSEMBLY 1

13 SELECTOR FORK LH 1

14 SELECTOR FORK CENTRE 1

15 SELECTOR FORK RH 1

16 SELECTOR FORK SHAFT 1

17 CIRCLIP 1

18 CAM PLATE ASSEMBLY 1

19 ROLLER 4

20 WASHER THRUST 1

04-26

Gear Shifting / Kick Starter

04-27

Gear Shifting / Kick Starter

1 SS ROCKER SHAFT ASSEMBLY, 1

2 PIN PIVOT 1

3 STRIKER, GEAR CHANGE 1

SPRING 1

5 SPRING, GEAR CHANGE STRIKER 1

6 SPACER 1

7 PIVOT BEARING, ROCKER SHAFT UPPER 1

8 HEX. SOCKET HEAD CAP SCREW, M6 X 12 2

9 PIVOT BEARING, ROCKER SHAFT BOTTOM 1

10 ASSEMBLY, GEAR LEVER SHAFT 1

11 STOP PIN 1

12 O-RING 1

13 HEX. SOCKET HEAD CAP SCREW, M5 X 40 2

Key No. Description Qty.

A1 KICKSTARTER SHAFT SUB ASSEMBLY 1

1 KICKSTART SHAFT 1

2 SPRING 1

3 PLUNGER 1

4 PAWL 1

5 WASHER, THRUST 1

6 KICKSTART GEAR ASSEMBLY 1

7 KICKSTARTER GEAR 35T 1

8 BUSH 1

9 CIRCLIP 1

10 SPRING 1

11 HEX SCREW M6 1

Key No. Description Qty.

04-28

CRANK SHAFT ASSY.

PISTON ASSY.

Cylinder Head, Barrel, Piston & Crankshaft

Key No’s

7,8,9,10,1 1

Key No’s

29,39

04-29

Cylinder Head, Barrel, Piston & Crankshaft

Key No. Description Qty.

A1 CYLINDER HEAD ASSEMBLY 1

A2 CYLINDER PISTON ASSEMBLY 1

1 CYL. HEAD SUB ASSY. (CYL. HEAD,

VALVE GUIDE, VALVE SEATS) 1

2 SPARK PLUG - M 14 1

3 DOWEL (6 MM) 8

4 SEAT, SPRING 2

5 VALVE STEM SEAL 2

6 VALVE SPRING 2

7 RETAINER, SPRING 2

8 SPLIT COLLAR 4

9 ROCKER BEARING SET-EXHAUST 1

10 ROCKER ARM, EXHAUST 1

11 ROCKER ARM - INLET 1

12 ROCKER BEARING SET-INLET 1

13 HEX. SOCKET HEAD CAP SCREW,

M6 X 55 8

14 GASKET, ROCKER COVER

EXHAUST 1

15 GASKET, ROCKER COVER INLET 1

16 ROCKER COVER - EXHAUST 1

17 ROCKER COVER - INLET 1

18 WASHER-SEAL 3

19 HEX. HEAD SCREW-

ROCKER COVER 3

20 WASHER SEAL 1

21 HEX. HEAD SCREW

ROCKER COVER 1

22 VALVE EXHAUST 1

23 VALVE INLET 1

24 DAMPER PAD -

CYLINDER BARREL 3

25 DAMPER PAD -

CYLINDER BARREL TAPPER 6

26 DAMPER PAD LH -

CYLINDER HEAD 2

27 DAMPER PAD RH -

CYLINDER HEAD 4

28 STUD, EXHAUST 2

29 CYL. BARREL ASSEMBLY 1

30 DOWEL PIN 1

31 DOWEL PIN 1

32 GASKET 1

33 MLS GASKET 1

34 PUSH ROD ASSEMBLY, EXHAUST 1

35 PUSH ROD ASSEMBLY, INLET 1

36 SPARK PLUG - M 10 - BOSCH

(UR 5DC) 1

37 CIRCLIP 2

38 RING SET STD 1

39 PISTON ASSEMBLY WITH

RINGS STD 1

04-30

570479/b

570482/b

570480/b

570482/b

570480/b

Damper pad

straight - Barrel

570482/b

Damper pad

taper - Barrel

INLET SIDE VIEW

EXHAUST SIDE VIEW

Damper Pad Position Details

570482/b

570478/b

570480/b

570482/b

570479/b

Part No.

Description

Quantity

per engine

Image

570478/b

Damper pad-

cylinder head LH

570479/b

Damper pad-

cylinder head RH

Part No.

Description

Quantity

per engine

Image

NUMBER OF DAMPER PADS PER ENGINE = 15

ENGINE DISMANTLING

INSPECTION & ASSEMBLY

SECTION

FIVE 05

05-2

COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM FRAME.

✰ Cylinder head assembly

✰ Cylinder block

✰ Magneto assembly

✰ Primary drive

✰ Clutch assembly

✰ Timing gears

✰ Oil pump Assembly

✰ Gearbox foot control mechanism

✰ Kick Main Spring replacement

✰ Self Starter Sprag Bearing

replacement.

ENGINE NEED TO BE REMOVED FROM THE FRAME FOR THE FOLLOWING JOBS:

✰ Crank case repair/change

✰ Crank case centre gasket change

i.e liquid sealant gasket.

✰ Crank shaft main bearings LH &

RH replacement.

✰ Gears, Mainshaft or Layshaft, Sleeve

Gear repair / replacement

✰ Mainshaft or Layshaft Bearings

replacement.

✰ Self starter Idler Gear jack Shaft

replacement.

✰ Kick Starter Gear, Pawl, Spring or

Plunger replacement.

✰ Roller Hydraulic Valve Lifter

(RHVL) replacement.

ENGINE DISASSEMBLY

✰ Cylinder Head Sub Assembly

✰ Cylinder Barrel Sub Assembly

✰ Cover RH Sub Assembly

✰ Components dismantling on Crankcase

✰ Cover LH Sub Assembly

✰ Components dismantling on Crankcase

✰ Opening / splitting of Crank case RH

& LH

✰ Gear Train removal

✰ Lay shaft and Main shaft sub Assembly

Engine Dismantling, Inspection & Assembly

05-3

DISMANTLING PROCEDURE

✰ Disconnect fuel hose. Take care to

ensure fuel does not spill.

✰ Disconnect fuel pump module and

low fuel sensor couplers.

✰ Remove the front and rear flange

nuts, washer at the front & rear mounting of the fuel tank.

✰ Lift the tank from the seat side &

remove.

CAUTION :

Keep a cloth on the front end of the fuel tank, (below the handle bar clamp) to avoid damage to the fuel tank while removing.

Engine Dismantling, Inspection & Assembly

✰ Remove the mounting bolts as shown

and remove the seat.

✰ Manual Bi starter

✰ Remove the 2 screws, at the bottom

of the LH switch module and separate the module from the handle bar.

05-4

✰ Remove the clutch cable from the

clutch lever at handle bar end.

REMOVAL OF THROTTLE CABLE

✰ Slacken the adjusters at the throttle

body end for both cables.

REMOVAL OF THROTTLE BODY

✰ Loosen the throttle body flange &

bellow clip.

✰ Remove the throttle body by pushing

towards Air Filter box.

CLUTCH CABLE REMOVAL

✰ Slacken the adjuster at the clutch

cover end and disconnect the cable from the lever.

✰ Take out clutch cable from the cover.

✰ Disconnect the cable from the lever.

Engine Dismantling, Inspection & Assembly

05-5

✰ Remove the rear mounting at the

pillion foot rest end

NOTE :

Loosen the rear brake rod adjuster nut so that the brake pedal can be depressed to allow the exhaust pipe to be removed.

✰ Remove the flange nut 2 nos. from

cylinder head.

✰ Remove the Silencer Assembly with

Exhaust pipe.

✰ Remove the Suppressor Cap

BATTERY REMOVAL

✰ Ensure ignition switch is in “OFF”

position.

✰ Remove battery cover on LH side.

REMOVAL OF SILENCER AND EXHAUST PIPE

✰ Remove the centre silencer bracket

mounting screw with plain washer.

Engine Dismantling, Inspection & Assembly

05-6

CAUTION :

Always remove earth wire terminal first.

✰ Remove the battery holding straps

pull the battery out & remove terminals.

✰ Lift the motor upwards and pull out

of the housing in the front.

REMOVAL OF E-START MOTOR

✰ Remove the cover screw

✰ Remove the terminal rubber boot.

✰ Remove the terminal nut & take out

the terminal wire lead.

✰ Remove the 2 mounting allen

screws.

✰ Gently lift the motor and remove the

motor along with the housing. Remove the 2 dowels for the housing drive.

✰ Remove 4 screws of the starter drive

housing and tap gently to free the housing.

Engine Dismantling, Inspection & Assembly

05-7

REMOVAL OF DRIVE CHAIN

✰ Rotate the rear wheel to bring the

chain lock to a convenient position and remove the chain lock.

✰ Remove the chain link and the drive

chain.

REMOVAL OF SIDE STAND

✰ Remove the mounting nuts and

remove the side stand.

REMOVAL OF REAR BRAKE SWITCH

✰ Disconnect the brake switch spring

from brake lever.

✰ Disconnect the rear brake switch

coupler from the wiring harness

✰ Slacken the nyloc nuts & remove the

brake light switch.

✰ Remove the piece mudguard bracket

bolt along with 2 plain washers & 1 star washer

✰ Remove rider foot rest LH & RH

(C5)

Engine Dismantling, Inspection & Assembly

05-8

CYLINDER HEAD ASSEMBLY

✰ Remove the 4 allen screws along with

rubber seals from Inlet and exhaust rocker covers.

✰ Remove the Inlet & Exhaust Rocker

cover, dowel & rubber gasket.

ENGINE OIL DRAIN

Always best to drain the engine oil in warm condition.

✰ Remove the 2 Flanged hex bolts.

Remove the drain cap with ‘O’ ring.

✰ Remove suction filter.

✰ Remove the magnetic drain plug

with washer.

✰ Remove the 4 allen screws each on

the rocker bearing inlet & exhaust.

✰ Remove the inlet and exhaust rocker

bearing with dowel and rocker arm.

Magnetic Drain Bolt

Engine Dismantling, Inspection & Assembly

05-9

✰ Remove the 6 flanged hex nuts,

securing the cylinder head.

✰ Remove the Spark plug

✰ Remove inlet and exhaust pushrods

✰ Remove the multi layer steel (MLS)

head gasket.

✰ Remove the Cylinder head assy.

REMOVAL OF VALVES

✰ Remove the Inlet & Exhaust valves

by using special tool No. ST25123-1 Valve spring compressor as shown

Engine Dismantling, Inspection & Assembly

05-10

✰ Remove the Inlet Valve spring

retainer, split collar and Spring.

✰ Gently tap Cylinder barrel and

remove along with 2 dowel pins.

CYLINDER BARREL SUB ASSY.

✰ Remove Inlet and Exhaust Valve

stem seal from valve guides.

NOTE : Always replace valve stem seal in case of removal of valve from Cylinder head.

NOTE :

Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel, as shown.

NOTE :

Ensure piston is at TDC.

NOTE: Similarly follow the same process to remove Exhaust Valve.

✰ Remove Inlet Valve as shown

✰ Remove gudgeon pin and piston.

Engine Dismantling, Inspection & Assembly

05-11

NOTE : Carefully remove the piston rings from the piston without deforming.

✰ Remove Cylinder barrel bottom

Gasket.

✰ Use Special tool No. ST - 25592-4 to

hold connecting rod as shown Fig.

REMOVAL OF COVER RH SUB ASSEMBLY :

✰ Remove kickstarter lever.

✰ Remove oil filter cover bolts.

CAUTION : Care must be taken while removing cover due to spring force.

✰ Remove oil filter cap, “O”ring &

Spring.

✰ Remove the 3 “O” rings, Oil filter

element spring cap, washer & Oil filter element.

Engine Dismantling, Inspection & Assembly

05-12

CAUTION :

Tap only at the places shown to avoid damage to the RH cover

✰ Remove Stator assembly by

removing 3 mounting screws.

✰ Remove Pulser coil by removing 2

screws

✰ Remove RH cover gasket & 2 dowels.

NOTE :

Remove the stator coupler from the wiring harness before removing RH Cover.

Place a plastic tray below the RH cover for collecting the oil that will drip while removing the cover.

✰ Remove the 11 bolts securing cover

RH. Gently tap & pull out the cover evenly

✰ It may be necessary to tap the cover

slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove

Engine Dismantling, Inspection & Assembly

05-13

✰ Remove Breather bolt and washer

✰ Remove 6 Nos. allen screws to

remove breather chamber cover

✰ Remove circlip, oil seal and jet

crankshaft

✰ Remove Ignition Timing check bolt

and washer (if not removed earlier).

✰ Remove breather chamber gasket

NOTE : This Oil seal is recommended to be replaced at every 20,000 kms interval.

✰ Remove oil filler cap and “O” ring

Engine Dismantling, Inspection & AssemblyEngine Dismantling, Inspection & Assembly

05-14

✰ Remove the 2 oil seals from the Kick

Shaft hole

COMPONENTS FOR DISMANTLING FROM CRANKCASE RH

REMOVAL OF ROTOR ASSEMBLY

✰ Loosen and remove magneto lock nut

and plain washer.

✰ Ensure the connecting rod is locked

properly with the special tool resting firmly and evenly on the crankcase top position.

✰ Use Special tool No. ST - 25128-2

Magneto removing tool to remove

rotor assembly.

✰ Remove the 3 allen screws & 2

dowels from Cam steady plate.

✰ Remove Cam steady plate and the

shims.

NOTE :

Check the number of shims on inlet and exhaust cams. It is important to reduce noise and axial play between the cam gear face and the cam steady plate.

OUTSIDE OIL SEAL

INSIDE OIL SEAL

Engine Dismantling, Inspection & Assembly

05-15

✰ Remove oil pump plastic gear after

removing circlip. Observe short boss of pump drive gear should face outwards in case of 350cc and long face should face outwards in case of 500cc

✰ Remove Cam gear inlet.

✰ Remove Cam gear Exhaust (Auto

decompressor sub assy).

✰ Exhaust cam with auto

decompressor.

✰ Remove flyweight along with return

spring over actuating pin lever as shown in Fig.

✰ Remove mounting allen screw on

flyweight sub assembly.

DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR

NOTE : Ensure spring bend lug being

seated inside flyweight hole properly.

Engine Dismantling, Inspection & Assembly

05-16

✰ Remove the actuating pin in the

Exhaust cam.

✰ Remove the 4 allen screws to remove

Oil pump assy.

✰ Remove the woodruff key.

CAUTION :

Ensure "O" ring must be located on the oil pump body outlet.

✰ Remove Gear lever shaft with bush

(spacer shaft).

✰ Remove the Oil pump assembly with

“O” ring.

✰ Remove Gear lever from engine LH

cover side.

Engine Dismantling, Inspection & Assembly

05-17

✰ Remove rocker shaft return spring

pivot pin with “O” ring by using special No. ST 25123-4 Extractor for 5 speed gear box pivot pin as shown in Fig.

✰ Remove the two bolts and remove the

rocker shaft upper pivot bearing with “O” ring.

✰ Remove the two screws holding the

lower pivot bearing ..

✰ Remove the rocker shaft assembly

by gently tilting and twisting out.

✰ Remove nut and lock washer.

✰ Straighten lock tab and Unlock the

FD sprocket nut.

Engine Dismantling, Inspection & Assembly

Royal Enfield Classic 500 2009, Classic 350 2009 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual