Royal Enfield Classic 500 2011 Owner's manual

Foreword

We congratulate you on your choice of the legendary Bullet motorcycle and welcome you to the exciting world of motorcycling on a Royal Enfield.This manual will help you to operate your Classic 500cc motorcycle, the right way and guide you to maintain your motorcycle meticulously. We have also provided tips on safe riding and on minor adjustments for the care of your motorcycle. Please avail the four free services at the nearest Authorised Service Point, at the appropriate time to maintain your Bullet motorcycle in top riding condition.Log on to the exciting world of Royal Enfield website: www.royalenfield.com to get to know more about the company, its products and exciting news from time to time. We request you to carefully read the terms and conditions of warranty and other useful information given in this manual before starting to use your Bullet Motorcycle.

Service Headquarters

Royal Enfield, A Unit of Eicher Motors Limited, Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. Phone : 044 - 4223 0400, Fax : 044 - 4201 1719 E-mail : customerservice@royalenfield.com Website : www.royalenfield.com

Part No. 591822 / b / Qty. 500 / Dec ‘11

Notice

All information in this manual is based on the latest product information available at the time of publication. Due to continues improvements or other changes, there may be discrepancies between information in this manual and your vehicle. Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold.

All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical specification are subject to change without prior notice.

Contents

PERSONAL & VEHICLE INFORMATION... 6

FREE SERVICE RECORD........................ 7

TECHNICAL SPECIFICATIONS................ 8

z Engine................................................ 8

z Ignition System................................... 9

z Transmission...................................... 9

z Electricals........................................... 10

z Chassis.............................................. 11

z Dimensions......................................... 12

z Weights.............................................. 12

SAFETY DEFINITIONS ............................ 13

SAFE DRIVING TIPS/GUIDELINES........... 14

SAFE & HAPPY RIDING........................... 18

RULES OF THE ROAD............................. 19

VEHICLE IDENTIFICATION...................... 21

z Chassis Number.................................. 21

z Engine Number................................... 21

KEY PARTS LOCATION........................... 22

z Top View............................................ 22

z Right Side View.................................. 23

z Left Side View .................................... 24

OPERATION OF CONTROLS ................... 25

z Ignition Switch .................................... 25

z Steering Lock...................................... 25

z Fuel tank cap ..................................... 26

z Side Box ............................................ 26

z Battery Carrier ................................... 27

z Utility Box .......................................... 27

z Head lamp switch ............................... 28

z Head lamp Day flash .......................... 28

z Dip Switch ......................................... 28

z Engine Start Switch ............................ 29

z Engine Stop Switch ............................ 29

z Turn Signal Switch ............................. 29

z Horn .................................................. 30

z Manual Bi Starter (choke) ................... 30

PRE OPERATIONAL CHECKS ................. 31

RUNNING IN ........................................... 32

Contents

ELECTRONIC FUEL INJECTION & MIL..... 33

z EFI .................................................... 33

z The Advantages of EFI ....................... 33

z Malfunction Indicator Lamp (MIL)......... 33

ROLL OVER SENSOR ............................. 34

STARTING ............................................. 35

GEAR SHIFTING ..................................... 38

PARKING ............................................... 39

z Center Stand ...................................... 39

z Side Stand ......................................... 39

TOOLS & FIRST AID KIT.......................... 40

RECOMMENDED LUBRICANTS ............... 41

PERIODICAL MAINTENANCE .................. 42

MINOR MAINTENANCE TIPS .................. 46

z Control Cables, Hand lever, Pivots,

Center / Side Stand Pivots .................. 46

z Oil Level Inspection ............................ 46

z Engine oil change ............................... 47

z Spark Plug ......................................... 48

z Brake fluid ......................................... 49

z Inspection of tyres and wheels............. 49

z Tyre pressure ..................................... 50

z Front Wheel removal .......................... 50

z Front Wheel reassembly ..................... 51

z Rear wheel removal ........................... 52

z Rear wheel reassembly....................... 53

z Adjustments-Clutch............................. 54

z Drive Chain free play .......................... 54

z Rear Brake Pedal Height .................... 55

z Rear Brake free play adjustment.......... 56

z Chain lock fitment .............................. 56

z Adjustment of gas shockabsorber........ 57

z Removal of Battery from the Vehicle.... 58

z Battery Maintenance........................... 58

z Reassembly of Battery on Vehicle ....... 59

CHANGING ELECTRICAL COMPONENTS.... 60

z Head Lamp Bulb Replacement .......... 60

z Reassembling the Head Lamp............. 61

Contents

z Tail Lamp bulb Replacement................ 62

z Trafficator bulb Replacement .............. 62

z Fuse .................................................. 63

z Blade fuse usage list ........................... 63

PILLION(REAR)SEAT REMOVAL & REFITTING 64

z Pillion (Rear) seat removal .................. 64

z Pillion (Rear) seat refitting ................... 65

WASHING PROCEDURE ......................... 66

z Precautions ....................................... 66

z After washing ..................................... 66

STORAGE PRECAUTION ........................ 67

z Preparing the motorcycle for re-use...... 68

LONG TRIP PRECAUTIONS .................... 69

COMPLETE WIRING DIAGRAM ............... 70

TROUBLE SHOOTING ............................ 71

z Engine fails to start ............................ 71

z Engine misfiring ................................. 72

z Poor pickup ....................................... 72

z White / Blue smoke ............................ 73

z Engine overheating ............................ 73

z Excessive fuel consumption ................ 73

z Brakes Poor........................................ 74

z Vehicle wobbles ................................. 74

z Electricals .......................................... 75

z Electronic Fuel Injection (EFI) ............ 75

WARRANTY ............................................ 76

EMISSION WARRANTY ........................... 78

FREE SERVICE COUPONS ..................... 82

PAID SERVICE / MAINTENANCE RECORD.. 91

LOG BOOK ............................................. 99

REGIONAL & AREA OFFICES ................. 100

ALL INDIA ROAD SIGNS ......................... 101

NOTES ................................................... 102

ANNEXURES

z Vehicle Installation Form z Pre-Delivery Inspection Report z Bike Installation Confirmation By Customer z Form 22

Personal & Vehicle Information

Name

Door No./Street

Locality

City State Pin

Contact Nos. Res: Off: Mobile: Email:

Engine No. Battery No.

Frame No. Battery make

Reg. No. Licence No.

Date of Sale Valid till dt.

Model Key No.

Tyre make Colour

Sold by Dealer Code

Vehicle Installation Form (VIF) No.

Free Service Record

It is our endeavour to provide excellent service to your Classic 500 at all times. Towards this we provide 4 free services at specific Intervals.

Please avail these services at the specified time, in any of the Royal Enfield Dealerships / Authorised Service Points 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.

Service 4th Service2nd Service

Date of Service Kms Covered Servicing ASP / Dealer’s Name Address

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

Service

Technical Specification

ENGINE

Engine ........................................................ 4 Stroke, air cooled, single cylinder, OHV, SI & FI Engine

Capacity ..................................................... 499 cc (Displacement)

Bore ........................................................... 84 mm

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

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

Max. Power @ RPM .................................. 27.2 BHP @ 5250 rpm

Max. Torque @ RPM................................. 41.3 Nm @ 4000 rpm

Air Filter Element ....................................... Corrugated Paper Element

Engine Oil Capacity ................................... 2.75 Litres.

Lubrication ................................................. Forced Lubrication, Wet Sump

Engine Oil Grade ....................................... MOTUL 3000 4T Plus 15W50 API SL JASO MA

Cooling system .......................................... Natural Air Flow

Fuel Supply ............................................... Electronic Fuel Injection Programmed (PGM-EFI)

Technical Specification

IGNITION SYSTEM

Ignition system .......................................... Electronic Ignition (ECU / Variable)

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

Spark plug ................................................. WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10

TRANSMISSION

Clutch ........................................................ Wet Multiplate (7 Plates)

Primary drive ............................................. Duplex Chain

Primary Drive Ratio .................................. 2.15 : 1

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

Gear shift pattern...................................... 1 - N - 2 - 3 - 4 - 5

Gear Ratios ............................................... 1st-3.06:1 2nd-2.01:1 3rd-1.52:1 4th-1.21:1 5th-1:1

Secondary Drive (F.D. Sproket) .............. 18 Teeth

Final ratio ................................................. 2. 11 : 1

Drive Chain links ...................................... 102 links

Technical Specification

ELECTRICALS

Generation ................................................ Alternator

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

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

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

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

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

Pilot lamp .................................................. 12V, 2 W - 2 nos. & 12V, 4 W - 1 no.

Speedometer lamp ................................... 12V, 3.4 W - 1 no.

Turn signal / High beam indicator ........... 12V, 2 W - 2 nos.

Neutral Indicator ....................................... 12V, 2 W - 1 no.

Horn (Dual) ............................................... 12V, 2.5 Amp (Max.) X2

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

Technical Specification

CHASSIS

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

Tyre size .................................................... Front: 90 / 90 - 19” - 52 P Rear: 120 / 80 - 18” - 62 P

Tyre pressure ............................................ Front- Solo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI)

............................................................ Rear- Solo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.25 Kg/cm2 (32 PSI)

Fuel tank capacity .................................... 13.5 Litres (MIN)

Low fuel warning....................................... 2.5 Litres

Dead stock of petrol (unusable fuel) ....... 0.75 Litres

Suspension ............................................... Front: Telescopic (Dia 35mm), Hydraulic Damping Stroke 130mm

............................................................ Rear: Swing arm with gas filled shock absorbers Stroke 80 mm

Front fork oil capacity ............................... 195 ml per leg

Fron fork oil ............................................... 1F Endurance (or Royal Enfield) fork oil

Brakes ....................................................... Front : Hydraulic 280 mm Ventilated Disc

............................................................ Rear : Foot Operated 153mm Single Lead Internal expanding

Brake oil capacity ..................................... 60 ml

Brake oil grade ......................................... DOT 3 or DOT 4

Technical Specification

DIMENSIONS

Length........................................................ 2170 mm

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

Height ........................................................ 1070 mm

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

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

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

WEIGHTS

Kerb Weight (with 90% Fuel) .................. 190 Kg

Max pay load ............................................ 178 Kg

NOTE :

1. Values given above are for your guidelines only.

2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.

Safety Definitions

The information given under the titles : Warning, Caution and Note are for your safety and for the care and safety to your motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others and damages to the motorcycle.

Warning

Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider or other persons.

CAUTION :

This message if disregarded may result in damage to the vehicle.

NOTE :

Indicates important and useful messages for clear understanding.

Safe Riding Tips / Guidelines

z Before operating your new motorcycle, it is your

responsibility to carefully read and follow the operating and maintenance instructions detailed in this manual for your own safety, your motorcycle and that of others.

z Know and respect the rules of the road. Be a

safe rider for your own safety and for other road users.

z Before starting the motorcycle, check for proper

operation of brakes, clutch, gear shifter, handle bar controls, tyre pressures, fuel and oil levels.

z Use only genuine Royal Enfield spare parts and

approved accessories. Use of other manufacturer’s performance parts may affect the performance of your motorcycle and render the motorcycle void of warranty. See your Royal Enfield dealer for details.

z Whenever refuelling your motorcycle, please

exercise utmost caution and carefully observe the following rules :

Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom made extended front forks or suspensions, which may adversely affect performance and handling. Removing or altering original parts may adversely affect performance and could result in an accident.

9 DO NOT smoke and please ensure that

there are no open flames or sparks near the motorcycle, when refuelling OR servicing the fuel system.

9 Switch OFF mobile phones and other hand

held electronic devices.

9 Open the fuel filler cap slowly.

9 Refuel in a well ventilated area with the

engine turned off.

9 DO NOT fill the tank to its brim. Please fill

fuel only till the bottom of the filler neck insert, so as to leave air space in the fuel tank to allow for fuel expansion.

Warning

Safe Riding Tips / Guidelines

z A new motorcycle must be operated according

to the special running-in-procedure. See running-in-procedure mentioned in Page No. 32.

z Operate motorcycle only at moderate speeds

and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions.

z DO NOT exceed the legal speed limit or drive

too fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control.

NOTE :

If you are an inexperienced rider we recommend that you obtain formal training on correct motorcycle riding techniques and become thoroughly familiar with the operation of your particular motorcycle. New riders should gain experience under various conditions while driving at moderate speeds.

Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to the following upsetting forces :

9 Wind blasts from passing trucks.

9 Rough uneven road surfaces.

9 Slippery road surfaces.

These forces may affect the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.

z Operate your motorcycle defensively.

Remember, a motorcycle does not afford the same protection as an automobile in an accident. One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist.

Safe Riding Tips / Guidelines

z Wear an approved helmet, clothing, and foot

gear suited for riding a motorcycle. Bright OR light colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.

z When carrying a pillion rider, it is your

responsibility to instruct them on proper riding procedures.

z DO NOT allow other individuals, under any

circumstances, to operate your motorcycle unless you know they are experienced, licensed riders and are thoroughly familiar with the operating conditions of your motorcycle.

Warning

Regularly inspect shock absorbers and front forks and look for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.

Warning

Avoid any contact with the exhaust system. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot, even after the engine is turned off. Failure to wear proper or protective clothing could result in serious injury.

Warning

Exhaust gases contains poisonous carbon monoxide and chemicals, known to cause Cancer, Birth Defects or other reproductive defects.

Safe Riding Tips / Guidelines

Warning

Motorcycle batteries contain lead and lead components, acids and chemicals known to cause cancer, birth defects or other reproductive harm. Exercise extreme caution while handling a battery. Wash hands thoroughly whenever a battery is handled.

Warning

Consult your Royal Enfield Dealer regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so may aggravate an initial problem, cause costly repairs & jeopardize your personal safety.

Warning

DO NOT tow a disabled motorcycle. The steering and handling of the disabled motorcycle will be impaired due to the force of the towline. If a disabled motorcycle must be transported, use a truck or a trailer. Towing a motorcycle may cause loss of control of the motorcycle in the front, leading to an accident.

Warning

DO NOT pull a trailer behind a motorcycle. Towing a trailer may cause reduced braking efficiency, tyre overloading and unstable handling. Towing a trailer may cause loss of control of the motorcycle in the front, leading to an accident.

Safe & Happy Riding

RIDING DRESS

z Please wear a proper riding apparel. z A pair of riding boots or shoes. z Soft leather gloves. z Goggles or spectacles to safe guard eyes. z A certified helmet. Affix light reflecting strips of

stickers at the front and rear.

NOTE :

A light coloured shirt enables greater visibility to other road users especially during nights.

CAUTION :

Loose clothing may get caught on moving parts of your motorcycle.

SITTING POSTURE

Correct sitting posture is a pre-requisite for stable and safe riding

z Sit Straight with your shoulders completely relaxed. z Keep your elbows close to your body.

z Keep your toes in straight ahead direction. z Slightly grip the petrol tank with both knees. z Hold the handle bar grips, close to its inner end. z Look extensively ahead, including rear view

mirrors, without turning the head.

BRAKING

z Apply front and rear brakes gently and

simultaneously for maximum braking efficiency.

WARNING

Applying any one of the brakes suddenly may cause the vehicle to skid. The hydraulic disc brake fitted on your motorcycle requires very less effort. High effort or sudden application may lock the wheel. Please use utmost caution while applying the brakes.

z While riding on wet or bad road conditions use

brakes cautiously.

z Avoid excessive banking, otherwise footrest

may touch the ground and cause instability.

Rules of the Road

z Be sure your number plate is installed in the

position specified by law and is clearly visible at all times.

z Ride at a safe speed that is consistent with the

type of road surface you are on. Pay strict attention to whether the surface is :

9 Dry

9 Oily

9 Icy

9 Wet

z Watch for loose debris, such as leaves, slippery

substances or loose gravel that can hamper the stability of your vehicle.

z DO NOT exceed the legal speed limit or drive

z Keep to the correct side of the road center line

when meeting oncoming vehicle.

z Always sound your horn, actuate your turn

signals, and exercise caution when passing other vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up/or down a hill.

z At street intersection give the right-of-way to

the vehicle on your left or right. DO NOT presume you have the right-of-way.

z Always signal when preparing to stop, turn or

pass.

z While turning either right or left, watch for

pedestrians, animals, as well as vehicles.

z All traffic signs, including manual controls at

intersections, should be obeyed promptly. SLOW DOWN at traffic signs near schools and CAUTION signs at railroad crossings.

Rules of the Road

z When intending to turn, signal at least 100 feet

(30.5 meters) before reaching the turning. Be close to the center line (unless local rules require otherwise), slow down and then turn carefully.

z Never jump a traffic light. When a

change is imminent from GO to STOP (or vice versa) at intersections, slow down and wait for the light to change to green. Never run through a yellow or red traffic light.

z DO NOT leave the curb or parking area without

signaling. Be sure your way is clear to enter moving traffic. A moving line of traffic always has the right-of-way.

z Park your motorcycle on a firm and flat surface

to prevent it from falling over.

z Protect your motorcycle against theft. After

parking your motorcycle, remove Ignition key from switch and lock the steering head.

Red

Yellow

Green

SIDE VIEW MIRRORS

Your motorcycle is equipped with convex mirrors and have a curved surface. This type of mirror is designed to give a much wider view to the rear than a flat mirror; however, cars and other objects seen in this type of mirror will look smaller and farther away than when seen in a flat mirror.

Use care when judging the size or distance of objects seen in these mirrors.

NOTE :

To help you establish the relative distance of vehicles behind your motorcycle, adjust each mirror in such a way, that a small portion of your shoulder is visible and a large portion behind your motorcycle is seen clearly.

Vehicle Identification

CHASSIS NUMBER

Punched on the streering head tube

ENGINE NUMBER

Punched on top of the engine LH side.

Key Parts Location

TOP VIEW

4 5 6

7 8 9 10

1. Turn signal switch

2. Horn button

3. Clutch lever

4. Day flash switch

5. Head lamp dip switch

6. Manual Bistarter / Choke

7. Ignition switch

8. Speedometer

9. Malfunction / Low fuel Indicator

10. Engine Kill switch

11. Pilot head light switch

12. E-Start Switch

13. Fuel tank cap

Key Parts Location

RIGHT SIDE VIEW

1. RH Trafficator front

2. Brake Pedal

3. Starter Motor

4. Utility Box

5. Air Filter Box

6. RH Trafficator Rear

Key Parts Location

LEFT SIDE VIEW

1. Trafficator front LH

2. Horn

3. Spark plug

4. Gear Change Pedal

5. Battery Cover

6. Side Stand

7. Centre stand

8. Trafficator rear LH

Operation of Controls

IGNITION SWITCH

OFF

STEERING LOCK

Turn key clockwise to lock.

z Lock the steering when

leaving bike parked.

CAUTION :

Protect your motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head.

DO NOT lubricate barrel locks with petroleum based lubricants or graphite. Inoperative locks may result in damage to your vehicle.

Operation of Controls

FUEL TANK CAP

Turn key clockwise to open. Press cap to lock with key in position.

NOTE :

z Key can be removed only in

locked position.

z Use high quality unleaded

high octane petrol (91 octane and above) for enhanced performance.

SIDE BOX

SIDE BOX LH AIR FILTER BOX RH

Turn Key anti-clockwise to open Turn Key anti-clockwise to open

NOTE :

z Key is common for ignition, petrol tank cap, steering lock, side

boxes and battery cover.

z Key for fuel tank and tool boxes can be removed from the lock

only in locked

Operation of Controls

BATTERY CARRIER

Battery Box Cover

Turn Key clockwise & lift the battery box cover gently

UTILITY BOX

To remove cover turn key anti clock-wise and pull the oval cover by applying finger pressure

Operation of Controls

HEAD LAMP SWITCH

z OFF

PRESS FOR HEAD LIGHT FLASH

PILOT LIGHT ON

DIP SWITCHHEAD LAMP DAY FLASH

LOW BEAM

HIGH BEAM

Operation of Controls

ENGINE START SWITCH

TURN SIGNAL SWITCH

OFF (PUSH TO OFF)

PRESS

ENGINE STOP SWITCH

ENGINE ON

LEFT RIGHT

ENGINE OFF

Operation of Controls

HORN

MANUAL BI STARTER (CHOKE)

Pre Operational Checks

A careful check of the following must be carried out every time before riding and specially after long periods of storage to determine if additional maintenance is necessary.

1. Tyres for correct pressure, abrasions or cuts.

2. Rear chain for proper tension.

3. Brakes, steering and throttle for responsiveness.

4. Cable for fraying or crimping and free operation.

5. Engine oil level.

6. Wheel spoke for proper tightness, no breakage,

7. Headlamp, tail lamp, brake lamp and indicator lamps for proper operation.

Warning

For your personal welfare and safety, all the points mentioned above should be performed periodically. Failure to do so, may affect safe operation and damage your motorcycle and could result in an accident causing serious injury.

Running In

Proper running-in is very important for obtaining maximum life and performance of a new motorcycle. The following guidelines explain proper running-in procedures.

Since the engine is brand new, it should not be loaded excessively for the first 2,000 kms. During the first few hundred kms, the various parts in the engine wear and polish themselves to the correct operating clearances. Driving with prolonged full throttle operation, or any high speed conditions might result in excessive heating of the engine and cause abnormal wear of the moving parts and hence must be avoided.

1. 0 - 500 Kms :

The recommended speeds for the first 500 Kms is below 50 Kmph. During this period avoid operating the motorcycle with full throttle opening. Stop the motorcycle for about 5 to 10 minutes to let it cool down, after every hour of running. Vary the speed of the motorcycle regularly during running but avoid using the motorcycle above ½ throttle opening position.

2. 501 - 2000 Kms.

The recommended speed is below 80 Kmph. Avoid

driving the motorcycle with full throttle opening. Vary the speed of the motorcycle regularly but avoid using the motorcycle above 3/4 throttle opening position.

3. 2,001 kms and above

Avoid prolonged full-throttle operation. Vary speed occasionally.

CAUTION :

After covering the first 500 kms. please replace the engine oil and oil filter element.

Royal Enfield engines are air-cooled and consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature. Extended periods of idling may over heat the engine, resulting in serious engine damage.

DO NOT run the engine at extremely high RPM with clutch disengaged or transmission in neutral as it can cause serious engine damage.

An engine running long distances at high speed must be given close attention to avoid over heating and possible engine damage.

Electronic Fuel Injection & MIL

ELECTRONIC FUEL INJECTION (EFI)

An electronic control unit (ECU) monitors engine performance and provides exact requirement of Air / Fuel mixture to the engine, through the fuel injector by taking inputs from various sensors provided in the motorcycle.

THE ADVANTAGES OF EFI ARE

z Faster response of the engine to suit road/load

conditions.

z Better power output

z Lower emission

z Better reliability

z Excellent cold startability

z Engine Diagnostic capabilities

z Maintenance free

MALFUNCTION INDICATOR LAMP (MIL)

A Malfunctioning Indicator Lamp (MIL) is provided in the small meter located on the right side of the head lamp casing.

There are two indications in this unit.

Low fuel indication & EFI Mal-function Indicator Lamp (MIL). When both the Ignition & Engine kill switch is “ON”, the MIL will glow for few seconds and will go “OFF”. This indicates that all the functions of Electronic Control Unit (ECU) and other sensors are working perfectly and the motorcycle can be used.

Incase of any malfunctioning of the ECU or other sensors etc., the MIL will glow continuously. In the event of any such phenomenon, it is recommended to take the vehicle to a nearest Royal Enfield authorised service point for inspection and further necessary action.

Rollover Sensor

ROLLOVER SENSOR

Your motorcycle is fitted with a unique “Roll Over Sensor” under rider seat. This is a safety feature.

In the event of an accident OR if the motorcycle falls over on its side with the engine running.

The “Roll Over Sensor” will switch off Ignition and cut off fuel supply to prevent the motorcycle from moving suddenly, if it is in gear.

To re-activate the system after the motorcycle has been made upright, please switch off both the Ignition & Engine kill switch, wait for a few seconds and switch “ON” again.

This will help to RESET the “Roll Over Sensor” and the engine can be started / run.

Starting

Warning

Before starting engine, always shift gears into neutral.

CAUTION :

Do not force the gear lever while attempting to shift to neutral. Move the motorcycle back & forth and simultaneously press gear lever to come to neutral. Ensure neutral indicator light comes “ON”’ in the Speedometer.

NOTE :

z If the engine does not start on the first attempt in

cold climate, release the starter button, wait for 30 seconds before pressing the starter button again.

z Press starter button and release starter switch once

the engine starts.

z A clutch switch is provided in the system for the

safety of the rider. This is to prevent the vehicle from starting when the vehicle is in gear. To start the engine when it is in gear, pull clutch lever, press starter button and release as soon as the engine starts.

z Turn ignition

switch ‘ON’

z Ensure the side

and main stands are in released position

z Ensure that gears

are in neutral and

neutral lamp is glowing

Starting

z Ensure Engine

stop switch is in “RUN” position

CAUTION :

Never accelerate the engine immediately after a cold start. The engine should be allowed to run slowly for 15-30 seconds. This will allow the engine to warm up and let oil reach all surfaces needing lubrication. Failure to adhere may result in damage to the Engine.

z Press Clutch

Lever.

z Press Starter

Button and release as soon as engine starts

z Manual bi

(choke) Starter

NOTE:

It may be necessary to operate and hold the manual bi starter, when starting the engine for the first time in cold mornings, temperatures below 100C or at high altitudes, to prevent the stalling and to keep the idling RPM steady.

Starting

As soon as the engine attains the operating temperature, the RPM will raise, at which time the manual Bi Starter should be released.

z Warm up engine for 2 minutes - till idling is

consistent.

Prior to starting, check to see if the low fuel indicator is glowing continuously.

This will glow continuously, if the fuel level in tank is below 2.5 litres.

CAUTION :

Please ensure the motorcycle is not used with the low fuel indicator lamp “ON” continuously. It may not only result in the motorcycle running out of fuel. But will also cause serious damage to the fuel pump. Please ensure fuel is filled up as soon as the low fuel lamp comes “ON”.

Gear Shifting

z Warm up engine

for 2 minutes till idling is

consistent/stable GEAR SHIFT PATTERN 1 N 2 3 4 5

z Press clutch lever towards the hand grip. z Press gear pedal with toe to engage 1st gear. z Gently open throttle and release clutch

simultaneously. If clutch is released suddenly, the engine may stall and cause a jerky start.

CAUTION :

The clutch must be fully disengaged before attempting a gear shift. Failure to fully disengage the clutch may cause a jerky start and / OR stalling the engine besides causing damage to transmission parts.

z Press the gear

pedal with heel to engage 2nd and higher gear.

z Follow the same

procedure for 3rd, 4th and 5th gear.

NOTE :

Always start motorcycle with gear in neutral position.

Always move the motorcycle in first gear position only.

When engine speed decreases, while climbing a gradient or running at a reduced speed, shift to the appropriate lower gear to prevent the engine from stalling or straining to pull.

Parking

PARKING VEHICLE ON CENTER STAND

z Select a firm, flat surface z Hold handle bar straight z Lower center stand, and ensure that both the

legs of the stand are resting evenly on firm ground.

z Apply pressure on the fulcrum lever on the

center stand and pull vehicle backwards, gently.

PARKING VEHICLE ON SIDE STAND

z Select a firm, flat surface

z Lower Side Stand and gently tilt motorcycle to

the left till it rests firmly.

Warning

Always park the motor cycle on a firm and flat surface. Parking in a soft ground may cause stand to sink and the motorcycle to fall, causing injury to you or to others and damage to the motorcycle parts.

Tools & First Aid Kit

12 34 5 678 109

S.No. Description Qty.

1. Tool bag 1

2. Box spanner 21x24 1

3. Screwdriver 1

4. Double end spanner 1/4 x 5/16 1

5. Double end spanner 10x12 2

6. Tool- Spark plug 1

7. Tomy bar 1

8. Tubular spanner 12x13 1

9. Single end ring spanner - 17 1

10. Extension tube 1

S.No. Description Qty.

1. Antiseptic cream 5 gms 1

2. Gauze bandage 5 cm x 2 cm 1

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

4. Wash proof plaster 1.9 cm x 7.2 cm 2

5. Sterilized Gauze Swab 5 cm x 5 cm 2

6. Sterilized elastic plaster 7 cm x 6 cm 1

7. First aid kit pouch 1

NOTE :

This Tool Kit is kept in Utility box. Refer Page No. 27

Recommended Lubricants

Engine oil MOTUL 3000 4T Plus 15W50 API SL JASO MA (Royal Enfield Engine Oil)

Capacity 2.75 Litres

Front Fork 1F Grade Endurance (or Royal Enfield )Fork Oil

Capacity 195 ml / leg.

Brake Fluid DOT 3 or DOT 4

Capacity 60 ml.

Warning

DO NOT switch oil brands indiscriminately because some oil interact chemically when mixed. Use of inferior oils or nondetergent oils can damage the engine.

Periodical Maintenance

The maintenance schedule detailed here will help you to maintain your Royal Enfield motorcycle meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carried out.

The frequency of the maintenance must be shortened depending upon the severity of the driving condition OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water etc., Contact a nearest Royal Enfield Dealer for expert advice and to carry out the periodical maintenance.

Warning

For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the motorcycle to malfunction and stall abruptly resulting in an accident and cause serious injury.

Periodical Maintenance

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

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

2 Engine oil filter paper element R R R R R R

3 Engine suction filter & secondary drain magnetic plug

4 Spark plugs (2 nos.) 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 II

6 Fuel hose & clip/Injector ‘O’ Ring/ Seal Ring I I I I R I I I R I I

7 Fuel Pump (under tank) Check for screw tightness in all services

8 Accelerator & Throttle pully cable free play A A A A A AAAA AA

9 Rubber hose, Air filter to Throttle body I I I I R I I I R I I

10 Rubber hose, Inlet manifold / Adaptor I I I I R I I I R I I

DESCRIPTION

FREE SERVICE

whichever is earlier

Check level every 1000 Kms or earlier as required

PAID SERVICE

Periodical Maintenance

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

11 Air filter element C C C C R CCCR CC

12 Inlet / Exhaust valve seating I I

13 Cylinder head (Combustion chamber) D

14 Clutch lever free play Adjust every 1000 Kms or earlier as required

15 PAV pipes & hose clip I I I I I IIII II

16 Rear brake pedal pivot L L L L LLLLL LL

17 Battery terminals (apply petroleum jelly) C C C C C CCCC CC

18 Battery Electrolyte level I I I I I IIII II

19 Earth wire eyelet (behind battery carrier) I I

20 Rear Wheel Drive Chain

DESCRIPTION

FREE SERVICE

whichever is earlier

Adjust for every 1000 Kms / Clean, Lubricate & adjust

every 3000 kms or earlier as required

PAID SERVICE

Periodical Maintenance

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

21 Front Fork oil I R I R I

22 Rear brake pedal free play Adjust every 1000 Kms or earlier as required

23 Rear brake cam L L L L L

24 Steering ball races / play adjustment L L

25 Spokes tightness & Wheel rim run out I I I I I I

26 Swing Arm pivot bush & spacer L L L R L

27 Tyre wear (Front & Rear) I I I I IIII II

28 Hand levers & kick starter lever pivot Lubricate every 1000 Kms or earlier as

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

DESCRIPTION

FREE SERVICE

whichever is earlier

PAID SERVICE

NOTE :

For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultation with a Royal Enfield Dealer / Authorised Service Point.

Minor Maintenance Tips

The following minor maintenance can be carried out easily with simple tools. However, In case, if it is felt that the adjustments are best done by an expert, we recommend that the motorcycle be taken to a nearest Royal Enfield Dealer / Authorised Service Point.

CONTROL CABLES, HANDLE BAR LEVER, PIVOTS, CENTRE / SIDE STAND PIVOTS

Lever Pivot

z Lubricate after using the motorcycle in rain,

after waterwash or if used in dusty conditions.

z Wipe the area free of dirt / grease.

z Apply a few drops of oil on the pivots.

Main & Side Stand Pivot

OIL LEVEL INSPECTION

MAX

MIN

z Place motorcycle on its centre stand on a firm

surface.

z Warm up engine for a few minutes & switch off

z The level is correct if the oil level is in the

middle of the oil level window.

z Top up with recommended oil if required.

Minor Maintenance Tips

ENGINE - OIL CHANGE

Secondary Drain Plug

(Refer Periodical Maintenance Chart for frequency)

z Place motorcycle on its centre stand on a firm

flat surface.

z Start engine and warmup for 2 minutes.

z Keep a clean tray below the engine

z Remove primary drain cap, to drain oil & clean

suction filter, magnet.

z Then remove secondary drain plug to drain oil

& clean the magnet.

Primary Drain Cap

TILT VEHICLE

RH & LH

z Remove the oil filter element on the Crankcase

Cover RH.

z Allow the oil to drain by tilting the motorcycle

to both sides.

z Wash the drain plug and the suction filter

thoroughly and refit on the crankcase after all the oil is drained out.

z Soak a new oil filter element in the oil and refit

on the Crankcase Cover RH.

Minor Maintenance Tips

z Fill recommended

oil to engine till the oil level is upto “MAX” level mark in the oil window in Crankcase Cover RH.

SPARK PLUG

Max

NOTE :

Replace oil filter element whenever oil is being replaced.

Min

CAUTION :

Filling up oil over MAX mark may cause smoke and / or loss of power. Do NOT allow oil level to fall below MIN mark. Doing so may result in engine internal damage or malfuncton.

Cleaning and adjusting gap (Refer Periodical Maintenance Chart for frequency)

z Remove HT Lead and the spark plug from the

cylinder head using the plug spanner and tommy bar.

z Clean the insulator tip and electrodes of the

plug carefully using a pointed scraper or spark plug cleaner.

z Set the gap between 0.7 to 0.8 mm.

z Refit the spark plug on the cylinder head and

connect H.T. Lead.

Minor Maintenance Tips

BRAKE FLUID

MAX

MIN

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

CAUTION :

Please take care that it does not spill over any other parts of the motorcycle. Please wipe the spilled brake fluid immediately, if there is any spill over, using a soft cloth (preferably a wet cloth) to avoid damage to paint work or other parts.

INSPECTION OF TYRES AND WHEELS

z Inspect the tyre periodically for tread wear,

cracks and cuts.

Minimum tread depth :

Front tyre : 1mm Rear tyre : 2 mm

z Check and remove stone, splinters, nails or

other particles embedded in the tyre treads.

z Bald spots / swelling may be caused by internal

damage. Replace the tyres, if defective.

z Replace tyres when the tread depth has

reached the minimum as specified.

z Periodically inspect wheels for spokes

breakage and wheel rim run out.

z Check proper seating of the tyre beading on

the rim whenever the tyre is reassembled.

z Whenever a new tyre is installed, ensure rim

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

Minor Maintenance Tips

z Use only standard tyres & tubes inflated to

correct pressure.

TYRE PRESSURE

Front Rear

Frontt

Solo 1.41 kg/cm2 2.11 kg/cm2

(20 PSI) (30 PSI)

With Pillion 1.55 kg/cm2 2.25 kg/cm2

(22 PSI) (32 PSI)

Rear

Warning

Tyres, rims and air valves must be correctly matched to wheel rims. See your Royal Enfield Dealer. Mismatching tyre, tubes, rims and air valves may result in damage to the tyre bead during mounting, allow tyre slippage on the rim and cause tyre failure.

FRONT WHEEL REMOVAL

z Place the vehicle on center stand

z Place a wooden block the front end of engine

to support the vehicle.

z Disconnect speedo cable. z Loosen the pinch bolt on the RH fork guide. z Remove the axle nut along with washer. z Tap and remove the front wheel spindle

z Tilt the vehicle to RH Side and take out the

wheel along with speedo drive and RH side spacer.

Minor Maintenance Tips

z Take out Speedo drive and bush on the RH

side.

CAUTION :

Do not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper.

z Place a 4 mm thick wooden piece or cardboard

sheet between the brake pads to avoid pads activation in the event the front brake lever is accidently pressed.

FRONT WHEEL REASSEMBLY

z Remove the wooden piece / card board sheet

placed between the brake pads

z Place the speedo drive bush in position and

place speedo drive over it.

z Insert the wheel along with speedo drive and

RH spacer between the front fork ends ensuring the brake disc is located between the brake pads.

z Insert and tap the front wheel axle gently inside.

z Refit the washer and tighten the nut firmly.

Minor Maintenance Tips

z Tighten the pinch bolt on the RH fork guide.

z Rotate the wheel and check for smooth

rotation.

z Connect the speedo cable to speedo drive and

check for proper working of speedo meter.

z Press brake lever 2 or 3 times to check front

brake efficiency

NOTE :

Ensure that the speedo drive is correctly located such that the cable can be connected without difficulty.

REAR WHEEL REMOVAL

z Place the vehicle on

center stand on a firm and flat surface.

z Note and mark the

position of the chain adjuster butting with the stopper on the right side.

z Remove split pin and castle nut on the RH side.

z Remove wheel

spindle from LH side along with chain adjuster, taking care not to drop the wheel collar and spacer from the LH side of the wheel.

z Tilt vehicle to RH side and slide out rear wheel.

Minor Maintenance Tips

REAR WHEEL REASSEMBLY

z Ensure the four

cush rubbers are in position inside the rear wheel hub.

z Tilt vehicle to

right and insert wheel assembly between the swing arms.

z Position the rear wheel with cush rubber on the

rear chain sprocket.

z Hold wheel collar and spacer in position.

z Assemble the wheel spindle along with chain

adjuster from the LH side of vehicle and gently tap it through the wheel

z Ensure that the chain adjuster notch butts with

the stopper as appropriate when both the front & rear wheels are aligned.

z Tighten the castle nut firmly and ensure that

the hole on axle shaft and the slot on castle nut are aligned to enable split pin fitment.

z Fit the split

pin.

CAUTION :

Do not force the spindle into the wheel as the threads may get damaged. Tap it through the wheel gently.

Warning

Ensure the vehicle does not come off centre stand while assembling / disassembling the wheel assembly. Failure to adhere could result in damage or serious injury.

Minor Maintenance Tips

ADJUSTMENTS - CLUTCH

2 to 3 mm

Clutch Lever (free play 2 to 3 mm)

Clutch Free Play Adjustment

z Loosen the cable outer lock nut (A).

z Turn the Nut (B) Clockwise to reduce the play

or Anticlockwise to increase the free play.

z Check free play 2 to 3 mm at Clutch lever pivot

on handle bar end.

z Tighten lock nut ( A) after adjustment is done.

DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM)

z Remove rear wheel split pin.

z Loosen castle nut, spindle nut, anchor nut and

brake rod nut.

z Turn the RH adjuster cam as appropriately, till

25 to 30 mm slackness is achieved on the top run of the chain.

z Check that the front and rear wheels are

correctly aligned.

Minor Maintenance Tips

z Turn the LH adjuster cam appropriately, to align

both the wheels.

z Check and ensure that the notches on the cam

are resting on the pin in the swing arm on both sides.

z Apply brake and tighten all nuts.

z Finaly Torque the anchor Nut.

z Check brake pedal free play, If nessasary.

adjust.

REAR BRAKE PEDAL HEIGHT

z Loosen the lock nut.

z Turn in or out the pdeal stop pin bolt till the

brake pedal and front footrest are in the same height / level as shown in above fig.

z Tighten the lock nut

z Check for free rotation of rear wheel.

Minor Maintenance Tips

REAR BRAKE FREE PLAY ADJUSTMENT

20 - 30 mm

z Turn in or out the adjuster nut at the brake rod end.

The recommended brake pedal travel is 20-30 mm.

z Check that the brake is not binding and the rear

wheel rotates freely.

Warning

Please ensure brakes are adjusted to their maximum efficiency. Inefficient brakes can cause an accident.

Please ensure adequate caution while applying brakes. Sudden application OR pressing the levers fully can caused the wheels to lock. This may cause the motorcycle to skid with possible loss of control and result in an accident causing. Brake shoes must be inspected for wear every 4000 Kms. If you ride under adverse conditions, (steep hills, heavy traffic, etc.) a more frequent inspection at 1600 Kms or less, is required.

CHAIN LOCK FITMENT

The open end of the chain lock to face opposite to normal direction of chain rotation

Warning

The fitment in wrong direction can lead to falling off of chain link thus disengaging the drive. This will lead to potentially hazardous situation which, if not avoided, could result in serious injury.

Minor Maintenance Tips

ADJUSTMENT OF GAS SHOCKABSORBER

z The rear gas shock absorber is of adjustable type

i.e., the spring tension can be increased or reduced.

z Increase the spring tension for high load operation.

z Reduce the spring tension for low load operation.

z The adjuster provided on the bottom of the

spring has five notches.

z Insert 4 mm tommy bar into the eyelet provided

on the adjuster.

z Turn the adjuster such that the adjuster moves

up to increase the spring tension and vice versa to reduce the spring tension.

z Adjust both left hand and right hand shock

absorbers so that the same notch rests on the pin in both sides.

Warning

Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident.

Regularly inspect shock absorbers and front forks for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.

NOTE :

Ensure no fouling of any accessories with rear shock absorber. Check for sufficient gap availability between the shock absorber and the attachments when the rear end of the motorcycle is fully loaded and the shock absorbers are fully compressed.

Minor Maintenance Tips

REMOVAL OF BATTERY FROM THE VEHICLE

z Unlock (turn the key clockwise) and remove the

battery cover.

z Remove the battery holding two rubber straps

gently.

z Pull out the battery and turn, then disconnect

both the terminal wires (negative and positive respectively)

z Take out the battery.

BATTERY MAINTENANCE

z The vehicle is provided with 12V - 14 AH

battery.

z The battery must be periodically checked for

 Cleanliness and corrosion free terminals.  Electrolyte level.  If electrolyte level is low, top up with

distilled water only.

NOTE :

Incase of poor contact or loose fitment of Battery terminals may cause the failure of ECU.

Minor Maintenance Tips

Warning

Always disconnect the negative (-) battery cable first and then the Red positive (+) cable while removing the battery connections.

NOTE :

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

CAUTION :

z Do not use battery with low electrolyte level as

the battery internals will get damaged.

z Do not overfill the battery electrolyte level as it

will spill out through the overflow pipe and cause corrosion to vehicle parts.

z Use only distilled water meant for use in batteries

to avoid damage to battery.

z Electrolyte should be filled only between minimum

& maximum levels indicated in battery as “MIN” & “MAX”.

REASSEMBLY OF BATTERY ON VEHICLE

z Position the battery in the battery carrier such

that the negative terminal of the battery is towards fuel tap.

z Ensure ignitiion switch is in ‘OFF’ condition. z Connect the positive terminal (Red wire) first. z Connect the negative terminal (Black wire) last. z Smear the terminals with petroleum jelly. (Do

not use grease).

z Refit the rubber strap bracket to hold the

battery.

z Refit LH side panel.

NOTE :

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

CAUTION :

Connect the +ve and -ve cables to the respective battery terminals. Failure to do so may result in damage to the motorcycle electrical system.

Minor Maintenance Tips

CHANGING ELECTRICAL COMPONENTS HEADLAMP BULB REPLACEMENT

z Loosen the head lamp

holding top screw. Then pull out head lamp assembly.

z Detach bottom lug from

the head lamp housing body.

z Disconnect head lamp

wire connectors Green, orange and blue color terminals.

z Remove rubbergrommet

from the reflector assembly

z Gently press the bulb

holding U clip from both the sides downwards and release it from reflector slot as shown.

z Pull out head lamp bulb

and inspect its filament for fuse

AUTION :AUTION :

AUTION :

AUTION :AUTION :

Never touch the bulb with your fingers, Finger prints with etch the glass and decrease bulb life. Always grab the bulb with paper or clean dry cloth during handling.

Minor Maintenance Tips

REASSEMBLING THE HEADLAMP

z Refix the new head lamp

halogen bulb into reflector unit by locating the wide protrude on top side mounting.

z Fix bulb holding U clip

into reflector body knotch,then press the both ends of clip and lock in its slot.

z Fit the rubber grommet.

z Connect the wire couplers

as mentioned below

TOP SIDE: GREEN COLOUR RIGHT SIDE: BLUE COLOUR

LEFT SIDE:ORANGE COLOUR

z Position the reflector ring

bottom lug into head lamp casing slot and slide it, then tidhten the top mounting screw.

NONO

TE :TE :

TE :

NONO

TE :TE :

After connecting above said procedure,turn ignition switch to “ON” condition and then check,ensure that flash light working in HIGH BEAM mode.

Minor Maintenance Tips

TAIL LAMP BULB REPLACEMENT

z Remove the two nuts holding the rear number

plate of RH & LH side.

z Remove the three screws holding the tail lamp

to the bracket.

z Twist the bulb holder anticlockwise and remove. z Remove the old bulb and replace with a new bulb. z Refit the bulb holder and turn clockwise to lock

the bulb holder.

z Refit the tail lamp on the bracket and rear

number plate in the reverse order of removal.

TRAFFICATOR BULB REPLACEMENT

z Remove the 2

screws & take out trafficator glass cover.

z Press bulb gently & Turn anticlockwise to take

out the bulb.

z Position the new bulb inside the holder,

ensuring that the pins in the bulb, match with the slots in the holder.

z Press the bulb and turn clockwise to lock the

bulb in the holder.

z Refit the trafficator cover cut slot mark facing

downwards and tighten the 2 screws.

Minor Maintenance Tips

FUSE

ECU

123456

z Open the LH tool box z The fuse holder is located inside with 3 fuses

of 20 Amps each - One for Charging circuit, One for Other electrical loads and one for the EFI System.

z Replace the required fuse with the spare fuse

available in the fuse carrier.

Please ensure to replace a spare fuse in the holder at the earliest oppurtunity.

BLADE FUSE USAGE LIST

Fuse No.

1 Spare Fuse (20A)

2 Spare Fuse (20A)

3 Spare Fuse (20A)

4 Main Fuse (20A)

5 RR Unit Fuse (20A)

6 EFI Fuse (20A)

Remarks

Warning

Electronic Control Unit (ECU) may get failure due to

a. In case of loose electrical / sensors wire connectors /

couplers or Battery terminals.

b.While doing Arc welding on Motorcycle, its is

recommended to “SWITCH OFF” ignition, disconnect the Battery terminals & ECU from Main Wiring Harness.

Pillion Seat Removal & Refitting

PILLION (REAR) SEAT REMOVAL

(A)

(A) Loosen front

mounting nut of the rear seat under the rider seat with 12mm tubular spanner.

(B) Loosen both LH and

(B)

(C)

RH shock-absorber top mounting nuts by holding the bolt with 3/8” x 15/16” double end spanner and turning the doom nut with 17mm eyelet spanner

mounting bolt of the rear seat from the bracket under the rider’s seat.

(D) Pull the rear seat

(D)

(E)

with its sub frame towards back so that it will become free from the shock absorber mounting bolts.

(E) Take out the rear

seat sub assembly

(F) Re-tighten the

shock absorber mounting bolts & nuts before using the vehicle.

Pillion Seat Removal & Refitting

PILLION (REAR) SEAT REFITTING

(A) Loosen shock

(A)

(B)

(C)

absorber upper mounting nuts and place the pillion seat in the position over the rear mudguard, inserting the front end of its sub frame goes to its mounting under the rider’s seat.

(B) Ensure the slit of

rear mounting brackets are seated properly in the LH & RH shock absorber mounting bolts.

mounting bolt through the bracket under the rider seat.

(D) Tighten the front

(D)

mounting nut with 12mm tubular spanner holding the bolt with 13mm double end spanner from other side.

(E)

(E) Tighten both LH &

RH rear shock absorber top mounting bolt and nuts.

Washing Procedure

PRECAUTIONS

z Wash vehicle when the engine is cold.

z Cover the silencer tail end and control switches with

suitable plastic bags and tie it firmly to prevent water entry into them.

z Remove ignition key and seal key hole using

adhesive tape.

z Use a suitable engine degreaser, available with your

local parts store, to remove dirt or grease from the engine external parts if required. Follow the directions in the label carefully before using the degreaser.

z Use low pressure jet of water to clean the entire vehicle. z Never spray water with great force on head lamp,

speedometer, flasher lights, front and rear wheel hubs, electrical connections and wires, control cables, EFI components, sparkplug, battery, etc.

z Use luke warm water and mild detergent on the

painted components to remove dirt, etc.

z Rinse vehicle thoroughly with plain water to remove

the detergent and wipe vehicle dry.

z If possible, use compressed air and blow off water

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

AFTER WASHING

z Ensure, the vehicle is throughly dry by wiping with

a clean soft absorbent cloth or chamois leather.

z Remove all plastic bags and adhesive tapes. z Lubricate control cables, pivot and rear chain with

lube oil

z Polish the painted and plated surfaces using

polishing wax.

z Start engine and allow to run at idling speed for a

few minutes to warm up engine.

z Drive the motorcycle slowly, applying both brakes

intermittently to dry up the brake shoes.

z Test brakes for full efficiency.

Warning

Observe warnings and cautions given on labels of cleaning compounds.

When washing your motorcycle, be careful not to get the brakes, engine, mufflers or air cleaner etc., too wet. Wet brake shoe and / or drum can affect braking. Engine can be started after washing. Ensure brakes and engine are operating properly before riding in traffic.

Storage Precautions

Incase your Motorcycle is not going to be used for a month or more, we advice the following precautions to the taken.

z Carryout required repair / adjustments on the

motorcycle.

z Wash the motorcycle thoroughly and lubricate

as per the maintenance chart.

z Start the engine, warm up for a few minutes

and switch off.

z Drain out the fuel completely from the fuel tank

and fuel lines.

z Remove spark plug. Pour in about 30ml of

clean engine oil through spark plug hole. Close the hole and crank engine several times and refit sparkplug.

z Clean rear chain thoroughly and apply a thin

film of lub oil.

z Remove battery from the bike. Clean the

terminals free of corrosion.

z Maintain electrolyte level between max or min

mark, by adding distilled water and wipe the battery dry.

z Store the battery in a cool, dry and well

ventilated place.

z Do not place the battery in direct sun light, near

open flame or where temperature is above 40 or below 0

z Cover the silencer with plastic bags to prevent

moisture entry. Set the motorcycle on its center stand.

z Apply anti rust solution on all chrome plated

parts. Take care not to apply this solution on

rubber or painted parts.

z Store motorcycle in a clean covered area free

- of moisture and keep it covered to prevent dust settling on it.

Storage Precautions

PREPARING THE MOTORCYCLE FOR REUSE

z Remove anti rust solution from all chrome

plated parts and clean the motorcycle.

z Inflate the tyres to the correct tyre pressure.

z Ensure battery is fully charged and proper

electrolyte level is maintained.

z Connect the battery.

z Lubricate all control cables and pivots.

z Check proper level of oil in engine.

z Fill fuel tank with fresh petrol.

z Check fuel line for any cracks or cuts.

z Clean the air filter.

z Remove plastic covering from the silencer.

z Remove spark plug on cylinder head and pour

in a few drops of engine oil. Crank engine a few times to lubricate cylinder walls and piston. Clean spark plug and refit.

z Switch on ignition switch.

z Start vehicle and warm up engine for a few

minutes before riding the vehicle.

NOTE :

Do not raise the engine rpm the moment it is started, but allow the engine to run at idling speed.

CAUTION :

Proper long-term storage is important for the safe, trouble-free operation of your Royal Enfield motorcycle.

Long Trip Precautions

CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY

z Service the motorcycle throughly at Royal

Enfield Dealer / Authorised Service Point as per periodical maintenance chart. (Ref. Page No. 43, 44 & 45)

z Sufficient quantity of petrol in the fuel tank for

the journey planned.

z Check and correct tyre pressure if necessary.

CHECKS AFTER EVERY 1500 KMS OF RUN

z Tightness of all fasteners.

z Tyre tread condition and wear of tyres.

z Battery condition and electrolyte level.

z Correct oil level in engine.

z Working of all lights and horn.

z Proper drive chain tension.

ITEMS TO BE CARRIED

z Tools kit.

z First aid kit.

z Bulbs for Headlight, Trafficator light, Rear Tail

Lamp and Blade Fuse (20 Amps).

z Accelerator, Choke, Clutch and Speedo Cable.

z Rear chain master link lock assembly.

z Spare tube, tyre, puncture repair kit - cold

vulcanising type.

z Foot operated Air Pump.

z Insulation tape.

z Spark plugs (M14 & M10), Fuel hose.

Complete Wiring Diagram

NOTE :

Complete Wiring Diagram is attached along with this page.

VEHICLE STARTING PROCEDURE

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

1. When ignition key is switched “ON”, please wait until the malfunction indicator lamp(MIL) goes off, (EFI models only) before attempting to start.

2. In cold condition of the engine or for initial start, it is advised to use electric start (ES) only.

3. Apply choke in cold start condition. (ambient temperature <25°C)

4. DO NOT ATTEMPT – “HALF START” BY CASUALLY PRESSING ELECTRIC START BUTTON.

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

6. If engine doesn’t start in the first attempt, release the ES button and repeat the above procedure.

7. It is advised not to apply excessive throttle during starting.

Trouble Shooting

Warning

The trouble shooting section of this Owner’s Manual is intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before performing any work. Repair and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield Dealer only. Improper repair and/or maintenance could result in the motorcycle not functioning properly or serious injury.

Warning

Electronic Control Unit (ECU) may get failure due to

a. In case of loose electrical / sensors wire

connectors / couplers or Battery terminals.

b. While doing Arc welding on Motorcycle, its is

recommended to “SWITCH OFF” ignition, disconnect the Battery terminals & ECU from Main Wiring Harness.

CAUSES REMEDIES

I. ENGINE FAILS TO START

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

2) Vent hole clogged in fuel tank cap ... Clean vent hole.

3) Spark plug cap / lead not connected Fix cap / lead firmly

4) Spark plug electrode dirty / fouled ... Clean spark plug

5) Spark plug insulation cracked .......... Replace spark plug

6) Clutch slipping ................................... * Adjust clutch cable free play

* Contact Dealer / Authorised Service Point

Trouble Shooting

CAUSES REMEDIES

II. ENGINE MISFIRING

1) Water in petrol tank ........................... * Clean petrol tank. Fill tank with fresh petrol.

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

3) Spark plug fouled .............................. Clean spark plug or non specified heat range plug.

4) Any sensor loose connections.......... * Check MAP or TPS sensor wiring/coupler loose connections

III. POOR PICKUP

1) Accelerator cable free play excessive Adjust cable free play

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

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

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

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

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

* Contact Dealer / Authorised Service Point

Trouble Shooting

CAUSES REMEDIES

IV. WHITE/BLUE SMOKE

1) Oil level in sump above the Top line. * Check and drain excess oil

in the oil level window ....................... * Worn out valve stem, oil seal

V. ENGINE OVERHEATING

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

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

3) Low engine oil level ........................... Check and top-up if necessary

VI. EXCESSIVE FUEL CONSUMPTION

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

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

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

* Contact Dealer / Authorised Service Point

Trouble Shooting

CAUSES REMEDIES

VII. BRAKES POOR

1) Not adjusted properly ........................ * Adjust properly

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

3) Linings worn / Uneven wear ............. * Replace linings

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

VIII. VEHICLE WOBBLES

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

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

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

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

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

* Contact Dealer / Authorised Service Point

Trouble Shooting

CAUSES REMEDIES

IX. ELECTRICALS

Bulbs do not light

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

2) Bulb fused .......................................... * Replace bulb

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

Horn not working

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

Trafficators not working

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

2) Bulb fused .......................................... Replace

Brake light remains on

(1) Switch link not adjusted properly ..... * Adjust connecting links properly

(2) Switch sticky ...................................... * Replace switch

X. ELECTRONIC FUEL INJECTION (EFI)

Malfunctioning Indicator Lamp (MIL) glowing continuously

(1) Sensor Coupler Loose Connection .. * Check for any EFI sensor coupler loose connection and correct them

(2) Any EFI Sensor Failure ....................... * Check & replace the same

* Contact Dealer / Authorised Service Point

Warranty

Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material and workmanship.

Royal Enfield (RE) warrants Classic 500 EFI Motor Cycle to be free from manufacturing and material defect under normal use subject to following conditions.

1. RE will replace or repair defective part / parts at their Dealers, Authorised Service Point, free of charge

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

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

3. The warranty shall be applicable only if all the free services are availed at the respective period / kilometer

range as per the schedule given in the owner’s manual from RE Dealers/ Authorised Service Points.

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

or parts of the vehicle, which on examination to have manufacturing defect. Such defective part / parts which have been replaced become property of RE.

5. Cost of oil, oil filter, fuel and other consumables are chargeable to the customer.

6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken up with respective

manufacturer or their authorised agents in the area directly by customer. RE shall not be liable in any manner to replace them though their Dealers will provide assistance in preferring such claims on their manufacturer.

7. Warranty shall not apply to:

(a) Normal ageing, detoriation or rusting of plated parts paints coat, rubber parts, soft items, glass items,

plastic parts etc.

Warranty

(b) Components like fuel filter, oil filter element, control cables, brake shoes, clutch plates, which are subjected

to normal wear and tear.

(d) Damages due to use of non-genuine parts.

(e) Damages due to lack of proper maintenance of the vehicle.

(f) Damages due to incorrect driving or riding habits.

(g) Parts damaged due to accidents, collision, abuse etc.

(h) Irregularities not recognized as affecting the quality or function of the vehicle such as slight vibration, oil

leakage, blue discoloration of exhaust bent pipe / silencer / soft or hard shock absorber etc.

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

(j) Vehicle serviced / repaired at unauthorised service points.

(k) Vehicle used for competition / racing.

(l) Electrical component likes bulbs, fuses etc. & Electronic components failure due to repairs by arc welding.

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

other such adjustments

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

9. RE reserves the right to make changes in Design of the vehicle without any obligation to install these changes on previously supplied vehicles.

Emission Warranty

In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal Enfield certifies that the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its range of motorcycles, in normal use to which it may be subjected to.

This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000 Kms. or 36 months, whichever occurs earlier, from the date of sale to the first customer and is in addition to and parallel to the warranty policy, conditions and obligations laid down in the Owner’s Manual.

Royal Enfield further warranty that if on examination by its Authorised Service Point, the motorcycle fail to meet the specified emission standards, then the Authorised Service Point shall take necessary corrective measures and shall at its sole discretion, repair or replace free of charge such components of the emission control system to meet the required emission standards.

The method/s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfield and / or our Authorised Service Points and results of such examination will be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royal enfield will have the right to charge all, or part of the cost of such examination to the customer in addition to the cost of the components.

In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge, the component/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeable to the customer as per actuals.

In case any of the components covered under emission warranty or the associated parts, are not independently replaceable, Royal Enfield will have the sole discretion to replace either the entire assembly or parts of the assembly, through suitable repairs.

Emission Warranty

Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace any part, in addition to the repair or replacement of the components covered under emission warranty, to establish compliance to in-use emission standards. Such repairs / replacements will be chargeable to the customer.

All parts removed for replacement under warranty will become the property of Royal Enfield. Royal Enfield will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised

Service Point OR for any loss due to non availability of the motorcycle during the period of examination and repairs by Royal Enfield and / or their Authorised Service Points.

Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on account of failure to comply with the in-use emission standards.

That cost/s incurred to check emission of the motorcycle will have to be borne by the customer. Emission warranty will be applicable irrespective of the change of ownership of the vehicle provided all the

conditions as laid down in this document are met from the date of original sale of the motorcycle.

THE WARRANTY SHALL APPLY IF THE CUSTOMER

z Observes all the important instructions and any other precautions listed in the owner’s manual. z Under all circumstances uses lubricants and fuel as recommended by Royal Enfield. z Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the

details in the Log book.

z Immediately approaches the nearest Authorised Service Point upon discovery of failure to comply with the

IN-USE emission standard inspite of having maintained and used the vehicle in accordance with the instructions in the owner’s manual and having carried out such repairs and adjustments as may be required with a view to establish such compliance.

Emission Warranty

O Produce the ‘Pollution Under Control’ certificate valid for the period immediately preceding the test during

which the failure is discovered, the test having been carried out either for obtaining a new certificate or pursuant upon being directed by an officer as referred to in sub rule (2) of rule 116 of the Central Motor Vehicles Rules (CMVR).

O Produce the Owner’s Manual and Log book for verification details. O Produce receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date of

original purchase of the vehicle.

O Produce valid certificate of Insurance and R T O registration certificate.

THE EMISSION WARRANTY SHALL NOT APPLY IF

O A valid “Pollution under control” certificate is not produced. O The motorcycle is not serviced by Authorised Service Points as per the service schedule described in the

maintenance chart.

O The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met

with an accident.

O Replacement parts not specified and approved by Royal Enfield have been used. O The motorcycle, or parts thereof, has been altered, tampered with or modified or replaced in an unauthorised

manner.

O The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, so

that the actual distance covered cannot be readily determined.

O The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records.

Emission Warranty

O On examination by Royal Enfield or its Authorised Service Points, if the motorcycle shows that any of the

conditions stipulated in the Owner’s manual with regard to use and maintenance have been violated.

O The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by Royal

Enfield in the Owner’s manual or any other document given to the customer at the time of sale of the motorcycle.

O The emission related components are tampered with. O All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced. O All maintenance activities carried out on the vehicle during the tenure of the emission warranty is not entered

in the log book.

TIPS TO BE ON THE RIGHT SIDE OF LAW

O Always get your vehicle checked to meet the emission regulations through and authorised emission checking centre. O Always carry a valid ‘Pollution Under Control’ certificate with you at all times during the validity of the emission

warranty (30,000 Kms / 3 years from the date of first sale)

TIPS TO REDUCE POLLUTION

1. Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal Enfield Authorised Service Point.

2. Use only Unleaded petrol (> 91 octane) from reputed fuel pumps.

3. Ensure the fuel used is not adulterated.

4. Use correct spark plug as recommended in the owner’s manual.

5. Use lubricants as per recommendations given on grade / brand in the owner’s manual.

Free Service Coupons

It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide four free services at specific Intervals.

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

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

The cost of fuel, oil, oil filter element, grease etc. used for free service is chargeable to the customer.

1st Free Service

1 FREE SERVICE

500 Kms or 45+8 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

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

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

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:

Serviced Date:

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

1st Free Service Activities

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

2. Electrolyte ....................................................... Check level & top-up

3. Battery terminals ............................................. Clean and apply petroleum jelly

4. Drive chain free play ........................................ Check, clean, lubricate & adjust

5. Rear brake pedal pivot..................................... Lubricate

6. Rear brake....................................................... Adjust

7. Wheel rim ........................................................ Check spokes tightness

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

9. Front fork oil .................................................... Check level & top up

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

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

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

13. Fuel pump........................................................ Check mounting screws

14. Fuel hose......................................................... Inspect for cracks

15. Rubber hose, Air filter to throttle body.............. Inspect for cracks

16. Accelerator cable ............................................ Adjust play

17. Clutch cable..................................................... Adjust play

18. Engine oil sump strainer .................................. Clean

19. Engine oil ........................................................ Replace

20. Engine oil filter paper element ......................... Replace

21. Hand levers & kick starter pivot........................ Lubricate

CUSTOMER COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

ASP / Dealer’s

Stamp & Signature

2nd Free Service

2 FREE SERVICE

3000 Kms or 90+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

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

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

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:

Serviced Date:

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

2nd Free Service Activities

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

2. Electrolyte ...................................................... Check level & top-up

3. Battery terminals ............................................ Clean and apply petroleum jelly

4. Drive chain free play ....................................... Check, clean, lubricate & adjust

5. Rear brake pedal pivot .................................... Lubricate

6. Rear brake ...................................................... Adjust

7. Wheel rim ....................................................... Check spokes tightness

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

9. Front fork oil .................................................... Check level & top up

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

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

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

13. Fuel pump......................................................... Check

14. Fuel hose ........................................................ Inspect for cracks

15. Rubber hose, Air filter to throttle body.............. Inspect for cracks

16. Accelerator....................................................... Check & adjust play

17. Clutch cable .................................................... Adjust play

18. Steering free play ............................................ Check & Adjust

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

20. Hand levers & kick starter pivot ....................... Lubricate

CUSTOMER COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

ASP / Dealer’s

Stamp & Signature

3rd Free Service

3 FREE SERVICE

6000 Kms or 180+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

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

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

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:

Serviced Date:

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

3rd Free Service Activities

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

2. Electrolyte ...................................................... Check level & top-up

3. Battery terminals ............................................. Clean and apply petroleum jelly

4. Drive chain free play ....................................... Check, clean, lubricate & adjust

5. Rear brake pedal pivot .................................... Lubricate

6. Rear brake....................................................... Cam clean, lubricate & Adjust play

7. Wheel rims ...................................................... Check spokes tightness

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

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

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

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

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

13. Fuel pump ....................................................... Check

14. Fuel hose ....................................................... Inspect for cracks

15. Rubber hose, Air filter to throttle body ............. Inspect for cracks

16. Accelerator / TPS / Carb. cable ....................... Check & adjust play

17. Clutch cable .................................................... Adjust play

18. Engine oil sump strainer .................................. Clean

19. Engine oil ........................................................ Replace

20. Engine oil filter paper element ......................... Replace

21. Hand levers & kick starter pivot ....................... Lubricate

22. PAV System ................................................... Check & Clean

CUSTOMER COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

ASP / Dealer’s

Stamp & Signature

4th Free Service

4 FREE SERVICE

9000 Kms or 270+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

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

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

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:

Serviced Date:

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

4th Free Service Activities

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

2. Electrolyte ....................................................... Check level & top-up

3. Battery terminals ............................................ Clean and apply petroleum jelly

4. Drive chain free play ....................................... Check, clean, lubricate & adjust

5. Rear brake pedal pivot .................................... Lubricate

6. Rear brake / cam ............................................. Lubricate & Adjust

7. Wheel rim ....................................................... Check spokes tightness

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

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

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

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

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

13. Fuel pump ....................................................... Check

14. Fuel hose ........................................................ Inspect for cracks

15. Rubber hose, Air filter to throttle body ............ Inspect for cracks

16. Accelerator / TPS / Carb. cable ....................... Check & adjust play

17. Clutch cable .................................................... Adjust play

18. Engine oil ....................................................... Check & top-up

19. Hand levers & kick starter pivot ....................... Lubricate

20. Steering free play ............................................ Check & Adjust

21. Tyres................................................................ Check wear and tread depth

CUSTOMER COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

ASP / Dealer’s

Stamp & Signature

Paid Service / Maintenance Record

CUSTOMER COPY

12,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

15,000 + 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 :

Dealer’s Stamp & Signature

DEALER / ASP COPY

15,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

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

CUSTOMER COPY

12,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

15,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

CUSTOMER COPY

18,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

21,000 + 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 :

Dealer’s Stamp & Signature

DEALER / ASP COPY

21,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

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

CUSTOMER COPY

18,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

21,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

CUSTOMER COPY

24,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

27,000 + 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 :

Dealer’s Stamp & Signature

DEALER / ASP COPY

27,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

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

CUSTOMER COPY

24,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

27,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

CUSTOMER COPY

30,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

33,000 + 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 :

Dealer’s Stamp & Signature

DEALER / ASP COPY

33,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

Paid Service / Maintenance Record

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

CUSTOMER COPY

30,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

CUSTOMER COPY

33,000 + 250 Kms. Service

Brief Work Done :

Dealer’s Stamp & Signature

Royal Enfield Classic 500 2011 Owner's manual

Specifications and Main Features

Frequently Asked Questions

User Manual