Royal Enfield Himalayan ls 410 Service Manual

PREFACE

·FIRST

Royal

TIME

Enfield

techniques to

free

nuai

Engine,

this

ma

performance

will

of the

trouble

This

ma
reassembly
cooler

Wh

ile

improvements

from the

Please
suggestions

With

actual

do

warm

feel

or f eedback.

regards

RIGHT"

nuai

is

a very important element for

is

committed to upgradethe skills

ensure

in a simple

"FIRST

at

all

help

in

complete understanding of

new

range

and

is

updated

being

parts

with latest Information

done

to

fitted

in

free to write to

TIME

RIGHT"

times.

of

Royal

scientific

improve

the

engine.

us

at

Enfield,

manner.

performance,

customerseryjce@royaleafield,com.

and

practices

systematic

LS

410Single

and

enhancing

Customer

knowledge

and

carry

out

procedures

Cylinder, 4 Stroke,

Specifications,

some

of the

of

technicians
repairs

at

data,

illustrations

Satisfaction.

so

that they follow scientific repair

accurately

for dismantling,

Overhead

the time of

going

etc.,

if

you

have

so

that

inspection,

Cam,

to print,

in

any

customers

Air

due

this

manual

queries,

will enjoy

diagnosis

Cooled

with

to

continuous

may

clarification,

and

Oil

differ

SERVICE

Royal

HEAD

Enfield,
Thiruvottiyur
Phone:
E-mail:
Website:

"©

shall
remains

044 ­[e-mail]

www.royalenfield.com

Copyright

be

copied,

the

QUARTERS

A Unit of

High

Road,

4223

0400,

2017

Royal

distributed

sole

owner of this

Eicher

Motors Limited,

Thiruvottiyur,

Fax:

044 -

Enfield

or

otherwise dealt without the

manual

42011719

(A

Unit

."

Chennai

Eicher

- 600

Motors

019.

Limited).

express

Ali

Rights

permission

Reserved.

in

written

No

part of this

from

1 PartNo:

the

Service

Royal

Manual

Enfield

/Oct.

who

'17

ROYAL ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

1

01

CONTENTS

SL.NO.

1.

Engine

2.

Technical

3.

Exploded

4.

Gear

5.

Oil

DESCRIPTION

Views

LH & RH

Specifications .................................... 4

Views

Operating

Circulation

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

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

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

Positions -LS

410

PG.NO.

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

17

19

SL.NO.

12.

Wear

13.

Torque

14.

Precautions

15.

Trouble

DESCRIPTION

Limits -

LS

410

......................................... 66

Values-

Shooting ...........................................

LS

Before

410

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

Engine

Reassembly

PG.NO.

67

.........

69

117

6.

Periodical

7.

Servicing / Overhauling

8.

Components

9.

10.

11.

Special

Importance

Engine

Engine

Tools

From

Dismantling

Maintenance

Dismantling

Usage

List

Notice

Before

Frame

Procedure

Chart -LS

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

Sequence

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

Dismantling .......... 24

410

............ 20

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

Sequence

......

21

22

23

25

02

1 ROYAL ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

ENGINE

VIEWS

LH &

RH

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

03

TECHNICAL SPECIFICATIONS

ENGINE&

A.

ENGINE

1

Type
Bore

2

Stroke

3

Displacement

4
5

Compression
Max

6
7

Max

8

ldleRPM
9 Starting
10

Air

11

Lubrication

Engine

complete

12

Engine
Subsequent refills)

Engine

13

14

Cooling

B.

TRANSMISSION

1

Clutch
Primary

2
3

Primary
Gear

4

Gear

st

1

nd

2

5

rd

3

th

4

th

5
Secondary

6
7

Secondary

C.

FUEL

1

Fuel

D.

IGNITION

1 Ignition

Spark

2

Spark

3

E.

ELECTRICALS

System

1

ENGINE

Power@
Torque @ RPM

filter element

oil

tank

Engine

oil

tank capacity(Routine

oil

grade

drive

ratio
box
Ratios

Gear

Gear

Gear

Gear

Gear

drive

ratio

Advance
plug
plug

gap

SYSTEMS

LS410

Single

Cylinder, 4 Stroke

ratio 9.5:1
RPM

24.5

BHP(18.02

1250

Forced

capacity

st

(1

Dry

fill/

fill

after

Overhaul)

Oil

change/

SAE

15W

Forced

5

5/8"

Digital

/ Ignition

System

5 - 30° /

Electronic

SOHC.
78mm
86mm

411

cc

Kw@

32

Nm@4000

± 50

RPM @ EOT

Electric

Paper

element

Lubrication,

2.3

litres

2.0

litres

50

API

SL

Grade

Air

Cooled

Wet,

Multiplate
Gear

2.312:

Speed

Constant

2.916

1.833:1

1.428:1

1.173:1

1:000:1

Chain & Sprocket

533:1

2.

Petrol

Spark

Ignition -

Ignition,

Bosch-

UR5CC

0.7to0.8mm

12V-

DC

Air

Start

with

1

:1

2 Generation Alternator

Alternator Output

3

170W @ 1500

cooled,

6500

RPM

RPM

80

deg

Wet

Sump

JASO

MA

Oil

Cooler

Mesh

TCI

System

ECU/Variable

RPM

Fuel

2

Injection

04

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

EXPLODED VIEWS

CYLINDER

2

HEAD

2---f1

COYER

ASSEMBLY

,s--rr

9

S.NO.

1
2

3

4

5

6

7

8
9

Cover • Tappet
Hex

Flange

Boit-MG X 21

'0'

Ring -Camshaft
Plug -Camshaft
Hex

Flange

Boit -

Hex

Flange

Boit -

Hex

Flange

Boit -

Gasket

Washer -6.2 X 14

Cover -Tappet

DESCRIPTION

lnlet

Hole

Hole

MG X 16
MG X 55

MG X 60

X 1

Exhaust

S.NO.

10

11

12

13

14
15
16
17
18

ROYAL

0'

Ring -Tappet

Hex

Flange

Boit·
Nut -Tappet
Screws
Arm
Shaft
Copper
Plug -Rocker
Hex

Tappet

comp

valve

Valve

Washer

Flange

Boit-

ENFIELD I EURO

DESCRIPTION

MG

X 40

Adjusting

Adjusting

Rocker

Rocker

Arm

Shaft

MG X 45

IV • SERVICE

MANUAL

lS

410 1

0$

CYLINDER

HEAD

ASSEMBLY

S.NO.

Cylinder

1

Hollow

2

Seat

3
4
5

6
7
8
9

10

11

12

06

I ROYAL ENFIELD I EURO

Valve

Seal

Valve

Seal

Valve
Spring
Spring

Retainer
Cotter
Spark

Boit

Cylinder

Washer

DESCRIPTION

Head & Cover

Dowel

(0D 9

Spring

Stem

-lntake

Stem • Exhaust

Valve

lnner

Valve

Outer

Valve

Spring

Valve

Plug

Head

Cyl

Head

Box

X12),

MlO X 170

Boit

IV·

SERVICE

Assembly

Cover

cylinder

MANUAL

LS

410

S.NO.

13

14
15
16
17

18
19
20
21
22
23

Cover-

Cam

(enter

Hex

Flange

Boit -MG X 16

Hex

Flange

Boit -MG

Valve

Exhaust

Valve

lnlet
NutMSXl.25
Stud

Exhaust
Damper
Damper
Damper
Damper

Pad -Cylinder
Pad
Pad • Cylinder

Pad

DESCRIPTION

X 30

Head

RH -Cylinder

Head

LH • Cylinder

Front

Head

Back

Head

CYLINDER

BARREL & PISTON

ASSEMBLY

Al

4

S.NO.

1
2
3
4

s

5

6

~

Gasket -Cylinder
Hollow
Hex
Gasket -Cylinder
Pin

Dowel

Flange

Piston

DESCRIPTION

Head

(0D

13X18) -Cylinder

Nut -MG

X

Barrel

MLS

1.

Cylinder

7

8
9

Barrel

Barrel

S.NO.

6

7

8
9
10

Circlip -Piston
Ring -Piston
Ring -Piston
Ring -Piston
Damper

Pads

DESCRIPTION

Pin

1st

2nd

oil

Cylinder

barrel

ROYAL

ENFIELO I EURO

IV·

SERVICE

MANUAL

LS

410 1

07

CAM

CHAIN

1

5

ASSEMBLY

12

B

S.NO.

1

Pin,

2

Pin

Arm,

3

4

Spring,

5

Cam
Pin,

6

7

'C'

Lock

8

9 Boit -

Contrai

Assy

Shaft

Camshaft

Ring,

Arm

Decomp

Decompression

Contrai

Assy

Sprocket

Camshaft

Washer,

M6 X 12,

Camshaft

DESCRIPTION

Pivot

Contrai

Arm

Sprocket

Camshaft

Sprocket

S.NO.

10

11

12

13

14

15
16
17
18

f

18

17

Sprocket­Cam
Guide
Tensioner
Gasket -Chain
Auto
Hex.
Boit
Washer-

cam

Chain

pad

Pad

Chain

Socket

Stepped

6 X

Tensioner

Head.

18 X 1,

DESCRIPTION

shaft

Tensioner

Assy

Cap

Screw,

M6 X 14,

Cam

Cam

chain

M6 X 25

Chain

Tensioner

Tensioner

Boit

08

I ROYAL ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

CRANKTRAIN

S.NO.

1

2

3

4

5

6

7

Crank

Shaft

Washer

Washer

Hex

10.5 X 28 X 2.5,

Belleville,

Flange

Boit·

Sprocket -Oil

Chain

oil

pump

Sprocket -Oil

DESCRIPTION

with

Balancer

Crank

MlO

X 20

pump

Driven

pump

Drive

Shaft

Crank

Balancer

Balancer

Assembly

Lock

S.NO.

8

9

10

ROYAL

DESCRIPTION

Nut-

LH·

M18,

Oil

Pump

Washer,

Oil

Pump

Washer-22X4X1.5,
Thrust

ENFIELD I EURO

IV -

Drive

sprocket

Primary

SERVICE

Gear

Lock

Drive

MANUAL

Gear

LS

410 1

09

E-START

SYSTEM

7

Al

9

1

S.NO.

Al

1

2

3

4

5

10

1

ROYAL

Starter

Gear,

Spacer

Gear,

Shaft

Shaft

Clutch

Starter ldle

-ldler

Starter ldle

Starter ldle

Starter ldle

ENFIELD I EURO

DESCRIPTION

Assernbly

No.2

Gear

No.1

(Double

Gear

No.2

Gear

No.1

IV -

SERVICE

Gear)

MANUAL

LS

410

S.NO.

G

7

8

9

·o·

Ring

Starter Motor

Starter Motor

Hex

Flange

Boit -

Hex

Soc.

Head

DESCRIPTION

Assy

MG

X 30

Screw-

MG

X 20

COVERLH

7~

6

Al

~

S.NO.

Al

Magneto

DESCRIPTION

Assembly

3

S.NO.

7

Hex

Socket

DESCRIPTION

Head

Screw

MS X 15

1

CoverLH

2 Hollow

Hex

3

4

5

G

Flange

Copper

Plug,

Oil

Hex

Socket

Dowel -0D13 X 18,

Boit

MG X 35

Washer,

Check-

Head

Oil

Check

M14 X 12

Screw

MS

Cover

Plug

X 30

LH

8

9

10

11

12

13

Clamp

Hex

ORing

Cover

Hex

Gasket.

ROYAL

Starter

Flange

Boit

Crankshaft

Socket

Head

Cover

ENFIELD I EURO

Wire

MG X SS

(enter

Screw

LH

IV·

SERVICE

MG X 14

MANUAL

LS

410 1

11

CRANKCASE

20

21

•

LH

rJ,n

,>À./

17

19

22

24

{b

A2

Al

S.NO.

Al
A2
1
2

3
4
5

6
7

8

9
10

11

12

13

14
15
16
17

18

19

Magneto
Starter
Hex
Key
Hex
Hex

Terminal

Pin,
Spring,
Oil
Hex
Plug
Copper
Cover,
0-Ring,

Strainer

Hex

Gasket

Hex
Jet
0-Ring -4 X

Assemblv

Clutch

Flange

Woodruff
Soc.

Head

Flange

Gear

Gear

Position

Gear

Seal,

Gear

Flange

M14 X 12,

Washer

Strainer

Oil

Corno.

Flange

Washer -8.2 X 16

Soc.

Head

Corno,

DESCRIPTION

Assembly

Nut-

M12 X 1.25P

Screw -MG X 20

Bolt-M6X16

Position

Position

Shift

Shaft

Boit -

MG X 20,

Oil

Drain

Drain

Strainer

Boit

Starter

Cover

Ene:ine

MS X 12.

Screw -MG X 12

Clutch

1.2,

Oil

Jet

Gear

Switch

Pin

olug

Oil

Oil

X

Oil

X ll(W),

Position

Oil

Strainer

Gallerv

1.

Oil

Magneto

Switch

Gallerv

Cover

Boit

S.NO.

20
21
22
23
24
25
26
27

28
29
30
31
32
33
34
35
36
37
38
39

Jet

Corno,
Bearine:
Bearine:
Stud

MG X 37,
Hollow
Bearine:
Oil

Seal.
0-Rine:.
Soacer,

Sorocket
Tab

Washer

Nut

M20,
Retainer,
Boit

MG X 10,

Sorocket

Hex

Flane:e

Hex

Flane:e

Hex

Flange

Hex

Flange

Hex

Flange

DESCRIPTION

Piston

Oil
(#6204),Crank
(#6203LU),COUNTER

Cylinder

Dowel -Od13 X 18,

(#6305LU).

Drive

Shaft

Soacer

Engine

Ene:ine

Sorocket

Comp -Final

M20,

Engine

Drive

Shaft

Drive

Cover

Boit -MG X 35
Boit -MS
Boit­Boit­Boit -MG X 85

Barrel

Drive

Sorocket

Drive

Engine

Sorocket

Oil

Shaft

X 100

MS X 70

MG

X 60

Balancer

Crankcase

shaft

Ene:ine

Sorocket

Seal

Oil

Seal

SHAFT.LH

Lh

LH

15T

(#525)

Lock

Retainer

12

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

CRANKCASE

RH

17

n,.....-18

:!...,-19

S.NO.

1
2
3
4
5

6

7

8
9

10

11

12

DESCRIPTION

Circlip

Oil

Pump
Washer
Hex
Pump

8 X

Flanged

Assy,

16 X 0.5

Boit -

Oil
Gasket
Stopper,

Gear

Shift
Bearing-#16005,
Hex

socket

head
Retainer,
Circlip
Washer
Spacer

Counter

17 X 1,

Kick

-17 X 28 X 1,

Drive

Shaft

Shaft

Oil

pump

sprocket

MG X 30

Arm

Gear

Shift

Drum

screw -MG X 12

Shaft

Bearing

ldle

Gear.

Kick

ldle

Gear

RH

Thrust

S.NO.

13

14
15
16
17

18

19
20
21

22

23

24

ROYAL

DESCRIPTION

Hollow
Bearing
Bearing -6203,
Bearing- 6306,

Dowel

-6304,

(Od13X18},

Counter

Drive

Crankshaft
Bearing -6204,Crank
Oiljet

1.2,

Oil

0-Ring- 4 X
Copper
Plug

Washer

oil

check
Sprocket -Oil
Chain

oil

pump

Sprocket -Oil

ENFIELD I EURO

Jet

Drain
M14
pump

pump

IV -

SERVICE

Cover-RH

Shaft

Shaft

Balancer

plug

Drive

Driven

MANUAL

RH
RH

RH

LS

410 1

l3

COVERRH

S.NO.

1

Caver

2

Hex
Hollow

3
4 OilFilter

Spring

5

0
Cap
Hex
Hex
Bracket,
Hex
0

ROYAL

Ring

Ring

6

7

8
9

10

11

12

14 1

RH

Assembly

Flanged

Oil

Flange
Flanged

Dowel

Oil

Filter

Oil

Filter

Filter

Boit

(0D13X18),

Boit -

Boit

Clutch

Flange

Boit -

Oil

Filler

ENFIELD I EURO

DESCRIPTION

MG

X 1 X

30

Caver-RH

MG X 70

MG

X 1 X 20

Release

MG X 37

IV -

SERVICE

MANUAL

LS

410

S.NO.

13
14
15
16
17
18
19
20
21
22
23
24

PlugOil
Seal

Clutch
Washer
Spring
Hex

flange

Shaft

Clutch
Gasket
Hex

Socket

Plate

Retainer

Oil

Seal

Jet,

Crank

Lens

Oil

DESCRIPTION

Filler

Release

Clutch

Release

Clutch

Release

boit

MG

Caver

RH

Head

Crankshaft

Shaft

Level

Check

X 7

Screw

RH

RH

MG X 12

CLUTCH

2

14

6

,~

/ '

,,.

>

7

8

13

S.NO.

1 Friction

2

Plate
Wheel

3
4 Thrust

Housing

5
6 Belleville
7

Plain
Hub

8
9

10

Clutch
Compression
Holder

Plate

Clutch

Clutch

Washer

Assembly

Spring

Washer

With

Clutch

DESCRIPTION

(Jadder

(Jadder

Ring

Spring

spring)

washer)

17

S.NO.

11

12

13

14

15
16

ROYAL

HexBoltMG

Washer,

Nut
Bearing
Bearing
Pin,

Clutch

M20 -Clutch

Cup
17X35X10

Clutch

ENFIELD I EURO

DESCRIPTION

Sleeve

Sleeve

Release

IV -

SERVICE

Hub

Hub

Lock

MANUAL

LS

410 1 15

TRANSMISSION

B

,,,\

37

36

35

38

S.NO.

1
2
3
4
5
6

7

8
9

10

11

12

13

14
15
16
17

18

19

20
21

DESCRIPTION

Washer
Bush,
Gear,
Washer
Gear,
Circlip
Washer,
Bush.
Gear,
Washer,

Washer,3rd
Gear,
Wheel.

Bush,
Gear,
Shaft
Gear,
Gear,
Washer -25 X 34 X 1,
Gear,
Bush,

-17 X 28 X 1,

1st

Driven

1st

Driven

-20 X 30 X

5th

Driven

25 X 1.2,

3rd

& 4th

3rd

& 4th

4th

Driven

thrust

& 4th

3rd

Driven

Sliding

2nd

Driven

2nd

Driven

Comp,

Drive

2nd

Driven

3rd

& 4th

5th

Drive

5th

Drive

Gear

5th

Drive

Driven

Driven

Washer

Driven

Dog

Gear

Drive

Gear

Drive

1,

1st

5th

Shaft

Driven

Gear

Gear

Gear

Lock

Gear

Drive

thrust

Gear

thrust

Gear

thrust

thrust

S.NO.

22
23
24
25
26

27

28
29
30
31
32

33
34
35
36
37
38
39
40
41

Shaft

Corno,
Spacer
Fork,
Shaft,
Fork,
Fork,
Cam
Star
Steooed
Boit
Arm
Washer
Soring,
Circlip-14
Washer
Shim,
Spring,
Shaft
Plate,
Spring,

primary drive

Gear

Gear
Gear
Gear

Comp,

Index,

Steooed,

Stopper

-6 X

Gear

14 X 25

Gear

Gear

Corno.

Gear

Gear

DESCRIPTION

Counter

Shift

Shift
Shift
Shift

Gear

Gear

Boit

Hex

Gear

Comp,
18 X 1,
Shift

X

1.

Gear

X 0.8,

Shift

Shift
Gear

Shift

Shift

No.1

Fork
No.2
No.3

Shift

Shift

Soc.

Shift

Gear

Tensioner

Cam

Shift

Gear

Shaft

Shaft
Shift

Cam

Drive

Cam

Cam

Hd , Star

Cam

Shift

Stoooer

Shaft

Shift

Return

Drive

Index

Stoooer

Cam

Boit

Shaft

Plate

Thrust

16 1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

OILCOOLER

7

8

S.NO.

1

Copper

2 Boit -

Pipe

3

4

Hexagonal

Washer

Union

Comp

DESCRIPTION

Crankcase

Engine

Oil

Nut

MG

No

1

7

S.NO.

5

G

7

8

~@

1

0

Ring

OilCooler

Hex.Socket
Pipe

Oil

Comp

~

Coole

Head

Engine

'

DESCRIPTION

Cap

Screw

MG X 25

Oil

No

2

ROYAL

ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410 1 17

GEAR OPERATING POSITIONS - LS

1STGEAR

1

Drive

Shaft

2NDGEAR

Gears

~11

Sth

114th

113rd

Œ!J~~~~

1

Counter

1

~

Drive

1

Sth

Shaft

Shaft

114th

Gears

Gears

113rd

l l

2ndl

l l

2ndl

1

1

I

410

...--------.

.........._ _ ____.

Final

Driv

Sprocket

3RDGEAR

18 1 ROYAL ENFIELD I EURO

IV·

SERVICE

MANUAL

Œ!J~~~~

I

Counter

1
~1Sthll4thll3rdll2ndl

Drive

Shaft

Shaft

Gears

Gears

Œ!J~~~~

1

LS

Counter

410

Shaft

Gears

I

1

...--------.

~-~

1

4THGEAR

STHGEAR

1

Drive

Shaft

Gears

~11

Sth

114th

113rd

Qill~§J~~

1

Counter

1

ŒIJ

Drive

I

Sth

Shaft

Shaft

114th

Gears

Gears

113rd

l l

l l

2ndl

2ndl

I

Final

Sprocket

1

I

Final

Sprocket

Driv

Driv

Qill~§J~~

1

Counter

Shaft

Gears

ROYAL

1

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1 19

OIL CIRCULATION

LHVIEW

ENGINE-OIL

Oil

Strainer

FLOW

screen

RHVIEW

Oil

Pump

Oil

Oil

Filter

Gallery

20

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ROYAL

ENFIELD I EURO

OIUET

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• •

SUMP

IV •

SERVICE

1

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LS

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PRES5UR\E

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COYBt~

RELIEF

PERIODICAL MAINTENANCE CHART - LS

The

Periodical maintenance

which

lntervals at

Himalayan

your

If

in

case

the motorcycle

stagnant water

regular

motorcycle meticulously

etc.,

the

schedule

inspections.

is

used

frequently

maintenance

detailed below

adjustments.

in

very dusty environment /

will

need

ta

is

based

replacements

be

done

earlier

upon

average

and

lubrications

as

may

riding conditions

must

severe

be

climatic conditions /

required.

be

carried

410

and

indicates the

out ta help maintain

Poor

Roads

/

Contact
any

expert

S.

No.

1

Engine

2

Oil
Engine

3

4 lnlet /

Rubber

5

6

Oil
Spark

7

a nearest

Filter

cooler inlet & outlet

Royal

advice.

Oil

(Level

Element

oil strainer

Exhaust

hase.

plug

Enfield

DESCRIPTION

check/

on

Tappet

lnlet manifold • 1 1

Authorised

Dealer / Service

Kms(xl000)

Months

Replace)

crankcase

setting

pipes

LH

• 1 1 1

Center

Whichever

0.5

1.5

ta carry out the periodical

FREE

SERVICE

is

earlier

10

12

15

18

5

6

maintenance

PAID

SERVICE

20

Whichever

25

30

35

is

earlier

40

45

24 30 36 42 48 54

and

R 1 R 1 R 1 R 1 R 1 R

eckl

~velé

teVE

rylO

0OK

nsor

earli

~ras

Cl

equi

R R R R R R

C

l&A l&A

C&A

C C

l&A

R

C&A R C&A

C&A

l&A

1

R

l&A l&A

1

R

1 1

C&A

C C

l&A

l&A

1

R

1 1

R

R

C&A

l&A

l&A

1

R

R

C&A R C&A

for

50
60

ed

C

l&A

R

1

8 Accelerator

9

Clutch

10

Cam

Chain/

lnlet /

11

A :

Adjust

•

Refer

Service

#

Check

every time after

For

maintenance after 50,000

Enfield Authorised Dealer/

Cable

Plates

Chain

Exhaust

Ma

nuai.

Pads

valve

C :

vehicle

/ Auto

seating

Clean

Kms

Service

chain

(compression

is

used

for off

.•

please

Center.

Tensioner

test) •

1 :

road

repeat

lnspect

riding

same

1

1

R

1

R

R

1 1 1 1 1 1

L : Lubricate R : Replace

frequency specified

ROYAL

ENFIELD I EURO

above.

1

R 1 R

1

R R

1 1 1

1

1 1

in

consultation with a

IV •

SERVICE

MANUAL

LS

Royal

410 1

R

l&R

21

SERVICING / OVERHAULING
WITHOUT

DISMANTLING

ENGINE

FRAME

POSSIBL~

FROM

• lnlet &

• Auto
chain.

•

Cylinder

•

Cylinder

•

Clutch

•

Oil

•

Gears

•

Magneto

• Starter

• Starter Motor

•

Gear

•

Final

Exhaust

Chain

pads

assembly

pump

operating

Clutch

position

Drive

Tappet

Tensioner.

Head

assembly

Barrel,

Piston&Rings

assembly

mechanism/

Stator/

Assembly

replacement

sensor

sprocket.

Rotor

switch •

adjustments
Cam

shaft

gear

shift

Assembly

SERVICING / OVERHAULING

WHICH
FROM

•

ENGINE

FRAME

Crankcases

HAS

opening

TO

BE

REMOVED

assembly.

shaft

oil

FOR

Cam

seals

•

Crank

shaft /
Shaft / Gears / Gear
Drum.

•

Crank

case

22

1

ROYAL

ENFIELD I EURO

Balancer

bearings.

Shaft / Main

Operator

IV •

SERVICE

Shaft / Counter

forks / Gear

MANUAL

LS

Selector

410

COMPONENTS DISMANTLING SEQUENCE

COMPONENTS

1

Skid

Plate

on

Engine

oil

(Drain

oil

strainer

cover

RH

Oil

Cooler a long

Fuel

hose & Pulse

Battery

connections

TPS/Magneto/Gear position/

couplers

!

Starter

Spark

disrnantle

rnotor

plugsuppressor

DISMANTLING

Frame

bottorn.(Hirnalayan

when

warrn.

Rernove

on

crankcase

with inlet & outlet

Air

valve

connections

LH & Oil

pipes.

connections

Side

+

cap

SEQUENCE

rnodels)

drain

filter

on

stand

switch:

plug
Cover

TO

/

REMOVE

Rear

Chain

FD

sprocket

CoverRH

Oil

purnp

gears / Oil

Crank

shaft

1

Balancer

1

Clutch

Gear
on

shaft

center

shift

shaft

shift shaft

ENGINE

(Rernove

nut (loosen)

purnp

Nut

(LEFT

Boit

nut &

Clutch

assernbly

frorn

LH

FROM

frorn

FD

sprocket)

HAND

THREADED)

+

+

assernbly

(Rernove

crankcase

FRAME

circlip & washer

side

first)

1

Engine

steady

bracket

1

Contrai

(ables

(Clutch / Accelerator)

1

Exhaust

1 Gearshiftlinkage

1

Starter

1

CoverLH

1

Gear

Magneto

Starter

pipe & Silencer

rnotor

position indicator

rotor

assernbly

idler

gears

sensor

includingStarter

with

bush & spindles

clutch

1

Carn

shaft

1

Autornatic

1

Carn

shaft

1

Cylinder

1

Chain

Tensioner

1

Cylmder

Cradle
rnounting

Cradle

Rear

top

frorn

bottorn suitably)

Four

rnounting

covers / Cylinder

chain

tensioner

gear & carn

Head

Sub

Assernbly

Pads

Barrel

Sub

frame top rnountings (with connecter)

to

frame

frame

bottorn

head

shaft

Assernbly

Assernbly

rnounting

cover

LH&

RH

on

frame

-1-

engine

rnounting

studs

of

Engine

on

frame

to

(support

cradle

engine

frame

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410

1

23

SPECIAL TOOLS USAGE LIST

Part

No.

Description

Photo

Usage

purpose

ST-27527-2

ST-27528-2

ST-27529-2

ST-27530-2

ST-27531-2

Tappet

Valve

Spring

Piston

Support

Magneto

Clutch

Locking

Adjusting

Compressor

Plate

Rotor

Puller

Plate

Tool

To

adjust

For

removal

valves

To

support

Tappets

from

of lnlet/

cylinder

Piston

Clearance

Exhaust

head

during
assembly / Dismantling
cylinder
installation of

To
from

To

barrel

remove

Magneto

Crankshaft

compress

& for removal/

circlips

in

piston

rotor

Clutch

springs

during dismantling/assembly

clutch

of

plates

ST-27532-2

ST-27533-2

ST-27534-2

24

1

ROYAL

Piston

Circlip

Crank

Gears

Magneto

sprocket

ENFIELD I EURO

Installer

locking

rotor &

locking

IV •

SERVICE

FD

Tool

Tool

MANUAL

LS

410

For

To

Iock

installing

Piston

Crankshaft

pin

/Clutch
for removing/ tightening
Crankshaft / clutch

To

Iock

Magneto

sprocket for

nut

rotor/FD

removing

tightening nut.

circlips

gear

IMPORTANT

1.

Engine

oil

should

always

2.

Ensure

oil

cooler

pipes

3.

Ensure piston is
compression

•

Remove
visually
magneto rotor
reference

•

If

the
caver­&rotate magneto rotor nut

CLOCKWISE

reference
with the

stroke:

inspection

check

if

the timing

mark

on

marks

are

crankshaft centerfromcover

direction,

mark

on

mark

on

NOTES

are

boit

is

aligned with the

caver

not aligned, remove

magneto

caver

BEFORE

be

drained

dismantled

at

TDC

on

caver

mark

LH.

ONLY

till

rotor

LH.

on

the

aligns

when

on

LH

the

LH

IN

"+"

from

to

DISMANTLING

the

engine

engine

is

and

warm

Oil

cooler

and

before

is

removed

ENGINE

engine

is

dismantled

from

the

FROM

from the

frame.

FRAME

frame

..

4.

Remove

5.

Remove

connection

6.

Slide
lifting

7.

Remove

8.

Remove

9.

Remove

10.

Disconnect
throttle position switch,

11.

Remove

12.

Remove

13.

Remove

14.

Remove

15.

Remove
supporting the

pillion & rider

fuel tank mounting fasteners at the

coupler to wiring

fuel

tank

up

or

while sliding

side

panel
pulse
exhaust

ail

engine

gear

shift
clutch & accelerator
rear

chain.

the bolts & studs mounting

seat

towards

air

electrical

engine

the

towards

RH,

Remove

valve

-inlet & outlet

pipe & silencer.

connections&

gear

steady

plate from cylinder

linkage

at the bottom.

harness.

rear

and

gently

the

rear.

the battery holding

pipe

position

from

gear

shaft

cable

connections

pull

connections

couplers:

indicator,

head

on

frame

cradle

frame to

rear

out

fuel

spark
side

&frame

from

end,

tank

strap,

from

plug

stand

LH

side

engine.

main

Lift

up

tank slightly

from

frame.

Disconnect

inlet manifold

suppressor

switch&

frame at the front,

battery

earth

Take

care

and

cap,

magneto,

terminais.

and

disconnect fuel level

not to

damage

connections.

cylinder

head.

pulsar

coil.

rear

& bottom after suitably

fuel

tank while

E start

sensor

motor,

16.

Remove

the

bolts &

nuts

mounting

engine

to

cradle

frame.

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

lS

410 1 25

ENGINE DISMANTLING SEQUENCE

S.

No.

1.

Aggregate

Oil

cooler

• Remove
Banjo union bolts from
LH&
respectively & allow oil

to

• Ensure

are
pipes/

to

Assemble/

Instructions

lnlet

& Outlet

RH

Crankcase

drain.

the

4 washers

removed from the oil

banjo Union

Boit

Union:

Socket

Fastener,

M17

Spanner:23mm

Size,

NOTE:

Ensure

Oil

cooler mounting

bolts are removed from

frame bracket before

removing oil cooler.

Tool

Usage,

Precautions.

Photos

Remove

•
with inlet & outlet pipes.

2.

Oil

drain

• Remove hex plug
copper washer from oil
strainer housing on
crankcase

3.

Oil

strainer

• Remove 2 hex flange
bolts from strainer
cover.

• Remove cover
ring.

oil cooler along

plug

LH.

with

with

Hex

Plug:

M14 X 12

Socket

Spanner:

CAUTION:

Dispose drained oil
through
recycling agency to prevent
environment pollution.

Hex
Hex

an

flange

Socket: 8 mm

·o·

21

authorized

boit:

M6

mm

only

X 20

26

1

ROYAL

• Pull

out

gently from crankcase

ENFIELD I EURO

the

strainer

IV • SERVICE

MANUAL

LS

410

S.

Aggregate

No.

4.

Oil

Filter

• Remove 1 long Hex
flange
bottom

to

Instructions

boit

of

Assemble/

from

the

il filter

cover.

Fastener,

Hex

flange

boit:

Hex

socket:

8mm

CAUTION:

Remove bolts
slowly since cover
loaded.

evently

Size,

M6 X 70

is

spring

Tool

&

Usage,

Precautions,

Photos

• Remove 2 Hex flange
bolts from the top
oil filter cover.

• Gently pull out

filter element.

of

the oil

of

the

Ensure
from cover.

Hex
Hex

·o·

flange

socket:

ring

is

bolts:

8mm

removed

M6 X 20

NOTE:

The

filter

element

in

cover

RH.

on

the inside

due

tight
rubber
the element seating
spout.

seal

will

to

on

be

the

of

the

5. Starter motor

• Remove 2 Hex flange
bolts from
side.

Crankcase

Hex

flange

boit:

Socket

RH

spanner:

NOTE:

Ensure Earth

disconnected from the Hex

flange boit.

M6 X 30

8mm

terminal

is

ROYAL

ENFIELD I EURO

IV -SERVICE

MANUAL

LS

410 1

27

S.

Aggregate

No.

5.

Starter motor

• Gently pull out starter
mot
crankcase

6.

Sprocketcover

•

Remove
bolts, holding sprocket
caver

•

Remove

to

Instructions

or

from the spigot

to

crankcase

caver.

Assemble/

in

LH&

remove.

2 hex flange

LH.

Hex

flange

Socket

Fastener,

boit:

Spanner-

Size,

M6 X 35

8mm

Tool

Usage,

Precautions,

Photos

7.

8.

28

Cover

crankshaft

center

•

Remove
head

caver

Remove

•

CoverLH

•

Remove

flange bolts from the
rear

1

ROYAL

ENFIELO I EURO

2 hex socket

screws, from the

crankshaft center

caver.

3 long hex

side

of

caver

IV -

LH.

SERVICE

Hex

socket
M6X14
Allen

Key:

MS

NOTE:

Remove

caver

Hex
3Nos.
Hex
SNos.
Socket

·o·

LH.

flange
flange

Spanner-

NOTE:

Ensure

the

Magneto & Gear
position
are

removing

MANUAL

sensor

disconnected before

caver

LS

410

hd.

ring

boit:
boit:

wire

screw:

if

stuck to

M6 X 55:
M6 X

8mm

couplers

LH

35:

S.

No.

8.

Aggregate

to

Assemble/

Instructions

CoverLH

Remove 8 short hex

•

flange bolts from
front

& center

LH.

Gently tapon the tabs in

•

LH

caver

-

Statorfrom
magneto

From

-

dowel
bottom
crankcase

ta

release:

the

atthe

of

rotor

locating

of

LH.

the

caver

.

Fastener.

Size.

Tool

Usage.

Precautions.

Photos

9.

Remove

•

Final

gasket.

drive

sprocket

nut:

Straighten locking tab

•

overhex U nut. using a
suitable chisel.

Locate special tool

•

sprocket & remove hex
"U" nut.

Remove Iock washer &

•

sprocket.

on

FD

Special
ST-27534-2,
Rotor & FD

locking

Hex
Hex

Tool-

Tool

"U"

Nut:

Socket:

Magneto

sprocket

M20

32mm

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

29

S.

No.

10.

Aggregate

Instructions

Gear

position

indicator

to

Assemble/

Hex
Hex

Fastener,

flange

Socket:

boit:

8mm

Size,

M6 X 16

Tool

Usage.

Precautions.

Photos

• Remove 2 hex flange
bolts.

• Gentlyrotate &pull out

from

crankcase

•

Rem

ove

the pin & spring

from counter shaft.

11.

Starter

• Remove 2 bushes from

• Remove idle gear

klle

idle gear spindles.

(middle).

LH.

gears

NOTE:

Ensure
along
indicator.

·o·

with

ring

is

removed

gear position

30

• Remove double gear
(top).

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

Aggregate to Assemble/

No.

11.

12.

Instructions

Starter ldle gears

•

Remove

Magneto

Locatethe special

•

on 3 hex socket head
screws inside magneto
rotor
rotating while loosening
hex nut.

Remove

•

magneto
ing special

threaded portion

rotor.

the 2 spindles.

Rotor

ta

prevent

nut

rotor

it

& locate

remov-

tool

on the

of

tool

from

the

Special

Tool-ST-27534-2,
Magneto
sprocket

Hex

nut:

Hex

Socket:

Special

Tool:

Magneto

Fastener,

rotor & FD

locking

M15

Tool

X

18mm

ST-2753O-2,

Rotor

Puller

Size,

Tool

Usage,

Precautions,

Photos

Tighten center

•

remove magneto rotor,
along with starter clutch
assembly from

LH

boit

shaft.

ta

NOTE:

Ensure
threaded
damage
center. ta prevent

NOTE:

Ensure
removed from

special tool

on

the magneto

ta

the rotor.rotor

woodruff

LH

is

fully

key is

shaft.

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410

1

]1

S.

No.

13.

Aggregate

to

Instructions

Starter

Clutch

Assembly

•

Gently

rotate outer

anticlockwise

from starter clutch.

Assemble/

gear

&

remove

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

14. Starter

Clutch

Assembly

• Remove 6 hex socket
head

screws

magneto rotor

15.

remove
with starter clutch.

•

Remove
from outer

CoverRH

•

Remove 2 Hex

bolts holding clutch
bracket to

outer

from

inside

and

ring

along

starter clutch

ring.

flange

cover

RH

Hex

socket

M6X20

Allen

Key:

Hex

flange

Hex

flange

Hex

Socket:

hd

MS

boit:
boit:

8mm

screw:

M6 X 30
M6 X

37

]2

1

ROYAL

ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

15.

Cover

• Removesmall Hexflange
boit
from front

to

Instructions

RH

(f

ully

Assemble/

threaded)

of

cover

RH.

Fastener,

Hex flange boit:
Hex Socket: 8mm

MS

Size,

X

20

Tool

Usage,

Precautions,

Photos

• Remove balance

flange bolts.

• Gently
release

the
crankcase
simultaneously
activating
leverto

tap

cover

the

same

locating dowels on

RH

the

rem

ove cover

11

Hex

to

from

while

clutch

RH

Hex

flange

bolts:

Hex

Socket:

NOTE:

Ensure
does
removing Cover

8mm

the clutch push

not

fall

M6 X 37

off

while

RH

pad

:

'

~

. '

,.

··_,

1

'

.,

. -

.~.

._

~

-

.

..

"

•

•

..

:r

•

C

-~

,c

• Remove

gasket.

RH

cover

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1 33

S.

Aggregate

No.

16.

Jet-Crankshaft.

to

Instructions

CoverRH:

• Remove

head screw with retainer
plate.

• Removeoilseal&jetfrom
caver

RH.

Assemble/

hex

socket

Hex

socket
M6X12
Allen

Fastener,

hd

key:

MS

Size,

screw:

Tool

Usage,

Precautions,

Photos

17.

Oil

jet

in

crankcase

RH

• Gently pull out the
located in the oil gallery
nearthe oil pump gear in
Crankcase

18.

Balancer

• Locate special
between
gear & clutch housing
gear at
Iock crankshaft.

• Loosen & remove
Flanged hex boit

• Removebig&smallblack

thrust washers.

shaft

the

Oil

RH.

boit

tool

crankshaft

bottom

Jet

to

the

Special
Crank

Gears

Hex

flange

Hex

Socket:

Tool-

locking

boit:

14mm

ST-27533-2,

Tool

M10

X 20

34

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

19.

Crank

• Locate special
between crankshaft
gear
gear at
Iock crankshaft.

• Loosen hex
rotating

WISE.

• Remove small
washer.

to

Instructions

shaft

& clutch housing

the

& remove.

20. Cutch Nut

•

Remove
with

clutch bearing

collar.

Assemble/

nut

tool

bottom

it

·noCK·

nut

thrust

to

by

Fastener,

Special
Crank

Tool:

Gears

ST-27533-2,

locking

CAUTION:

LH

thread nut. Loosen by

rotating

Nut

LH

Hex

thread:

Socket:

M18

24mm

Size,

Tool

Tool

Usage,

Precautions,

Photos

• Locate special
between clutch gear &

crank shaft gear at the
bottom
housing.

Loosen

•

ta

Iock clutch

hex nut.

tool

Special
Crank

Tool:

Gears

locking

Hexnut:M20
Hex

Socket:

27mm

ST-27533-2,

Tool

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1 35

S.

No.

21.

Aggregate

Instructions

Oil

pump

&

chain

•
pump

•

Remove

•

Remove
alongwith the
on
&chain

assembly

Remove

shaft.

crankshaft

to

Assemble/

sprodœt

circlip

thrust

pump

on

washer

sprocket

small

assembly

oil

gear

Fastener.

Size.

Tool

Usage.

Precautions.

Photos

22.

Oil

pump

•

Remove
bolts holding
remove

•

Remove

assembly

4 hex flange

oil

pump

pump.

pump

gasket.

&

Hex
Hex

flange

Socket:

bolts:

8mm

M6 X 30

36

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

23.

Clutch

• Remove splined washer
from clutch main shaft.

to

Instructions

Assemble/

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

24.

Remove

•

from clutch housing

autch

Remove 2 hex screwsat

•

diagonally opposite
ends
holding plate.

Position special

•

over clutch holding plate
such that the mounting
hales
aligned with the 2 hales
on

Assemble 2

•

screws over
&tighten till the special
tool rests
clutch holding plate.

Loosen & remove the 4

•

hex screws from
clutch holding plate.

Loosen

•

slowly & remove special
tool.

clutch assembly

plates

of

the

of

the

clutch holding plate.

long

the

firmly

the

2 screws

clutch

tool

tool

MG

tool

on the

the

is

Hex

Screw:

Hex

Socket:

Special
Clutch

M6 X

10mm

tool:

ST-27531-2,

locking

10

plate

ROYAL

ENFIELD I EURO

IV -SERVICE

MANUAL

LS

410 1

37

S.

No.

Aggregate

Instructions

to

Assemble/

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

24. autch

• Remove clutch holding

• Remove clutch hub

• Remove

plates

and

plate

along

with

plates.

pressure plates, steel
plates, Belleville & steel
washers.

the 6 springs.

the

clutch

the

clutch

38

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

S.

No.

25.

Aggregate

Instructions

autch

•

•

housing

Remove
main

shaft.

Remove

with

bush

shaft.

to

Assemble/

washer from

clutch

housing

from main

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

26.

27.

Crank

•

•

Gear

•

shaft

Remove

Remove

bush.

Remove
blackened
gear shift shaft on
side.

thrust

splined

Shift Shaft

circlip
washer

Gear

washer.

gear

and

from

LH

&

1

Outside

CAUTION:

Gear
are

on

shift shaft

removed

not

removed

LH

side.

cirdip

if

circlip

plier

cannot

&washer

from

be

shaft

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

39

S.

Aggregate

No.

27.

Gear

• Removecirclipfromgear
shift shaft

•

Remove

&

to

Instructions

Shift

washer.

gear

selector.

Assemble/

Shaft

on

RH

side.

spring

Fastener.

Size,

Tool

Usage.

Precautions.

Photos

28.

•

Remove

spring & washer.

with

Gear

Star

stopper

•

Remove
holding
Crankcase.

gear

shift lever

Index

stepped boit

arm

stopper to

Stepped
Hex

Socket:

Boit:

10mm

MS

40

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

to

Assemble/

Instructions

28. Gear Star Index

stopper

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Remove arm
along
spring

with

stopper

washer &

29. Gear Star Index

• Remove

Socket Head
holding
selector drum.

• Remove star index

stepped

star

index

hex

boit,

to

Hex
Allen

socket

key:

Hd

MS

screw:

0

M6

30.

Drive

• Remove circlip on drive

•

shaft

shaft.
Remove

spacer

& 2

st

1

nd

Spacer

thrust

washer,

thrust

washer.

I

Outside

Circlip

Player

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1 41

S.

Aggregate

No.

31.

Auto chain

tensioner

to

Assemble/

Instructions

Hex
Hex

Fastener,

flange
Socket:

boit:

12mm

MS

Size,

Tool

Usage,

Precautions,

Photos

• Remove hex
spring from the center

auto chain
body.

• Remove 2 hex socket
head screws
pull

out

tensioner assembly.

•

Remove

boit

tensioner

&gently

auto chain

gasket.

with

of

CAUTION:

Open

slowly &carefully sino

spring loaded boit.

NOTE:

Ensure

from housing.

Hex
M6X2S
Allen

·o·

Socket

Key:

ring

Hd

MS

is

screw:

removed

32. lnlet manifold

• Remove 2 hex socket
head screws.

• Remove inlet manifold

with "O" ring

42

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

Hex
M6X25

Allen

MANUAL

Socket

key:

LS

410

HdScrew:

MS

S.

Aggregate

No.

33.

Cover-

• Remove 2 hex flange
bolts & remove cover

34.

Plug

to

Instructions

cam

-

camshaft

Hole

•

Remove

hex flange boit.

Assemble/

Center

Hex
Hex

Hex
Hex

Fastener,

flange

Socket:

flange

Socket:

bolts:

8mm

boit:

8mm

Size,

M6 X

M6 X

16

16

Tool

Usage,

Precautions.

Photos

• Rotate plug clock-

wise gently.
ATTEMPT
plug forcefully from the
cylinder

head

DO

to

cover.

NOT

remove

35. Tappet cover inlet

• Remove 2 hex flange
bolts & remove cover
withOring.

NOTE:

The plug will

cylinder

Do

not attempt to remove

before loosening all the

cylinder

Hex

flange

Hex

Socket:

head

head

bolts:

be

tight

caver.

cover bolts.

M6X21

8mm

in

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

43

S.

No.

Aggregate

Instructions

to Assemble/

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

36. Tappet caver

exhaust

• Remove 2 hex flange
bolts

& remove cover

withOring.

37.

Plugs

• Loosen 2hex socket

38.

Cylinder

• Remove 2

rocker

head plugs from cylinder
head cover
not remove plugs fully)

RH

head

RH

bolts

side.

flange
aluminum washers from
the top

shafts

side.(Do

cover

long

with

hex

Hex

flange

bolts:

M6X21

Hex

Hex
Allen

Hex
Hex

Socket:

Socket

flange

Socket:

key:

8mm

plug:

MS

boit:

8mm

M14 X 12

M6 X

60

NOTE:

Aluminum washers are

to

provided
through the bolts.

prevent oil leak

44

• Remove 3 long hex
flange bolts from the top

LH

side

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

Hex
Hex

MANUAL

flange

Socket:

LS

410

boit:

8mm

M6 X

60

S.

Aggregate

No.

38.

Cylinder

• Remove 3 medium Hex
flange bolts from the
side.

to

Instructions

head

Assemble/

cover

LH

Fastener,

Hex

boit:

MGX55Hex

Socket:Smm

Size,

Tool

Usage,

Precautions,

Photos

• Remove 2
flange
side.

• Remove 2 fully threaded
Hex flange
inlet & Exhaust tappets
opening.

39.

Plug

bolts

camshaft

long

from

bolts

hole

Hex

RH

from

Hex
Hex
Hex

Hex
Hex

flange
flange

Socket:

boit:

MGXlG

Socket:

boit:

boit:

8mm

8mm

MG X 40

MG

X 45

EX

IN

• Remove small

caver.

cam

shaft

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

45

S.

No.

40.

Aggregate

Instructions

Cylinder

to

Assemble/

head

cover

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

41.

• Remove
caver by gently tapping
on the

Rocker

cylinder

pegs

Shaft

screws

• Remove the 2 hex socket
plug screws (Loosened
earlier) with their copper
washers
cylinder head caver.

42.

Shaft-Rockeranns

• Locate 2

MS

hex screws into the
rocker
pull out the shafts.

shaft

provided.

Plug

from

long

suitable

threads &

head

the

Hex
Hex

flange
Socket:

bolts:

10mm

MS

43.

Rocker

• Remove inlet & exhaust

rocker arms.

46

1 ROYAL ENFIELD I EURO

anns

IV·

SERVICE

MANUAL

LS

410

S.

No.

44.

45.

Aggregate

Instructions

Spark

•

cam

plug

Rem

ove

cylinder

shaft

to

Assemble/

spark

plug

head.

assembly

from

Spark
Deep

Fastener,

plug

M10

Hex

Socket

Size,

16mm

Tool

Usage,

Precautions,

Photos

• Rotate
that the hait
will corne
cylinder

•

Removethe

• Rotate
necessary
hex

boit

for loosening.

cam

head

Cam

such

can

shaft

Iock

up

from the

slot.

hait

shaft
that

be

accessed

such

washer

washer.

if

One

Hex
Hex

boit:

M6 X

Socket:

12

10mm

• Straighten Iock tab

remove

st

1

hex

boit.

&

ROYAL

EN

FIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1 4 7

S.

Aggregate

No.

45.

cam

• Rotate
access

• Straighten Iock tab
remove hex boit, along
with Iock plate.

• Release sprocket from
the dowel
increase chain slack.

to

Instructions

shaft

Cam

the 2

Assemble/

assembly

shaft

nd

hex boit.

in

cam

shaft to

Fastener,

CAUTION:

to

Ensure
washer does not drop into
the

&

cam

the

chain

Size,

Lock tab and

Tool

Usage,

Precautions,

Photos

Release

•

the
and pushing
the sprocket.

Lift

•
remove sprocket.

• Remove

cam

Sprocket by

cam

cam

chain from

lifting

it

behind

shaft

and

shaft.

NOTE:

Hold chain securely,
prevent
into cylinder head.

it

from dropping

to

C ,

0

l,

48

1

ROYAL

ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

S.

No.

46.

Aggregate

Cylinder

to

Instructions

head

assembly

• Remove 4 Long hex
bolts

cylinder

• Remove 2 hex flange

bolts from the
the cylinder

from

head

Assemble/

inside

LH

side

of

head

caver.

Hex
Hex

Fastener,

boit:

M10 X 170

Socket:

12mm

Size,

NOTE:

Take

care

not

to

drop
thefour thick washers from
the bolts.

Tool

Usage,

Precautions,

Photos

47.

• Gently
cylinder head,
care
chain
barrel.

Cylinder

tap

not to drop the

into

head

gasket

Remove cylinder head

gasket.

and

cylinder

lift

up

taking

cam

Hex

flange

bolts:

M6 X 30

Double

end

spanner:

8mm

NOTE:

2 dowels are provided in

to

cylinder barrel
cylinder head.

locate the

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

49

S.

No.

48.

Aggregate

Valves

to

Instructions

in

Head

• Locate valve spring
compressor tool
valve such

sleeve

resting on the retainer

valve spring &

bottom

centrally located
valve.

• Tighten special tool

springs are compressed
fully & the
free
stem.·

• Remove both cotters
loosen special
springs are
expanded & tool
easily removed.

• Remove special
retainer.
inner spring
seat from
head.·

• Remove
pulling

cylinder head.

Remove

•

from
top.

•

Repeat
to
valve.

with

of

from

inlet

it

from bottom

Valve

the

above

dismantle exhaust

Assemble/

Cylinder

on

inlet

that

the

screw is

the

the

tool

on

the

cotters are

the

valve

tool

till

fully

can

tool.

outer

spring.

& spring

the

cylinder

valve by

stem

seals

valve guide

procedure

Fastener,

Special
Valve
Tool

is

Tool:

Spring

CAUTION:

Ensure special

till

correctly located before
attempting
valve springs.

&

NOTE:

Ensuresplit collars are

be

removed before releasing
springs

NOTE:

The valve guides & valve
seat inserts should not

of

removed
head
affect

ln

the
out. complete cylinder
head

replaced

OR

reworked

engine

event

assy.

from

should only

Size,

ST-27528-2

Compressor

tool

to

compress

cylinder

as

it

will

performance.

of

any wear

is

be

be

Tool

Usage,

Precautions,

Photos

49.

50

Chain

•

Remove
located in the
the
pulling

1

ROYAL

guide

cylinder head. by

ENFIELD I EURO

pads

chain guide

front

it

from the top.

IV -

pad

on

SERVICE

MANUAL

LS

410

S.

No.

49.

Aggregate

Instructions

Chain

guide

to

Assemble/

pads

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Release the
the

from
crankshaft and remove
from the engine.

• RemoveBolt- Stepped,

holding chain tensioner
pad

to

crankcase

• Remove

guide

pad

50.

Cylinder

barrel

assembly

• Remove 2 hex flange

nuts on
cylinder barrel.

cam

chain

sprocket on

LH.

fixed

from the top.

LH

chain

side

of

Boit

Stepped:

Allen

Key:

s

CAUTION:

Take

care

to

remove
washer behind
tensioner pad.

Hex

flange

nut:

Double

8mm

end

spanner:

M6 X

the

M6

14

the

chain

lift

• Gently
up
piston.

• Remove cylinder base
gasket.

• Locate special
connecting rod below
piston on

support piston

cylinder barrel

to

remove

inlet

from

tool

side,

on

to

NOTE:

Ensure
removed from crankcase
LH.

Special
Piston
tool.

the

2 dowels are

/ cylinder barrel

Tool:

ST-27529-2

support

special

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

51

S.

No.

51.

52.

Aggregate

Piston

•

Remove
side
gudgeon pin from
opposite

•

Remove
Connecting

Piston

•

Remove
expanding the rings at

their
lifting towards the top of
the piston.

to

Assemble/

Instructions

Pin

circlip

from

of

piston & push

side.

Piston from

rod

rings

piston

open

ends

slightly &

rings

one

out

by

Fastener,

Special
Piston
tool.

NOTE:

Do
much

The
piece

Tool:

ST-27529-2

support

not expand rings too

since

oil contrai ring

set.

special

they will

Size,

break!

is

a 3

Tool

Usage,

Precautions,

000

00

Photos

53.

54.

Oil

Jet

barrel

•

Remove
Crankcase
seating

Oil

Jet

LH

(outside)

•

RemoveHex

screw from

LH

Cylinder

seating

area.

-

Crankcase

oil

jet from

/ barrel

socket

Crankcase

area

RH

head

Hex

Socket

M6X12

Allen

Key:

Hd

MS

Screw:

52 1

ROYAL

ENFIELD I EURO

IV.

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

54.

Oil

LH

•

55.

Crankcase

Fasteners
Remove

•

to

Assemble/

Instructions

Jet -

Crankcase

(outside)

Gently

pull

out &

remove

oil

jet.

Hex

socket
from crankcase
front.

head

screw

LH

Fastener.

NOTE:

Ensure
removed
in

Hex
M6X12

Allen

the

small

from

crankcase / behind

Socket

Key:

Hd

MS.

·o

'ring

seating

Screw:

Size,

is

area

oil

jet.

Tool

Usage,

Precautions.

Photos

• 3

hex

bolts from

case

LH

magneto

• 1 Hexflange boltfrom
crankcase near starter

housing.

motor

crank­area.

LH

Hex

boit:

MS

Hex

Socket:

Hex

boit:

M6 X 60

Hex

Socket:

NOTE:

8

Hex

Bolts
housing, 4 in

motor
3 at bottom
same

length.)

6

Hex

bolts

the

longest

X 70

12mm

8mm

(1

near

are

on

rear

Starter

front &

shorter &

end

are

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410 1 53

S.

Aggregate

No.

55.

Crankcase

to

Instructions

Fasteners

Remove

• 4 Hex flange bolts from
LH

crankcase front.

• 6 Hex

from

bolts

LH

crankcase

Assemble/

(Longest)

rear.

1 Hexbalt:

Hex

Socket:

Hex

Flange

Hex

Socket:

Fastener.

M6X60

8mm

boit:

M6 X

10mm

Size,

85

Tool

Usage.

Precautions.

Photos

• 3

Hex

case

56.

Crankcases

• Split crankcases
locating 2 suitable short
Hex
between the front

tabs on the crankcases.

• Unscrew

such
cases

• Gently
using small plastic

to

separate crankcases

further.

bolts from crank-

LH

bottom

splitting

bolts

with

nuts,

& rear

nuts

evenly

that

the

crank-

separate.

tap

on

the

ma

by

tabs

Ilet

Hex

boit:

Hex

Socket: 8mm.

M6 X 60

54

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

57.

Crankcase

removal

to

Assemble/

Instructions

RH

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Remove Crankcase
from the shafts by gently
tapping
simultaneously. using a
small plastic mallet

58.

Balancer
assembly

• Gently
shaft out
from
LH.(Partial blind hole)

on

shaft

tap

of

the

RH

the

shahs

balancer

the bearing

Crankcase

NOTE:

Please ensure
washer on
does not

counter

fait

thrust

shaft

off

NOTE:

The gear has a high
interference

and

shaft

separated from the shaft.

fit in balancer

hence cannot

be

59.

Crank
Assembly

• Remove crank
assembly by
rotating & tapping from

LH

shaft

shaft

slightly

side (magneto side).

NOTE:

The

LH

shaft main bearing

is

integral
shaft
should
serviced separately.

with

the

assembly. hence

NOT

be

removed or

crank

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

lS

410 1 55

S.

Aggregate

No.

60.

Oil

aankcaseLH

(inside)

•

RemoveHexsockethead
screw from
LH.

•

Gently

oil

to

Assemble/

Instructions

Jet·

pull

out &

jet.

Crankcase

remove

Fastener,

Hex

Socket

M6X12

Allen

Key:

Head

MS

NOTE:

Ensure
removed
in

the

small

from

seating

crankcase / behind

Size,

Screw:

'O

'ring

oil

is

area

jet.

Tool

Usage,

Precautions.

Photos

61.

Gear Operator

Forks

•

Remove
holding the operator
forks to the gear drum
assembly.

•

Remove

forks from the

the 2 spindles

three operator

gears.

NOTE:

Both the long operator

forks

are

located towards

rear

end

of

crank

the
the

small

the

center.

The

forks

2 & 3 for

operator fork at

are

easy

identification.

case

numbered

&

1,

56

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

No.

62.

Aggregate

Instructions

Gear

shifter

to

Assemble/

drum

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Remove gear
drum from crankcase

63.

Drive

shaft

assembly

• Remove thrust washer

• Remove 1

floating bush.

st

gear

shifter

LH

with

• Remove thrust washer

ROYAL

ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410 1

57

S.

No.

Aggregate

Instructions

to

Assemble/

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

63. Drive

assembly

•

Remove

• Gently

from
remove from crankcase
LH.

• Remove

spacer
LH

shaft

Sthgear.

tap

the

from

outside.

drive

LH

side &

drive

crankcase

shaft

shaft

Caution:

The bush will be
drive shaft. due
ring inside the

Gently
remove from crankcase

Take
the threads while tapping
on

tap the

care

not

the shaft.

tight

ta

bush.

shaft

ta

damage

the

on

·o·

ta

LH.

64.

58

Gears

•

1

ROYAL

in drive

Remove

circlip.

ENFIELD I EURO

shaft

IV -

SERVICE

1

External

MANUAL

LS

circlip

410

pliers

, •

'

•

,······.·,,

,,

'

'

..

S.

No.

64.

Aggregate

Instructions

Gears

•

in

Remove

with31ugs.

to

Assemble/

drive

shaft

thrust washer

Fastener,

Size,

Tool

Usage,

Precautions.

Photos

•

Remove

•

Remove

internai

th

4

gear

bush

splines.

with

•

Remove

with

splined

outside

tabs.

washer

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

59

S.

Aggregate

No.

64.

Gears

• Rotate thrust washer
with internai splines

such
free

&

shaft.

to

Instructions

in

drive

that

to

move

remove

Assemble/

shaft

the

splines

in

the

shaft

washer

from

are

Fastener.

Size.

Tool

Usage.

Precautions.

Photos

•

Remove

•

Remove

rd

3

gear.

splined

bush.

60

1

ROYAL

•

Remove

ENFIELD I EURO

thrust

washer.

IV •

SERVICE

MANUAL

LS

410

S.

No.

64.

Aggregate

Instructions

Gears

•

•

in

Remove

Remove

to

Assemble/

drive

circlip.

sliding

shaft

bush.

External

circlip

pliers

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

•

Remove

Remove

•

circlip

collared

bush.

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

lS

410 1 61

S.

No.

64.

65.

Aggregate

Gears

•

Remove

Counter

to

Instructions

in

drive

2

shaft

assembly

• Pull out main shaft with
gears

from

LH.

Assemble/

shaft

nd

gear.

crankcase

Fastener,

Size,

CAUTION:

Ensure

main
misplaced while removing
main shaft

thrust

shaft

washer on

does

not

get

Tool

Usage,

Precautions,

Photos

66.

Gears
shaft

•

Remove

Remove

•

in

counter

2ndgear.

circlip.

External
pliers

circlip

62

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

No.

66.

Aggregate

Instructions

Gears

in

shaft

•

Remove

gears.

•

Remove

to

Assemble/

counter

rd

th

3

& 4

sliding

thrust

washer.

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

•

Remove

Remove

•

circlip.

th

5

gear.

External

circlip

pliers

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

63

S.

No.

66.

Aggregate

Gears

to

Instructions

in

counter

shaft

•

67.

Crankcase

Remove

bush.

seals

• Open Iock tabs and
remove 2 Hex bolts

with

along

from

outer side.

crankcase

Assemble/

LH

oil

Iock plate

LH

Fastener.

NOTE:

1•1 gear

is

integral

with main shaft

Hex

boit:

M6 X

Hex

Socket:

10mm

10

Size,

Tool

Usage,

Precautions,

Photos

• Remove drive shaft oil

seal

from the crankcase

LH

outer side.

Remove

•

double lipped oil seal

from

outer side.

gear shift shaft

crankcase

LH

64

1 ROYAL ENFIELD I EURO

IV·

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

68.

Crankcase

to

Instructions

bearings

A.

Selector

• Remove 2 hex socket
head screws
retainer plates from
crankcase

drum

Assemble/

RH

bearing:

with

RH

outer

side.

Hex

Socket

M6X12

Allen

Key:

Fastener,

Hd.

Screw:

MS

Size,

Tool

Usage,

Precautions.

Photos

• Using a suitable

drive out the ball bearing
from

the

inner side

crankcase

B.

Drive

• Using a suitable

drive out the ball bearing
from
crankcase

C.

Counter

• Remove hex socket
head screw along
retainer platefrom the
inner side
RH.

• Using a suitable

drive out the ball bearing
from
crankcase

shaft

the

shaft

the

RH.

outer

RH.

of

outer

RH.

drift.

bearing:

drift.

side

bearing:

with

crankcase

drift.

side

of

of

of

Bearing

mallet.

Hex

Socket

M6X12

Allen

Key:

Bearing

mallet.

drift

Head

MS

drift

& plastic

Screw:

& plastic

D.

Crankshaft

• Using a suitable

drive out the ball bearing
from
crankcase

the

bearing:

outer

RH.

drift,

side

of

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

65

S.

Aggregate

No.

68.

Crankcase
bearings

E.

•

69.

Crankcase
bearings

A.

to

Assemble/

Instructions

RH

Balancer

Use
drive the ball bearing out
from the outer side
crankcase

shaft

a suitable

RH.

bearing:

drift

LH

Drive

shaft

bearing:

to

of

Bearing
mallet.

Bearing

mallet.

Fastener,

drift

& plastic

drift

& plastic

Size,

Tool

Usage,

Precautions,

.

-~•"<:

. . \ .

•. • t

•

...

'NI

Photos

.~

.-

- -. "

~

-

...

•

..

,·\

~

·~

\'

-

\

~

l

• Using a suitable
drive out the ball bearing
from

the

outer

crankcase

B.

Counter

•

Use
puller to pull out the ball
bearing from the blind
hole inside crankcase
LH.

C.

Balancer

• Using a suitable

drive out the ball bearing

from

crankcase

LH.

shaft

a suitable

shaft

the

outer

LH.

bearing:

two

bearing:

drift,

side

drift.

side

of

jaw

of

1 Two

Bearing

mallet.

Jaw

puller.

drift

& plastic

66

1 ROYAL ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410

WEAR LIMITS ·

New

components
inspection.
performance

Use

of

seriously.

must

parts

be

within the limits

beyond

service

LS

li mit

410

specified.
can

reduce

Components

the operating lite of

within

service

the

component

limits

(Ali

may

and

units

be

reused

affect the

in

mm

after

unless

careful

motorcycle

specified)

Component

Cylinder
Piston
Cylinder Bore/Piston
Piston
Piston
Top
Middle
Oil
Balancer
Crankshaft

Crankshaft

Piston

Connecting

Cylinder
Cylinder

Valve

Valve
Valve
Valve
Valve/
Valve / Guide
Valve
Valve
Valve
Cam
Camshaft
Camshaft
Camshaft
Cam
Clutch
Clutch
Clutch
Clutch

Friction
Shifter

Shifter

Bore

ID

OD

ring

top 1

ring

top 2 working

ring

ring

scrapper

shaft

Lobe Lobe

ring

Shaft

Assembly
Assembly

Pin

rod

head / cover

head / barrel

guide

lnlet

guide

Exhaust

stem

lnlet 6.960

stem

Exhaust

Guide

lnlet

Exhaust
seat/valve
Spring

lnner 36.70 34.70

Spring

Outer

Journal

Spring
Steel

Plate
Friction
Steel/

Drum
Forks

Plate

Plates

Where / What

Top,

Middle & Bottom

Top,

Middle

& Bottom of

Clearance
Rings

End

Gap

area
Clearance
groove & piston
assembled
Run
Crankshaft
Big
Piston
Connecting
Warpage
Warpage

Internai

StemOD

Valve
Contact

Overall
Run

Journal
Journal
Oil

groove

Free

Thickness
Thickness

Distortion

Groove
Guide
Lug

between

condition

out

assembly

End

Axial

Pin

Diameter

rod

ID

stem

to

area

Length

out

Dia

Bore

clearance

Height

Length

width

Pin

Dia

Thickness

Play

Dia

to

Measure

in

Bore

in

bore.

rings

small

Guide

of

Piston

working

piston

at the topmost

Piston

ring

in

run

out

end

ID

Clearance

area

ring

Minimum

78.000 78.030 78.100

77.940

0.015

0.15

0.20

0.03 0.07

0.03 0.07

0.03 0.07

-

-

Maximum

77.970

0.040

0.30

0.40

0.03 0.05

0.05

- -

19.992

20.010

19.997

20.019

- -

- -

7.000

7.000

6.945

43.90

21.959

21.988

7.015

7.015

6.975

6.960

1.00

0.02

21.980

22.025

- -

36.92

1.550

2.950 3.050

6.05 6.20

5.85

5.30

36.96

33.60

1.650

0.10

5.95

5.40

Service

77.870

0.20

0.60

0.70

0.10

0.10

0.10

0.09

0.065

19.977

20.050

0.01

0.01

7.070

7.100

6.945

6.920

0.01

0.14

1.50

41.90

0.05

21.930

22.088

0.05

36.76

32.60

1.533

2.830

0.30

6.30

5.75

5.20

Limit

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410 1

67

TORQUE VALUES - LS 410

Agregate

Crankcase

Magneto

CoverLH

LH

Side

Component

Piston

Oil

Jet

Clutch

Starter
Cam

Chain

Tensioner

Gear

Position

Oil

Strainer

Cap

Oil

Passage
Crankcase
Drive
Final

Sprocket

Rotor

Magneto
Clamp,
Stator
TDC

Drain

Shaft

Oil

Drive

Sprocket

Caver

RingAssembly

Rotor

Stator

Coil

Screw

Inspection

Oil

Jet

Switch

Seal

Retainer

Wire

Plug

Pad

Fastener

HexSocket
Hex

Socket

Boit

Stepped

Hex

Flange

Hex

Flange

Hex

Flange
PlugM14X12
Hex

Boit-

M6 X 10
HexNutM20
Hex

Flange
HexSocket
Hex

Flange
HexSocket
Hex

Socket
Plug-

M14X12

Head
Head

-M 6 X
Boit­Boit­Boit-

Boit ­Head
Nut

M12
Head
Head

Screw

M6 X 12

Screw

M6 X 12

14
M6 X 16
M6 X 20,
MS X 12

M6 X 3S

Screw

M6X20

Xl.25 X 11

Screw

MS X 15

Screw

MS

X 30

Qty

(Nm)

8-12 0.8-1.2

1
1 8-12 0.8-1.2

10-12

1

2

6.8Max

8-12 0.8-1.2

2

20-24 2.0-2.4

3

20-25 2.0-2.5

1

8-12 0.8-1.2

2

130-160

1

8-12 0.8-1.2

2

10-12

6
1

70-80

2 8-10 0.8-1.0

8-10 0.8-1.0

3
1 20-25 2.0-2.5

Torque

Range

(Kg.M)

1.0-1.2

0.68Max

13-16

1.0-1.2
70-8.0

Crankcase

Crankcase

Gear

shifting

LH & RH

RH

Caver

LH

Mounting

Caver

LH

Logo

Crankcase

Starter Motor
Cam
OilPump
Stopper,
Pump
Balancer
Clutch

Star
Gear

Drum

Drive

Center

Index

Shift

boxing

Bearing

Gear

Shaft

Cam

Shift

Gear

Stopper

Retainer

Arm

Hex

Flange

Boit-

M6 X 35

Hex

Flange

Boit-

M6 X 55

HexSocketHeadScrewM6X21
HexSocket
Hex
Hex
Hex
Hex
Hex

Hex
Hex
Nut
Hex
HexNutM20
HexSocket

Hex

Flange
Flange
Flange
Flange

Socket

Flange
Flange

(LH

Thread)

Flange

Boit

Stepped

Head
Boit-

Boit-

Boit-

Boit­Head
Boit­boit

Boit-

Head,

Screw

MBX

100

MS

X 70

M6 X 85

M6

X 60

M6

X 30 2

Screw

M6 X 12

M6

X 30 4

MS

M18

MlO

X 20

Stepped

Boit

8-12 0.8-1.2

8
3 8-12 0.8-1.2
2 8-12 0.8-1.2

20-24 2.0-2.4

1

20-24 2.0-2.4

3

8-12 0.8-1.2

6

8-12 0.8-1.2

8

10-12
8-12 0.8-1.2

2

7-9
10-12

1
1

85-90

1

40-60

1

40-60

1

10-12
10-12

1

1.0-1.2

0.7-0.9

1.0-1.2

8.5-9.0

4.0-6.0

4.0-6.0

1.0-1.2

1.0-1.2

68

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

Agrepte

CoverRH

Component

Caver

Oil

Jet

Clutch

shaft

spring.

Caver

RH

Cap-Oil Filter

Plug,

Oil

Check

Seal

Retainer

Fastener

Hex

Socket

Hex

Flanged

Hex

Flange

Hex

Flange

Hex

Flange

Hex

Flange

Hex

Flange

Plug-

M14 X 12

Head

Boit-

Boit-

Boit
Boit­Boit­Boit-

Screw

MG X 10

MG X 37

MG

X 30

MG

X 20

MG X 70

MG X 20

MG X 12

Qty

1 8-12 0.8-1.2

1
8
5

1

1 8-12 0.8-1.2
2

1 20-

Torque

(Nm)

10-12
8-12 0.8-1.2
8-12 0.8-1.2
8-12 0.8-1.2

8-12 0.8-1.2

25

Range

{Kg.M)

1.0-1.2

2.0-2.5

Cylinder

Cylinder

Head

Barrel

CylinderHead

Cylinder
Camshaft & Sprocket
Cylinder
De

Compresser
PAV
SparkPlug
AdapterCarb
Cylinder
Auto

&

Spring

Cylinder

Cover

Pipe

Chain

Head

Head

Side

Fly

Mounting

Ta

barrel

side

Tensioner

boit

Head

Caver

Special

Hex

Bolts-

MlO X 170

Hex

Boit­Flange

Socket

Plug
Socket
Flange

Hex
Flange
Flange
Flange
Flange
Flange
Flange

MG X 12

Boit­Head

(MlO)-

Head

Nut

MG

Boit M 8
Boit­Boit­Boit­Boit­Boit-

Boit-

MG

X 2 8-12 0.8-1.2

Screw

X 2 8-12

CR8E

Screw-

M 6

X 1

MG

X 60
MG X 55
MG X 45
MG X 40
MG

X 20

MG X 21

Lock

Mount

Weight

Cyl

Head

Mount

Mtg HexSocketHeadScrewM6X25 2

Hex
Hex
HexSocketHeadScrewM

Spark

Hex

Hex

Special
Hex
Hex
Hex
Hex
Hex
Hex

40-45

4
2

10-12

3-5

1

1

10-15

2 8-12 0.8-1.2

8-12 0.8-1.2

2

10-12

8-10 0.8-1.0

1

10-14

5

10-14 1.0-1.4

3

10-14 1.0-1.4

1

8-12 0.8-1.2

1

8-12 0.8-1.2

6

8-12 0.8-1.2

2

4.0-4.5

1.0-1.2

0.3-0.5

0.8-1.2

1.0-1.5

1.0-1.2

1.0-1.4

CamCover

OilCooler

TappetCover
Plug,

Camshaft

Rocker

Shaft
Caver-Cam
Oil

Cooler

Pipe

Oil

Cooler

pipe

Hale

Plugs

(enter

banjo

Mtg

Hex

Flange

Hex

Flange

Hex

Socket

Hex

Flange

Boit.

Union

HexSocket

Boit-MG X 21

Boit-

MG X 16

Head

Plug-M14 X 12

Boit-

MG X 16

M 2 35-38 3.5-3.8

Head

Screw

M 4 8-12

ROYAL

ENFIELD I EURO

4 8-12 0.8-1.2

8-12 0.8-1.2

1
2 25-30 2.5-3.0

8-12 0.8-1.2

2

0.8-1.2

IV -

SERVICE

MANUAL

LS

410 1

69

PRECAUTIONS BEFORE ENGINE REASSEMBLY

•

Please

and

•

Lubricate

•

Replace

ensure

all

reassembly.

all

moving

parts

like:

parts

are

parts

Gaskets,

thoroghly

prior to

"O"

reassembly.

Rings,

cleaned

Oil

seals,

and

Dust

stored

seals,

in a sequence

Rubber

items,

for

inspection

Aluminum

washers,

Circlips

wheneverthey

NOTE:

While fixing bearings. bushes

Crankcase.

are

removed

or

oil seals.

OR

it

du

ring a complete

is

NOT

necessary

engine

to

overhaul.

heat the

70

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

ENGINE ASSEMBLY SEQUENCE

S.

Aggregate

No.

1.

Crankcase
Bearings

A.

Balancershaft

Beartng:·

• Locate bearing in
Crankcase
innerside & gently tap
using a suitable drift
plastic mallet

B.

Counter

• Locate bearing in
blind hole in Crankcase
LH

gently
suitable drift

mallet

to

Assemble/

Instructions

LH

LH

shaft

bearing:

frominner

tap using a

side &

and

from

and

the

plastic

Fastener,

Bearing

mallet.

drift

NOTE:

Ensure
is
crank
the bearings.

bearing outer

flush

with

case

Size,

& plastic

race

housing in

after pressing

Tool

Usage,

Precautions,

Photos

C.

Drive

shaft

bearing:

• Locate bearing

case

LH

from innerside

&

gently
suitable drift
mallet

tap using a

in

and

Crank-

plastic

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

71

S.

No.

2.

Aggregate

Crankcase

to

Instructions

Bearings

A.

Balancershaft
bearing:

• Locate bearing in
crankcase

inner

side & gently tap

using a suitable drift
plastic mallet.

B.

Crankshaft

• Locatebearing in
crankcase
inner side & gently tap
using a suitable drift
plastic mallet.

Assemble/

RH

RH

from

and

bearing:

RH

from

and

Fastener.

Bearing
mallet.

drift

& plastic

NOTE:

Ensure bearing outer

is flush
crank
the bearings.

with

case

after pressing

housing in

Size,

race

Tool

Usage.

Precautions.

Photos

C.

Counter

Shaft

Bearing:

• Locate bearing in crank-

case

RH

from inner side

&

gently
suitable drift
mallet.

• Position retainer plate
between
crankcase
with
screw.

tap using a

and

plastic

the

slots in

RH

& tighten

Hex Socket Head

Hex

socket

hd.

screw:
M6X12
Allen

Key:

5mm

Torque:

0.8-1.2Kg.M

(8-12Nm)

NOTE:

Ensure retainer plate
properly located over
bearing outer
tightening

race

screw.

is

, before

72 1

ROYAL

ENFIELD I EURO

IV • SERVICE

MANUAL

LS

410

S.

Aggregate

No.

2.

Crankcase

to

Instructions

Bearings

D.

Drive

Shaft

• Locate bearing in
crankcase
inner

side&
using a suitable
plastic mallet.

E.

Gearselector
bearing.

• Locate bearing in

Crankcase
outer side& gently tap

using a suitable
plastic mallet.

Assemble/

RH

Bearing:

RH

from

gently

drift

drum

RH

drift

tap

and

from

and

Bearing

mallet.

Fastener,

drift

& plastic

Size,

Tool

Usage,

Precautions,

Photos

• Position
latesbetween the slots in
crankcase
with
screws.

3.

Crankcase

seals

A.

Gear

seal.

• Locate double lip oil
in Crankcase

outer

using a suitable
plastic mallet.

two

retainer

RH

& tighten

Hex Socket Head

LH

Oil

shift

shaft

oil

seal

LH

from

side& gently tap

drift

and

Hexsockethdsaew:M6X12

Allen

Key:

5mm
Torque:
(8·12

0.8-1.2Kg.M

Nm)

NOTE:

Ensure retainer plate is
properly
bearing outer
tightening

Bearing
mallet.

located over

race,

before

screw.

drift

& plastic

NOTE:

Ensure

oil

seal

outer

face

is
facing outside &
with housing in crank

is

flush

case.

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1 73

S.

Aggregate

No.

3.

Crankcase

seals

B.

•

•

•

4.

Piston

•

to

Assemble/

Instructions

LH

Oil

Drive

shaft

oil

seal:

Locate

oil

seal

on

crankcase

LH

from

outer

side&

gently

tap

usinga

suitable

plastic

mallet.

Locate

retainer

seal

& tighten

Hex

with 2
Bend

the

retainer

tabs

over

the
prevent them from
loosening

Oil

Locate
case

·o·

LH

inside.

plate

bolts.

hex

Jet

ring

drift

over

in

position

plate

bolts. to

in

crank-

and

oil

Iock

Fastener.

NOTE:

Ensure
facing outside &
with

Torque:
12Nm)

Hex
Hex

oil

seal

housing

Boit:

M6 X

Socket

0.8-1.2Kg.M

outer

in

crank

10

spanner:

NOTE:

Apply

grease

on

hold

it

in

place.

is

·o·

Size,

face

flush

case.

8mm

(8-

ring

is

ta

Tool

Usage,

Precautions.

Photos

• Locate oil
case
spout

• lighten with
Head

74

1 ROYAL ENFIELD I EURO

jet

in

LH

inside with its

facing

upwards

Hex

screw.

IV·

crank-

Socket

SERVICE

Hex
M6X12
Allen
Torque:
12Nm)

MANUAL

Socket

key:

0.8-1.2Kg

lS

410

Hd

5mm

Screw:

M (8-

S.

No.

5.

Aggregate

Instructions

Starter

Clutch

Jet.

•

Locate

·o·

case

LH

to

Assemble/

ring

in

outside.

Oil

Crank-

NOTE:

Apply

grease

hold

it

Fastener,

on

in

place.

'O'

Size,

ring

to

Tool

Usage,

Precautions,

Photos

&.

Locate

•
case

LH

spoutfacing

•

Tighten
Head

screw.

Sub

Assembly of

gears

• lnsert 2
shaft

recess

side

of the

on

the

in

such

collar

oil jet

outside

downwards.

with

Drive

nd

gear

that the

in

the

gear

of

in

Crank

with its

Hex

Socket

Shaft

on

the

small

machined

is

seated

the

shaft.

-

Hex

Socket
M6X12
Allen

key:
Torque:
12Nm)

Hd

Screw:

5mm

0.8-1.2KgM

(8-

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1 75

S.

Aggregate

No.

6.

SUb

gears

• lnsert collared bush on
the shaft,
bush will enter into the
gear and
facing outside and
seated flush

gear.

to

Instructions

Assembly of

in

Drive

Assemble/

Shaft

such

that

the

the

collar is

with

the

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

that

st

circlip.

on

the shaft,

it

is

facing 2nd

nd

circlip.

• Assemble 1

• lnsert bigger side

sliding dog
such
gear.

• Assemble 2

of

the

Outside
Circlip

Outside
Circlip

Plier

Plier

76

1 ROYAL ENFIELD I EURO

IV

• SERVICE

MANUAL

LS

410

S.

Aggregate

No.

&.

Sub

gears

• Assemble thrust washer
with
splines

to

Instructions

Assembly

ln

Drive

three
on

Assemble/

of

shaft

internai

the shaft.

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

lower

on

washer

shaft

the

the

and

and

• Align oil hole in
splined bush with the oil
hole in shaft
fully.

• Assemble 3

shaft with its slot facing
the sliding dog.

• Assemble thrust washer

with
external splines on the
shaft. align the internai

with

tabs
shaft, just above the 3
gear and rotate washer
such
locks in
cannot be removed.

and

rd

gear

internai

the groove in

that

the

the

CAUTION:

Ensure

it

hole
isaligned
withoil
in shaft.

rd

in

oil

bush

hole

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

lS

410 1

77

S.

No.

&.

Aggregate

Instructions

Sub

Assembly

gears

•

in

Assemble
with

outside tabs such

that

the
washer locks
slots in
washer.

to

Assemble/

of

Drive

Shaft

thrust washer

tabs in

into

the

thrust

the
the

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Align oil hole in
splined
hole in shaft

fully.

• lnsert 4thgear on

shaft, with the slot in the
gear facing outside
locate
bush.

• Assemble 2
washer
internai splines.

bush

with the oil

and

lower

it

on the splined

nd

with

the three

the

the

and

thrust

CAUTION:

Ensure

it

hole
isaligned
with oil hole
in shaft.

in

oil

bush

78

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

Aggregate

No.

6.

Sub

gears

• Assemble 3rd Circlip.

7.

Sub

gears

to

Instructions

Assembly of

in

Drive

Assembly of

in

counter

shaft

• Assemble bush on
counter shaft. from the
non-threaded end
the shaft.

Assemble/

shaft

of

Fastener.

Outside

Circlip plier

Size.

Tool

Usage.

Precautions.

Photos

• Assemble S

that the lugs
are towards
threaded end
counter shaft.

• Assemble 1st
washer.

th

gear such

of

the gear

the

non-

of

thrust

the

ROYAL ENFIELD I EURO

IV -SERVICE

MANUAL

L5

410

1

79

S.

No.

7.

Aggregate

to

Assemble/

Instructions

Sub

Assembly

pars

in

counter

shaft

•

Assemble

•

Assemble3
gear
that the larger gear
facing

1

on

the shaft

the 5

st

circlip.

rd

& 4

th

of

th

gear.

sliding

such

is

Fastener.

Outside
Circlip

plier

NOTE:

Larger

gear

must

be

towards the

st

gear.

1

Size.

Tool

Usage.

Precautions.

Photos

•

Assemble

•

Assemble2ndgear.

nd

2

circlip.

Outside
Circlip

plier

NOTE:

Collarin the
gear

should

face

towards

1•1gear.

80

1

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410

S.

No.

8.

9.

Aggregate

Counter
thrust

•

Place
counter shaft bearing in
CrankcaseLH.

Counter
Drive

to

Instructions

shaft

washer

thrust washer over

shaft

shaft

Crankcase

• Locate the shafts in their
respective locations in
CrankcaseLH, ensuring
the gears in both shafts
are aligned.

Assemble/

&

in

LH

Fastener.

Size.

NOTE:

Apply
washer
falling
main shaft.

grease on

to

preventit from

off

when locating

thrust

NOTE:

Ensure
counter
upwards
main shaft

Crankcase
Gently tap both shafts into

bearings simultaneously
for

threaded

shaft

is

& threaded end

is

inserted into

LH.

proper seating.

end

facing

of

of

Tool

Usage.

Precautions,

Photos

10.

Sub

Assembly

gears

• AssembleSthgear such

• Assemble thrust washer.

in

Drive

that

the

facing towards

of

shaft

gear side is

st

l

gear.

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1 81

S.

Aggregate

No.

10.

Instructions

Sub

Assembly

gears

• Assemblelstgear bush.

in

to

Assemble/

of

Drive

shaft

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Assemble 1
the

bush such
deep groove in 5
facing towards 1

• Assemble thrust washer
1'1 gear

over

11

Selector

st

gear over

that

th

st

Forks

the
gear
gear.

is

NOTE:

Ensure gears in
counter shaft & drive shaft
are aligned.

both

• Locate selector
No.2, inside sliding dog

of

on drive shaft,
thefork
above.

82

1 ROYAL ENFIELD I EURO

fork

with

lug facing

IV • SERVICE

MANUAL

LS

410

S.

No.

11.

Aggregate

Instructions

Selector

to

Assemble/

Forks

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Locate operator
Nol

in

shaft Sthgear.

• Locate operator

No.3

th

4

gear.

12.

Gear Shift Drum
Assembly

the

recess

in

counter shaft

in

fork

drive

fork

on

• lnsert long end
Drum Assembly
Crankcase
offset

pegs
assy must be facing
outside.)

• Lock selector forks in
position by locating the

spindles in Crankcase

LH.

of

Shift

into

LH.

(thetwo

in the drum

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

83

S.

No.

13.

Aggregate

to

Assemble/

Instructions

Crank

shaft

Assembly

Locate bearing in the

•

housing
and
gently tilt the bearing
seated

in

Crankcase

press crankshaft

completely.

Fastener,

NOTE:

Smear

oil

on

race.

LH

Hold

crankshaft vertically

& ensure bearing enters

is

crankcase

LH

bearing

squarely.

Size,

outer

Tool

Usage,

Precautions,

•

Photos

•

14.

Balancer
Assembly

•

15.

Crankcase

•

Rotate Crankshaft

that the

at

the dot

in crankshaft

towards the front.

crank

their lowest position &

mark

on

webs

the

is

facing

such

are

gear

shaft

Position balancer shaft

such

that the dot mark

on

balancer shaft gear

aligns

with dot
crankshaft gear and
gently press balancer
shaft into the
crankcase

LH

mark

bearing

on

in

Boxing

Ensure
applied evenly
uniformly

surface

Gasket

on

the mating

of

crankcase

sealant

and

LH

NOTE:

Ensure

crankshaft
shaft gear are matched
correctly.

dot marks

gear & balancer

NOTE:

is

Apply Loctite
the mating
case

surface

LH.

No

5699

of

crank

on

on

Ensure

•

located
Locate Crankcase

•

over crankcase
gently tap
gently
shafts

Ensure

•

fully
case
rotating freely.

84

1 ROYAL ENFIELD I EURO

dowels

in

crankcase

it

rotating the

Crankcase
seated
LH

over

& all shafts

are

LH.

RH

LH

and

in white

RH

is

crank-

are

IV· SERVICE

MANUAL

LS

410

S.

No.

Aggregate

Instructions

to

Assemble/

Fastener.

Size,

Tool

Usage,

Precautions,

Photos

16. Crankcase
Fasteners

Assemble

•

Hex

Socket

in

Crankcase

Barrel

seating

• 3

hex

bolts

area

in

crankcase

• 1

Hex

flange boit in
crankcase
starter motor

Head

LH

area.

in

magneto

LH

housing

screw

below

LH.

near

Hex

Socket

Hd

Screw:
M8X100
Allen

key:

M6

Torque:

2-2.4KgM

24Nm)

Hex

Flange
Socket
Torque:

Boit-

spanner:

2-2.4KgM

MS

12mm

24Nm)

Boit-

Hex Flange
60

Socket spanner: 8mm

Torque:

0.8-1.2KgM

M6

12Nm)

(20-

X 70

(20-

X

(8-

• 4 Hex flange bolts
crankcase

• 6

Hex

crankcase

bolts

LHfront.

(Longest)

LHrear.

in

Hex Flange Boit­60

Socket spanner: 8mm

Torque: 0.8-1.2KgM (8-

12Nm)

in

Hex Flange Boit­Socket spanner: 8mm
Torque: 0.8-1.2KgM (8­12Nm)

M6

M6

X

X 85

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

85

S.

Aggregate

No.

16.

Crankcase

Fasteners

Assemble

• 3

17.

Piston
Assembly

•

to

Assemble/

Instructions

Hex

bolts from

case

LH

bottom

Rings

Assemble
with stiffener

rd

3

Oil

groove.

crank-

contrai

ring

in

ring

the

Hex

Flange
Socket
Torque:

12Nm)

spanner:

0.8-1.2KgM

NOTE:

Tighten

all
diagonally,
of

the

crankcase

NOTE:

Ensure

correctly
the 2 oil

stiffener ring

Contrai

Fastener,

Boit-

M6 X

8mm

fasteners

for

located

evenly

proper

joints

between

rings.

Size,

60

(8-

&

sealing

is

Tool

Usage,

Precautions,

Photos

000

00

•

Assemble
ring in the middle

groove.

•

Assemble
ring
groove.

nd

2

compression

1st

compression

in

the top most

NOTE:

Ensure
in
"TOP
ring
top of the

Lubricate rings well &
position ring
120°
assembly

the

words

compression ring &

st

l"

in

1

compression

facing

towards the

piston.

end

to

each

other,

of cylinder

2

nd

are

"TOP"

gaps
for

easy

barrel.

at

2

86

1 ROYAL ENFIELD I EURO

IV -SERVICE

MANUAL

LS

410

S.

Aggregate

No.

18.

Oil

19.

Cylinder
Gasket

• Locate the

to Assemble/

Instructions

Jet

• Locate oil
case

RH.

barrel seating

area

with its slotted end
facing up and
crank-case gently.

Barrel

on

Crankcase

jet

press

two

LH.

in Crank-

into

dowels

Fastener,

Size,

NOTE:

Ensure
damaged during assembly.

Ensure slotted end
facing outside.

·o·

ring does not get

of

jet

NOTE:

Apply
seating surface.

grease on gasket

Tool

is

Usage,

Precautions.

Photos

• Locate gasket

Piston

20.

Connecting

•

•

on

Crank-

case

ensuring the

for the oil

positioned.

jet

Assembly

recess

is

correctly

on

Rod

Assemble circlip on
piston, on one side
insert

piston pin

the

other

side. Ensure

the

pin is pressed
sufficiently
piston and
protruding into piston

Support connecting rad
using special
hold

it

assembling piston.

into

vertically

tram

tool

&

just

the
not

to

for

caution:

Gasket is unidirectional

it

is

hence ensure

correctly.

CAUTION:

Ensure
and does
crankcase.

Remove
assembling circlip.

Special
Piston

circlip locks in place

not

cloth

Tool:

Support.

fitted

fall

into

after

ST-27529-2,

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

87

S.

No.

20.

Aggregate

Piston

to

Instructions

Assembly

Connecting

• Position piston on
connecting
the piston pin holes in
both piston & connecting
rod are aligned.

• Lubricate piston pin &
gently insert into piston
till

it

rests on the circlip

• Cover crankcase spigot
suitably & assemble the

21.

other
piston.

Cylinder

circlip on

Barrel

piston

• Lubricate piston rings,
piston

& cylinder barrel,

with oil. for
piston
barrel.

into

Assemble/

on

Rod

rod,

ensuring

the

on

easy

entry

of

cylinder

Fastener,

Size,

NOTE:

Ensure

marking,

piston is facing towards

crankcase front.

"EX"

on

the

CAUTION:

Ensure circlip locks
and does
crankcase.

Remove cloth after assembl­ing circlip.

not

in

fall

place

into

Tool

Usage,

Precautions,

Photos

• Ensure Piston
supported vertically.

• Gently
over piston

simultaneously
compressing rings
easy

• Remove piston support-

ing
fully into

lower

entry.

tool

& lower barrel

Crankcase.

barrel

while

for

is

88

1 ROYAL ENFIELD I EURO

IV

• SERVICE

MANUAL

LS

410

S.

No.

21.

Aggregate

Cylinder

to

Instructions

Barrel

piston

• Rotate Crank Shaft

Assembly

to

piston

Assemble/

on

to

bring

TDC.

Fastener,

Hex

Flange

D E

Spanner: 8 mm
Torque:
12Nm)

0.8-1.2KgM

Nut:

M6

Size,

X 1

(8-

Tool

Usage,

Precautions,

Photos

• Tighten barrel
Crankcase using 2

22.

Flanged
LH

Cylinder

Hex

side.

head

Gasket

• Locate 2 dowels on
cylinder barrel
side.· Locate cylinder
head gasket over

cylinder barrel.

23.

Cam

Chain

•

lnsert

chain tensioner

pad

through

barrel.

• Apply grease on

thrust washer
in

place

over

location in crankcase

• Position chain pad over

thrust washer
with

hex socket Head

stepped boit.

nuts

top

Pads

cylinder

to

the

threaded

& tighten

on

the

hold

to

the

LH

the

it

LH.

NOTE:

Apply grease on cylinder

for

head gasket
seating.

Stepped
Bolt:M6X14
Allen
Torque:
12Nm)

Hex

Key:

1.0

MS

proper

socket

-1.2KgM

(10-

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

89

S.

No.

23.

Aggregate

to

Assemble/

Instructions

Cam

Chain

•

lnsert
through
barrel & locate
crank shaft

•

Ensure
supported at the top
prevent
into the crankcase.

•

lnsert
pad
barrel & locate

crankcase

Pads

the

the

gear.

chain

it

from dropping

fixed

through

LH

cam chain

cylinder

it

on the

is

properly

to

cam chain

cylinder

it

in the

Fastener,

Size,

NOTE:

Apply grease on the gear &

to

hold

the

chain
place.

chain in

NOTE:

Ensure
locked in position in cylinder
barrel.as well
LH.

fixed

chain pad is

as

crankcase

Tool

Usage,

Precautions,

Photos

24.

Valves
Head

•

lnsert
valve guide from inside
cylinder head.

• Assemble spring seat.
inner spring.

spring &retainer.
the top

• Locate valve spring

compressing
the retainer & compress
spring till the valve stem
cornes

retainer.

90

1 ROYAL ENFIELD I EURO

in

Cylinder

inlet

valve

of

cylinder head.

tool

out

through the

into

outer

from

over

IV • SERVICE

NOTE:

Ensure
on

Ensure denser coils
spring are seated on
spring seat

MANUAL

stem

seals

the valve guide.

in

cylinder

LS

410

are fitted

of

the
the

head.

S.

No.

24.

Aggregate

to

Assemble/

Instructions

Valves

in

Cylinder

head.

•

lnsert
retainer.
seated correctly against
valve stem and retainer

& release puller slowly.

split

Ensure

collars on

they

are

5peclal

Fastener,

tool:

Size,

ST-27528-2,

Tool

Yalvesprtngcompressor.

Usage,

Precautions,

Photos

25.

Repeat

•
ta
valve.

Cylinder

above procedure

assemble exhaust

Head

Assembly

• Position cylinder head
assembly over cylinder
barrel.

• Holding the cam chain
tram

the

through

cylinder
and locate the cylinder
head on

correctly.

top.
the

head

the

route

slot
bottom

barrel

CAUTION:

Ensuresplit collars are

correctly locked between

retainer

& valve stem.

NOTE:

Apply grease

place.

& chain

it

tram

sprocket
in

Secure chain from top
prevent

it

into crankcase.

in

on

crankshaft

ta

dropping

hold

it

ta

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1 91

S.

Aggregate

No.

25.

Instructions

Cylinder

Assembly

• Locate 4 special
bolts with washer &

tighten

•

Locate 2 Hex
on

cylinder

and

to

Head

diagonally.

tighten.

Assemble/

Hex

flange

bolts

head

LHside

Special
Hex

Socket:
Torque:
45Nm)

Hex

flange
DE

Spanner:
Torque:
12Nm)

Fastener,

Hex

Bolts:M10X170

12mm

4-4.SKgM

bolts:

0.8-1.2KgM(8-

(40-

M6X30

8mm

Size,

Tool

Usage,

Precautions,

Photos

26.

Cam

Chain

Sprocket

•

Locate
with
head.

•

Ensure
on

cam
chain
marking

facing

• Rotate
without disturbing the
sprocket till the dowel
the shaft

hole

•

Ensure
slack
into sprocket
the dowel locates into
the sprocket.

&

Assembly

cam

shaft

sprocket

on

in

& lnsert

on

sprocket

shaft & locate

sprocket with

'T'

on

up.

cam

aligns

the

sprocket.

chain

cam
such

cylinder

sprocket

with the

has

along

is

free

shaft.

no

shaft

that

in

NOTE:

Ens

ure

Key

is

facing

up

TDC

on

compression

CAUTION:

Ensure
cam

sprocket &
shaft
aligned.

Crankshaft
TDC

position.

way

in

crankshaft

so

that

piston

reference

are

parallel &

keyway

is

stroke.

lin

es

on

cam

is

at

at

92

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

S.

No.

26.

Aggregate

to

Assemble/

Instructions

Cam

Chain

Sprocket

•

Fix 1 hex
plate
tighten just sufficiently.

•

Rotate
& tighten
through the

&

Assembly

boit with Iock

on

sprocket &

camshaft slowly

2nd

Iock

Hex

plate.

boit.

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

• Tighten bath bolts &
bend

Iock

bolts.

27.

Cam

Shaft

11C11

washer.

• Align slot
with the groove in

28.

cylinder

lnsert

•

cylinder head

axial

cam

Auto

head.

"C"

movement

shaft

Chain

Assembly

Ensure

•

spring
assembly.

center boit with

is

removed from

plate

over the

Lock

in

cam

shaft

washer into

to

Iock

of

the

Tensioner

Hex

Boit:

M6X12

Hex

Socket: 8 mm

Torque:

12Nm)

1-1.2KgM

(10-

NOTE:

Ens

ure

"C"

washer
correctly into the slot in
cylinder
the cylinder head caver
cannot

head

seat

is

located

failing which

properly

NOTE:

Ensure
on
Assembly.

the

gasket

Auto

is

chain

assembled

tensioner

J

Release

•

tensioner body
depress

Iock

pad

on

chain

&

completely.

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

93

S.

No.

28.

Aggregate

Auto

to

Instructions

Chain

Assembly

• Locate chain tensioner
assembly in
barrel&
Hex socket head screws.

• Locate

chain tensioner body.

• lnsert spring

tensioner
with special Hex boit.

tighten

·o·

Assemble/

Tensioner

cylinder

with

ring

in

the

into

chain

and

tighten

Fastener.

NOTE:

Ensure Iock in chain

tensioner assembly

downwards

2

Hex

Socket
M6X25
Allen
Torque:
12Nm)

Special
Hex

socket:
Torque:
10Nm)

Hd

Key:

5mm

1-1.2KgM

Hex

boit:
10mm

0.8-1.0KgM (8-

Size,

is

facing

Screw:

(10-

MS

Tool

Usage,

Precautions,

Photos

29.

Spark

• Assemble spark plug on

Plug

cylinder head.

30. lnlet Manifold

• Assemble lnlet manifold
PAV

with the

facing downwards.

• Tighten

socket head screws with
copper washers.

inlet nipple

with

2 Hex

NOTE:

Ensurespark plug gap

0.7-0.Bmm

Socket

Torque:

Spanner:

1-1.SKgM

16mm

(10-

15Nm)

NOTE:

Ensure
the lnlet manifold.

Hex
M6X25
Allen
Torque:
12Nm)

·o·

ring

Socket

key:

0.8-1.2KgM

Hd

5mm

is

located in

screw:

(8-

is

set

94

1

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410

S.

No.

31.

Aggregate

Instructions

lnlet

Rocker
shaft
head

in

Cylinder

cover

to

Assemble/

arm

&

Fastener.

Size.

Tool

Usage.

Precautions,

Photos

• Position inlet rocker

inside cover such
the tappet adjustment
screw

on

the rocker

is

facing outside &roller

facing inside.

•

Assemble
the cylinder
such
the internai threads in
the
outside.

• Ensure
rocker shaft
pendicular
mounting hole in the

cylinder
that the cover mounting
boit
the slot in
shaft.

rocker shaft

that

shah

the

head

can

pass

head

the

slot and

are facing

slot in

is

to

the top

cover

through

the

rocker

arm

that

arm

is

in

cover

0 0

the

per-

such

0

32.

Exhaust

&

shaft

head

• Position exhaust rocker
arm inside cover such
that
ment screw on
rocker arm
outside &roller
inside.

Rocker

in

cover

the tappet adjust-

arm

Cylinder

the

is

facing

is

facing

ROYAL

ENFIELD I EURO

IV -

SERVICE

MANUAL

LS

410 1

95

S.

Aggregate

No.

32

Exhaust

&

shaft

head

• Assemble rocker shaft in
the cylinder head cover
such
the
the
outside.

• Ensure

rocker
perpendicular
mounting
cylinder head cover such
that the cover mounting
boit
the
shah.

to

Instructions

Rocker

in

cover

that

internalthreads

shaft

the

can pass

slot

Assemble/

arm

Cylinder

the

slot

are facing

slot

in

shaft

to

the top

hole in

through

in

the

rocker

and

in

the

is

the

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

0 0

• Assemble 2 Hex Socket
pre coated plugs
copper washers in
cylinder head cover.

n.

Cylinder

Head

Cover

•

Apply
gasket

head mating surface.

• Locate
cover
and

• Assemble 2
flange
aluminum washers in
the top

Loctite

sealant

cylinder

on

the cylinder

ensure

RH

on

proper

long

bolts

side.

with

the

5900

cylinder

head

head

seating.

Hex

with

Hex

Socket

Hd

plug:

M14X12

Allen key:

Torque:

lONm)

8mm

2.5-3.0KgM (25-

NOTE:

Ensure

the 2 dowels are

located in cylinder head.

Aluminum washers are
provided
leak through the bolts.

to

prevent oil

96

1

ROYAL

ENFIELO I EURO

IV -

SERVICE

MANUAL

LS

410

S.

No.

33.

Aggregate

Cylinder

to

Instructions

Head

Cover

• Assemble 3 long Hex
flange bolts
side.· Assemble 2 long

Hex flange bolts
aluminium washers in
the centre

• Assemble 3 long Hex
flange bolts
side.

• Assemble medium
length

Hex

the

RH

side

• Assemble small Hex
flange
front.

• Assemble 2
threaded Hex flange
bolts inside the inlet
Exhaust tappet housing
areas.

boit

Assemble/

in

the top

RH

in

the top

flange boit

rear.

in

side.

RH

RH

with

side

fully

Fastener,

Hex

flange

bolts:

Socket

Hex
Socket

Spanner:

flange

Spanner:

bolts:

NOTE:

Aluminium washers are
provided to prevent oil leak
through the bolts.

LH

Hex

flange

bolts:

in

&

Socket

Hex
Socket

Hex
Socket

Hex
Socket

Spanner:

flange

bolts:

Spanner:

flange

bolts:

Spanner:

flange bolts:

Spanner:

Size,

M6X55

8mm

M6X60

8mm

M6X60

8mm

M6X45

8mm

M6X40

8mm

M6X21

8mm

Tool

Usage,

Precautions,

Photos

•

Tighten

just

sufficiently.

torque tighten

all

the

bolts

Do

fully

not

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

97

S.

No.

34.

Aggregate

camshaft

to

Instructions

small.

• Locate
shaft cover small.

• Locate
in cylinder head
fixing hole.

• Assemble Hex flange
boit (fully threaded).

• Tighten Hex flange
on
small AND
on cylinder head cover.

diagonally using
socket

respective torque

·o·

cam

cam

Assemble/

Cover

ring in cam

shaft cover

& align

boit

shaft

cover

the

12

bolts

8mm

spanner

values.

Fastener,

NOTE:

Apply Loctite
sealant on seating face
before locating on cylinder
head

cover

Hex

flange

boit:

5ocket

Hex
M6X55, M6X45& M6X40
Torque:

14Nm)

Hex
Torque:

to

12Nm)

spanner:

flange

1.0-1.4KgM

flange

0.8-1.2KgM

bolts:

bolts:M6X21

Size,

5900

M6X16

8mm

M6X60,

(10·

gasket

(8-

Tool

Usage,

Precautions,

Photos

35.

Cam

Shaft

Big

• Assemble cover and

tighten with
bolts (fully threaded)

36.

Tappets

•

If
fitted

- Ensure key way on
crankshaft
piston

•

If
on crankshaft

- Rotate magneto

·cLOCKWISE
that the reference mark
the
inspection hole
Reference mark on
Crankcase

Adjustment

Magneto

on crankshaft:

is

at

Magneto

rotor

Cover

2 Hexflange

rotorNOT

is

facing up &

TDC

rotor

is

ONL

aligns

with

on

cover

LH.

fitted

rotor

v·such

on
the
LH/

Hex

flange

boit:
Socket
Torque:

spanner:

0.8-1.2KgM

12Nm)

NOTE:

Tappets
0NLYWHEN:

MUST

be

is

is

cold

at

Engine
Piston

Comoression stroke.

M6X16
8mm

(8·

adjusted

TDC

on

98

1 ROYAL ENFIELD I EURO

IV

• SERVICE

MANUAL

LS

410

S.

No.

Aggregate

Instructions

to

Assemble/

Fastener,

Size,

Tool

Usage,

Precautions,

Photos

36. Tappets
Adjustment

• Locate special
loosen adjuster Iock nut
by turning the long lever
anticlockwise.

• Using a
strip, set
gap by
knurled head
special tool:

-

pointed

Clackwise

gap.

- Anticlackwise ta

increase

• Hold the knurled head
firmly

sa

that the tappet
adjustment daes nat get
gets disturbed
tappet locknut firmly by
turning long lever clock-

wise.

37.

Tappet Adjuster
Cover lnlet

• Locate O Ring in caver
inlet

& position caver

over cylinder head
caver.·
with 2 Hex bolts.

tool

the

specified

rotating

of

ta

reduce

gap.

& Iock the

Tighten

&

feeler

the
the

Special
Tappet
pointed,

Tappet

lnlet:
Exhaust:

Tool:

ST-27527-2,

adjusting

long

feeler

Setting:

0.08 -

0.10mm

0.23 -0.25mm

tool

&

strip.

CAUTION:

DO

NOT

adjust the tappets

tao

tight

as

it

will result in

heavy load coming on the

and

bolts:

damaging

head

M6X21

8mm

(8-12

rocker shafts
the bore in the cylinder
caver.

Hex

flange
Socket
Torque:

Spanner:

0.8-1.2KgM

38. Tappet Adjuster
Cover Exhaust

• Locate O Ring in caver
exhaust
caverovercylinderhead
caver.

• Tighten with 2 hex bolts.

& position

Hex

flange

Socket

Torque:

Nm)

bolts:

Spanner:

0.8-1.2KgM

M6X21

8mm

(8-12

ROYAL

ENFIELD I EURO

IV •

SERVICE

MANUAL

LS

410 1

99