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EURO IV
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FOREWORD
Congratulations. You now own a piece of history!
The Royal Enfield Interceptor is our heritage-inspired machine, built for the modern, intrepid traveller.
With your new machine, we mark the return of one of Royal Enfield’s most loved classic motorcycles - the Interceptor.
Harking back to a time when all that mattered was that the California sun was out and the surf was up, this motorcycle retains the
charm that made it legendary.
Designed to be simple and robust with solid and precise engineering, the Interceptor has been built to be your faithful companion
on rides and adventures, big and small. Powered by our brand-new air-cooled 648cc twin cylinder engine and robust twin cradle
chassis developed at our state-of-the-art technology centre in the United Kingdom, we hope you enjoy riding your motorcycle as
much as we enjoyed building it for you.
This manual is your friend, philosopher, and guide when it comes to taking care of your motorcycle. In the pages that follow, you
will find ways of looking after your machine so that it remains a reliable partner in your travels and exploration for decades to
come.
Please do avail of all the services at your nearest Authorised Service Centre to make sure that your motorcycle gets the right
treatment which it so deserves. Please also read through the terms and conditions of warranty and other useful information in
this manual before riding o into the sunshine.
Keep riding pure.
To know more about Royal Enfield, our products, and other news, go to www.royalenfield.com
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NOTICE
All information in this manual is based on the latest product information available at the time of publication. Due to
continuous improvements, there may be discrepancies between the information in this manual and your motorcycle.
Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any
obligation to make the same or similar changes to motorcycle previously built or sold.
“© Copyright 2018 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this manual shall be
copied, distributed or otherwise dealt without the express permission in writing from Royal Enfield”.
All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical
specifications are subject to change without prior notice.
Avail further details on the products Repair and Maintenance Instructions at https://serviceinfo.royalenfield.com
through paid subscription.
Disclaimer
l This model fitted with “tubeless tyre” is provided with an inner tube.
l Failure to use an inner tube in a spoked wheel will cause deflation of the tyre resulting in loss of motorcycle control.
l The approved tyres marked with “TUBELESS” are suitable for use with inner tube.
Part No. RAM00010/A / Qty. 500 / Oct. ‘18
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CONTENTS
Safety Definitions ........................................................................................................................................................................ 5
Personal and Motorcycle Information ....................................................................................................................................... 6
Safe Riding Tips / Guidelines ..................................................................................................................................................... 7
Rules of the Road ......................................................................................................................................................................... 13
Accessories and Luggage ............................................................................................................................................................ 16
Technical Specifications .............................................................................................................................................................. 18
Recommended Lubricants ......................................................................................................................................................... 26
Motorcycle Identification Numbers ........................................................................................................................................... 28
Engine Number Details ............................................................................................................................................................... 30
Location of Key Parts ................................................................................................................................................................... 31
Operation of Controls .................................................................................................................................................................. 34
Warning Indications and Safety Systems .................................................................................................................................. 45
Pre-Operational Checks .............................................................................................................................................................. 49
Running in Period ........................................................................................................................................................................ 50
Starting ......................................................................................................................................................................................... 52
Gear Shifting, Riding and Stopping ........................................................................................................................................... 56
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CONTENTS
Park ing.......................................................................................................................................................................................... 60
Tools Kit ........................................................................................................................................................................................ 62
Minor Maintenance Tips ............................................................................................................................................................. 63
Long Trip Precautions .................................................................................................................................................................. 100
Washing Procedure ..................................................................................................................................................................... 102
Storage Precautions .................................................................................................................................................................... 104
Trouble Shooting .......................................................................................................................................................................... 105
Wiring Diagram ............................................................................................................................................................................ 113
Periodical Maintenance Chart .................................................................................................................................................... 1 16
Service Maintenance Record ...................................................................................................................................................... 120
Warranty Terms and Conditions ................................................................................................................................................ 123
Emission Warranty ...................................................................................................................................................................... 126
EVAP .............................................................................................................................................................................................. 132
Environment Care ....................................................................................................................................................................... 134
Notes ............................................................................................................................................................................................. 136
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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.
CAUT I O N
This message, if disregarded, may result in damage to the motorcycle.
NOTE
Indicates important and useful messages for better understanding.
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PERSONAL AND MOTORCYCLE INFORMATION
Name
Do or No ./Stre et
Loca lity/ To wn
City Co unt ry
Co ntac t
Licence No. Val id til l :
Model Col or :
Eng ine No.
VIN . No.
Tyre make Fro nt : Rear :
Tyre N os. Fro nt : Rear :
Battery ma ke Battery No.
Sol d b y
Date of Sal e
Res : Off :
Mobile : Email :
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SAFE RIDING TIPS / GUIDELINES
n
Before operating your new motorcycle, we request you to carefully read and follow the operating and maintenance
instructions detailed in this manual for the safety of your own, your motorcycle, and also that of others.
n Know and adhere to the rules of the road with respect to your driving country.
n Before starting the motorcycle, check for proper operation of brakes, clutch, gear shifter, handle bar controls, tyre
pressures, fuel and oil levels, etc.
n Use only genuine Royal Enfield spare parts and approved accessories. Use of other manufacturer’s parts may affect
the performance of your motorcycle and render the motorcycle void of warranty. Visit your Royal Enfield Authorised
Service Centre for details.
n Whenever refueling your motorcycle, please exercise utmost caution and carefully observe the following guidelines.
« Refuel in a well ventilated area with the engine turned off condition.
« Open the fuel filler cap slowly.
« Switch OFF mobile phones and other hand held electronic devices.
« DO NOT smoke and please ensure that there are no open flames or sparks near the motorcycle, when refuelling OR
servicing the fuel system.
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SAFE RIDING TIPS / GUIDELINES
« DO NOT fill the tank to its brim. Please fill fuel till the bottom of anti splash plate, so as to leave sufficient air space
in the fuel tank to allow for fuel expansion.
WARNIN G
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 accident.
n A new motorcycle must be operated according to the special running-in-procedure. See running-in-procedure
mentioned in respective section.
n 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.
n DO NOT exceed the legal speed limit or ride too fast for existing conditions. Always reduce speed when poor riding
conditions exist. High speed increases the influence of any other condition affecting stability and increases the
possibility of loss of control.
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SAFE RIDING TIPS / GUIDELINES
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 motorcycle. New riders should gain experience under various
conditions while driving at moderate speeds.
Pay strict attention to road surfaces and wind conditions. Any motorcycle may be subject to the following upsetting
forces:
« Wind blasts from passing vehicles.
« Rough or uneven road surfaces.
« Slippery road surfaces.
These forces may affect the handling characteristics of your motorcycle. If this happens, reduce speed of the motorcycle
to a controlled condition. Do not apply brake abruptly.
n Operate your motorcycle defensively. Remember that a motorcycle does not afford the same protection as an
automobile in an accident. One of the most common accident situations occurs when the rider / driver of the other
motorcycle / vehicle fails to see or recognise a motorcycle and turns into the oncoming motorcyclist.
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SAFE RIDING TIPS / GUIDELINES
n Wear an approved helmet, clothing, and footwear suited for riding a motorcycle. Bright/light colours are best for
greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.
n When carrying a pillion rider, it is your responsibility to instruct them on proper riding procedures.
n 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 shockabsorbers and front forks and look for leaks. Replace worn out parts. Worn out parts can adversely
affect stability and handling.
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/durability/longevity operation of your motorcycle.
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SAFE RIDING TIPS / GUIDELINES
WARNING
Avoid any contact with the exhaust system when hot. 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 to touch, even after the engine is turned off.
Failure to wear proper or protective clothing could result in serious injury.
WARNING
Exhaust gas contains poisonous carbon monoxide and chemicals, known to cause cancer, birth defects or other
reproductive defects.
WARNING
Motorcycle batteries contain lead, 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.
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SAFE RIDING TIPS / GUIDELINES
WARNING
Consult your Royal Enfield Authorised Service Centre 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 and jeopardize your personal safety.
WARNING
DO NOT tow a motorcycle. The steering and handling of the towed motorcycle will be impaired due to the force of the
towline. If a motorcycle must be transported, use a truck or a trailer.
WARNING
DO NOT pull a trailer behind a motorcycle. Towing a trailer may cause reduced braking efficiency, tyre overloading and
unstable handling, as it may cause loss of control of the motorcycle in the front, leading to an accident.
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RULES OF THE ROAD
Be sure your number plate is installed in the position specified by law and it is clearly visible at all times.
n
n Ride at a safe speed that is consistent with the type of road surface you are on. Pay strict attention while riding on the
following surfaces :
« Dusty
« Oily
« Icy
« Wet
« Sand
n Watch for loose debris, such as leaves, slippery substances or gravel that can hamper the stability of your motorcycle.
n Keep to the correct side of the road centre line when meeting oncoming vehicles.
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RULES OF THE ROAD
Actuate your turn signals and exercise caution when passing other vehicles going in the same direction. Never try to
n
pass another vehicle going in the same direction at street intersections, on curves, or when going up/or down a hill.
n At street intersection give the right-of-way to the motorcycle on your left or right. DO NOT presume you have the
right-of-way.
n Adhere to the rules of the road with respect to your country when preparing to stop, turn or pass. While turning either
right or left, watch for pedestrians, animals, as well as other vehicles.
n 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.
n When intending to turn, signal at least 100 feet (30.5 meters) before reaching the turning. Be close to
the centre line (unless local rules require otherwise), slow down and then turn carefully.
n 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.
n DO NOT leave the curb or parking area without signalling. Be sure your way is clear to enter moving
traffic. A moving line of traffic always has the right-of -way.
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RULES OF THE ROAD
n When parking the motorcycle, park on a firm and flat surface to prevent it from falling over.
n Protect your motorcycle against theft. After parking your motorcycle, ensure that the steering head is locked and then
remove the ignition key.
SIDE VIE W 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 of the rear than a
normal flat mirror. However, vehicles 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 vehicles / objects seen in these
mirrors.
NOTE
To establish the relative distance of vehicles / objects behind your motorcycle through the mirrors, 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 with
reference to your riding posture.
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ACCESSORIES AND LUGGAGE
Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested
alongside the motorcycle.
Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying
additional weight. (Max. pay load: 200 kg)
Please adhere to the following guidelines when carrying a pillion, luggage or when fitting any accessories.
DO NOT exceed 110km/h / 70 mph when riding solo, carrying a pillion or payload on an accessory equipped motorcycle.
n Keep luggage weight concentrated close to the motorcycle and as low as possible; this minimizes sudden shift in the
motorcycle’s centre of gravity.
nnDistribute weight evenly on both sides of the motorcycle.
n DO NOT load bulky items behind the rider or add weight to the handlebars or front forks.
n DO NOT exceed
n Re-check the luggage periodically to ensure it is secured and will not shift while riding. Accessories mounted loosely
may affect the riding of the motorcycle and affect the handling and stability of the motorcycle.
n Large surfaces such as fairings, windshields, backrests and luggage racks can adversely affect handling of the
motorcycle. Use Royal Enfield Genuine Motorcycle Accessories which are model specific and follow installation
procedure.
6.6 pounds (3 kgs)
maximum weight in each Royal Enfield Genuine motorcycle accessory pannier.
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ACCESSORIES AND LUGGAGE
WARNING
DO NOT load weight or install accessories incorrectly on the motorcycle. Doing so may affect the motorcycle’s stability,
handling characteristics and safe operation and could result in an accident causing serious injury or loss of life.
WARNING
Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested
alongside the motorcycle.
WARNING
Royal Enfield cautions you against use of nonstandard parts such as aftermarket and custom made extended front forks
which may adversely affect the performance and handling of the motorcycle. Removing or altering original parts may
adversely affect the performance of the motorcycle, causing an accident, which could result in serious injury or loss of life.
WARNING
DO NOT ignore model / design specifications. Doing so constitutes both motorcycle and accessories misuse which may
adversely affect the handling and performance of the motorcycle causing an accident, which could result in serious
injury or loss of life.
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TECHNICAL SPECIFICATIONS
ENGINE
Engine Type ........................................... Inline Twin Cylinder, 4 Stroke, SOHC
Bore ........................................................ 78 mm
Stroke ..................................................... 67.8 mm
Swept volume ....................................... 648cc
Compression ratio ................................. 9.5:1
Max Power ............................................. 34.9 kw @ 7250 rpm
Max Torque ............................................ 52.3 Nm @ 5150 rpm
Idle RPM ................................................. 1200+
Starting ................................................... E-Start
Air filter element ................................... Paper element
Lubrication ............................................ Forced lubrication, Wet sump with pump driven oil delivery
Gear Box ................................................. 6 Speed Constant Mesh
80 RPM
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TECHNICAL SPECIFICATIONS
Engine oil capacity Dry Fill ....... 3.9 litre / 1.03 imperial gallon
Refill .......... 3.1 litre / 0.82 imperial gallon
Engine oil grade .................................... TOTAL ELF MOTO 4 TECH SAE 10W50 API SL, JASO MA2, SYNTHETIC
Fuel Supply ............................................. Fuel Injection
Cooling .................................................. Air cooling
IGNITION SYSTEM
Ignition ................................................... Digital Spark ignition
Ignition Advanced ................................ 11.25 BTDC
Spark Plug .............................................. BOSCH UR5CC
Spark Plug Gap ...................................... 0.7 to 0.8 mm
o
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TECHNICAL SPECIFICATIONS
TRANSMISSION
Clutch ..................................................... Wet multiplate
Primary drive .......................................... Gear
Primary ratio ........................................... 2.05 : 1
Gear box ................................................. 6 Speed Constant Mesh
Gear Ratio ............................................... 1 2.615:1
.........................................................nd2 1.813:1
.........................................................
.........................................................
.........................................................
.........................................................th6 0:962:1
Secondary drive ...................................... Sprockets and Chain (5/8” Pitch)
Secondary Ratio.....................................2.533:1
st
rd
3 1.429:1
th
4 1.190:1
th
5 1:040:1
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TECHNICAL SPECIFICATIONS
CHAS SIS
Frame ..................................................... Steel Tubular, Double Cradle Frame
Suspension
Front ................................................ 41 mm Front Fork, 110 mm travel
Rear ................................................. Single Coil-over Shocks, 88 mm travel
Hydraulic Disc Brakes ........................... Front and Rear with ABS system.
............................................... Front: 320 mm disc, ABS
................................................. Rear: 240 mm disc, ABS
................................................. ABS: BOSCH 9.1
Brake Fluid:
..............................................
.........................................
Tyre size:
Front ................................................
Rear.................................................
Brakes:
Grade: DOT 4
Capacity:
Dual Channel ABS
Fr ont:
100/90-18, Pirelli Phantom Sports Comp
130/70-18, Pirelli Phantom Sports Comp
50 ml
Rear:
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100 ml
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TECHNICAL SPECIFICATIONS
Tyre Pressure:
Solo
Front................................................
Rear..................................................
With Pillion
Front................................................ 32 psi/2.20 kg/cm
Rear.................................................. 39 psi/2.74 kg/cm
Steering Lock.......................................... Combination Lock
Fuel Type ................................................ Unleaded Gasoline
Ethanol content ...................................... E10 or less
Minimum Octane Rating ....................... 91 RON (Research Octane Number) or Higher
Induction ................................................ Fuel Injected
Fuel tank capacity ................................... 13.7* litre / 3 *imperial gallon
Low Fuel Warning .................................. 2.9* litre / 0.63 *imperial gallon
Dead Stock.............................................. 0.75* litre / 0.16* imperial gallon
*
The above values are approximate and the actual fuel filling capacity will vary from the values mentioned.
32 psi/2.20 kg/cm
36 psi/2.53 kg/cm
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TECHNICAL SPECIFICATIONS
ELE CTRICALS
System .................................................... 12V - DC
Generation .............................................. Alternator
Alternator Output ................................... 156 W @ 1100 rpm
Battery .................................................... 12V - 12 Ah VRLA
Head lamp .............................................. 12V, H4 60/55 W
Brake/Tail lamp ...................................... 12V, P21/5W (Halogen)
Turn signal .............................................. 12V, R10W
Instrument Cluster .................................. Digital Instrument Cluster with LCD
Horn ........................................................ 320 Hz Low and 420 Hz High Tone
Starter Motor .......................................... 12V, 0.8 KW
WA RN I N G
Using bulbs / other electrical accessories other than specified rating may lead to over loading / erratic behaviour /
premature failure of electrical system. Modifications on the motorcycle which are not approved by Royal Enfield may
not only disqualify for warranty, but will also affects the performance of the motorcycle.
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TECHNICAL SPECIFICATIONS
DIM EN SIONS
Rake ........................................................ 24 degrees
Front Wheel ............................................ 18 M/C x MT 2.50
Rear Wheel ............................................. 18 M/C x MT 3.50
Length..................................................... 2119 mm
Width .............................................. 857 mm (with mirrors)
Height .............................................. 1120 mm
Wheel base ............................................. 1398 mm
Ground Clearance ................................... 174 mm
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TECHNICAL SPECIFICATIONS
WEIGHT S
Kerb weight (90% Fuel and Oil) ........... 213 kg
Max. pay load.......................................... 200 kg (Inclusive of rider mass)
NOTE
n Values / dimensions given above only for your guidance.
n In view of continuous improvements being done on our products, the specifications could change without prior
notice.
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RECOMMENDED LUBRICANTS
Engine Oil
TOTAL ELF MOTO 4 TECH SAE
Grade
Capacity
CAUTION
Use of wrong oil grade will reduce the life of the moving parts and seriously affect performance.
NOTE
Recommendation subject to change without notice.
10W50 API SL, JASO MA2,
SYNTHETIC
1st Dry Fill :
3.9 litre /
1.03 imperial gallons
Routine Oil Change :
3.1 litre /
0.82 imperial gallons
Front Fork Oil
Grade 2W 25 HPCL
Capacity
*
DO NOT Mix DOT 4 or
other brake fluids together.
26
473 ml / Fork
Grade
Capacity
Brake Fluid
DOT 4
Front: 50 ml
Rear: 100 ml
Brake System
Dual Channel ABS
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ISO 14001 OPERATION CONTROL PROCESS
As per the guidelines in ISO 14001 Environmental Management System, customers are advised to carry out timely
replacement of engine oil, fork oil and brake fluid, ONLY through a Royal Enfield Authorised Service Centre for the safe
disposal of the used oils to prevent environmental pollution.
In case the oils are replaced privately, it is advised to ensure the old / removed oils are collected carefully and disposed
through a certified disposal agency.
Similarly, hazardous waste such as old / discarded batteries, tyres, tubes, cables, gaskets, oil filters etc. should also be
disposed off carefully and properly, through a certified disposal agency.
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MOTORCYCLE IDENTIFICATION NUMBERS
The VIN is a 17 digit number punched on the right side steering head tube in the form of label.
Sample VIN : ME3 X X XX X X J X X X X X X X
Manufacturer’s code
Type of Frame
Type of Engine
Commercial Name
Ignition System
Transmission Type
Production Year
(2017:H, 2018: J, 2019: K)
Assembly factory
(C-Chen nai, K-Kan chipuram)
Production Serial No.
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MOTORCYCLE IDENTIFICATION NUMBERS
CHASSIS NUMBER
Punched on the steering head tube right side
VIN INFORMATION LABEL
CAUTION
It is illegal to tamper with the VIN information label as it is the only means of identifications of the motorcycle.
29
ME3CNEHT6HK000001
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ENGINE NUMBER - DETAILS
The engine number is punched above the oil filter location. it is the means of identification of the engine serial number
and its production details. It is illegal to tamper with the engine number as it is the only means of identifications of the
engine.
Engine Family
Engine Capacity
Type of Cooling
Transmission
Fuel Feed
Production Month
(A - Jan., h - Aug ., K - Sep., N - DEC.)
Year of Manufacturing
(2017:H, 2018:J, 2019:K)
Place of Manufacturing
(0-Chennai, 1-Kanchipuram)
Production Serial Nos.
P
A 6 F K H 1
7
000086
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LOCATION OF KEY PARTS
6 10
89
7
45
3
100
120
R.P.M. x 1000
140
km/h
160
1
180
200
E
F
km
ODO
002000400060008000
00
00
00
00
00
00
00
00
00200300400500600700800900
ABS
N
OFF
2
1
11
1. Horn Button
2. Turn Signal Switch
3. Clutch Lever
4. Day Flash Switch
5. High Beam / Low Beam Switch
6. Instrument Cluster
7. Ignition Switch
8. Malfunction Indicator Lamp
12
9. RPM (Tacho) Meter
10. Engine Kill switch
11. Electric Start Switch
12. Fuel Tank Cap
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LOCATION OF KEY PARTS
8
2
1
7
6
45
3
32
1. Right Trafficator R ear
2. Right Trafficator Front
3. Horn
4. Starter Motor
5. Brake Pedal
6. Brake Lever Rear
7. Right Side Panel
8. Brake Lever Front
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LOCATION OF KEY PARTS
3
1. Left Trafficator Front
1
2
7 6
5
4
33
2. Left Trafficator Rear
3. Left Side Panel
4. Side Stand
5. Centre stand
6. Gear Change Pedal
7. Spark plug
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OPERATION OF CONTROLS
IGNITION SWITCH
OFF: Steering unlock, ignition “OFF”
ON: Steering unlock, ignition “ON”
NOTE
n Key is common for ignition, petrol tank lock, steering lock and side panels.
n Key can be removed from fuel tank, side panel only in locked position from the key slots.
STEERING LOCK
n Turn the handle bar to extreme left or right position.
n Push the key inside at “OFF” position, press and further turn to anticlockwise direction to
lock the steering and remove the key.
n
To unlock, insert the key in steering at lock position, and turn clockwise direction.
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OPERATION OF CONTROLS
FUEL TANK CAP
n Lift key flap on fuel tank cap and insert key.
n Turn key clockwise to open.
n Press cap to lock with key in position.
n Remove key from cap and close flap
WARNING
n DO NOT overfill the fuel tank.
n Fill fuel only till the bottom of anti splash plate.
n Over filling may result in gasoline entering the EVAP canister and may damage the Evaporative Emission System.
CAUTION
Gasoline vapour is highly explosive. Please ensure there are no open flames or sparks nearby while refueling and fill fuel
only in a well ventilated area.
Please ensure gasoline does not spill on painted surfaces. In case fuel spills over the painted surfaces wipe it off immediately
as it may leave a permanent stain.
Do not smoke while refueling or when fuel tank cap is open.
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OPERATION OF CONTROLS
FUEL FILLING LEVEL
1. Fuel filler collar
2. Anti splash plate
3. Maximum fuel level
ENGINE KILL SWITCH
Engine "OFF"
CAUT I O N
n Turn off ignition switch when engine is not running. Failure to do so will discharge the battery due to the headlamp
being continuously "ON".
Engine "ON"
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OPERATION OF CONTROLS
E-START SWITCH
Depress and hold untill engine starts for a maximum of 5 seconds.
HORN
Press the horn button to sound horn.
HI BEAM / LOW BEAM SWITCH
n When the headlamp is in ON condition “High / Low beam” will be selected by toggling
the switch. High beam indicator lamp located in instrument cluster will glow when high
beam is selected.
High beam
Low beam
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OPERATION OF CONTROLS
DAY FLASH
Press the switch for Day flash.
TURN SIGNAL SWITCH
Left turn signal "ON"
Right turn signal "ON"
"OFF" (Push to cancel)
Push the button from “OFF” position to either left or right before turning as needed and restore to “OFF” position to stop
blinking.
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OPERATION OF CONTROLS
SIDE PANEL LEFT
n To access the left side panel remove the seat and retaining screw, pull and disengage the
side panel from locater and gently remove the side panel.
SIDE PANEL RIGHT
n Turn key clockwise to unlock the side panel.
n Pull the side panel along with key to gently remove the side panel.
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OPERATION OF CONTROLS
INSTRUMENT CLUSTER
This instrument cluster consists of the following:
1. Speedometer
2. Odometer
3. Selection Button
4. Trip Meter 'A' and 'B'
5. Turn Signal Indicator
6. Hi beam Indicator
7. Engine Malfunction Indicator
8. Battery Low Voltage Indicator
9. Fuel Level Indicator
10. ABS Indicator
1 2 4 9 3 13 5 7 6 810 11 12
11. Neutral Indicator
12. Low Oil Pressure Indicator
13. Tachometer
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OPERATION OF CONTROLS
1. SPEEDOMETER
The Speedometer indicates the speed at which motorcycle is travelling and has both kms/
miles calibration.
2. ODOMETER
The default display in the odometer is the total kms/miles, the motorcycle has covered
NOTE
The last selection mode will be displayed whenever ignition is switched "ON".
WARNIN G
It is illegal to tamper with the odometer display or reset the total kms/miles, the motorcycle has covered.
It is illegal to ride the motorcycle after disconnecting the speed sensor of the motorcycle.
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OPERATION OF CONTROLS
3. SELECTOR BUTTON
The selector knob will help to select between odometer, Trip ‘A’ or Trip ‘B’.
4. TRIP METER A AND B
A light push for less than one second on the select button switch will change the display from odometer Trip ‘A’. Again
another press on the select button switch will change the display from Trip ‘A’ to Trip ‘B’.
NOTE
1. Set the display as Trip ‘A’ or Trip ‘B’ as current mode.
2. Press the select button for more than 3 seconds.
3. Automatically the display will become zero.
WARNING
Do not attempt to change any setting while riding the motorcycle. It may cause loss of control leading to an accident.
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OPERATION OF CONTROLS
5. TURN SIGNAL INDICATOR
Indicates that either the left or right indicators are “ON”.
6. HI BEAM INDICATOR
Indicates that the high beam head lamp is “ON”.
7. ENGINE MALFUNCTION INDICATOR LAMP
A Malfunctioning indicator lamp (MIL) is provided in the tachometer.
When both the ignition and engine kill switch is in “ON” position and after vehicle is started, the
MIL will glow for few seconds and switch “OFF” this indicates that all the functions of Electronic
fuel injection (EFI) system is functioning normally. In the event of any malfunction in the EFI system MIL will glow
continuously. It is recommended to take the motorcycle to a nearest Royal Enfield Authorised Service Centre for a detailed
inspection and correction of EFI system.
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OPERATION OF CONTROLS
8. BATTERY L OW VOLTAGE INDICATOR
When the ignition switch is turned in “ON” position, low voltage indicator symbol will glow.
As soon as the engine is started the battery low voltage indicator turns “OFF” automatically.
In case the battery voltage is below 12 volt and the battery is not charging when the engine is
started, the battery low voltage indicator will continue to glow in the instrument cluster.
CAUT I O N
DO NOT ride the motorcycle if the battery low voltage indicator is glowing continuously and please get the charging
system checked through an Royal Enfield Authorised Service Centre immediately.
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WARNING INDICATIONS AND SAFETY SYSTEMS
Your motorcycle is fitted with the fol lowing warning indications and safe ty systems:
9. FUEL LEVEL INDICATOR
The fuel level indicator indicates the level of fuel in the fuel tank.
The display bars of the fuel meter fades towards the empty (E) when the fuel level decreases
from full tank level (F).
The last bar of the fuel level indication in the instrument cluster will blink continuously when the fuel is less than 3 litre
(0.8 imperial gallon).
Please do not ride the motorcycle with the low fuel indication blinking continuously as it may not only result in the
motorcycle running out of fuel, but will also cause serious damage to the fuel pump. Please refuel as soon as the low fuel
indication starts blinking.
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WARNING INDICATIONS AND SAFETY SYSTEMS
10. ANTI-LOCK BRAKING SYSTEM (ABS)
Anti-Lock Braking System (ABS) will help prevent the brakes from locking the wheels,
during sudden application of the brakes at high speeds or at low friction surfaces. This will
help the rider to have better traction and control over the motorcycle and prevent the
motorcycle from skidding which can cause an accident.
In the event of a sudden and hard application of the brakes by the rider, the sensors in the braking
system will signal the ABS modulator to momentarily and continously reduce the hydraulic
pressure and thereby prevent the brakes from locking the wheels while reducing the speed of
the vehicle. This will help the rider to control the motorcycle.
An ABS indicator lamp is provided in the cluster (as shown in the adjacent image) to warn the rider in the event of any
malfunction of the ABS.
When the ignition and engine kill switch are switched in “ON” position the ABS sign will glow and remain "ON" till the
motorcycle attains a speed of 5 kmph / 3 Mph and turns “OFF”. This indicates the ABS is functioning properly. If the
ABS indicator lamp does not switch "OFF" and remains continuously "ON" at higher speeds, it is recommended not to
drive the ABS motorcycle. Get the brake system inspected and corrected through a nearest Authorised Royal Enfield
Service Centre. Failure to do so can result in a serious injuries and loss of life.
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WARNING INDICATIONS AND SAFETY SYSTEMS
CAUTION (ABS)
ABS is a safety feature to help prevent locking of wheels during panic application of brakes. It is by no means a substitute
for good riding practices and anticipatory braking.
Please ride carefully and apply brakes cautiously, especially while cornering. ABS cannot estimate the “weight shifts” and
momentum of the motorcycle while negotiating a corner and therefore prevent skidding due to loss of traction.
Please anticipate the stoppin g distance required for the speed of travel and apply brakes well in advance so as to bring the
motorcycle to a safe stop.
Please apply both brakes simultaneously to stop with better traction and control of the motorcycle.
Failure to adhere to the above can cause an accident resulting in serious injuries and loss of life.
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WARNING INDICATIONS AND SAFETY SYSTEMS
DO’S AND DONT’S : (ABS)
DO’S
n While starting the engine do check the ABS indicator glows “ON” and
turns OFF when the vehicle speed exceeds 5 km/h (3.1 mph).
n Please check the brake fluid at “MAX” level in the front and rear brake
reservoir and ensure there is no leak in the brake systems.
n Apply both the brakes simultaneously for better efficiency.
n In the event of the ABS indicator remaining continuously “ON”, please
take the motorcycle to a nearest Authorised Royal Enfield Service Centre
to inspect the brake system.
11. NEUTRAL INDICATOR
This indicator glows when the vehicle is in neutral position.
12. LOW OIL PRESSURE INDICATOR
This indicator glows whenever the oil pressure is too low. When the ignition switch is in “ON” position with the
engine not running condition the indicator goes off when the engine oil pressure is high enough / normal condition.
48
DON T’S
DO NOT RELEASE
n
pedal when pulsations are felt during
hard application of the brakes in an
emergency situation. The pulsations
only indicate that the ABS is
activated.
n DO NOT APPLY only the front OR rear
brake as it can lead to inefficient
braking.
the brake lever/
Page 50
WARNING INDICATIONS AND SAFETY SYSTEMS
CAUTION
When the indicator glows continously and if the engine speed is above idle, stop the vehicle immediately and get the
engine inspected and corrected through a nearest Authorised Royal Enfield Service Centre. Failure to do so can cause
engine damage.
13. TACHOMETER
This indicates the engine speed in RPM.
ROLL OVER SENSOR
In the event of motorcycle falling over on either of its sides with the engine running and the gear engaged the roll over
sensor will disable both the ignition and fuel systems and switch “OFF” the engine. This is to prevent further damage to
the motorcycle and the rider.
To reset the roll over sensor and reactivate the ignition and fuel systems.
n Ensure the motorcycle is parked upright on a firm surface.
n Ensure gear is in neutral position and the neutral lamp is glowing in the instrument cluster.
n Turn “OFF” ignition and switch “OFF” engine kill switch, wait for a few seconds and turn “ON” the Ignition and switch
“ON” engine kill switch once again, to start the engine.
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PRE OPERATIONAL CHECKS
A careful check on the following aspects must be carried out every time before riding and especially after long periods of
storage to determine if any additional maintenance is necessary.
1. Adequate fuel in the tank for the journey planned.
2. Tyres for correct pressure, abrasions or cuts.
3. Ensure chain for proper tension and sufficient lubrication.
4. Brakes, clutch, steering and throttle for proper responsiveness.
5. Handle bar controls for smooth operation.
6. Engine oil level.
7. Wheel spokes for proper tightness and damage.
8. Headlamp, tail lamp, brake lamp and indicator lamps for proper functioning.
9. Proper functioning of all the warning lamps in the instrument cluster.
WARNING
For your personal welfare and safety, all the points mentioned above should be performed periodically. Failure to do so
may affect safe operation, damage your motorcycle and could result in an accident causing serious injury or loss of life.
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RUNNING IN PERIOD
The Royal Enfield Motorcycle as you would be experiencing is capable of consistent high speeds. However as with any
new motorcycle, a “RUNNING-IN” procedure is essential to help in proper “Bedding-In” of the various moving parts in
your motorcycle and to achieve optimum performance subsequently.
1. DO NOT exceed maximum specified pay load.
2. Warm up the engine for a few minutes at idling speed to allow engine oil to lubricate all the moving parts in the engine
before riding the motorcycle.
3. Avoid full throttle operation and do not ride at constant throttle continuously. Vary the speed by 10% while riding.
4. It is recommended to use half clutch condition when commuting in the city traffic condition alone (Engine RPM
around idling to 2000 RPM) at 1st gear condition. In Other gears and higher RPM avoid using half clutch which will
proportionately reduce the clutch life. During acceleration/ deceleration disengage the clutch completely, shift the
gear and engage the clutch gradually (Not too slowly).
5. Ride at proper speed and avoid sudden accelerations and braking.
6. Avoid riding motorcycle continuously for over an hour, it is recommended to take brief stop.
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RUNNING IN PERIOD
During the first 2000 Kms of run, do not exceed the speed limits as shown in the table below.
Motorcycle Speed
Gear
1
NOTE
The below table indicates the recommended engine speed in rpm for optimum performance of the engine.
Distance Covered Max. Engine Speed
0 to 800 kms ( 0 to 500 miles) 4000 rpm
800 to 1600 kms ( 500 to 1000 miles) 6000 rpm
First 500 kms 501 - 2000 kms
20 kmph15 kmph
30 kmph25 kmph2
40 kmph30 kmph3
55 kmph45 kmph4
70 kmph60 kmph5
85 kmph75 kmph6
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STARTING
To shift into neutral, move the motorcycle back and forth gentl y, while
n
simultaneously shifting the gear. Ensure gear is in neutral position and the
neutral lamp is glowing in the instrument cluster.
n Turn ignition key to “ON” position and engine kill switch on right hand side
handle bar to “RUN” position .
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STARTING
When both the ignition and engine kill switch is in "ON" position and after the
n
vehicle is started, the MIL will glow for a few seconds and turns “OFF”, this indicates
that all the function of the electronic fuel injection (EFI) system is functioning normally.
In the event of any malfunction in the EFI system the MIL will glow continuously.
CAUT I O N
n In case the malfunction indicator DOES NOT turn “OFF”, get the motorcycle checked
through an Royal Enfield Authorised Service Centre for rectification.
n Check the fuel level indicator in the cluster for adequate fuel in the fuel tank. In case the
last bar is blinking continuously, it indicates low fuel leve l in the tank. Please re-fuel
immediatel y.
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STARTING
Disengage clutch by pulling in the clutch lever and hold it in depressed condition.
n
n Depress and hold electric start switch until engine starts for a maximum of
5 seconds.
NOTE
In case the engine does not start within 5 second, release starter switch and wait for about 5 second before attempting to
start the engine again.
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STARTING
CAUT I O N
If the engine does not start. DO NOT hold the starter switch in depressed condition for long periods, this will cause the
battery to drain below the threshold level of 10 volt. Please get the motorcycle checked through an Royal Enfield Authorised
Service Centre to identify and correct the reason for not starting.
CAUT I O N
NEVER accelerate as soon as the engine starts, especially in cold condition. The engine should be allowed to run in idle
RPM for at least 2 minute for the engine oil to circulate and lubricate all the internal moving parts and for the engine
temperature to raise. Failure to adhere to this important information will cause serious damage to the engine internals.
Accelerate only after the idling RPM has stabilised and it is consistent.
Ensure side stand is in fully retracted position. Failure to do so will cause the engine to switch “OFF” as soon as gear
n
is engaged.
WARNIN G
Please exercise extreme care while riding the motorcycle. Failure to do so can result in an accident causing injury to you
or to other road users / passerby.
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GEAR SHIFTING, RIDING AND STOPPING
The clutch lever must be fully depressed before attempting a gear shift. Failure to fully
depress the clutch lever will cause a roughstart OR stalling of the engine besides causing
damage to transmission parts.
n When the vehicle is in Neutral position, press gear shift lever down with toe to engage
1st gear.
GEAR SHIFT PATTERN
1 -- N -- 2 -- 3 -- 4 -- 5 -- 6
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GEAR SHIFTING, RIDING AND STOPPING
CAUT I O N
n If the clutch lever is released abruptly and throttle opening is done insufficiently the motorcycle will have a rough start
and cause the engine to stall.
n If the acceleration is very high and clutch lever is released abruptly, it will cause motorcycle to move suddenly, which
will lead to loss of control leading to an accident resulting in injury and or loss of life to rider / other road users / passed
by, besides damage to the motorcycle.
n Always exercise utmost caution while releasing clutch and riding the motorcycle.
n Lift gear shift lever up with toe to shift to 2nd and subsequent gears.
n As soon as the motorcycle reaches a speed of 20 kmph in 1st gear position, shift to
2nd gear and to higher gears as the speed of the motorcycle increases.
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GEAR SHIFTING, RIDING AND STOPPING
NOTE
Always start motorcycle with the gear in neutral position.
When the engine speed decreases or 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.
n Always shift to lower gears as appropriate whenever slowing down to stop the vehicle.
n Shift gears to neutral position just before bringing the vehicle to a complete stop always.
n Close throttle fully and release the clutch lever slowly ensuring the motorcycle is in neutral position and neutral lamp
is glowing.
n Stop the motorcycle in a safe place, turn “OFF” ignition and switch “OFF” engine kill switch.
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PARKING
PARKING MOTORCYCLE ON CENTRE STAND
n Select a firm, flat surface.
n Hold handle bar firmly in a straight position.
n Lower centre stand, such that, both the legs of the stand are resting on a firm ground.
n Apply pressure on the fulcrum lever on the centre stand and pull the motorcycle backward.
n Lock the steering and ensure the handle bar is locked firmly before removing the key from
the ignition barrel.
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PARKING
PARKING MOTORCYCLE ON SIDE STAND
n Select a firm, flat surface.
n Extend side stand. Tilt the motorcycle to the left side, till it is supported firmly on the
ground.
WARNING
Ensure both stands are fully retracted before riding the motorcycle.
Please exercise extreme care while parking and ensure it is parked on a firm and flat surface to avoid the motorcycle from
falling over and causing injury to you or to others and damage to the motorcycle parts.
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TOOLS KIT
The tool kit is located in the right side panel of the motorcycle.
S.No. Description Qty.
1. C Spanner 1
2. Allen Key 6mm 1
3. Allen Key 5mm 1
4. Allen Key 4mm 1
5. Extension Tube 1
6. Ring Spanner 24 x 14 Combination 1
7. Screwdriver 06 x 160 1
8. Double End Spanner 10 x 12 2
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MINOR MAINTENANCE TIPS
The following simple maintenance activities will help maintaining your motorcycle. However, for an complete
maintenance, we recommend you to get in touch with a Royal Enfield Authorised Service Centre.
HAND LEVERS, CENTRE AND SIDE STAND PIVOTS
n Clean the pivot points and ensure they are free of any dirt, grime, rust, etc.
n Lubricate the pivots.
NOTE
Wipe off the excess lubricant to prevent dirt and grime from accumulating.
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MINOR MAINTENANCE TIPS
DRIVE CHAIN
n Spray drive chain with recommended chain cleaning solvent while simultane-
ously rotating rear wheel.
n Ensure the drive chain has been sufficiently and completely covered with the
cleaning solvent. If necessary use a suitable brush to remove hard deposits from
the chain.
n Wait for a few minutes and clean the chain thoroughly from any dirt, grime, etc.
n Rotate rear wheel slowly and simultaneously apply recommended chain
lubricant on the chain links.
Wipe off excess chain lubricant after a few minutes with a clean cloth.
n
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MINOR MAINTENANCE TIPS
OIL LEVEL INSPECTION
n Ensure motorcycle is in upright position on a firm and flat surface on its centre
stand.
n Start the engine and allow it to run in idling rpm for about 2 minute and switch
off the ignition.
n Wait for 2 minute for the oil to settle down and check oil level through the
window on RH cover of the engine.
n The level is correct only if the oil is found between the “MIN” and “MAX” marks on the cover RH.
n If necessary top up ONLY with recommended engine oil till the level is between the “MIN” and “MAX” markings.
CAUTION
Use of wrong grade or spurious oils can seriously affect motorcycle performance and damage to moving parts. DO NOT
over fill beyond the “MAX” level or allow oil level to drop below the “MIN” level.
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MINOR MAINTENANCE TIPS
n Remove the engine oil filler cap for adding the engine oil.
n Place a clean tray under the engine oil magnetic drain plug. Remove it along
with the washer to drain oil completely from the engine.
WARNING
DO NOT spill the engine oil. Store used oil in a separate container and dispose it.
Avoid skin or body contact with the oil. Promptly wash the affected areas with
soap and water till it is cleaned thoroughly.
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MINOR MAINTENANCE TIPS
NOTE
Ensure the engine oil is drained completely. Drain the oil completely and to avoid oil spilling.
ENGINE OIL FILLING
n Place a container under engine oil drain bolt.
n Gently apply thread sealant on drain plug thread.
Insert the drain plug bolt along with new washer.
n
Tighten the drain plug bolt to 35 Nm.
n
Refill the engine oil recommended level.
n
n Close engine oil filler cap.
n Start and warm up engine for 2 to 3 minutes and then turn it off. Check oil level
through oil level window.
CAUTION
DO NOT over fill engine oil as excess oil will spill over through the crankcase
breathing system and clog the air filter.
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MINOR MAINTENANCE TIPS
SPARK PLUG
CLEANING SPARK PLUG AND ADJUSTING GAP
n Disconnect spark plug caps from the spark plugs.
n Locate spark plug spanner on the spark plug, loosen spark plug and remove it from
cylinder head.
n Check spark plug for carbon deposits and centre electrodes for uneven wear.
n Clean spark plug by positioning it in a spark plug cleaning machine.
Remove spark plug from the cleaning machine, check and set electrode gap between 0.7 to 0.8 mm.
n
n Position spark plug in the spark plug testing machine and check for proper functioning of the spark plug.
n Always replace spark plugs ONLY as per recommended specification.
n Apply a thin film of “anti seize” on the spark plug mounting and threads fix the spark plug by hand tightening.
n Tighten spark plug to torque 10 to 15 Nm by using a spark plug spanner.
68
Gap 0.7 to 0.8 mm.
Page 70
MINOR MAINTENANCE TIPS
BRAKE FLUID FRONT AND REAR
Ensure motorcycle is upright on a firm flat surface on its centre stand.
n
n Check brake fluid level in the window on front and rear reservoirs.
n The level is correct if the oil level is between the “MIN” and “MAX” marks.
n Open the reservoir cover and remove diaphragm carefully to top up
the brake fluid.
n Top up only with DOT 4 brake fluid untill level is between “MIN” and “MAX” marks in the reservoir.
n Replace diaphragm correctly and close cover firmly.
n Wipe off any excess / spilled brake fluid immediately with a clean cloth.
CAUTION
Brake fluid is highly corrosive and can cause damage to painted parts. Please ensure that brake fluid does not spill on any
part of the motorcycle. In the event of a spill, please clean the area immediately with a soft wet cloth to avoid damage to
the affected part.
DO NOT mix different brake fluid grades. Use ONLY DOT 4 Brake fluid.
69
Front Bra ke Rear Brake
Page 71
MINOR MAINTENANCE TIPS
INSPECTION OF TYRES AND WHEELS
n Inspect the tyres periodically for tread wear, cracks and cuts.
Minimum tread depth :
Front tyre : 1 mm Rear tyre : 2 mm
n Check and remove stone, splinters, nails or other particles embedded in the tyre treads.
n Periodically inspect wheels for spokes damage and wheel rim for wobbling or run out.
n Check uniform seating of the tyre beading on the rim whenever the tyre is reassembled.
n Use only recommended tyres and tubes, inflated to correct air pressure as given below.
Front Rear
Solo 32 psi/2.20 kg/cm 36 psi/2.53 kg/cm
With Pillion 32 psi/2.20 kg/cm 39 psi/2.74 kg/cm
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MINOR MAINTENANCE TIPS
FRONT WHEEL REMOVAL
n Ensure motorcycle is upright on a firm and flat surface.
n Place a wooden block on the front end of engine to support the motorcycle and ensure
front wheel is off the ground by minimum 2 inches.
n From wiring harness RH side disconnect the speedo drive coupler.
n Loosen the pinch bolt on the front fork bottom right side.
n Remove the axle nut along with washer, hold the wheel axle on the right side and loosen
hex nut on the left completely.
n Remove axle nut and washer from wheel axle.
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MINOR MAINTENANCE TIPS
n Tap and remove the front wheel spindle, gently tap axle from left side while supporting
wheel at the bottom then remove axle from the right side.
CAUTION
Take care to secure the wheel spacers and speed sensor while removing the axle from the
forks.
n Slide out the front wheel from the forks.
CAUTION
Do not press the brake lever when front wheel is removed as this will result in the brake pads coming too far out of the
brake caliper.
n
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.
n Take care not to damage the front brake disc or tonering as it will affect the braking system and ABS.
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MINOR MAINTENANCE TIPS
FRONT WHEEL REASSEMBLY
n Remove the wooden piece / cardboard sheet placed between the brake pads
n Locate speedo drive to its correct position on the right side.
n Locate stepped spacer to the wheel hub on left side.
n Insert the wheel along with speedo drive and spacer between the fork ends. Ensure the
brake disc is located between the brake pads.
n Support front wheel at the bottom and ensure the mounting holes are aligned to insert
the wheel axle along the right side fork end. Gently tap axle into wheel till the threaded
portion of axle is fully visible on the left side fork end.
n Assemble washer and nut on axle.
n Hold the wheel axle firmly on right side and tighten axle nut firmly on left side to a
torque of 70 Nm.
n Tighten pinch bolt completely on fork end to a torque of 25 Nm.
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MINOR MAINTENANCE TIPS
n Rotate wheel to check for smooth rotation.
n Connect the speedo wire coupler and check for proper working of speedometer.
n Press brake lever and check front brake efficiency.
CAUTION
Please exercise utmost caution while reassembling the front wheel on the motorcycle.
please ensure the wheel is fitted correctly before attempting to ride the motorcycle.
Failure to do so may result in the motrocycel not performing correctly, may lead to an accident causing injury to you /
other road users and may lead to loss of life.
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MINOR MAINTENANCE TIPS
REAR WHEEL REMOVAL
n Ensure motorcycle is upright on a firm and flat surface with the rear wheel atleast
6 inches raised above from the surface.
n Observe and mark the alignment indexes on both chain adjuster on left and right
side swing arm.
n Loosen the lock nuts and adjuster nuts fully on the left and right side chain adjuster.
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MINOR MAINTENANCE TIPS
n Hold wheel spindle on left side firmly and loosen hex nut on right side.
n Remove the nut and washer from the wheel spindle.
n Push rear wheel fully into the swing arm.
n Support rear wheel from bottom and pull out wheel spindle from the left side swing
arm.
n Release the brake hose gently and remove caliper assembly from swing arm on
right side.
CAUTION
n
Ensure brake hose does not get damaged or kinked while removing.
n Support caliper assembly suitably and away from swing arm.
n Release the chain from the sprocket and ensure it does not get jammed or damaged
when removing rear wheel.
n Remove support from wheel bottom and gently slide out rear wheel from the swing
arm with rear sprocket, brake disc and spacers.
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MINOR MAINTENANCE TIPS
CAUTION
Do not press the rear brake pedal when the rear wheel is being removed as this will cause the brake pads to dislocate from
the brake caliper.
n Place a 4 mm thick wooden piece or cardboard sheet between the brake
pads to avoid activation of brake pads if rear brake pedal is accidentally
pressed.
CAUTION
DO NOT pull up the rear brake pedal to lift or raise the motorcycle for any reason.
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MINOR MAINTENANCE TIPS
REAR WHEEL REASSEMBLY
n Ensure that the long stepped spacer is located on the brake disc side and the short spacer
is located on the sprocket side of the wheel hub firmly.
n Ensure that the chain adjuster are located properly inside the swing arm left and right
sides.
n Locate caliper assembly on the tab along the swing arm right side.
n Locate rear wheel with the sprocket to the left side ensuring the brake disc in-between
the brake pads on right side.
n Lift up the rear wheel and ensure that the slots in the swing arm brake caliper bracket
holes in chain adjusters and the centre hole in the hub are aligned.
n Support rear wheel suitably and insert rear wheel spindle along the left side swing arm
into the wheel hub.
n Ensure that the long stepped spacer is located along the brake side and the short spacer
is located along the sprocket side on the wheel hub.
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MINOR MAINTENANCE TIPS
n Tap spindle gently into wheel hub slot till the threads are completely visible on the right
side.
n Assemble the drive chain on the sprocket and ensure it is seated correctly.
n Check for free and smooth rotation of the rear wheel.
n Assemble washer and hex nut on wheel spindle on right side.
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MINOR MAINTENANCE TIPS
DO NOT TIGHTEN HEX NUT FULLY
n Tighten chain adjuster nuts on left and right adjuster such that the index marks are aligned correctly on both sides of
the swing arm.
n Check and ensure correct chain tension and wheel alignment.
n Hold spindle firmly on left side and tighten hex nut on right side set torque to 70 Nm.
n Locate the brake hose in the clips along the swing arm right side.
n Check rear brake for proper operating efficiency.
CAUTION
Please exercise utmost caution while reassembling the rear wheel on the motorcycle.
Please ensure the wheel is fitted correctly before attempting to ride the motorcycle.
Failure to do so will result in poor performance of motorcycle which may lead to an accident causing injury to you / other
road users and may lead to loss of life.
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MINOR MAINTENANCE TIPS
ADJUSTMENTS - CLUTCH
n Loosen the cable outer lock nut .
n Turn the nut clockwise to reduce the play or anticlockwise to increase the free
play.
n Tighten lock nut after adjustment is done.
n Check free play 2 to 3 mm at clutch lever pivot on handle bar end, if desired free
play is not achieved readjust.
REAR BRAKE LIGHT
The brake light glows once you press the brake lever.
If brake light is not glowing, check the brake light switch wire for proper connection.
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MINOR MAINTENANCE TIPS
DRIVE CHAIN TENSION
Park motorcycle up right on a firm and flat surface.
n
n Ensure the motorcycle is in neutral position.
n Measure the drive chain free play as shown. The drive chain free play is 20 mm
to 30 mm.
1. If the drive chain free play is found to be incorrect adjust as follows:
a. Loosen the axle nut of the rear wheel axle.
b. Loosen the lock nut on the adjuster at both end of the swing arm.
c. To reduce the free play, tighten the adjuster nut on the adjuster evenly.
(Free Play 20-30 mm)
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MINOR MAINTENANCE TIPS
d. To increase the free play, loosen the adjuster nuts evenly and push the rear wheel forward.
e. Check the chain for correct chain tension.
f. Ensure that the index marks on the adjuster and swing arm are same on both left and right side of the swing arm.
g. Hold spindle firmly to the left side and tighten rear hex nut to a torque of 70 Nm.
h. Tighten the adjuster locknut using a 24mm spanner.
WARNING
Chain slackness beyond 30mm will lead to chain slippage and may also cause increased wear rates to chain and
sprockets.
Maintain drive chain slackness within the specified limits at every 1000 kms interval.
Please ensure t he both wheels are aligned correctly, after adjusting the chain and before tightening the rear wheel spindle
nut.
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MINOR MAINTENANCE TIPS
BATTERY AND MAINTENANCE
n The Motorcycle is provided with 12V - 12 Ah battery.
n The battery must be periodically checked for cleanliness and corrosion free
terminals.
NOTE
The poor contact or loose fitment of battery terminals may cause ECU failure.
DISMANTLING
n Switch “OFF” the engine and remove ignition key from the key barrel.
n Disconnect battery negative (- ve) terminal bolt.
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MINOR MAINTENANCE TIPS
n Remove 3 Nos. Hex head bolts from tool box to access the battery.
n Disconnect battery positive (+ve) terminal from battery.
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MINOR MAINTENANCE TIPS
n Pull battery strap (belt) downwards and release strap lock from battery
strap bracket.
n Loosen and remove hex flange head screw from battery strap bracket.
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Page 88
MINOR MAINTENANCE TIPS
n Remove battery strap bracket from battery tray.
n Remove battery from tray.
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MINOR MAINTENANCE TIPS
WARNING
Always disconnect the black negative (-ve) battery cable first and then the red positive (+ve) cable while removing the
battery connections.
NOTE
For checking the battery voltage contact Royal Enfield Authorised Service Centre or battery service centre.
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MINOR MAINTENANCE TIPS
ASSEMBLY
n Assemble battery in to tray.
n
Place battery strap bracket into battery tray.
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MINOR MAINTENANCE TIPS
n Locate and tighten flanged head screw into battery strap bracket.
n
Pull battery strap (belt) downwards to fix strap lock into battery strap bracket.
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MINOR MAINTENANCE TIPS
n Connect battery red positive (+ve) terminal bolt.
n
Locate and tighten 3 nos. hex head bolts into tool holder.
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MINOR MAINTENANCE TIPS
n Connect red battery negative (-ve) terminal bolt.
CAUTION
Connect the black (-ve) negative terminal after connect red (+ve) positive
terminal only.
NOTE
Clean the wire terminals free from corrosion and keep the terminals coated with petroleum jelly.
CAUTION
Keep the red (+ve) positive terminal and (-ve) negative terminal cables firmly connected to the respective battery terminals.
Failure to do so may result in damage to the motorcycle electrical system.
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MINOR MAINTENANCE TIPS
CHANGING ELECTRICAL COMPONENTS
HEADLAMP BULB REPLACEMENT
n Loosen the rim holding screw on top and take out the head lamp dome.
n Disconnect electrical connections.
n Thumb push and remove the bulb holding clamp gently.
n Remove the bulb using a clean and soft cloth.
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MINOR MAINTENANCE TIPS
n Position the new bulb inside the reflector such that the three projections on the bulb
align with the slot on the reflector.
n Refit the bulb holding clamp.
n Connect the electrical connections.
n Position head lamp dome onto the head lamp shell and tighten the mounting screw on
top.
NOTE
Never touch the bulb with your fingers. Finger prints will etch the glass and decrease bulb
life apart from causing burns to your fingers.
Always hold the bulb with gloves and clean dry cloth during handling.
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MINOR MAINTENANCE TIPS
TAIL LAMP BULB
n Unlock the side panel RH.
n Remove the seat assembly by pulling seat lock cable.
n Remove the tail light cover by unscrewing its mounting
screw.
n Hold the bulb, press inside and rotate anticlockwise to
remove the tail light bulb from its holder using a clean cloth.
n Replace the bulb 12V 21 / 5W using a soft clean cloth.
n Re-assemble the tail light in the reverse order of dismantling
process.
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MINOR MAINTENANCE TIPS
TRAFFICATOR BULB REPLACEMENT
n Remove the screw from the trafficator housing.
n Open the indicator housing.
n Remove the bulb holder with help of a screw driver.
n Remove the bulb and replace the same using a soft and clean
cloth.
n Refit the holder to its proper position.
n Fix the rubber gasket cover.
n
Assemble the indicator housing cover.
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MINOR MAINTENANCE TIPS
FUSE AND FUSE CARRIER
n The fuse carrier is located under the seat.
n Unlock side panel RH.
n Release seat lock by pulling knob and remove the
seat.
WARNING
Electronic Control Unit (ECU ) may fail due to loose electrical connections, loose battery terminals, etc. Hence, it is very
important to keep all the electrical connections are intact.
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MINOR MAINTENANCE TIPS
MINI BLADE FUSE USAGE LIST
Fuse ID Color Rating Remarks
Number
1 V 30 A Alternator
2 R-W 30 A Main Fuse
3 G-W 15 A Ignition Fuse-EFI
4 R 10 A Signalling Fuse
5 BR 10 A Horn Fuse
WARNING
Please get the electrical system of your motorcycle checked thoroughly and get the faults corrected immediately after
experiencing any fuse failure. Failure to do so may result in repeated fuse failure.
Usage of fuses other than specified rating will damage the complete electrical system.
Fuse ID Color Rating Remarks
Number
6 R 15 A Lighting Fuse
(Head Lamp)
7 R-W 10 A Accessory Fuse
8 R 10 A ABS Fuse
9 R-W 25 A ABS Fuse
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MINOR MAINTENANCE TIPS
AIR FILTER
CLE AN AND REFIX : EVERY 500 0 kms
n Remove the screw from the side panel bottom side
and remove side panel.
n Remove the air filter cover screws and then take out
air filter box cover.
n Pull out filter element and check for dirt. Clean filter element carefully.
NOTE
Usage of high pressure compressed air is not recommended to clean air filter element.
Fitment of air filter element is in the reverse order of removal process.
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