FOREWORD
CongratulationsonyourchoiceoftheThunderbirdTwinSpark.Yourmotorcyclerepresentsabreakthroughinengineering technology. It’s Unit Construction Engine delivers greater power and torque, while brand new ergonomics ensure enhanced comfort and safety. Aesthetics have also been refined, resulting in a sleeker, more aerodynamic profile while preserving the classic lines of the Thunderbird.
This manual is designed to give you complete control over your bike. It contains important information on efficient operation and maintenance. We’ve also put in tips on riding safely, as well as some suggestions as to how you can enhance your motorcycling experience.
Your safety is of prime concern to us and we urge you to be a responsible biker. Please make a careful selection of ridinggear inaccordance withyour application,style andweather conditions which will goa longway inproviding you with a feeling of confidence that goes on to enhance the riding and ownership pleasure that comes with this and every other Royal Enfield machine. Also please ensure the same for your pillion rider as well. Respect the rules of the Road and ride safely.
Best of all, your Thunderbird TwinSpark automatically makes you a member of the legendary Royal Enfield community. You can locate your nearest club or sign up for the next big ride at www.royalenfield.com
Enjoy the Trip!
We request you to carefully readthe terms and conditions of warranty and otheruseful informationgiven inthis manual before you begin to cruise on your Thunderbird TwinSpark.
SERVICE HEADQUARTERS
Royal Enfield, Tiruvottiyur High Road, Tiruvottiyur, Chennai-600019. Phone: 044-4223 0400, Fax: 044-4201 1719
E-mail: customerservice@royalenfield.comWebsite: www.royalenfield.com
1
NOTICE
All information in this manual is based on the latest product information available at the time of publication. Due to continues improvements or other changes, there may be discrepancies between information in this manual and your vehicle. Royal Enfield reserves the right to make product changes at any time without prior notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold.
All images shown are for reference only and to explain. They need not to be exactly the same on the model you own. Technical specifications are subject to change without prior notice.
“© Copyright 2006 Royal Enfield. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt, without the express permission in writing of Royal Enfield.
Part No. 580589/b /Qty. 500/Oct. ‘10
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CONTENTS
Personal and vehicle informa tion |
.............. 4 |
Storage precautions ................................ |
43 |
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Free service record .................................. |
5 |
Long trip precautions .............................. |
45 |
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Specifications.......................................... |
6 |
Caring for Mileage ................................ |
46 |
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Safety Definitions ..................................... |
9 |
Wiring diagram ...................................... |
48 |
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Safe and happy riding ........................... |
10 |
Trouble shooting |
49 |
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Vehicle identification numbers ............... |
11 |
Warranty terms and conditions |
56 |
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Location of key parts ............................. |
12 |
Emission Warranty |
58 |
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Operation of controls ............................ |
16 |
All india Road Signs |
63 |
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Pre-Operational Checks ........................ |
22 |
Regional & Area Offices |
64 |
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Running in............................................ |
23 |
Log Book |
65 |
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Starting |
24 |
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Free Service coupons |
68 |
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Gear Shifting, Riding & Stopping |
26 |
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Paid Service/Maintenance Record |
77 |
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Parking |
27 |
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Notes |
85 |
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Tools & First aid kit |
28 |
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ANNEXURES |
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Periodical maintenance chart |
29 |
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Vehicle Installation Form |
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Recommended lubricants ...................... |
31 |
Pre-Delivery Inspection Report |
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Do it yourself ......................................... |
32 |
Bike Installation Confirmation By Cutomer |
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Washing procedure ............................... |
42 |
Form 22 |
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3 |
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PERSONAL&VEHICLEINFORMATION |
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Name |
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Door No./Street |
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Locality |
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City |
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State |
Pin |
Contact Nos. |
Res: |
Off: |
Mobile : |
Email : |
Engine No. |
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Battery No. |
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Frame No. |
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Battery make |
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Reg. No. |
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Licence |
No. |
Date of Sale |
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Valid till |
dt. |
Model |
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Key No.: |
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Tyre make |
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Colour |
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Sold by |
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Dealer Code |
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Vehicle Installation Form (VIF) No.
4
FREESERVICERECORD
It is our endeavour to provide excellent service to your Thunderbird Twinspark at all times. Towards this we provide four free services at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Dealerships / Authorised service centres nearest to you and as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, to the service outlet.
Availing the free services in the specified time is a prerequisite to warranty consideration. The cost of fuel, oil, grease etc. used for free service is chargeable to the customer.
1ST Service |
2nd Service |
3rd Service |
4th Service |
Date of Service
Kms Covered
Servicing
Dealer’s Name
Address
Note : Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.
5
SPECIFICATIONS
Engine and Engine systems
Engine Type .................. |
4 Stroke, air cooled, |
................................... |
single cylinder |
Bore ............................ |
70mm |
Stroke .......................... |
90mm |
Swept volume ............... |
346cc |
Compression ratio ........ |
8.5:1 |
Max Torque @ rpm....... |
28 Nm @ 4000 rpm |
Idle rpm ....................... |
1050±200 rpm |
Starting ........................ |
E’Start |
Air filter element ........... |
Paper element |
Carburettor .................. |
Ucal - BS 29 |
Lubrication ................... |
Wet Sump |
................................... |
pressure lubrication |
Engine oil capacity... ...... |
2.75 lits |
Engine oil grade ........... |
Motul 3000 4T Plus |
................................... |
15W 50 API SL Grade |
Cooling ....................... |
Natural air flow |
6
Transmission |
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Clutch ......................... |
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Wet multiplate (6plates) |
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Primary drive ................ |
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3/8” Duplex chain |
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& sprocket |
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Primary ratio................. |
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2.15 : 1 |
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Gear box ..................... |
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Constant mesh 5 Speed |
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Gear ratio ................. |
1st |
- |
3.06 |
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1 |
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2nd |
- |
2.01 |
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1 |
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3rd |
- |
1.52 |
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1 |
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4th |
- |
1.21 |
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1 |
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5th |
- |
1 |
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1 |
Secondary drive ........... |
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5/8” Chain & Sprocket |
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Secondary ratio ............ |
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2.53 : 1 |
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Drive Chain links .......... |
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100 L |
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F.D. Sprocket ................ |
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15 T |
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SPECIFICATIONS
Chassis |
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Frame.......................... |
Tubular |
Suspension : Front ...... |
Telescopic, hydraulic |
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damping, Stroke 130 mm |
Rear ........ |
Swing arm with |
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gas shock absorbers |
Fr. Fork oil capacity ..... |
265 cc+ 2.5 cc per |
................................... |
limb assy |
Front fork oil make ..... 1F Grade Gabriel /
........................................ Royal Enfield Fork Oil
Brakes : |
Front ..... |
Hydraulic 280 mm |
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ventilated disc |
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Rear ....... |
Foot operated 153 mm |
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single lead, internal |
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expanding |
Brake Oil Capacity ..... |
60ml |
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Brake Oil Grade ......... |
DOT 3 or DOT 4 |
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Tyre size : |
Front ...... |
3.25´´ ×19´´ |
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- 4PR/6PR |
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Rear ....... |
3.5´´ ×19´´ |
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- 4PR/6PR |
7
Tyre pressure |
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Solo : |
Front ..... |
1.41 kg/cm2 (20psi) |
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Rear ....... |
2.11kg/cm2 (30psi) |
With Pillion : |
Front ..... |
1.54 kg/cm2 (22psi) |
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Rear ....... |
2.25 kg/cm2 (32psi) |
Steering lock |
................ |
In built |
Fuel tank capacity ....... |
13.5 litres (MIN) |
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Reserve ....................... |
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2 litres |
Electricals |
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Generation ................. |
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Alternator AC-3 |
Phase |
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System ......................... |
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12V - DC |
Ignition ....................... |
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Digital Dual spark |
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Ignition TCI System |
Battery .......................... |
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12V - 14AH |
Spark plug ................... |
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Mico-WR5DC - 1 No. |
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Bosch-UR5DC - 1 No. |
Spark plug gap ........... |
0.7 to 0.8 mm |
Head lamp .................. |
12V, 35 / 35W |
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Halogen bulb |
Tail lamp ..................... |
12V, 5W |
Brake lamp .................. |
12V, 21W |
Speedometer lamp ...... |
12V, 3.4W - 1 No. |
Hi beam indicator ........ |
12V, 1.7W |
Neutral lamp Tell tale .. |
12V, 1.7W - 1 No. |
Turn Signal Tell Tale ..... |
12V, 1.7W - 2 Nos. |
Turn signal .................. |
12V, 10W - 2 Nos. |
Horn ........................... |
12V DC |
Starter Motor .............. |
0.7KW |
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SPECIFICATIONS |
Weights |
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Kerb weight ................. |
182 Kgs. |
Max. pay load ............. |
168 Kgs. |
Dimensions |
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Length ......................... |
2120 mm |
Width ........................... |
780 mm |
Height .......................... |
1080 mm |
Wheel base ................... |
1370 mm |
Ground clearance ......... |
135 mm |
Saddle height ............... |
750mm |
Performance |
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Max. speed ................... |
120 Km/hr |
Values given above are for your guidance only.
In view of continuous improvements being done on our products, the specifications are likely to change without prior notice.
8
SAFETYDEFINITIONS
The information given under the titles : Warning, Caution and Note are for your safety and for the care and safety to your motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others and damages to the motorcycle.
Warning :
Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider or other persons.
Caution :
This message if disregarded may result in damage to the vehicle.
Note :
Indicates important and useful messages for clear understanding.
9
Riding dress
A proper riding apparel
Note :
A light coloured shirt enables greater visibility to other road users especially during nights.
Caution :
Loose clothing may get caught on moving parts of your motor-cycle.
A pair of riding boots or shoes.
Soft leather gloves.
Goggles or spectacles to safe guard eyes.
An ISI certified helmet. Affix light reflecting strips of stickers at the front and rear.
Sitting posture
Correct sitting posture is a pre-requisite for stable and safe riding :
Sit Straight with your shoulders completely relaxed.
SAFEANDHAPPYRIDING
Keep your elbows close to your body.
Keep your toes in straight ahead direction.
Slightly press the petrol tank with the knees.
Hold the handle grip close to its inner end.
Look extensively, including rear view mirror, without turning the head.
Braking
Use both front and rear brakes together for maximum braking efficiency.
Warning:
Applying any one of the brakes suddenly may cause the vehicle to skid.
The hydraulic disc brake, fitted on your Thunderbird Twinspark requires very less effort and high effort or sudden application may lock the wheel. Please use utmost caution while applying the hydraulic disc brake.
While riding on wet or bad road conditions use brakes cautiously.
10
VEHICLEIDENTIFICATIONNUMBERS
Frame Number
Punched on steering head tube RH side.
Engine Number
Punched on top of the engine LH side.
11
LOCATIONOF KEYPARTS
1 2 3 4 5 6
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N |
8 |
7 |
1. |
Trip meter knob |
4. |
Neutral indicator |
7. |
Turn signal indicator RH |
2. |
Speedometer |
5. |
RPM meter |
8. |
Turn signal indicator LH |
3. |
High beam indicator |
6. |
Fuel Gauge |
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12 |
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LOCATIONOF KEYPARTS
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3 |
4 |
5 |
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2 |
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1 |
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6 |
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7 |
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9 |
8 |
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10 |
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1. |
Clutch lever |
5. |
Head light switch |
9. |
E-Start Button |
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2. |
Head lamp dimmer switch |
6. |
Ignition Kill switch |
10. |
Horn button |
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3. |
Turn signal switch |
7. |
Front brake lever |
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4. |
Handle bar |
8. |
Throttle control |
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13 |
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LOCATIONOF KEYPARTS
1 |
2 |
3 |
4 |
6 |
7 |
5
8
9
15
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14 |
13 |
12 11 |
10 |
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1. |
Rear Trafficator |
6. |
Fuel tank cap |
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11. |
Horn |
2. |
Side panel RH |
7. |
Front Trafficator |
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12. |
Rear brake pedal |
3. |
Side panel lock |
8. |
Head light |
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13. |
Kick Starter lever |
4. |
Carburetor |
9. |
Front number plate |
14. |
Silencer |
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5. |
Fuel tank |
10. |
Steering lock |
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15. |
Rear number plate |
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14 |
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LOCATIONOF KEYPARTS
1 |
2 |
3 |
4 |
5 |
6 |
7
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12 |
11 10 |
9 |
8 |
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1. |
Fuel tap |
6. |
Pillion back rest |
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11. |
Rider foldable foot rest |
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2. |
Side panel LH |
7. |
Tail lamp |
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12. |
Gear shift lever |
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3. |
Side panel lock |
8. |
Pillion foot rest |
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4. |
Seat |
9. |
Side Stand |
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5. |
Side handle |
10. |
Center Stand |
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15 |
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OPERATIONOFCONTROLS
Ignition switch |
Electric Start Switch |
OFF
ON
Depress gently to start Engine
16
OPERATIONOFCONTROLS
Ignition Stop switch |
Head light switch |
OFF |
OFF |
Pilot ON
ON
Head lamp ON
17
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OPERATIONOFCONTROLS |
Dimmer switch |
Turn signal switch |
High beam |
Left turn signal ON |
Low beam |
OFF (Push to Cancel) |
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Day Flash |
Right turn signal ON |
18
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