Royal Enfield 2006 Thunderbird TwinSpark Owner'S Manual Download Page 1

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Summary of Contents for 2006 Thunderbird TwinSpark

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Page 3: ...election of riding gear in accordance with your application style and weather conditions which will go a long way in providing 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 T...

Page 4: ... 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...

Page 5: ...kit 28 Periodical maintenance chart 29 Recommended lubricants 31 Do it yourself 32 Washing procedure 42 CONTENTS Storage precautions 43 Long trip precautions 45 Caring for Mileage 46 Wiring diagram 48 Trouble shooting 49 Warranty terms and conditions 56 Emission Warranty 58 All india Road Signs 63 Regional Area Offices 64 Log Book 65 Free Service coupons 68 Paid Service Maintenance Record 77 Notes...

Page 6: ...r No Street Locality City State Pin Contact Nos Res Off Mobile Email Engine No Battery No Frame No Battery make Reg No Licence No Date of Sale Valid till dt Model Key No Tyre make Colour Sold by Dealer Code Vehicle Installation Form VIF No ...

Page 7: ...ry 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 FREESERVICERECORD Note Please ensure that the free service details are recorded in this sheet immediately after the service i...

Page 8: ...ttor 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 Transmission Clutch Wet multiplate 6plates Primary drive 3 8 Duplex chain sprocket Primary ratio 2 15 1 Gear box Constant mesh 5 Speed Gear ratio 1st 3 06 1 2nd 2 01 1 3rd 1 52 1 4th 1 21 1 5th 1 1 Secondary drive 5 8 Chain Sprocke...

Page 9: ... 153 mm single lead internal expanding Brake Oil Capacity 60ml Brake Oil Grade DOT 3 or DOT 4 Tyre size Front 3 25 19 4PR 6PR Rear 3 5 19 4PR 6PR Tyre pressure Solo Front 1 41 kg cm2 20psi Rear 2 11kg cm2 30psi With Pillion Front 1 54 kg cm2 22psi Rear 2 25 kg cm2 32psi Steering lock In built Fuel tank capacity 13 5 litres MIN Reserve 2 litres Electricals Generation Alternator AC 3 Phase System 12...

Page 10: ...rn signal 12V 10W 2 Nos Horn 12V DC Starter Motor 0 7KW Weights Kerb weight 182 Kgs Max pay load 168 Kgs Dimensions Length 2120 mm Width 780 mm Height 1080 mm Wheel base 1370 mm Ground clearance 135 mm Saddle height 750mm Performance Max speed 120 Km hr SPECIFICATIONS Values given above are for your guidance only In view of continuous improvements being done on our products the specifications are ...

Page 11: ...f 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 C a u t i o n This message if disregarded may result in damage to the vehicle N o t e Indicates important and useful messages for clear understanding SAFETYDEFINITIONS ...

Page 12: ...raight with your shoulders completely relaxed 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 brake...

Page 13: ...11 VEHICLEIDENTIFICATIONNUMBERS Frame Number Punched on steering head tube RH side Engine Number Punched on top of the engine LH side ...

Page 14: ...12 LOCATIONOF KEYPARTS 1 Trip meter knob 2 Speedometer 3 High beam indicator 4 Neutral indicator 5 RPM meter 6 Fuel Gauge 7 Turn signal indicator RH 8 Turn signal indicator LH N 1 2 3 4 5 6 7 8 ...

Page 15: ...EYPARTS 1 Clutch lever 2 Head lamp dimmer switch 3 Turn signal switch 4 Handle bar 5 Head light switch 6 Ignition Kill switch 7 Front brake lever 8 Throttle control 9 E Start Button 10 Horn button 1 2 3 4 5 6 7 8 9 10 ...

Page 16: ...3 Kick Starter lever 14 Silencer 15 Rear number plate 1 Rear Trafficator 2 Side panel RH 3 Side panel lock 4 Carburetor 5 Fuel tank 6 Fuel tank cap 7 Front Trafficator 8 Head light 9 Front number plate 10 Steering lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 17: ...S 1 2 3 4 5 6 8 9 10 11 12 11 Rider foldable foot rest 12 Gear shift lever 6 Pillion back rest 7 Tail lamp 8 Pillion foot rest 9 Side Stand 10 Center Stand 1 Fuel tap 2 Side panel LH 3 Side panel lock 4 Seat 5 Side handle 7 ...

Page 18: ...16 ElectricStartSwitch Depress gently to start Engine OPERATIONOFCONTROLS Ignition switch OFF ON ...

Page 19: ...17 OPERATIONOFCONTROLS Ignition Stop switch OFF ON Head light switch OFF Pilot ON Head lamp ON ...

Page 20: ...18 OPERATIONOFCONTROLS Dimmerswitch High beam Low beam Day Flash Turn signal switch Left turn signal ON OFF Push to Cancel Right turn signal ON ...

Page 21: ...19 OPERATIONOFCONTROLS Fuel tap OFF Main ON Reserve ON Fuel tank cap Turn Key Clockwise to open Turn Key Anti Clockwise to close ...

Page 22: ... lock steering Lock OPERATIONOFCONTROLS Choke ON Pull the knob OFF Push the knob C a u t i o n Choke should be used only to start a cold engine Riding the motorcycle with the choke ON will result in engine running erratic high fuel consumption loss of power increased exhaust emission ...

Page 23: ...in f o r w a r d direction Tripmeter N o t e The odometer records the total distance the vehicle has been driven The trip meter can be used to measure the distance travelled on short trips or between fuel fillings C a u t i o n Keep track of your odometer reading and carry out the maintenance schedule regularly for appropriate services Increased wear or damages to certain parts can result in failu...

Page 24: ...smoothness of all operating cables 4 Free movement of steering 5 B a t t e r y electrolyte level 6 Any cuts cracks in the tyre and correct tyre pressure PREOPERATIONALCHECKS Min 7 Brake fluid is above the minimum level in the master cylinder 8 Oil level between upper lower mark when engine is cold Top up if necessary 9 Operation of all electrical parts Max ...

Page 25: ...of a new motorcycle 1 During the first 2000Kms of run do not exceed the following speed limits 2 Do not exceed maximum pay load as specified 3 Warm up the engine for a few minutes to allow oil for all engine parts before riding the bike 4 Do not ride in constant throttle for long distances Vary the speed by 10 5 Avoid sudden revving and racing starts Vehicle Speed Gear First 500 kms 501 2000 kms 1...

Page 26: ... degree centigrade Switch on ignition Ensure gears are in neutral N o t e Neutral position is indicated by neutral light on the cockpit To shift into neutral move the motorcycle back and forth gently while shifting the gear C a u t i o n Attempting to shift gears without moving the motorcycle back and forth may damage gears ...

Page 27: ...efore starting the motorcycle Depress Starter button and release starter switch once the engine starts A Clutch switch is provided in the system for the safety of the rider When the vehicle is in gear the vehicle cannot be started Shift gear to neutral before attempting to start the engine If the engine has to be started with the Motorcycle in gear depress clutch and then depress the starter butto...

Page 28: ...y the engine may stall and cause the motorcycle to move with a jerk To shift to 2nd and higher gears close t h r o t t l e depress the clutch lever and press the gear lever with heel N o t e Gear shift lever is on the left side of the motorcycle To stop the vehicle close throttle apply front brake with right hand and rear brakes with right leg gently Shift gears into neutral before the motorcycle ...

Page 29: ...d pull vehicle backward Parkingvehicle on side stand Select a firm flat surface Extend side stand Tilt the motorcycle to the left till it is supported firmly Warning Ensure both the stands are retracted fully before riding the motorcycle Please exercise extreme caution when parking and ensure the vehicle is parked firmly to avoid the motorcycle from falling over which may cause injury to you and o...

Page 30: ... x 5 cm 2 5 Sterilized elastic plaster 7 cm x 6 cm 1 6 Elastic Gauze bandage 8 cm x 1 mtr 1 7 First aid kit pouch 1 TOOLS FIRST AID KIT 1 Tool wallet 1 2 Tommy bar 1 3 Tubular spanner 16mm 1 4 Tubular spanner 21 x 24mm 1 5 Screw driver 1 6 Double end spanners 10 x 12 mm 2 S No Description Qty S No Description Qty 1 5 7 2 4 3 6 ...

Page 31: ...o DESCRIPTION FREE SERVICE Whichever is earlier PAID SERVICE A Adjust C Clean D De carbonise I Inspect L Lubricate R Replace Kms x 1000 0 5 3 6 9 12 15 18 21 24 27 30 Months 1 5 3 6 9 1 Engine Oil R R R R R R Check level every 500 Kms or earlier as required 2 Engine oil filter R C R C R C R C R C R 3 Engine sump filter Secondary drain magnet plug C C C C C C 4 Spark plug 2nos A A A A A R A A A A R...

Page 32: ...attery terminals apply petroleum jelly C C C C C C C C C C C 20 Battery Electrolyte level I I I I I I I I I I 21 Earth wire eyelet behind battery carrier I I 22 Rear Drive Chain R R Adjust every 1000 Kms or earlier as required Lubricate every 3000 Kms or earlier as required 23 Fork oil R R Check level every 1000 Kms or earlier as required 24 Hand levers kick starter pivot Lubricate every 1000 Kms ...

Page 33: ...ance Note Recommendation subject to change without notice Common oil for Engine Gear box Clutch Engine Oil Grade MOTUL 3000 4 T Plus 15 W 50 API SL Grade Capacity 2 75 Litres Refil Qty 2 35 Litres Front Fork Oil Make 1F Grade Gabriel or Royal Enfield Fork Oil Capacity 265ml leg Brake Fluid Grade DOT 3 or DOT 4 Capacity 60ml ...

Page 34: ...e motorcycle in rain after waterwash or if used in dusty conditions Hand lever Kick starter pivots Wipe the area free of dirt grease Apply a few drops of oil on the pivots Centre Side Stand Pivots Apply a few drops of oil on the pivots after cleaning the area of dirt OilLevelInspection Place motorcycle on its centre stand on a firm surface Warm up engine for a few minutes switch off b e f o r e ch...

Page 35: ...okes breakage and wheel rim run out Check proper seating of the tyre beading on the rim whenever the tyre is reassembled Whenever a new tyre is installed ensure rim and spokes do not get damaged on account of using wrong levers M i n i m u m t r e a d d e p t h Front tyre 1mm Rear tyre 2 mm Spark plug Cleaning and adjusting Plug gap Two spark plugs M10 M14 sizes are provided in your vehicle Remove...

Page 36: ...rd tyres tubes inflated to correct pressure Tyre pressure Front Solo 1 41 kg cm2 20PSI With Pillion 1 54 kg cm2 22PSI R e a r Solo 2 11 kg cm2 30 PSI With Pillion 2 25 kg cm2 32 PSI DOIT YOURSELF FrontWheelremoval Place the vehicle on center stand Place a wooden block the front end of engine to support the vehicle D i s c o n n e c t speedo cable Loosen the pinch bolt on the RH fork guide ...

Page 37: ...eedo drive and check for proper working of speedo meter DOIT YOURSELF Take out Speedo drive and bush on the RH side Place a 4 mm thick wooden piece or cardboard sheet between the brake shoes to avoid brake shoes getting locked C a u t i o n Do not depress the front brake lever when wheel is removed as this will result in brake shoes getting locked FrontWheel Reassembly Remove the wooden piece card...

Page 38: ...n position inside the rear wheel hub Tilt vehicle to right and insert wheel assembly between the swing arms Position the rear wheel with cush rubber on the rear chain sprocket Hold wheel collar and spacer in position Introduce the wheel spindle along with chain adjuster from the LH side of vehicle and gently tap it through the wheel Ensure that the mark on the chain adjuster notch butts with the s...

Page 39: ...cable play 2 3 mm a Clutch Play Adjustment Loosen lock nut A Turn the nut B clockwise to reduce play OR anticlockwise to increase the play A B Warning Please ensure brakes are adjusted to their maximum efficiency Inefficient brakes can cause an accident b Pedal Play adjustment Play 25 30mm Turn in or out the adjuster nut for correct pedal play ...

Page 40: ...ension Adjust both left hand and right hand shock absorbers so that the same notch rests on the pin in both Warning Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to on accident DOIT YOURSELF Drive Chain tension play 25 30 mm Remove rear wheel split pin Loosen castle nut spindle nut anchor nut and brake rod nut Turn the adjuster cams o...

Page 41: ...olyte level BatteryMaintenance The vehicle is provided with 12V 14 AH m a i n t e n a n c e free battery The battery must be p e r i o d i c a l l y checked for Cleanliness and corrosion free terminals Electrolyte level If electrolyte level is low top up with distilled water N o t e For checking the battery voltage and electrolyte specific gravity contact authorised battery service centre ...

Page 42: ...he head lamp shell and tighten the mounting screw DOITYOURSELF Reassembly of Battery on Vehicle Position the battery in the battery carrier such that the negative terminal of the battery is towards fuel tap Connect the positive terminal Red wire Connect the negative terminal Black wire Smear the terminals with petroleum jelly Do not use grease Refit the bracket to hold the battery Refit LH side pa...

Page 43: ...holder ensuring that the pins on the bulb match with the holder Press bulb and turn it clockwise Fit the tail lamp cover Note Please ensure to replace a spare fuse in the holder at the earliest oppurtunity Trafficator bulb Remove the screws take out trafficator glass cover Press bulb gently Turn anti clockwise to take out the bulb Position the new bulb inside holder ensuring that the pins in the b...

Page 44: ...cycle slowly applying both brakes intermittently to dry up the brake shoes Test brakes for full efficiency Precautions Wash vehicle when the engine is cold Cover the silencer tail pipe carburetor and control switches with suitable plastic bags and tie it firmly to prevent water entry to them Remove ignition key and seal key hole using adhesive tape Brush engine area with kerosene diesel to remove ...

Page 45: ...nd apply a thin film of lub oil Remove battery from the bike Clean the terminals free of corrosion Maintain electrolyte level between max or min mark by adding distilled water and wipe the battery dry Store the battery in a cool dry and well ventilated place Do not place the battery in direct sun light near open flame or where temperature is above 40o C or below 0o C Cover the silencer with plasti...

Page 46: ...evel of oil in engine Clean and remove the motor oil from tank and fill tank with fresh petrol Clean carburetor and air filter Remove plastic covering from the silencer Remove spark plug on cylinder head and pour in a few drops of engine oil Crank engine a few times to lubricate cylinder walls and piston Clean spark plug and refit Switch on ignition switch Start vehicle and warm up engine for a fe...

Page 47: ...tness of all fasteners Tyre tread condition and wear of tyres Battery condition and electrolyte level Correct level of oil in engine front fork and break Working of all lights and horn Proper chain tension Items to be carried Tool kit First aid kit Bulbs for headlight trafficator light rear tail lamp and fuse 15Amps 10Amps Accelerator clutch front brake Rear chain link lock assembly Spare tube tyr...

Page 48: ...ng parts wear prematurely Always use recommended fuel unleaded 87 octane petrol and oils only Ride at costeffective speed Cost effective speed in top gear is 45 to 50 Km per hour Both lower and higher road speeds cause low kilometers per litre of petrol Perform preventive Maintenance as per recommendations Regularpreventivemaintenanceensures Correctly inflated tyres Fasteners tightened to correct ...

Page 49: ... burnt friction plates of clutch loss of power and engine overheating Avoidfrequent braking Braking arrests the road speed Motorcycle momentum is reduced Additional fuel is burnt for subsequent acceleration For better mileage use front and rear brakes only when absolutely needed Control vehicle speed with throttle and gear like smart riders always do Avoidover loading Over loading tires the engine...

Page 50: ...48 Complete Circuit WIRINGDIAGRAM ...

Page 51: ...k in closed position Ensure correct movement of float 7 Spark plug cap lead not connected Fix cap lead firmly 8 Loose HT connections Fix connections firmly 9 HT Lead Damaged Replace HT Lead 10 Spark plug electrode dirty fouled Clean spark plug Reset gap 11 Spark plug insulation cracked Replace spark plug 12 Poor compression Auto Decompressor not working Ensure free motion of flyweight in exhaust c...

Page 52: ... fresh petrol 2 Leak through intake hose Tighten rubber hose suitably Replace if necessary 3 Loose spark plug cap Fix cap lead firmly 4 Spark plug fouled insulation broken Clean reset gap or replace 5 Poor Compression Refer 1 12 III Engine starts but runs irregularly stops 1 Faulty fuel supply Clean the fuel line tap vent hole 2 Very low idling speed Increase idling speed ...

Page 53: ...carburetor mounting Tighten clamps firmly 5 Brakes adjusted too tight Re adjust properly 6 Rear chain adjusted too tight Re adjust properly 7 Clutch Slipping Adjust clutch cable free play 8 Under inflated tyres Inflate to correct pressure V White blue smoke 1 Oil level in tank is above the max mark in the Check and drain excess oil oil level window Contact Dealer Authorised Service Centre Causes R...

Page 54: ... intake air leakage Check and correct 4 Incorrect carburetor adjustments Check and correct VII Excessive fuel consumption 1 Fuel leakage Check and rectify 2 Worn out carburetor jets Change the defective jets 3 Incorrect carburetor adjustments Check and adjust correctly 4 Choked air filter Clean Replace 5 Poor compression Refer I 12 6 Under inflated tyres Inflate to correct pressure Causes Remedies...

Page 55: ...lining or disc Clean and refit 3 Linings worn Uneven wear Replace linings X Vehicle wobbles 1 Wheel rim runout Rectify 2 Loose Broken spokes Tighten Replace spokes 3 Tyres not fitted correctly Refit tyres correctly 4 Wheels misaligned Ensure proper alignment 5 Under inflated tyres Inflate to correct pressure Causes Remedies TROUBLESHOOTING Contact Dealer Authorised Service Centre ...

Page 56: ...correct 2 Bulb fused Replace bulb 3 Fuse blown Replace fuse 4 Switch defective Replace switch Hornnotworking 1 Loose connections Check and correct 2 Requires tuning Tune horn 3 Switch Defective Replace Trafficators not working 1 Loose improper connections Check and correct 2 Bulb fused Replace 3 Switch defective Replace 4 Flasher defective Replace ...

Page 57: ... glowing Bring the vehicle in neutral 2 If vehicle is without neutral indicator Press the clutch lever start switch together 3 Loose Connection Check Correct 4 Starter relay not working Check Replace 5 Malfunctioning of clutch switch Check Replace 6 Malfunctioning of Starter switch Check Replace 7 Battery discharge Check Recharge 8 Motor not working Check Replace 9 Battery not fully charged Check ...

Page 58: ...as per the schedule given in the owner s manual from RE Dealers authorised service points 4 During the warranty period RE s obligations shall be limited to repairing replacing free of charge such part or parts of the vehicle which on examination to have manufacturing defect Such defective part parts which have been replaced become property of RE 5 Cost of oil oil filter fuel and other consumables ...

Page 59: ... the quality or function of the vehicle such as slight vibration oil leakage blue discoloration of exhaust bent pipe silencer soft hard shock absorber etc i Defects arising from fitment of unauthorised additional Electrical loads j Vehicle serviced repaired at unauthorised service points k Vehicle used for competition racing l Electrical component likes bulbs fuses etc m Normal maintenance operati...

Page 60: ...of charge such components of the emission control system to meet the required emission standards The method s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfield and or our authorised service centers and results of such examination will be final and binding If on examination the warranty conditions of the p...

Page 61: ...the motorcycle during the period of examination and repairs by Royal Enfield and or their Authorised Service centres Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on account of failure to comply with the in use emission standards That cost s incurred to check emission of the motorcycle will have to be borne by the customer Emission warranty w...

Page 62: ...ding the test during which the failure is discovered the test having been carried out either for obtaining a new certificate or pursuant upon being directed by an officer as referred to in sub rule 2 of rule 116 of the Central Motor Vehicles Rules Produces the owner s manual and Log book for verification details Produces receipts covering maintenance of the motorcycle is specified in the owner s m...

Page 63: ... races and rallies or for the purpose of establishing records On examination by Royal Enfield or its authorised service centers if the motorcycle shows that any of the conditions stipulated in the Owner s manual with regard to use and maintenance have been violated The motorcycle has been run on adulterated leaded fuel or lubricant other than those specified by Royal Enfield in the Owner s manual ...

Page 64: ...mission warranty 30 000 Kms 3 years from the date of first sale Tips to reduce pollution 1 Ensure that the periodical maintenance is carried out as stipulated in the owner s manual through a Royal Enfield authorised service center 2 Use only Unleaded fuel 87 octane petrol from reputed fuel pumps 3 Ensure the fuel used is not adulterated 4 Use correct spark plug as recommended in the owner s manual...

Page 65: ...Royal Enfield A Unit of Eicher Motors Limited Tiruvottiyur High Road Tiruvottiyur Chennai 600 019 Ph 91 44 4223 0400 Fax 91 44 4201 1719 Website www royalenfield com ...

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