Royal Enfield Classic 350 2021 Owner'S Manual Download Page 47 | Manualshive

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45

MINOR MAINTENANCE TIPS

BRAKE PAD WEAR

n

Brake pad wear depends upon the severity of
usage, the type of riding and road condition.

Check the wear indicator mark on each pad. If either
pad is worn to the wear indicator mark. Replace both
pads as set. Visit royal enfield dealer for this service.

Check the wear indicator mark on each pad. If either
pad is worn to the wear indicator mark. Replace both
pads as set. Visit royal enfield dealer for this service.

Wear indicator

mark

Front Brake

Rear Brake

Wear indicator

mark

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Summary of Contents for Classic 350 2021

Page 1: ...BS VI SIGNALS ...

Page 2: ......

Page 3: ...ments for the care of your motorcycle Please avail four free and three paid services at the nearest Royal Enfield Authorised Dealer Service Center at the appropriate time to maintain your Bullet motorcycle in top riding condition Log on to the exciting world of Royal Enfield website www royalenfield com to get to know more about the company its products and exciting news from time to time We reque...

Page 4: ...istributed or otherwise dealt without the express permission in writing of Royal Enfield NOTE BS VI This motorcycle meets Emission Norms Bharat Trem Stage VI Disclaimer Applicable for all Matt finish motorcycles 1 Do not polish matt finished paint surfaces in your motorcycle as it will increase the gloss level 2 Wash the painted parts only with plain water and do not use any strong solvents cleani...

Page 5: ...19 Running in Period 20 Warning Indications Safety Systems 21 Starting 25 Gear Shifting Riding Stopping 26 Parking 27 Periodical Maintenance Chart 28 Tools First Aid kit 31 Wheel Removal Assembly 32 Minor Maintenance Tips 37 Long Trip Precautions 48 Washing Procedure 49 Storage Precautions 50 Trouble Shooting 51 Warranty Terms Conditions 53 Emission Warranty 55 EVAP 58 Environment Care 60 Service ...

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

Page 7: ...o 2 50 l subsequent refills Engine oil grade SAE 15 W 50 API SL Grade Above JASO MA2 Semi Synthetic Cooling Natural air flow IGNITION SYSTEM Ignition system Electronic ignition ECU Variable Spark plug Electrode gap WQR8DC 0 80 to 0 90 mm Spark plug WQR8DC M14 Bosch TRANSMISSION Clutch Wet multiplate 6 plates Primary drive Duplex chain Primary ratio 2 15 1 Gear box Constant Mesh 5 Speed st Gear Rat...

Page 8: ...capacity 13 5 l approx Low fuel warning 4 0 5 l approx The above values are approximate and the actual fuel filling capacity will vary from the values mentioned ELECTRICALS Generation Alternator III Phase System 12 V DC Battery 12 V 12 Ah MF Head lamp 12 V H4 60 55 W Halogen Brake Tail lamp 12 V P21 5 W Parking lamp 12 V 2 W X 2 Nos Position lamp 12 V 4 W CHASSIS Type Single downtube using engine ...

Page 9: ... Kerb weight 90 fuel oil 195 kg Gross Vehicle Weight 350 kg Luggage load carrier Should not be more than 15 kg n Values Dimensions given above are for your guidance only n In view of continuous improvements being done on our products the specifications are likely to change without prior notice WA R N IN G Using bulbs other electrical gadgets other than specified rating may lead to over loading err...

Page 10: ...ical maintenance Use of Wrong grade oil will reduce the life of the moving parts and seriously affect performance CAU T ION Engine Oil DO NOT Mix DOT 4 Other brake fluid together Grade Royal Enfield Front Fork Oil or 1F Grade Endurance Capacity 195 ml leg Front Fork Oil Capacity Front 100 ml Rear 100 ml Grade DOT 4 Brake Fluid NOTE Recommendation subject to change without notice ...

Page 11: ...es to the motorcycle W A R N I N G Indicates a potentially hazardous situation Disregarding this message may result in injury to rider or other persons C AU T I O N This message if disregarded may result in damage to the motorcycle NOTE Indicates important and useful messages for clearer understanding All Images shown in subsequent pages are for reference to explain and need not to be exactly the ...

Page 12: ...10 MOTORCYCLE IDENTIFICATION NUMBERS FRAME NUMBER ENGINE NUMBER Punched on steering head tube right side Punched on crankcase left top side ...

Page 13: ...rn Signal Switch 2 Horn Button 3 Cluth Lever 4 Day Flash 5 Head Lamp Dip Switch 6 Ignition Switch 7 Speedo Meter 8 Warning Indicator 9 Engine Kill Switch 10 Brake Lever 11 E Start Switch Button 12 Fuel Tank Cap 13 Rear View Mirrors ...

Page 14: ... Rear 2 Right Trafficator Rear 3 Tail Lamp 4 Shockabsorber gas filled 5 Air filter box 6 Pilot Lamp Right 7 Head Light 8 Number Plate Front 9 Right Trafficator Front 10 Steering lock 11 Brake Pedal 12 E Start Motor 13 Kick Start Lever 14 Silencer ...

Page 15: ... Pilot Lamp Left 3 Spark Plug 4 Fuel Tank 5 Battery Box Cover 6 Seat Rider 7 Electricals Tool Box Left 8 Seat Pillion Rider 9 Left Trafficator Rear 10 Number Plate Rear 11 Canister 12 Side Stand 13 Center Stand 14 ABS Module 15 Gear Change Lever 16 Horn ...

Page 16: ...ck n Turn Anticlockwise to Unlock IGNITION SWITCH FILTER ELECTRICAL BOXES n Turn anti clockwise to open BATTERY BOX n Turn anti clockwise to open OFF ON FUEL TANK CAP OPEN n Turn Key Clockwise lift the lid CLOSE n Gently press lid till it click into lock position ...

Page 17: ...Splash Arrestor Failure to do so will lead to canister damage or can cause fuel spill out of fuel tank Petrol is highly explosive Please ensure there are no open flames or sparks nearby while refueling and fill fuel tank only in a well ventilated area Please ensure petrol does not spill on painted surfaces Wipe immediately incase fuel spills over as otherwise it will leave a permanent stain on the...

Page 18: ...battery cover and tool boxes n Key can be removed only in locked position from fuel tank Filter box Electrical boxes locks in OFF position from Ignition switch n Turn handle bar to extreme left before attempting to lock steering Depress hold till engine starts HORN Press OPERATION OF CONTROLS E START SWITCH ...

Page 19: ...17 TURN SIGNAL SWITCH OFF Push to off Right turn signal ON Left turn signal ON DAY FLASH Press for Head Light Flash DIMMER SWITCH High beam Low beam ...

Page 20: ...free play in Front and Rear Brake levers FRONT BRAKE REAR BRAKE NOTE Start engine run for 2 min before checking Engine Oil Level 3 Free play and smoothness of all operating controls 4 Free movement of steering 5 Any cuts cracks in the tyre and correct tyre pressure 6 Operation of all electrical equipments 8 Engine Oil Level is between MAX MIN Level Brake Pedal FRONT BRAKE REAR BRAKE ...

Page 21: ...RE Correct sitting posture is a must for stable and safe riding n Sit Straight with your shoulders completely relaxed n Keep your elbows close to your body n Hold the handle grip close to its inner end n Slightly grip the fuel tank with the knees n Keep your toes in straight ahead direction n Before turning look extensively in the rear view mirror without turning your head BRAKING n Use both front...

Page 22: ...do not exceed the speed limits as shown in the table below 2 Do not exceed maximum specified pay load 3 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 4 Avoid full throttle operation and do not ride at constant throttle continuously Vary the speed by 10 while riding 5 Avoid sudden accelerations a...

Page 23: ...o the fuel pump Please refuel as soon as the low fuel indication comes ON 2 ENGINE MALFUNCTION INDICATOR LAMP A Malfunctioning Indicator Lamp MIL is provided in the small meter When both the Ignition Engine kill switch is ON 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 norm...

Page 24: ...event 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 console as shown in adjacent image to warn the rider in the event of any malfunction of the ABS When the ignition and kill switch are switched ON the ABS sign light up and remain ON till the motorcycle attains a speed of 5 kmph...

Page 25: ...tum of the motorcycle while negotiating a Turning roads and therefore prevent skidding due to loss of traction Please anticipate the stopping 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 to stop front brake momentarily earlier followed by rear brake to have better traction and control of the motorcy...

Page 26: ...ing While starting the engine do check the ABS indicator comes ON and switches OFF when the vehicle speed exceeds 5 kmph 3 1 mph n Please check the brake fluid at MAX level in the front and rear brake master cylinders and there is no leak in the brakes systems n Apply both the brakes simultaneously for better efficiency while braking n In the event of the ABS indicator remaining continuously ON pl...

Page 27: ... lever till a resistance is felt in the lever Slightly crank slowly and further till the compression eases over n Release Kickstarter lever to enable it to come to its top resting position n Apply a powerful swinging Kick on the lever to start the engine It may be necessary to open the throttle very slightly when starting on first time in the morning NOTE n It is recommended to switch off the engi...

Page 28: ...mes to a complete stop n Warm up engine for 2 min n Depress clutch lever n Press gear pedal with toe to st engage 1 gear n Gently open throttle and release clutch lever simultaneously If clutch is released suddenly the engine may stall and cause the GEAR SHIFTING RIDING STOPPING motorcycle to move with a jerk NOTE n Release the Starter button as soon as the Engine starts n If Engine does not start...

Page 29: ...le parking and ensure it is parked firmly to avoid the motorcycle from falling over and causing injury to you or to others and damage to the motorcycle parts C AU T I O N When Side stand is in extended position a Engine will start if vehicle is in neutral but will cut off ignition and fuel when gear is engaged b Engine will not start if gear is engaged already NOTE The Side stand is only designed ...

Page 30: ... S l N o DESCRIPTION PAID SERVICE FREE SERVICE whichever is earlier km x 1000 0 5 5 10 15 20 25 30 35 40 45 50 Months 1 5 6 12 18 24 30 36 42 48 54 60 1 Engine Oil R I R I R I R I R I R Check level at every 1000 km or earlier and Top up as required 2 Engine oil filter element R R R R R R 3 Engine sump filter oil retainer C C C C C C 4 Spark plug C A C A C A R C A C A R C A C A R C A 5 Magnetic dra...

Page 31: ... Fork oil Leak I I I I R I I I R I I 18 Rear Wheel Drive Chain I A Clean Lubricate every 1000 km Clean Lubricate Adjust every 5000 Kms or earlier as required 19 Steering ball races play I A Inspect Adjust if required lubricate for every 5000 km or earlier as required Replace if necessary 20 Spokes tightness Wheel rim run out front rear I I I I I I I I I I I 21 Swing Arm pivot bush spacer I Inspect...

Page 32: ...oved from the vehicle and cleaned with a dry Microfibre cloth Usage of throttle body cleaners or any 26 Throttle body similar solvent or alcohol based liquids for cleaning is strictly prohibited Throttle body cleaning every 10000 km 12 Months or earlier as required 27 Front Rear brake hose Banjo Bolt I I I I I I I I I I I 28 Hand levers kick starter lever pivot Lubricate every 1000 km or earlier a...

Page 33: ... Box spanner 21 X 24 1 3 Screw driver O6 X 160 1 4 Double end spanner 14 X 15 1 5 Double end spanner 10 X 12 2 6 Tool Spark plug 1 7 Tommy bar 1 8 Tubular spanner 12 X 13 1 9 Single end ring spanner 17 1 10 Extension tube 1 S No Description Qty 1 Antiseptic cream 5 gms 1 2 Wash proof plaster 1 9 cm x 7 2 cm 2 3 Gauze bandage 5 cm x 2 cm 1 4 Sterilized Gauze Swab 5 cm x 5 cm 2 5 Sterilized elastic ...

Page 34: ...e n Loosen the pinch bolt on the right side fork end n Hold the axle on the right side and loosen the WHEEL REMOVAL ASSEMBLY n axle nut on the left side Hold front axle by spanner and loosen axle nut then remove nut along with washer n Tap and remove the front wheel spindle from the right side n Tilt the motorcycle to right side and take out the wheel along with speedo drive and right side spacer ...

Page 35: ...SEMBLY n Remove the wooden piece card board sheet placed between the brake pads n Locate small spacer and speedo drive over the wheel hub on the right side n Locate stepped spacer in the left side of the hub with its larger face outside n Locate front wheel between the fork ends duly ensuring the spacer and the speedo drive do not fall off and the brake disc is correctly positioned between the bra...

Page 36: ...pipe and wheel speed sensor cable from the swing WHEEL REMOVAL ASSEMBLY arm clips Gently Pull the Brake Hose WSS cable together from the Clip by hand Do not use any screw Driver or metal rod for removal which may damage the Hose or Sensor cable n Remove the brake pads from the caliper assembly n Remove the caliper assembly with bracket by pulling out from the swing arm slot n Remove the left side ...

Page 37: ... through the wheel gently n Note the alignment index marks in the both side of swing arm REAR WHEEL REASSEMBLY n Ensure the four Cush rubbers are in position inside the rear wheel hub n Tilt motorcycle to right side and insert the wheel assembly between the swing arms n Position the rear wheel with cush rubber on the rear chain sprocket n Fix the left side spacer in rear wheel hub n Insert the cal...

Page 38: ...t braking performance Sharp edge instruments should not be used during WSS cable removal and reassembly n Insert the wheel speed sensor cable and Brake hose in to the clips provided on the Swing arm facing WSS sensor cable at the bottom n Ensure wheel speed sensor cable Brake Hose not entrapped between shock absorber mounting bolt and caliper bracket WA R N I N G Ensure the motorcycle does not com...

Page 39: ...tating the rear wheel Wipe off the excess lubricant OIL LEVEL INSPECTION n Place motorcycle on its center stand on a firm surface n Warm up engine for a few minutes switch off before checking oil level n The level is correct if the oil level is in the middle of the oil level window n HAND LEVER PIVOTS Wipe the area free of dirt grease Top up only with recommended Engine oil Apply a few drops of oi...

Page 40: ...yres periodically for tread wear cracks and cuts Minimum tread depth Front tyre 1 mm Rear tyre 2 mm CLEANING AND ADJUSTING PLUG GAP SPARK PLUG n Two spark plugs are provided in your motorcycle n Remove spark plug using the plug spanner and tommy bar n Clean the insulator tip and electrodes of the plug carefully n Check and set the electrode gap between 0 80 to 0 90 mm n Refit the spark plug on the...

Page 41: ...part of the motorcycle In the event of a spill please clean the area immediately with a soft cloth preferably a wet cloth to avoid damage Check if oil is below ëMINí level To top up remove cover and diaphragm then top up with DOT 4 as specified BRAKE FLUID DRIVE CHAIN TENSION Free Play 20 30 mm MINOR MAINTENANCE TIPS FRONT BRAKE REAR BRAKE ...

Page 42: ...stub axle nut n Loosen lock nutsof the chain adjuster on both ends of the swing arm n Tighten loosen the adjuster nut on right swing arm end to reduce increase free play n Rotate wheel slowly and check chain free play at the top run to be between 20 30 mm n Note the matching index marks on right swing arm and chain adjuster and tighten loosen adjuster nut on left swing arm side to ensure the marks...

Page 43: ...ly check the Battery for Cleanliness and corrosion free terminals REMOVAL OF BATTERY FROM THE MOTORCYCLE n The battery is located on the left side of the motorcycle near the electrical box n Ensure motorcycle is parked on its centerstand in a well ventilated area n Ensure the ignition switch and engine stop switch are in ìOFFî position n Insert the key into the battery cover lock turn anticlockwis...

Page 44: ...ch could result in serious injury WA R N I N G Battery terminals and internals contain lead and lead components known to cause cancer and birth defects or other reproductive harm Always wear approved protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AND ACID OUT OF REACH OF CHILDREN NOTE Usage of frequency for motorcycle is very important f...

Page 45: ...bulb holder n Pull out the bulb ASSEMBLING THE HEAD LAMP BULB 1 Refix the new halogen bulb into reflector unit of the headlamp 2 Gently press the bulb holding clip and lock the free end in its slot 3 Fit the rubber grommet 4 Connect the electrical connections carefully assemble the headlamp in the reverse order of dismantling C AU T I O N Never touch the bulb with your fingers Finger prints will e...

Page 46: ...fit the trafficator glass and screws ensuring the lens slot cut mark is at the bottom TAIL LAMP BULB n Remove the two nuts each from Right Left side of the rear number plate holder n Pull out Tail Lamp assembly along with bracket and twist the bulb holder in anticlockwise to remove bulb holder assembly n Turn old bulb to remove and replace with a new bulb n Refit the bulb holder and turn clockwise...

Page 47: ...mark on each pad If either pad is worn to the wear indicator mark Replace both pads as set Visit royal enfield dealer for this service Check the wear indicator mark on each pad If either pad is worn to the wear indicator mark Replace both pads as set Visit royal enfield dealer for this service Wear indicator mark Front Brake Rear Brake Wear indicator mark ...

Page 48: ...spare fuse in the holder at the earliest opportunity Spare Fuse 40 A F0 Main Fuse 40 A FUSE n Open the left tool box n Replace the required fuse with the spare fuse available in the fuse carrier n The blade fuses are located in the carrier and differently coloured for identification ...

Page 49: ...PARE FUSE 10 A SF2 SPARE FUSE 15 A SF3 SPARE FUSE 25 A C AU T I O N n Switch the ignition key to ìOFFî before replacing the fuse to avoid possible short circuits n When replacing a blown fuse it is important to use only a fuse having the correct amperage rating The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload If a properly rated fuse continu...

Page 50: ...G TRIP PRECAUTIONS Checks prior to the commencement of long journey n Spare tubes Service the motorcycle at a Royal Enfield Authorised Dealer Service Center n Ensure sufficient quantity of petrol in the fuel tank for the journey planned n Check and correct tyre pressure if necessary n Ensure sufficient Brake pad thickness available Checks after every 1500 km of run n Any loose fasteners n Conditio...

Page 51: ...icles from the obscure areas of the motorcycle electrical WASHING PROCEDURE connections etc n Once the motorcycle has been ridden in salty conditions or near coastal areas it is recommended to wash your motorcycle with cold water Please do not use warm water for washing as it may damage the motorcycle due to chemical reaction with the salt After washing process once the motorcycle is completely dr...

Page 52: ...in a cool dry and well ventilated place n Cover the silencer with plastic bags to prevent moisture entry Set the motorcycle on its center stand n Apply anti rust solutions on all plated parts Take care not to apply this solution on rubber or painted parts n Store motorcycle in a clean covered area free of moisture and dust n For re use after storage it is preferable to get the motorcycle prepared ...

Page 53: ...als not working Switch ON Ignition Engine stop switch Check Fuel level fuel meter and fill fuel Weak Discharged battery Contact Authorised Service Center 1 Battery completely dead Replace battery 2 Fuse Blown Replace appropriate fuse Note If fuse blows again contact Authorised Service Center Engine Does not start Engine Starts BUT shuts off immediately 5 Engine Cranking but not starting Spark plug...

Page 54: ...sively loose causing chain to slip on Sprocket Poor Pickup Engine Misfires Runs Erratically Stops Excessive Engine temperature Switch OFF Engine and allow to cool down Clutch is Slipping Check for sticky clutch clutch not having any free play Adjust Rear chain to correct tension Drain out entire fuel and Refill with fresh fuel from a reputed filling station ABS lamp continuously ON ABS Anti lock B...

Page 55: ...in the respective period kilometer ranges as per the schedule in the owner s manual from RE Authorised Dealer Service Center 4 During the warranty period RE s obligations shall be limited to repairing replacing part s of the motorcycle for free only if the part s on examination is deemed to have a manufacturing defect Defective part s which have been replaced will become the sole property of RE 5 ...

Page 56: ... Warranty is not applicable for discoloration of Exhaust Pipe Silencer as it is a natural process that will happen during usage h Defects arising from fitment of unauthorised or additional electrical loads i Motorcycle serviced or repaired at unauthorised service centers j Motorcycle used for competitions racing Stage Rallying etc k Electrical component like bulbs fuses etc and electronic componen...

Page 57: ... be final and binding If on examination the warranty conditions of the part s is are not established Royal Enfield will have the right to charge all or part of the cost of such examination to the customer in addition to the cost of the components In case of acceptance of the component s under Emission warranty Royal Enfield will replace free of charge the component s as required However the consum...

Page 58: ...used the motorcycle in accordance with the instructions in the owner s manual and having carried out such repairs and adjustments as may be required with a view to establish such compliance n Produces the Pollution Under Control certificate valid for the period immediately preceding the test during which the failure is discovered the test having been carried out either for obtaining a new certific...

Page 59: ...of the motorcycle n The emission related components are tampered with n All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced n All maintenance activities carried out on the motorcycle during the tenure of the emission warranty is not entered in the log book TIPS TO BE ON THE RIGHT SIDE OF LAW n Always get your motorcycle checked to me...

Page 60: ...m the date of first use of the motorcycle The Warranty period shall begin either on the date the motorcycle is delivered to the first retail purchaser OR from the first date the motorcycle is used as a demonstrator OR as a display and or trial motorcycle THE FOLLOWING ITEMS ARE NOT COVERED BY THE EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY 1 Failures which may arise as a result of misuse alterati...

Page 61: ...laced immediately due to which the exact distance covered cannot be determined 5 Normal ageing of parts such as fuel hoses vapor hoses gaskets rubber components RECOMMENDATIONS FOR REQUIRED MAINTENANCE IT IS RECOMMENDED THAT THE ROUTINE MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED INTERVALS AND ANY MAINTENANCE TO THE EVAPORATIVE EMISSION CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN ...

Page 62: ...ed elsewhere please ensure that items are segregated and kept in a suitable container or bag without allowing them to get into soil water or sewerage line drains water bodies like lake canal river Sea etc We strongly recommend that they are disposed off in accordance to the applicable law through Pollution Control Board approved agencies in the locality CLEANING OR WASHING YOUR ROYAL ENFIELD Pleas...

Page 63: ...th Paid Service 25000 km 30 Months 7 7th Paid Service 30000 km 36 Months NOTE Cost of parts lubricants filters and other consumables are chargeable to the customer on their respective service activities Refer the Periodic Maintenance Chart for the respective service activities S No Da te D e al e r C o d e Type of Jo b Ser vi ce Brief details of Card No servi ce k m Sched u le Labour is free for t...

Page 64: ...parts lubricants filters and other consumables are chargeable to the customer on their respective service activities Refer the Periodic Maintenance Chart for the respective service activities Labour is free for this services alone Da te D e al e r Jo b C o d e Brief details of Card No servi ce k m ...

Page 65: ...ness Park Opp Transport Nagar Saharanpur Road Majra Dehradun 248001 India SOUTH S1 Telangana Royal Enﬁeld A Unit of Eicher Motors Ltd Ground Floor No 8 3 166 B to F ErragaddaMain Road BesideGokulTheatreErragadda Hyderabad 500018 S3 Tamilnadu RoyalEnﬁeld A unit of EICHER Motors Ltd Plot No 9 10 OMR Road Palavakkam Opp to Apollo Hospital Chennai 600096 N2 Haryana RoyalEnﬁeld A unit of EICHER Motors ...

Page 66: ...64 NOTES ...

Page 67: ......

Page 68: ...Part No RAM00208 A ...

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