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Royal Enfield Classic 500 Owner'S Manual Download Page 78

73

TROUBLE SHOOTING

WARNING

The trouble shooting section of this Owner’s Manual is intended solely as a guide to diagnosing

problems.  Carefully  read  the appropriate  sections  of  this  manual  before performing  any  work.  Repair
and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield
Authorized Dealer only. Improper repair and/or maintenance could result in the motorcycle not functioning
properly, serious injury or  death.

   Causes

                 Remedies

I. Engine fails to start

1)

Stop switch in ‘OFF’ Position ..............................................

Push stop switch to ‘ON’ position.

2)

Side stand not retrieved .......................................................

Retrieve side stand.

3)

Vent hole clogged in fuel tank cap ......................................

Clean vent hole.

4)

Spark plug cap / lead not connected ..................................

Fix cap / lead firmly

5)

Spark plug electrode dirty / fouled ......................................

Clean spark plug

6)

Spark plug insulation cracked .............................................

Replace spark plug

7)

Clutch  slipping ..................................................................... *

Adjust clutch cable free play

* Contact Royal Enfield Authorized Dealer

Summary of Contents for Classic 500

Page 1: ...EURO IV ...

Page 2: ...intain your Motorcycle in top riding condition We have also detailed vital safety information for the rider and for the care and safety of the motorcycle Please read and follow these carefully to get maximum riding pleasure and for safe riding We request you to exercise utmost caution while riding Please ride cautiously safely and within the law Always wear a helmet good riding goggles and proper ...

Page 3: ...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 of Royal Enfield 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 n...

Page 4: ...uthorised Royal Enfield dealer If the motorcycle is being used by any friend relative or others it is responsibility of the owner to make certain that this owner s manual is read and fully understood prior to usage and has been instructed on it s safe and proper use The motorcycle is designed for normal on road use only Operation in off road usage in some areas may be illegal and could be dangerou...

Page 5: ...n indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Caution Caution used without safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage All images shown are for reference to explain and may not to be exactly the same on the model you own Technical specification are subject to change wi...

Page 6: ...OPERATION OF CONTROLS 27 PRE OPERATIVE CHECKS 30 SAFE HAPPY RIDING 31 RUNNING IN 32 WARNING INDICATIONS SAFETY SYSTEMS 34 STARTING 38 GEAR SHIFTING 40 PARKING 41 PERIODICAL MAINTENANCE 42 TOOLS KIT 46 MINOR MAINTENANCE TIPS 47 LONG TRIP PRECAUTIONS 67 WASHING PROCEDURE 68 STORAGE PRECAUTIONS 69 WIRING DIAGRAM 71 ABS WIRING DIAGRAM 72 TROUBLE SHOOTING 73 WARRANTY 78 EVAPORATIVE EMISSION CONTROL 80 ...

Page 7: ...E INFORMATION Name Door No Street Locality City Country Contact Res Off Mobile Email Licence No Valid till Model Color Engine No VIN No Tyre make Front Rear Tyre Nos Front Rear Battery make Battery No Sold by Date of Sale ...

Page 8: ...affect performance and handling Removing or altering original parts may adversely affect performance and could result in an accident causing serious injury Use only genuine Royal Enfield spare parts and approved accessories Use of other manufacturer s performance parts may affect the performance of your motorcycle and render the motorcycle void of warranty See your Royal Enfield Authorized Dealer ...

Page 9: ...cycle must be operated according to the special break in procedure See BREAK IN THE FIRST 300 MILES 500KM section SAFE OPERATING RULES 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 DO NOT exceed the legal speed limit or drive too fast for existing conditions Always reduce ...

Page 10: ...ke abruptly or force the handlebar Operate your motorcycle defensively Remember a motorcycle does not afford the same protection as an automobile in an accident One of the most common accident situations occurs when the driver of the other motorcycle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist Wear an approved helmet clothing and foot gear suited for riding a mo...

Page 11: ...eed 60 Km h 40 MPH for the first 24 hours after repair and the repaired tyre should Never be used over 90 Km h 55 MPH SAFE OPERATING RULES In emergency situations if a temporary repair is made ride slowly with as light a load as possible until the tyre is permanently repaired or replaced Failure to heed this warning could result in serious injury Safe motorcycle operation requires alert mental jud...

Page 12: ...y affect the safe operation of your motorcycle which could result in serious injury WARNING Avoid any contact with the exhaust system 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 even after the engine is turned off Failure to wear proper or protective clothing could result in serious injury WARNING Ex...

Page 13: ...ting of your motorcycle The Gross Motorcycle Weight Rating GVWR is shown on the information plate located on the frame Down tube GVWR is the sum of the weight of the motorcycle accessories and the maximum weight of the rider passenger and cargo that may be safely carried Exceeding GVWR may lead to instability of the motorcycle which could cause an accident and result in serious injury WARNING DO N...

Page 14: ... driving conditions exist High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control WARNING Avoid excessive speed and never travel at a speed faster than the speed limit Excessive speed may cause loss of control of motorcycle which could result in death or serious injury Keep to the correct side of the road center line when meeti...

Page 15: ...ine unless local rules require otherwise slow down and then turn carefully 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 DO NOT leave the curb or parking area without signaling Be sure your way is clear to enter moving traffic A moving line of tr...

Page 16: ...ury DO NOT exceed 70 MPH 110 Km h riding solo DO NOT exceed 55 MPH 90 Km h when carrying a passenger or cargo Keep cargo weight concentrated close to the motorcycle and as low as possible this minimizes the change in the motorcycle s center of gravity Distribute weight evenly on both sides of the motorcycle DO NOT load bulky items too far behind the rider or add weight to the handlebars or front f...

Page 17: ...ing so may affect its stability and could cause an acci dent resulting in serious injury 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 w...

Page 18: ...Wet Sump Fuel Supply Electronic Fuel Injection TECHNICAL SPECIFICATIONS Ignition system Ignition system Digital Electronic Ignition Spark plug gap 0 8 mm Spark plug WQR8DC Bosch Transmission Clutch Wet Multiplate Drive Chain links 102 pitch Primary drive Duplex Chain drive 3 8 pitch Gear box 5 Speed Constant Mesh Gear Ratios I 3 063 1 II 2 013 1 III 1 522 1 IV 1 212 1 V 1 000 1 Primary Drive Ratio...

Page 19: ...IFICATIONS Chassis Frame Tubular Frame Tyre size Front 90 90 19 52 V Rear 110 80 18 58 V Tyre pressure Front Solo 18 PSI Pillion 20 PSI Rear Solo 28 PSI Pillion 30 PSI Fuel tank capacity 14 5 1 Litres Suspension Front Telescopic Hydraulic Damping stroke 110 mm Rear Swing arm with gas filled shockabsorbers with adjustable 5 step spring tension load Brakes Hydraulic Disc Brakes Front Rear with ABS S...

Page 20: ...eed 128 kmph TECHNICAL SPECIFICATIONS NOTE 1 Values given above are for your guidelines only 2 In view of continuous improvements being done on our products the specifications are likely to change without prior notice Dimensions Length 2140 mm Width 800 mm Height 1080 mm Wheel base 1360 mm Saddle height 805 mm Ground clearance 140 mm ...

Page 21: ...or oils or non detergent oils can damage the engine OIL GRADE CAPACITY 1 Engine Oil 15W50 API SL 1 Dry Initial Fill 2 75 Litres JASO MA ESTER 2 Periodical Maintenance fill 2 30 to 2 50 Litres Semi synthetic oil Including filter replacement 2 Front Fork Fork oil 2W 35 195 ml leg 3 Brake Fluid Dot 4 and above Front 60 ml Rear 100 ml ...

Page 22: ... head tube and in the information plate rivetted to the frame down tube Sample VIN ME3 X X XX X X G X X X X X X X Manufacturer s code Type of Frame Type of Engine Variant Version Ignition System Transmission Type Production Year Assembly factory Production Serial No C Chennai K Kanchipuram 2016 G 2017 H etc ...

Page 23: ...ng head tube Caution It is illegal of tamper with the VIN information plate as it is the only means of identification of the motorcycle MOTORCYCLE IDENTIFICATION NUMBER DETAILS VIN INFORMATION PLATE Riveted on the frame down tube right side ...

Page 24: ...and its production details Please do not tamper with the engine number as it is prohibited by law Engine Family Engine Capacity Type of Start Type of Transmission Fuel Feed Manufacturing Plant Year of Manufacture Month of Manufacture Production Serial Number U 5 S 5 F X X X X X X X X X A Jan H Aug K Sep N Dec 0 TVT 1 ORG G 2016 H 2017 ...

Page 25: ...24 4 5 6 3 2 1 KEY PARTS LOCATION Right Side View 1 Right Trafficator Rear 2 Air Filter Box 3 ABS Cover 4 Right Trafficator Front 5 Starter Motor 6 Brake Pedal ...

Page 26: ... 9 8 6 7 5 4 3 7 Gear Change Lever 8 Spark plug 9 Horn 2 1 Left Trafficator Front 2 Electrical Tool Box 3 Left Trafficator Rear 4 Center stand 5 Side Stand 6 Battery Cover Left Side View KEY PARTS LOCATION ...

Page 27: ...signal switch 2 Horn button 3 Clutch lever 4 Day flash switch 5 Head lamp dip switch 6 Manual Bistarter 7 Rear View Mirrors 8 Ignition switch 9 Speedometer 10 Malfunction Low fuel Indicator 11 Engine Kill switch 12 Front Brake Lever 13 Starter Switch 14 Fuel tank cap 7 7 ...

Page 28: ... key from switch and lock the steering head CAUTION DO NOT lubricate barrel locks with petroleum based lubricants or graphite Inoperative locks may result in damage to your motorcycle Lock the steering when leaving motorcycle parked OPERATION OF CONTROLS Fuel tank cap To Open Turn cap anticlockwise To Close Locate cap and turn clockwise till click Sound is heard ...

Page 29: ...28 Kill switch Horn Run Stop Depress OPERATION OF CONTROLS DIP switch Low Beam High Beam Head lamp day flash Depress to flash ...

Page 30: ...29 OPERATION OF CONTROLS Turn Signal Switch Left OFF Push to off Right Engine Start Switch Manual Bi Starter Depress ...

Page 31: ... up if necessary Do not overfill 7 Rear chain for proper tension 8 Brakes steering and throttle for responsiveness 9 Wheel spoke for proper tightness no breakage 10 Headlamp tail lamp brake lamp and directional lamps for proper operation 11 Check ABs lamp glows as soon as ignition switch kill switch are ON and goes OFF as soon as vehicle reaches a speed of 5 Km h 3 mph WARNING For your personal we...

Page 32: ... body SAFE HAPPY RIDING Keep your toes in straight ahead direction Slightly grip the petrol tank with both knees Hold the handle bar grips close to its inner end Look extensively ahead including rear view mirrors without turning the head Braking Apply front and rear brakes gently and simultaneously for maximum braking efficiency WARNING Applying any one of the brakes suddenly may cause loss of con...

Page 33: ... abnormal wear of the moving parts and result in premature failure 1 0 500 Kms 0 300Miles The recommended speeds for the first 300 Miles 500 Kms is 50 60 Km h 35 40 MPH During this period avoid operating the motorcycle with full throttle opening Stop the motorcycle for about 5 to 10 minutes to let it cool down after every hour of running Vary the speed of the motorcycle regularly during running bu...

Page 34: ...nally CAUTION Royal Enfield engines are air cooled and consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature Extended periods of idling may over heat the engine resulting in serious engine damage CAUTION DO NOT run the engine at extremely high RPM with clutch disengaged or transmission in neutral as it can cause serious engine damage CAUTION ...

Page 35: ...erious damage to 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 f...

Page 36: ...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 3MPH and switch OFF This indicate...

Page 37: ... a corner 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 motorcycle Always ensure that you ride well within th...

Page 38: ...N the Ignition and stop switch again to start the engine Don ts DO NOT RELEASE the brake lever pedal when pulsations are felt during hard application of the brakes in an emergency situation The pulsations only indicate that the ABS is activated DO NOT APPLY only the front OR rear brake as it can lead to inefficient braking Do s While starting the engine do check the ABS indicator comesON and switc...

Page 39: ...h and simultaneously depress gear lever to come to neu tral Ensure neutral indicator light comes ON in the Speedometer NOTE If the engine does not start on the first attempt in cold climate release the starter button wait for 30 seconds before depressing the starter button again Depress starter button and release starter switch once the engine starts A clutch switch is provided in the system for t...

Page 40: ...y As soon as the engine sufficiently warms up the RPM will raise at which time the manual bistarter should be released Warm up engine for 2 minutes till idling is consistent Prior to starting check to see if the low fuel indicator is glowing continuously This will glow continuously if the fuel level in the tank in below 3 5 litres Please ensure the motorcycle is not used with the low fuel indicato...

Page 41: ...UTION The clutch must be fully disengaged before attempting a gear shift Failure to fully disengage the clutch may cause a jerky start and OR stalling the engine besides causing damage to transmission parts Lift the gear lever with toe to engage 2nd gear NOTE Always start motorcycle with gears in neutral Always move motorcycle in first gear When engine speed decreases while climbing a gradient or ...

Page 42: ...y cause stand to sink and the motorcycle to fall causing injury to you or to others and damage to the motorcycle parts Parking Motorcycle on Center Stand Parking Motorcycle on Side Stand Select a firm flat surface Lower side stand and gently tilt motorcycle to the left till it rests firmly A Safety switch is provided in the side stand If the side stand is in extended position and rider engages gea...

Page 43: ...he driving condition OR if the motorcycle is used in a very dusty environment severe climatic cold and hot conditions bad roads stagnant water etc Contact a nearest Royal Enfield Authorized Dealer for expert advice and to carry out the periodical maintenance WARNING For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at t...

Page 44: ... as required 2 Engine oil filter element R R R R R R 3 Engine sump filter oil strainer C C C C C C 4 Magnetic drain plug under gear box and secondary C C C C C C drain plug under crankshaft in crankcase right 5 Spark plug A A A A A R A A A A R 6 HT lead I I I I I I I I I I I 7 Fuel hose I I I I R I I I R I I 8 Fuel Pump Check for screw tightness in all services 9 Accelerator cable play A A A A A A...

Page 45: ...C R C C C R C C 13 Inlet Exhaust valve seating compression vaccum test I I 14 Cylinder head D 15 Exhaust system D 16 Clutch free play Adjust every 1000 Kms or earlier as required 17 Rear brake pedal pivot L L L L L L L L L L L 18 Battery terminals apply petroleum jelly C C C C C C C C C C C 19 Battery Electrolyte level I I I I I I I I I I I 20 Earth wire eyelet behind battery carrier I I 21 Rear W...

Page 46: ...ork oil R R R 23 Rear brake play Adjust every 1000 Kms or earlier as required 24 Rear brake cams L L L L L 25 Steering ball races play I A L A L A L A R A L 26 Spokes tightness Wheel rim run out front rear I I I I I I 27 Pivot Side Stand Center Stand Pillion Foot Rest L L L L L L L L L L L 28 Tyre wear pattern Front Rear I I I I I I I I I I I 29 Hand levers pivot Lubricate every 1000 Kms or earlie...

Page 47: ... TOOLS KIT S Description Qty No 1 Tool Wallet 1 2 Tommy bar 1 3 Tubular spanner 21 24mm 1 4 Screw driver 1 5 Double end spanners 10 13 mm 2 8 10 mm 1 14 15 mm 1 X 5 16 1 6 Allen Keys 5 mm 1 3 mm 1 6 mm 1 ...

Page 48: ... Control Cables Handle bar lever pivots Center Side Stand Pivots Lubricate after using the motorcycle in rain after waterwash or if used in dusty conditions Wipe the area free of dirt grease Apply a few drops of oil on the pivots Oil Level Inspection Place motorcycle on its center stand on a firm surface Warm up engine for a few minutes switch off The level is correct if the oil level is in the mi...

Page 49: ...uptly and result in an accident caus ing serious injury or death Engine Oil Change Refer Periodical Maintenance Chart for frequency Place motorcycle on its center on a firm flat surface Start engine and warm up for few minutes switch off the engine Keep a clean tray below the engine Remove the oil drain plug and the suction filter underneath the crankcase Remove the oil filter on the right Crankca...

Page 50: ...e cylinder head using the plug spanner and tommy bar Clean the insulator tip and electrodes of the plug carefully using a pointed scraper or spark plug cleaner Set the gap between 0 8 to 0 9 mm Refit the spark plug on the cylinder head and connect H T Lead Caution Brake fluid is highly corrosive Please take care not to spill brake fluid on painted plated buffed surfaces and other parts of the moto...

Page 51: ...er a new tyre is installed ensure rim and spokes do not get damaged on account of using wrong levers Use only standard tyres tubesinflated to correct pressure WARNING Tyres and tubes must be correctly fitted and seated to the wheel rims Only the approved specified tyres and tubes must be used for replacements Tyre fitments must also be carried out only by an experienced and authorised personnel Fa...

Page 52: ...e pinch bolt on the right side fork end Hold the axle on the right side and loosen the axle nut on the left side Remove the axle nut and washer MINOR MAINTENANCE TIPS Tap the axle out gently from the left side and remove completely from the right side Slide out the wheel from the fork legs along with the speedo drive and spacer on the left side Remove the speedo drive small spacer on the right sid...

Page 53: ...and speedo drive over the wheel hub on the right side Locate stepped spacer in the left side of the hub with its larger face outside 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 brake pads Ensure the peg in the speedo drive is correctly positioned in the slot in the right side fork end ...

Page 54: ...edo meter Depress brake lever 2 or 3 times to check front brake efficiency MINOR MAINTENANCE TIPS Place the motorcycle on its center stand on a firm and flat surface such that the rear wheel is about 4 inches 10 cms above the ground Hold the axle from the left side loosen and remove the axle nut on the right side Remove wheel spindle from left side Gently release the brake hose from the holding cl...

Page 55: ...ove the wheel from the swing arm CAUTION Do not press the rear brake pedal when wheel is removed as this will result in the brake pads coming too far out of the brake caliper Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the rear brake pedal is accidently pressed WARNING Ensure the motorcycle does not come off center stand while ass...

Page 56: ...sc is located in between the brake pads Ensure the Chain tensioner is correctly located inside the swing arm on the left side Position the spacer correctly between the hub and the caliper assembly Align the caliper bracket spacer hub and chain tensioner holes Insert the wheel spindle from left side fully Ensure that chain tensioner stopper plate is firmly seated against the left side swing arm Hol...

Page 57: ...INOR MAINTENANCE TIPS Drive Chain Tension Adjustment Place motorcycle on its center stand on a firm surface Ensure gears are in neutral and the rear wheel rotates freely Check the drive chain tension at the bottom run of the chain It must be 25 30 mm To adjust proceed as follows Hold the rear wheel axle on the left side and loosen rear wheel axle nut and sprocket nut on the right side ...

Page 58: ...ut on right side chain tensioner slowly to achieve the desired chain tension Wheels Alighnment Note the matching reference marks of the chain tensioner and the swing arm on the right side Hold the handle bar straight and visually also check for proper alignment of the front and rear wheels Tighten Loosen adjuster nut on the left side chain tensioner such that the same reference marks can be aligne...

Page 59: ...ife Drive Chain Lock Fitment If for any reason the chain link lock is removed it should be fitted such that the closed end of the lock is towards the direction of the chain rotation Please ensure the chain lock is located properly in the chain link and is locked in place MINOR MAINTENANCE TIPS Holding the adjuster nuts tighten the lock nuts against the adjuster nuts on both the left and right side...

Page 60: ...ustment ensure the adjuster notches are seated correctly against the peg in the shock absorber Pre load spring tension adjustment of rear shock absorber WARNING Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident In case of fitting any luggage rack or tying cargo to the rear end of the motorcycle please ensure they do not ham...

Page 61: ...g a soft and wet cloth Inspect the battery carefully for any deformation of its housing If found deformed replace the battery immediately Clean the terminals using a soft wire brush to remove any oxidations Check the electrolyte level to see if it is between MAX and MIN lines If necessary top up ONLY with pure and clean distilled water till the level is between the MAX and MIN lines DO NOT OVERFIL...

Page 62: ...y from an internal damage WARNING Always disconnect the ve terminal first and then the ve terminal while removing the cable connections Batteries contain lead sulphuric acids and other chemicals which are known to cause cancer and birth defects or reproductive harm Battery electrolytes are highly acidic and corrosive in nature Avoid contact with eyes skin clothing etc as it causes excessive burnin...

Page 63: ...lways ensure the battery charger is in OFF mode while connecting it to the battery for charging Failure to adhere to the above warnings can result in an explosion of the battery causing serious Injury or loss of life CAUTION Electrolyte should be maintained ONLY between the MAX and MIN levels indicated in the battery Using a battery with a low or weak electrolyte low battery charge can seriously h...

Page 64: ...properly located over the terminals to prevent any metal coming in contact with the terminals and causing a short circuit Position the battery correctly and fully inside the carrier and strap the battery securely using the two rubber straps Locate the battery cover over the battery and lock it in place Changing Electrical Components Head Lamp Bulb Loosen the rim holding screw on top and take out t...

Page 65: ...e bulb glass with bare fingers as it leave finger prints on the glass and reduce the lighting intensity Hold the bulb only at its base near the terminals Tail Lamp Bulb Remove the two nuts holding the rear license plate Remove the three screws holding the tail lamp to the bracket MINOR MAINTENANCE TIPS Refit the bulb holder and turn clockwise to lock the bulb holder Refit the tail lamp on the brac...

Page 66: ...pare fuse is used please ensure it is replenished at the earliest opportunity Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing frequently MINOR MAINTENANCE TIPS Fuse No Colour Remarks 1 White Charging Fuse 25A 2 White Main Fuse 25A 3 Blue Ignition EFI Fuse 15A 4 Red Signalling Horn Fuse 10A 5 Brown Spare Fuse 5A 6 Blue Lighting Fuse 15A 7...

Page 67: ...lter Cleaning Unlock and open the right filter box Remove the nut and take out the lid Remove the metal plate Remove the Air filter Element Tap off the dirt Blow compressed air on the Filter element from inside out Replace element if it is cracked or punctured Place element inside air filter box Fix the air filter cover plate Fix the Air filter lid and tighten the nut Close the filter box lid and ...

Page 68: ...ne brake master cylinders Correct tyre pressure and no loose broken spokes Proper chain tension Good battery condition Proper functioning of all lights horn etc Tightness of all fasteners NOTE It is recommended that the motorcycle be checked and serviced by an authorized Royal Enfield service center prior to embarking on a long ride LONG TRIP PRECAUTIONS ...

Page 69: ...l connections and wires control cables Throttle body spark plug battery etc Use luke warm water and mild detergent on the painted components to remove dirt etc Rinse motorcycle thoroughly with plain water to remove the detergent and wipe motorcycle dry If possible use compressed air and blow off water particles from the obscure areas of the motorcycle electrical connections etc After washing Ensur...

Page 70: ...the hole and crank engine several times and refit spark plug Clean rear chain thoroughly and lubricate Remove battery from the motorcycle Clean the terminals free of corrosion and apply petroleum jelly to terminals Maintain electrolyte level between max or min mark Store the battery in a cool dry and well ventilated place Cover the silencer with plastic bags to prevent moisture entry Set the motor...

Page 71: ...he battery Lubricate all control cables and pivots Check proper level of oil in engine Fill fuel tank with fresh petrol Check fuel line for any cracks or cuts Clean the air filter Remove plastic covering from the silencer Switch on ignition switch Start motorcycle and warm up engine for a few minutes before riding the motorcycle NOTE Do not raise the engine RPM the moment it is started but allow t...

Page 72: ...71 WIRING DIAGRAM ...

Page 73: ...72 WIRING DIAGRAM ...

Page 74: ...EURO IV ...

Page 75: ...EURO IV ...

Page 76: ...EURO IV ...

Page 77: ...EURO IV ...

Page 78: ...r repair and or maintenance could result in the motorcycle not functioning properly serious injury or death Causes Remedies I Engine fails to start 1 Stop switch in OFF Position Push stop switch to ON position 2 Side stand not retrieved Retrieve side stand 3 Vent hole clogged in fuel tank cap Clean vent hole 4 Spark plug cap lead not connected Fix cap lead firmly 5 Spark plug electrode dirty foule...

Page 79: ...lter blocked IV Poor pickup 1 Accelerator cable free play excessive Adjust cable free play 2 Faulty fuel supply Remove fuel pump clean Fuel pump filter blocked 3 Choked air filter Clean Replace air filter 4 Brakes adjusted too tight Re adjust properly 5 Rear chain adjusted too tight Re adjust properly 6 Clutch Slipping Adjust clutch cable free play 7 Under inflated tyres Inflate to correct pressur...

Page 80: ... Excessive fuel consumption 1 Fuel leakage Check and rectify 2 Choked air filter Clean Replace 3 Under inflated tyres Inflate to correct pressure VIII Brakes poor 1 Oil grease on brake pads disc Check Correct 2 Brake Fluid leaking Air in brake system Check Correct Bleed Brake System 3 Linings worn Uneven wear Replace linings 4 Brake Pads Disc Uneven wear Check replace Contact Royal Enfield Authori...

Page 81: ...s misaligned Ensure proper alignment 5 Under inflated tyres Inflate to correct pressure X Electricals Bulbs do not light 1 Loose improper connection Check and correct 2 Bulb fused Replace bulb 3 Fuse blown Check and Replace fuse Horn not working 1 Loose connections Check and correct Contact Royal Enfield Authorized Dealer TROUBLE SHOOTING Causes Remedies ...

Page 82: ...roperly Adjust connecting links properly 2 Switch sticky Replace switch XI Electronic Fuel Injection Engine MIL ON continuously 1 Sensor Loose Connection Check Correct XII ABS Anti lock Braking system 1 ABS lamp continuously ON Take the vehicle to service center for diagnosis Contact Royal Enfield Authorized Dealer TROUBLE SHOOTING Causes Remedies ...

Page 83: ...e 4 Proof of Ownership in the form of Sales Registration OR Proof of Purchase documentation of the motorcycle clearly mentioning the Engine VIN numbers must be provided to the Distributor s service facility OR their Authorized dealership s service facility 5 During the warranty period Royal Enfield s obligation is limited to repair or replacing free of charge such part or parts of the motorcycle w...

Page 84: ...e transportation of motorcycle etc 9 Royal Enfield reserves the right to finally decide on all warranty claims 10 Royal Enfield reserves the right to make changes in the motorcycle without any obligation to install these changes on previously sold motorcycles 11 Royal Enfield authorized distributors and or their dealers are independently owned and operated They may hence deal with other aftermarke...

Page 85: ...o meet applicable regulations period of 24 Months from 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 Fa...

Page 86: ...tance 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 THATTHE ROUTINE MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUTAT SPECIFIED INTERVALS AND ANYMAINTENANCE TO THE EVAPORATIVE EMISSION CONTROLSYSTEMS SHOULD BE PERFORMED ONLY BY AN AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USIN...

Page 87: ...82 SERVICE MAINTENANCE RECORD S No Date Brief details of work service Royal Enfield Authorized Dealer 1 2 3 4 5 6 7 8 Job Card No KMS Miles ...

Page 88: ...83 SERVICE MAINTENANCE RECORD S No Date Brief details of work service 9 10 11 12 13 14 15 16 Job Card No KMS Miles Royal Enfield Authorized Dealer ...

Page 89: ...84 NOTES ...

Page 90: ...ROYALENFIELD COM Part No 1010221 A ...

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