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Royal Enfield Thunderbird 500 Owner'S Manual Download Page 84

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Summary of Contents for Thunderbird 500

Page 1: ......

Page 2: ... meticulously We have also provided tips on safe riding and on minor adjustments for the care of your motorcycle Please avail the four free three paid services at the nearest Authorised Service Center at the appropriate time to maintain your motorcycle in top riding condition Log on to the exciting world of Royal Enfield on www royalenfield com to get to know more about the company its products an...

Page 3: ...6 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 NOTICE Part No 594069 B Qty 500 Nov 16 NOTE BS III This motorcycle meets Emission Norms Bharat Trem Stage III Disclai mer Following precautions are to be taken to ensure longer paint life of your motorcycle ...

Page 4: ...ing Riding Stopping 25 Parking 26 Periodical Maintenance Chart 27 Tools First Aid kit 30 Minor Maintenance Tips 31 Long Trip Precautions 43 Washing Procedure 44 Storage Precautions 45 Trouble Shooting 46 Warranty Terms Conditions 47 Emission Warranty 49 Service Coupons 52 Paid Service Maintenance Record 67 Regional Area Offices 69 Authorised Dealer Address 70 Notes 88 A nnex u r es Motorcycle Inst...

Page 5: ...or 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 Motorcycle Installation Form MIF No ...

Page 6: ...Fill only 2 30 to 2 50 litres subsequent refills Engine oil grade Royal Enfield 15W50 API SL JASOMA Cooling Natural air flow IGNITION SYSTEM Ignition system Electronic Ignition ECU Variable Spark plug Electrode gap 0 70 to 0 80 mm Spark plug WR8DP M14 Bosch UR6DC M10 Bosch TRANSMISSION Clutch Wet multiplate 7 plates Primary drive Duplex chain Primary ratio 2 15 1 Gear box Constant Mesh 5 Speed Gea...

Page 7: ...caliper Tyre size Front 90 90 19 52 P Rear 120 80 18 62 P Tyre Pressure Solo Front 20 psi 1 41 kg cm2 Rear 30 psi 2 11 kg cm2 With Pillion Front 22 psi 1 55 kg cm2 Rear 32 psi 2 25 kg cm2 Steering lock In built Fuel tank capacity 19 litres approx Low fuel warning Last bar blink system 5 5 0 50 litres approx Dead stock of Petrol 0 5 litre approx unusable fuel The above values are approximate and th...

Page 8: ...on light guides Hi beam indicator LED 12V X 1 No Neutral indicator 12V 1 4W X 1 No Turn signal indicator LED 12V X 2 Nos Turn signal 12V 10W X 4 Nos hazard warning Horn 12V 2 5 Amp Max X 2 Nos Starter Motor 12V 900 Watts Instrument Cluster Digital cluster with LCD panel Hazard indicator LED 12V X 1 No Side stand indicator 12V 1 4W X 1 No Malfunction LED 12V X 1 No Indicator Lamp MIL WA RN IN G Usi...

Page 9: ...ected carefully and reached to a certified disposal agency nearest to you to safely disposing the oils Similarly hazardous wastes such as old discarded Batteries Tyres Tubes Cables Gaskets Oil filters etc should also be disposed off carefully and properly only through a certified disposal agency CAU TION Use of Wrong grade oil will reduce the life of the moving parts and seriously affect performan...

Page 10: ...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 11: ...10 MOTORCYCLE IDENTIFICATION NUMBERS FRAME NUMBER Punched on steering head tube right side ENGINE NUMBER Punched on crankcase left top side ...

Page 12: ...1 Turn Signal Switch 2 Horn Button 3 Clutch Lever 4 Day Flash Switch 5 Head Lamp Dip Switch 6 Manual Bistarter Choke 7 Speedometer 8 Ignition Switch 9 Malfunction Low Fuel Indicator 10 Engine Kill Switch 11 Pilot Head Light Switch 12 E Start Switch 13 Fuel Tank Cap ...

Page 13: ...12 LOCATION OF KEY PARTS RIGHT SIDE VIEW 1 Right Trafficator Rear 2 Right Trafficator Front 3 Brake Pedal 4 Starter Motor 5 Air Filter Box Side Panel 6 Utility Box Tool Kit 2 1 6 5 3 4 ...

Page 14: ...ION OF KEY PARTS LEFT SIDE VIEW 1 Left Trafficator Front 2 Utility Box Fuse Carrier 3 Left Trafficator Rear 4 Center Stand 5 Side Stand 6 Battery Cover 7 Spark Plug 8 Gear Change Pedal 9 Horn 1 3 2 9 8 7 6 5 4 ...

Page 15: ...y in position SIDE PANEL LEFT BATTERY COVER Turn anti clockwise to open Pull the side panel outside for opening the same SIDE PANEL RIGHT Unscrew the indicated screw and then pull the side panel for opening the same NOTE Key is common for ignition petrol tank cap steering lock battery cover and tool boxes Key can be removed only in locked position from fuel tank Filter box Electrical boxes locks i...

Page 16: ... C AU T I O N Choke should be used only to start engine in cold climates less than 200 C or first time in the morning Riding with the Choke ON will result in Engine Misfiring Erratic behaviour High fuel consumption and increased Emission values HEAD LIGHT SWITCH OFF Pilot ON Head Lamp ON DIMMER SWITCH High beam Low beam DAY FLASH Press for Head Light Flash HORN Press ...

Page 17: ... 2 5 4 6 Turn Signal Indicator Left Turn Signal Indicator Right High Beam Indicator Neutral Indicator Hazard Warning Indicator MalfunctionIndicator Lamp Parking Lamp Indicator Side stand Indicator RIDER PILLION SEAT CABLE LOCK There are 2 cable hooks Black Yellow on right side of the battery below the hook Index mark R Rider P Pillion The allen key is located in the battery carrier rubber strap as...

Page 18: ... TO ZERO AND AVG SPEED TO ZERO RESET VALUES OF TRIP A AND AVG SPEED TO ZERO RESET VALUES OF TRIP B TO ZERO AND AVG SPEED TO ZERO RESET VALUES OF TRIP B AND AVG SPEED TO ZERO PRESS SET SWITCH 1 SEC TRIP A KM TIME AM PM TRIP A KM AVG SPEED TRIP A KMPH TRIP B KM TIME AM PM TRIP B KM AVG SPEED TRIP B KMPH PRESS SET SWITCH 3 SEC PRESS SET SWITCH 3 SEC PRESS SET SWITCH 3 SEC PRESS SET SWITCH 3 SEC PRESS...

Page 19: ...ast selection mode will be displayed If the current display mode is TRIP A you just turn off the ignition key Once you turn the ignition key the display mode remaining same TRIP METER MODE A brief push less than one second on the SELECT button switches the display from odometer to Trip meter TRIP A TRIP METER AVG SPEED MODE Again press the SELECT button switches the display from TRIP A to TRIP A A...

Page 20: ...ress the SET button more than 3 seconds 5 The Minutes will be blinking then press the SELECT button to change the Minutes NOTE Once you press the SELECT button the Hours Minutes will increase in ascending order only it not decrease The Hour Minutes blinks less than 1 minute within the time limit you have to reset the clock otherwise it will come out from the reset mode FUEL LEVEL INDICATOR The fue...

Page 21: ...at if your motorcycle is due for service The service reminder symbol will start blinking Kilometers ranges as shown below Service Due Kilometer 1 450 2 2900 3 5900 4 8900 W A R N I N G Do not change the setting while riding It may cause loss of control leading to an accident NOTE If the last bar of the fuel meter is blinking continuously after fueling visit the Royal Enfield authorised dealer chec...

Page 22: ...d sufficient lubrication 4 Brakes steering and throttle for proper responsiveness 5 Cable for fraying or crimping and free operation 6 Engine oil level 7 Wheel spokes for proper tightness and no breakage 8 Headlamp tail lamp brake lamp and indicator lamps for proper functioning W A R N I N G For your personal welfare and safety all the points mentioned above should be performed periodically Failur...

Page 23: ...orcycle SITTING POSTURE Correct sitting posture is a must for stable and safe riding Sit Straight with your shoulders completely relaxed Keep your elbows close to your body Hold the handle grip close to its inner end Slightly grip the fuel tank with the knees Keep your toes in straight ahead direction Before turning look extensively in the rear view mirror without turning your head BRAKING Use bot...

Page 24: ...ot 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 and r...

Page 25: ...tch ON Ignition and the Stop Switch to RUN Position USING THE KICK START LEVER Slowly Crank Engine with the Kickstarter lever till a resistance is felt in the lever Slightly crank slowly and further till the compression eases over Release Kickstarter lever to enable it to come to its top resting position Apply a powerful swinging Kick on the lever to start the engine It may be necessary to open th...

Page 26: ...r Gently open throttle and release clutch simultaneously If clutch is released suddenly the engine may stall and cause a jerky start NOTE Always start motorcycle with gear in neutral position Always move the motorcycle in first gear position only When engine speed decreases or while climbing a gradient or running at a reduced speed shift to the appropriate lower gear to prevent the engine from sta...

Page 27: ... firm ground Apply pressure on the fulcrum lever on the center stand and pull motorcycle backward WA R N I N G Ensure both the stands are retracted fully before riding the motorcycle Please exercise extreme care while 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 PARKING MOTORCYCLE ON CENTE...

Page 28: ...enter for expert advice and to carry out the required maintenance Sl No DESC RI PT I ON PAID SERVICE FREE SERVICE whichever is earlier Kms x 1000 0 5 3 6 9 12 15 18 21 24 27 30 Months 1 5 3 6 9 12 15 18 21 24 27 30 1 Engine Oil R I R I R I R I R I R Check level at every 1000 Kms or earlier as required 2 Engine oil filter paper element R R R R R R 3 Engine sump filter oil strainer Magnetic drain pl...

Page 29: ...r paper element C C C C R C C C R C C 13 Inlet Exhaust valve seating compression vaccum test I I 14 Cylinder head Combustion chamber D 15 Clutch lever cable free play Adjust every 1000 Kms or earlier as required 16 PAV pipes hose clip I I I I I I I I R I I 17 Battery terminals apply petroleum jelly C C C C C C C C C C C 18 Battery Electrolyte level I I I I I I I I I I I 19 Earth wire eyelet contac...

Page 30: ...rbo cleaner Carbclik or Fuel Line Cleaner Spray Make Wurth or ITW Chemin 23 Front Fork oil I I I R I I R I I R I 24 Steering ball races play I A L A L A L A R A L 25 Spokes tightness Wheel rim run out front rear I I I I I I 26 Swing Arm pivot bush spacer L L L R L 27 Tyre wear pattern Front Rear I I I I I I I I I I I 28 Hand levers kick starter lever pivot Lubricate every 1000 Kms or earlier as re...

Page 31: ...3 Gauze bandage 5 cm x 2 cm 1 4 Sterilized Gauze Swab 5 cm 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 S No Description Qty The tool kit is located in the left side Electrical box of the motorcycle A first aid kit is provided with the motorcyle for any emergency requirements Please familiarise yourself with the minor maintenanc...

Page 32: ...an the drive chain carefully Apply chain lubricant while simultaneously rotating the rear wheel Wipe off the excess lubricant OIL LEVEL INSPECTION Place motorcycle on its center stand on a firm surface Warm up engine for a few minutes switch off before checking oil level The level is correct if the oil level is in the middle of the oil level window Top up only with recommended Engine oil HAND LEVE...

Page 33: ...use damage to painted parts Please ensure that brake fluid does not spill on any part of the motorcycle In the event of a spill please clean the area immediately with a soft cloth preferably a wet cloth to avoid damage Don t mix DOT 3 DOT 4 Brake fluid together Check if oil is below MIN level To top Up remove cover and diaphragm then top up with DOT 3 or DOT 4 as specified BRAKE FLUID FRONT BRAKE ...

Page 34: ...move speedo sensor INSPECTION OF TYRES AND WHEELS Check and remove stone splinters nails or other particles embedded in the tyre treads Periodically inspect wheels for spokes breakage and wheel rim run out Check proper seating of the tyre beading on the rim whenever the tyre is reassembled Use only recommended tyres tubes inflated to correct air pressure Inspect the tyres periodically for tread we...

Page 35: ...esult in the brake pads coming too far out of the brake caliper FRONT WHEEL REASSEMBLY Remove the wooden card board spacer placed between the brake pads Locate wheel speed sensor lugs on the hub slot carefully Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the front brake lever is accidently pressed Insert wheel spindle from right fo...

Page 36: ...ide spacer from rear wheel hub Tilt motorcycle to right side and slide out rear wheel MINOR MAINTENANCE TIPS REAR WHEEL REASSEMBLY Ensure the four Cush rubbers are in position inside the rear wheel hub Tilt motorcycle to right side and insert the wheel assembly between the swing arms Position the rear wheel with cush rubber on the rear chain sprocket Fix the left side spacer in rear wheel hub Remo...

Page 37: ...e Insert and tap the rear wheel axle gently from left side C AU T I O N Do not force the spindle into the wheel as the threads may get damaged Tap it through the wheel gently C AU T I O N Please check the brake hose pipe routing from Reservoir to Master cylinder Master cylinder to Rear wheel caliper There should not be any twist or pinch in routing which may affect braking performance Fix the brak...

Page 38: ...AKE LIGHT SWITCH ADJUSTMENTS The brake light glows once you press the brake pedal If brake light is not glowing check the brake light switch wire connection bent broken switch spring and connection with brake pedal Adjustment nut Place motorcycle on its center stand on a firm flat surface Measure the drive chain free play on the top run of the chain The recommended free play is 25 to 30 mm If abov...

Page 39: ...inals Electrolyte level To adjust the free play Loosen rear wheel spindle nut Loosen rear sprocket stub axle nut Loosen lock nuts of the chain adjuster on both ends of the swing arm Tighten loosen the adjuster nut on right swing arm end to reduce increase free play Rotate wheel slowly and check chain free play at the top run to be between 25 30 mm Note the matching index marks on right swing arm a...

Page 40: ...TERY FROM THE MOTORCYCLE Unlock turn the key clockwise and remove the Left side panel Disconnect both the terminal wires negative first and positive next respectively Remove the battery carrier bracket by loosening the two screws Take out the battery WA R N I N G Always disconnect the Black negative battery cable first and then the Red positive cable while removing the battery connections NOTE For...

Page 41: ...ion and keep the terminals coated with petroleum jelly MINOR MAINTENANCE TIPS CHANGING ELECTRICAL COMPONENTS HEADLAMP BULB REPLACEMENT Motorcycle is provided with high and low beam Remove the head lamp holding 2 nos side screws Detach the bottom lug from the head lamp housing body Remove the rubber grommet upper for High beam another for Low beam from the reflector assembly Disconnect High beam wi...

Page 42: ... the new bulb inside the holder ensuring that the pins in the bulb match with slots in the holder Push the bulb and turn clockwise direction to lock the bulb in the holder Refit the trafficator cover with reflector and tighten the screw NOTE Do not over tighten the screw otherwise the lens may break MINOR MAINTENANCE TIPS Pull out the fused bulb NOTE Never touch the bulb with your fingers Finger p...

Page 43: ...5A 2 Blue Main wiring 15A 3 Blue EFI System 15A 4 Red General illumination Tail Trafficator Lamps 10A 5 Red Head Lamp Fuse 10A 6 Red Instrument Cluster Horn 10A 7 Red Spare Fuse 10A 8 Blue Spare Fuse 15A WA R N I N G Please get the electrical system of your Motorcycle checked thoroughly and get the faults corrected immediately after experiencing any fuse failure Not doing this can result in to rep...

Page 44: ...ure if necessary Checks after every 1500 kms of run Any loose fasteners Condition of the tyres Electrolyte level in the battery Correct oil level in engine Working of all lights and horn Proper drive chain tension Items to be carried Tool kit First aid kit Bulbs for Headlight Trafficator light and mini Blade Fuses 10 15 Amps Accelerator and Clutch cable Rear chain master link lock assembly Insulat...

Page 45: ...es or rubber parts 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 If possible use compressed air and blow off water particles from the obscure areas of the motorcycle electrical connections etc AFTER WASHING Ensure the motorcycle is thoroughly dry by wiping with a clean soft absorbent cloth or...

Page 46: ...m the motorcycle Clean the terminals free of corrosion and apply petroleum jelly to terminals 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 Cover the silencer with plastic bags to prevent moisture entry Set the motorcycle on its center stand Apply anti rust solutions on all plated part...

Page 47: ...y Replace Battery 1 Battery completely dead Replace battery 2 Fuse Blown Replace appropriate fuse Note If fuse blows again contact Authorised Service Center Spark plug Cap wire disconnected Reconnect Contact Authorised Service Center Motorcycle driven in Low gear High RPM Crowded places for long time Engine RPM raises improportinately to motorcycle speed Rear Chain excessively loose causing chain ...

Page 48: ...e 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 Cost of oil oil filter and fuel are chargeable to the custom...

Page 49: ...ght vibration oil leakage blue discoloration of exhaust bent pipe silencer soft or hard shockabsorber etc g Defects arising from fitment of unauthorised or additional electrical loads h Motorcycle serviced or repaired at unauthorised service centers i Motorcycle used for competitions racing Stage Rallying etc j Electrical component like bulbs fuses etc and electronic components failure due to repa...

Page 50: ... 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 51: ... 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 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 certifica...

Page 52: ...e of the motorcycle The emission related components are tampered with All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced 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 Always get your motorcycle checked to meet the...

Page 53: ...Dealer Service Center nearest to you and as a token of satisfactory service kindly return the service coupons duly filled in and signed to the service outlet Availing all the services in the specified time is a prerequisite to warranty consideration The cost of fuel oil oil filter element grease and consumables used during services is chargeable to the customer Please ensure the details of the per...

Page 54: ...in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by Dealer...

Page 55: ...ounting screws Leak 13 Fuel hose Inspect for cracks 14 Fuel filter element in fuel pump Clean 15 Rubber hose Air filter to throttle body Inspect for cracks 16 Rubber hose Inlet manifold Adaptor Inspect for cracks 17 PAV pipes hose clip Inspect 18 Accelerator Throttle pulley cables free play Check Adjust play 19 Clutch cable Lever free play Adjust play 20 Engine oil sump strainer magnetic drain plu...

Page 56: ...s in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by Deal...

Page 57: ...Inspect for cracks 12 Fuel pump under tank mounting Check mounting screws Leak 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Rubber hose Inlet manifold Adaptor Inspect for cracks 16 PAV pipes hose clip Inspect 17 Accelerator Throttle pulley cables free play Check adjust play 18 Clutch cable Lever free play Adjust play 19 Steering free play Check A...

Page 58: ...ls in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by Dea...

Page 59: ... mounting Check mounting screws Leak 14 Fuel hose Inspect for cracks 15 Rubber hose Air filter to throttle body Inspect for cracks 16 Rubber hose Inlet manifold Adaptor Inspect for cracks 17 Accelerator Throttle pulley cables free play Check adjust play 18 Clutch cable Lever free play Adjust play 19 Engine oil sump strainer magnetic drain plug Clean 20 Engine oil oil filter paper element Replace 2...

Page 60: ...ls in Free Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by Dea...

Page 61: ... gap 11 H T Leads Inspect for cracks 12 Fuel pump under tank mounting Check mounting screws Leak 13 Fuel hose Inspect for cracks 14 Rubber hose Air filter to throttle body Inspect for cracks 15 Rubber hose Inlet manifold Adaptor Inspect for cracks 16 PAV pipes hose clip Inspect 17 Accelerator Throttle pulley cables free play Check adjust play 18 Clutch cable Lever free play Adjust play 19 Engine o...

Page 62: ...ails in Paid Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by D...

Page 63: ...nting Check mounting screws Leak 15 Fuel hose Check Replace 16 Accelerator Throttle pulley cables free play Check adjust play 17 Rubber hose Air filter to throttle body Check Replace 18 Rubber hose Inlet manifold Adaptor Check Replace 19 Clutch cable Lever free play Adjust play 20 PAV pipes hose clip Inspect 21 Engine oil sump strainer magnetic drain plug Clean 22 Engine oil oil filter paper eleme...

Page 64: ...ails in Paid Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by D...

Page 65: ...ank mounting Check mounting screws Leak 13 Fuel hose Inspect for cracks 14 Fuel filter element in fuel pump Replace 15 Rubber hose Air filter to throttle body Inspect for cracks 16 Rubber hose Inlet manifold Adaptor Inspect for cracks 17 PAV pipes hose clip Inspect 18 Accelerator Throttle pulley cables free play Check adjust play 19 Clutch cable Lever free play Adjust play 20 Engine oil Check top ...

Page 66: ...ails in Paid Service Record Cost of oil oil filter element and other consumables used are chargeable to the customer Received the above motorcycle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASC Name Address Frame No Engine No Motorcycle Installation Form No ODO Reading Sold by D...

Page 67: ...by carbo spray 14 Fuel pump under tank mounting Check mounting screws Leak 15 Fuel hose Inspectfor cracks 16 Accelerator Throttlepulley cablesfree play Check adjust play 17 Rubber hose Air filter to throttle body Inspectfor cracks 18 Rubber hose Inlet manifold Adaptor Inspectfor cracks 19 Clutchcable Lever free play Adjust play 20 PAV pipes hose clip Inspect 21 Engine oil sump strainer magnetic dr...

Page 68: ...67 PAID SERVICE MAINTENANCE RECORD S No Date Brief details of service 1 2 3 4 5 6 7 8 Type of Service KMS Royal Enfield Authorised Dealer Service Center ...

Page 69: ...68 PAID SERVICE MAINTENANCE RECORD 9 10 11 12 13 14 15 16 S No Date Brief details of service Type of Service KMS Royal Enfield Authorised Dealer Service Center ...

Page 70: ...KATA 700707 Tel 033 40060206 0209 Royal Enfield A Unit of Eicher Motors Ltd 407 4th Floor Nirmala Plaza Forest Park BHUBANESWAR 751 009 Tel 0674 6540206 R7 ArunachalPradesh Assam Manipur Meghalaya Mizoram Nagaland Tirupura Royal Enfield Astha Plaza 4th Floor M4 2 G S Road Opposite Deorah College Ulubari GUWAHATI 781 00 Mob 918135846461 R8 Goa Maharashtra Royal Enfield Plot No 16 Sector 1 Sion Panv...

Page 71: ...253377 08518 253377 Nandyal Dheeru Motors 91 9133065553 91 9133065554 Narasaraopet Anu Auto Agencies 91 7893301444 086472 21787 Nellore Rishi Motors 91 8977713377 91 8977714477 Nellore Inside City Rishi Motors 91 8977713377 8977714477 91 9866162859 ANDHRA PRADESH Ongole Lekhana Automotives 91 8885002112 8885002113 Rajahmundry Sriram Automobiles 91 9246665513 0883 2422117 Srikakulam Lakshmi Automob...

Page 72: ...897353382 0891 2768887 2768886 ARUNACHAL PRADESH Naharlagun Itanagar Bucho Royal Enfield 91 9436219089 0360 2350103 ASSAM Barpeta G S Auto 91 8472987341 Dibrugarh Rider s 91 8472913182 0373 2370018 2370014 Guwahati Maligaon Chirag Enfield 91 9435400437 ASSAM Guwahati G S road Shahila Expositions Pvt Ltd 91 9435549786 0361 2335025 Jor hat Achharsingh Royal 91 9859736100 9207041076 Nagaon Bajrang Mo...

Page 73: ...zaffarpur Sitamahari Road Kumar Automobiles 91 9771123233 7283000384 Patna Boring Road Ambey Motors 91 9102999131 Patna Saguna More Siddhi Vinayak Automobiles 91 8092981877 0612 212948 Patna Zero Mile Sukhmani Motors Pvt Ltd 91 9709761441 0612 3297056 BIHAR Sitamarhi Nili Automobiles 91 9102999131 CHANDIGARH Chandigarh Sector 27 C Manmohan Auto Stores 91 9216227366 0172 5071351 Chandigarh Sector 3...

Page 74: ...vt Ltd 91 9099092594 9099092595 0281 2371070 Rajkot Mota Mava Kalawad Road Dev Motors 91 8401799993 0281 6458888 9157877331 Surat Adajan Hajira Main Adajan JSN Motors 91 8401600411 0261 2840023 Surat Sarthana Varacha Purav Automobiles 91 9979841546 9979841547 GO A Goa Margoa Saini Motors 91 7767006138 6139 6140 0832 2740343 2740345 Goa Panaji Auto Guides 91 9326102087 0832 2225865 GUJARAT Ahmedaba...

Page 75: ...Motors 91 9813131455 01275 240454 Panipat Monga Automobiles 91 9354140005 40006 40007 01274 251000 Rewari Premium Automation Pvt Ltd 91 8607482200 01274 251000 Ro htak Badhwar Co 91 8059880031 01262 242034 241173 Sirsa Gulzar Motor Agencies 91 9996147200 01666 221367 230459 HARYANA J in d Gill Automobiles 91 9416476459 Kaithal Raghav Automobiles 91 8199946000 91 9254312500 8199947001 Karnal Monga ...

Page 76: ...ajrang Nagar NH 33 Cruiser India 91 9204004142 Ramgarh Anjaney Automobiles Pvt Ltd 91 9431146297 91 9031000430 Ranchi Harmu Road RaghuramAutocare 91 9905110006 0651 6571607 Ranchi Kokar Sri Nivas Automobiles 91 9771420322 0651 2542789 HIMACHAL PRADESH Hamirpur ASP Parkash Royal Enfield 91 9816058483 01972 258483 Man ali Heaven On Earth Automobiles 91 9459300881 01902 205032 251151 08350854002 Kull...

Page 77: ... R Services 91 7829000350 9980762849 080 22133119 Bangalore Banaswadi CVS Motors 91 9886500045 Bangalore Bannerghatta Royal Enfield Company Store 91 9945592345 088 22440588 Bangalore Bellary Road CVS Motors 91 9886500042 080 23469600 23469601 KARNATAKA Bangalore BTM 2nd stage Royal Enfield Company Store 91 9902180044 080 40905108 26689975 Bangalore Electronic City Electronic City Motors 91 7026613...

Page 78: ...ngalore Chikkamangalore Motors 91 9742289955 Chitradurga Jilu Bikes 91 9845127397 91 8494900552ARNATAKA Davangere Royal Automobiles 91 9844053511 08192 256239 Gadag Gadag Motors 91 8147776496 Gulbarga Mukunda Wheels Pvt Ltd 91 9945249302 49300 49305 08472 225302 KARNATAKA Mysore ASP Kuvempu Nagar Abhyudhay Motor Services Pvt Ltd 91 9743721955 9538841412 0821 2462066 2462067 P u ttu r Frontline Aut...

Page 79: ... 9567863979 0495 2392200 2390770 Cochin Angamali Areeckal Junction Sanjo Motors 91 9809709999 0484 6888889 Cochin Chittoor Road St Mary s Motors 91 8891000691 9895118951 0484 4022819 Cochin Edapally Royal Enfield Company Store 91 7025233912 0484 6494991 6494992 KERALA Pathanamthitta Marikar Motors Ltd 91 8111871222 9388077007 0468 2223412 Pattambi Palakkad Intrepid Works 91 9744072921 0466 2970666...

Page 80: ...777 7736066716 0471 6506777 Trivandrum M G road Marikar Motors Ltd 91 8606068466 0471 2334621 Trivandrum Vetturoad Kazha kuttam Concept Bikes 91 9048400200 9048990546 Vadakara Grace Motors 91 7034775555 Valluvambaram Malappuram ABC Motors 91 7034166300 0483 2770700 MADHYA PRADESH Gwalior Rimik Motors Pvt Ltd 91 9827935616 9926435616 0751 4035616 Indore Nehru Market Krishna Motor Agency 91 98260340...

Page 81: ...6565 022 28590085 28590086 MAHARASHTRA Mumbai Thane Dombivali Pooja Motors 91 8425840752 0251 2470611 Mumbai Thane Godbu ndar Soniya Motors Pvt Ltd 91 9322315111 022 25893202 7208005207 7208005208 Mumbai Thane Mira road Unison Automobiles 91 9029234040 022 28456620 Mumbai Thane Vasai SPWheels 91 8446011105 0250 6511107 6511108 MAHARASHTRA Chandrapur Dinesh Motors 91 9028111383 07172 260555 Dhule S...

Page 82: ... Auto 91 7755932578 2579 91 9881171717 Pune Hadapsar Platiinum Auto 91 7030911278 7030911284 Pune Kasarwadi Dhone Automobiles 91 7028045684 Pune Khed Shivpur Siddh Auto 91 9673152266 Pune Kothrud Siddh Auto 91 9168376611 020 25280050 25280051 Pune Yerwada Dhone Automobiles 91 7028978074 020 60121812 MAHARASHTRA Nagpur Wardhaman Nagar Shri Krishna Automobiles 91 9372121346 0712 3191202 Nanded Jaira...

Page 83: ...ardha Sri Krishna Automobiles 91 9769169180 91 7410061121 Yavatmal Aaditya Riders Pvt Ltd 91 8055958119 9158632833 M AN IPU R Imphal Sanamahhi Motors 91 8259061598 0385 2449111 MEGHALAYA Shillong Merin s Royal Enfield 91 8258811320 0364 2590048 NEW DELHI NCR Delhi Jhandewalan Ext Ess Aar Motors 91 9810797099 011 65461901 23524426 Delhi Kailash colony Okhla Indust Area South Delhi Motorcycles 91 97...

Page 84: ...ASP M G Auto Sales 91 9810237417 011 27837439 NCR Faridabad Mathura Road Heighten Automotive Pvt Ltd 91 9911223811 91 9717475811 NCR NIT Faridabad Sohan Auto World 91 9811551530 0129 2429352 NCR Ghaziabad Nehru Nagar Rawal Automobiles Pvt Ltd 91 9350315311 0120 4104659 9211921227 NEW DELHI NCR Delhi Padapadganj Asco Motors 91 9582184488 011 2214888 Delhi Rama Road Lamba Enterprises Pvt Ltd 91 9711...

Page 85: ...t Motors 91 9855152204 01874 501644 Hamirpur Parkash Royal Automobiles 91 9418458483 01972 258483 Hoshiarpur Lagwal Automobiles 91 9256514321 01882 238586 Jalandhar GT Road Fateh Autos 91 9417231123 0181 2632880 Jalandar SatlujMarket Navyug Motors 91 9915630535 9878785796 0181 4627998 P UN J AB Abohar Aman Auto Zone 91 9814767900 91 9914767900 Amritsar Jaycee Motors Corporation 91 9780038349 91 97...

Page 86: ...283829760 9878667432 01887 229160 Nawanshahar HSEnterprises 91 9417654888 8146091105 01823 221194 Pathankot Cashmir Sales Corporation 91 9417412884 0186 2220148 2224672 Patiala Rajpura Road Sukhdev Automobiles 91 9876103017 0175 2305721 P UN J AB M oh ali Manmohan Motors 91 9216267888 9988317366 0172 6527366 6527367 Morinda Morinda Motorcycle Centre 91 8427242324 0160 2630357 2630072 Mukherian Lag...

Page 87: ... Sudershan Pura JMS Co 91 9460345047 9785415498 0141 4059277 Jhu njhu nu Balaji Motors 91 7733022411 01592 231061 Jo dh pu r Shree Rajpurohit Automobiles 91 9001744442 0291 2980473 Ko ta Mundra Motors Pvt Ltd 91 9352602347 0744 2361264 K ot pu tli Shree Motors 91 9468768300 9116011113 2912980473 RAJASTHAN Nagaur D D Autotech 91 9828943737 01582 243006 Pali RMD Motors 91 9829285357 0293 2227151 Sik...

Page 88: ...9092604447 Chennai OMR Perungudi Royal Enfield Company store 91 8939958655 044 42607777 42607555 Chennai Purasaiwalkam I Speed Motors 91 9094633712 044 45588047 Chennai Red Hills AKG Motors 91 9597082578 044 26322063 Chennai Tondiarpet Balaji Motors 91 9087521116 044 25910104 25910105 TAMILNADU Chennai Broadway Balaji Motors 91 9962997975 Chennai Chrompet The Legend Motors 91 7299042018 044 495958...

Page 89: ... 7867019831 Theni Coral Moto Hub 91 9500739686 9698933000 Thiruvannamalai AKAN Agency 91 9843033861 04175 233377 Thoothkudi Charles Motors 91 9944723062 0461 2321636 Tirunelveli DG Motors 91 9486729010 0462 2970031 TAMILNADU Kumbakonam A V Motors 91 7598707783 7598707785 0435 2415286 Madurai KK Nagar Madras Motors 91 9976755111 0452 2585686 Madurai Kazhavasal Theni main road Classic Motors 91 9629...

Page 90: ...ty Motors 91 9966173000 0878 6509993 TELANGANA Karimnagar CVNR Road Quality Motors 91 9030775252 Khammam Royal Automotives 91 9963886789 91 8297536789 Kothagudam Royal Motors 91 8297616789 91 8297626789 Mahabub Nagar Harshithh Automotives 91 7660022336 7660022334 Mancherial J V Aryan Motors 91 8179356458 91 8297388775 TELANGANA Miryalguda Sri Lakshmi Pavan Automotives 91 9666660606 Nalgonda Vijaya...

Page 91: ...911342 UTTAR PRADESH Bareilly Suri Sales P Limited 91 9359108047 7351007963 0581 2543334 Basti New India Merchant 91 9532211786 554 2281483 Bijn or Chaudhary Motors 91 8958994499 01342 264455 Bulandshahar Santhosh Enterprises 91 9760415515 05732 231326 Deoria Supreem Motors 91 9628755557 05568 229624 TRIP URA Agartala XED Motorcycles 91 8415951975 0381 2341098 UTTARKHAND Dehradun Karanpur Road Ahu...

Page 92: ...40484 Kanpur Khalasa Line Sareen Motors 91 7705905138 8799414243 8303220224 K an pu r S S Automobiles 91 7705006411 Lakhimpur Kheri Shree Vinayak Motors 91 9554155999 0587 2277734 Lucknow ASP Amafh Bullet Centre 91 9415018786 0522 4074200 UTTAR PRADESH Lucknow Alambagh Shreya Auto World Pvt Ltd 91 8400400842 850 0522 4037677 4041033 Lucknow Jankipuram Royal Motor works 91 7607777396 522 4078111 Ma...

Page 93: ...lo Coaches P Ltd 91 9903800400 033 32971712 32902346 Howrah Apollon Motors LLP 91 9804321122 Kharagpur Jain Motors 91 9476481717 91 9434692778 Kolkata Anandapur Royal Enfield Company store 91 9874852522 033 40060206 0209 AUTHORISED DEALERS UTTAR PRADESH Unnao Raj Auto World 91 7080903700 0515 2831098 Varanasi Maldahiya Khurana Automobiles 91 8934965655 0542 2207532 2207618 Varanasi Maqbool Anand r...

Page 94: ... Speed Wheels 91 9735586333 Midnapore Sri Sai Auto mart 91 9434043691 03222 275999 Raiganj Kalyani Solvex Pvt Ltd 91 9775517444 03523 253016 AUTHORISED DEALERS WEST BENGAL Siliguri Matigara Riders Corner 91 9002223222 Siliguri 2nd Mile Sevoke Road Siliguri Distributors 91 9775633225 0353 2778873 2547457 Titagarh Bishnu Oil Company 919874839911 9051365511 033 25833353 ...

Page 95: ...Saini Motors 91 8308808290 0832 2740343 2740345 GUJARAT Ahmedabad ShreejiAuto Traders 91 9173170931 9724722282 JamNagar New Chandra Motor Cycle House 91 9824211699 HARYANA Ambala Royal Motors 0171 2545795 Bhiwani Sheoran Automobiles 91 7056732216 01664 252216 JAMMU KASHMIR Jammu Yahoo Technocra 91 9419191241 JHARKHAND Hazaribagh Riders Point 91 9234343422 Jamshedpur Royal Auto Syndicate 72502 2228...

Page 96: ...069033 RAJASTHAN Jaipur Indra Bazar Shubham Agencies 91 9680465973 Jaipur Transport Nagar Shubham Agencies 91 9414067766 TAMILNADU Chennai Cyber Auto Parts 91 7358768669 Chennai Popular Motors Cycle Company 91 9698444568 044 43435365 43435364 Erode Senthilmurugan Auto Parts 91 9894756567 Madurai Senthilmurugan Auto Parts 91 9500786567 TELANGANA Hyderabad Cyber Automobiles Pvt Ltd 91 7702143186 UTT...

Page 97: ...96 NOTES ...

Page 98: ... Advice No Have you visited Royal Enfield website Yes No Motorcycle Regn No Telephone Office E Sales Representative or MOTORCYCLEINSTALLATIONFORM Motorcycle Installation Form MIF No Family Motorcycle Personal Motorcycle Royal Enfield s Motorcycle ...

Page 99: ...Motorcycle Motorcycle delivery and information given Motorcycle since childhood Motorcycle Motorcycle What Motorcycle do you own now ...

Page 100: ...to 7 7 Kgm 13 Front Tyre Condition Check Tyre Line Seating WF Good 14 Front Tyre Pressure Less 22PSI 15 Front Brake Light LED NW F 16 Speedo sensor cable coupler connection function NW 17 Clutch Operation H J SY Smooth 18 Clutch Lever Free Play EP Less 2 3 mm 19 Accelerator Operation SY EP LESS Smooth 20 Lever Brackets Saddle Position LF R Tight 21 Steering Movement T N Free 22 Handle Bar Position...

Page 101: ...rts Scratch Rust Chipped OFF SC R PO DU No Defects 61 Plated Parts Scratch Rusty SC R PO No Defects 62 Indicators Alignment M No Defect 63 Nuts bolts fasteners Torque LF Tight Right Left Cover Engine Foundation Accessories Wheel Nut 64 Owner s Manual Tool Kit Content 65 Spare fuse in fuse carrier NA 66 Starting Kick Start Self Start ST N Easy Start 67 Pulling P Straight 68 Motorcycle Vibration V S...

Page 102: ...ned 6 All Free Paid Services explained 7 Warranty Guidelines explained 8 Running in Period details shown in the manual explained 9 Service Center Address given and Location explained 10 Service Incharge Name Mobile No given 11 Motorcycle delivered in neat and clean condition 12 Tools First Aid Kit received and explained YES NO We congratulate you on becoming a proud owner of Royal Enfield motorcyc...

Page 103: ...ion for you KEEP RIDINGP 13 Control Switches Disc Brake System usage explained 14 Fuse Box location shown and explained 15 Recommended Tyre Pressure explained 16 Motorcycle starting Gear shifting procedure explained 17 Quantity of Fuel in Fuel Tank informed 18 Motorcycle orientation short distance drive provided 19 Date and Time of Installation 20 Name of Person who did Installation ...

Page 104: ...ies with the provisions of the Motor Vehicles Act 1988 and the rules made there under including the following mass emission norms Brand name of the vehicle Thunderbird 500 Chassis number Engine number motor number in case of battery operated vehicles Sub rule No of rule 115 2 i 115 14 F Emission norms Bharat Stage III Bharat Stage I II III Bharat Trem Stage III etc Date For ROYAL ENFIELD Quality A...

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Page 106: ...ROYALENFIELD COM Part No 594069 B ...

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