Royal Enfield Classic 500 2009 User manual

Service Manual
Classic 500 & 350

INTRODUCTION
SECTION
ONE 01

01-2
PREPARATION FOR SERVICE
Good preparation is very important for carrying out correct service job. The motorcycle
should be cleaned well before starting a repair job. Cleaning will occasionally uncover
sources of trouble. Availability of tools, measuring instruments and parts should be en-
sured before commensing an overhaul, since Interruption to locate tools or parts can
cause distraction and needless delay. Use of special tools will ensure a quality service.
USE OF GENUINE SPARE PARTS
Use only genuine Royal Enfield spares whenever replacing parts. Use of non genuine parts
can seriously affect motorcycle performance and may result in costly rework, vehicle down
time and above all customer dissatisfaction.
NOTE :
Proper service and repair is important for the safe and reliable operation of all mechanical
products. The service procedures recommended and detailed in this manual will help to
carry out correct repairs.
SAFETY
Every care is taken to ensure that the information given in this manual is correct at the
time of going to print. However, Royal Enfield does not assume responsibility for any
damage, loss or injury caused to the vehicle or to the person carrying out repairs, due to
errors or omissions in this manual.
IMPORTANT NOTICE
All images shown are only for reference to explain and may not be exactly the same on the
motorcycle. Technical specifications are subject to change without prior notice.
Because of changes that may occur in the manufacturing process, since this manual was
printed, it is possible some instructions or illustrations found within this manual may
differ from those found on the vehicle. However the technical information found within
this manual is correct at the time, when it was approved for printing.
Future modifications, improvements etc will be communicated to our Authorised Distribu-
tors / Importers as and when changes are done to the motorcycle.
Foreword
“ © Copyright 2009 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this
Sevice technical manual shall be copied, distributed or otherwise dealt without the express
permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the
sole owner of this manual .”

01-3
HOW TO USE YOUR SERVICE
MANUAL
Pictorial presentation of various activities,
make this manual easy to understand and
user friendly.
This service manual is divided into 10
Sections 01 to 10. Page numbers for each
section starts with 01. Thus, page 05-10
indicates 10th page of section 5.
The sections are subdivided into subjects
and presented in the following order.
SECTION ONE O1
INTRODUCTION
The manual and its arrangements
SECTION TWO 02
GENERAL
Salient features of the Unit construction
engine & engine management system
Four stroke cycle operation
Basic terminology of IC Engine
Technical specifications
Identification of Chassis & Engine No.
List of special tools & its applications
Control cables and wiring harness
routing.
SECTION THREE 03
SERVICE DATA
Service limits of components
Periodical maintenance chart
SECTION FOUR 04
ENGINE
Engine Lubrication system
Lubrication system
Hydraulic Tappets (RHVL)
Auto decompressor
Electric starting system & sprag mech.
Auto Chain Tensioner Assembly
Engine breather System
Inlet manifold & Throttle body
Blow up Charts
SECTION FIVE 05
ENGINE DISMANTLING
INSPECTION & ASSEMBLY
Engine dismantling procedure
- Vital parts - Description
- Unidirectional fittings list
- Torque Specification - Engine
SECTION SIX 06
ENGINE MANAGEMENT
SYSTEM (EMS)
Components description
Function of components
Identification of a malfunction
identification of EMS
Instruction Do’s & Dont’s on EMS
Trouble shooting - EMS
SECTION SIX 07
CV CARBURETOR
Exploded View
Function of Carburetor
Dismantling procedure of Carburetor
Assembling procedure of Carburetor
Carburetor maintenance
Trouble Shooting
Contents

01-4
SECTION EIGHT 08
CHASSIS, WHEELS & BRAKES
Torque Specification - Chassis
Front wheel removal & reassembly
Disc brake
- General instruction
- Overhauling caliper & master Cyl.
- Bleeding procedure
- Dis assembly of master cylinder
- Reassembly of master cylinder
- Dis assembly of Wheel caliper
- Caliper Assembly
- Wheel Disc inspection
- Brake Drum assembly
SECTION NINE 09
SUSPENSION AND STEERING
Front fork working principle
Front fork - disassembly
Steering stem removal & reassembly
Gas filled shock absorber
- Working principle
- Removal and assy. of shock absorber
- Recharging of shock absorber
Swing Arm
- Removal
- Assemblyly
Centre Stand Disassembly
SECTION TEN 10
ELECTRICALS
Electrical symbols
Battery
- Precautions
- Charging
- Maintenance
Spark plug maintenance & Inspecton
Checking procedure of electrical
components:
- Starter coil
- Pulsar coil
- Ignition coil
- Suppressor Cap
- Battery
- Horn
- Relay starter
- E-Starter motor
- IC Flasher
- RR Unit
Electrical parts Inspection
- Clutch switch
- Starter switch
Do’s and Dont’s
Complete Wiring diagram - Classic 500
Complete Wiring diagram - Classic 350
Trouble shooting - Electricals
SECTION ELEVEN 11
TROUBLE SHOOTING
SAFETY DEFINITIONSSAFETY DEFINITIONS
SAFETY DEFINITIONSSAFETY DEFINITIONS
SAFETY DEFINITIONS
Important aspects to be noted are given
as follows in the manual.
NOTE :
Provides important information that will
have to be adhered to while carrying out
repairs.
CAUTION :
Indicates activities that are important
to be noted. Non-adherance may result
in breakage and or functional failures of
the assembly.
SPECIAL TOOLS
Contains details of the special tools and
its usage, These tools have been specially
designed for a specific purpose.
Contents

GENERAL
SECTION
TWO 02

02-2
• HIGH TORQUE ENGINE
• ENHANCED POWER DELIVERY
• HYDRAULIC TAPPETS
• AUTO DECOMPRESSOR
• AUTO CHAIN TENSIONER FOR
PRIMARY CHAIN
• HIGH CAPACITY TRACHOIDAL
OIL PUMP FOR BETTER
LUBRICATION
• IMPROVED ACCELERATION &
HIGH SPEED CRUISING
• EXCELLENT COLD STARTING
ABILITY
• ACCURATELY CONTROLLED, AIR
FUEL MIXTURE & IGNITION
TIMING BY THE ENGINE
CONTROL UNIT
• IMPROVED PERFORMANCE AND
FUEL EFFICIENCY THRO FUEL
INJECTION SYSTEM.
FOUR STROKE CYCLE OPERATION
SUCTION COMPRESSION POWER EXHAUST
STROKE STROKE STROKE STROKE
Inlet Valve Open Closed Closed Closed
Exhaust Valve Closed Closed Closed Open
Piston Movement TDC to BDC BDC to TDC TDC to BDC BDC to TDC
Gas Flow Air Petrol Air Petrol Air petrol mix. Exhaust gas
mixture is mixture gets burns, gas flows out.
drawn into compressed. expands.
cylinder Piston is
Few degrees before pushed down.
BTDC, spark plug
produces spark.
Salient Features of the Unit Construction Engine & Engine
Management System
UNIT CONSTRUCTION ENGINE ELECTRONIC FUEL INJECTION
SYSTEM

02-3
Fuel
Air
Power
CUBIC CAPACITY / DISPLACEMENT :
It is a volume generated by piston when it travels from TDC to BDC. It is measured as Cubic
Centimeter (CC). It can be mathematically arrived at with the radious of the piston and the
stroke of the engine. (pr²× l, when ‘r’ is the radius of the piston and ‘l’ is the length of the
stroke, & p is a constant equal to 3.14). It is also
known as Swept Volume or Displacement volume
of the engine.
CLEARANCE VOLUME :
It is the nominal volume or the space available
above the piston when the piston is at the topmost
position (TDC).
ENGINE :
The Engine converts Chemical energy
availbale in petrol into heat energy then
to mechanical energy for motion. It is the
powerplant of the vehicle where the
power is generated for moving the
vehicle.
BORE :
Bore is the inside diameter of the
cyclinder block in which Piston moves up
and down.
TDC :
TDC stands for Top Dead Center. It is
the top most position to which the piston
can travel in the cylinder barrel.
BDC :
BDC stands for Bottom Dead Center. It is
the bottom most position to which the
piston can travel in the cylinder barrel.
STROKE :
It is a distance travelled by piston from
TDC to BDC or Vice Versa.
Basic Terminology of IC Engines

02-4
TOTAL VOLUME :
It is the sum of the swept voume (Displacement volume) and Clearance volume.
Total Volume = Swept volume + Clerance volume.
COMPRESSION RATIO :
It is a ratio between total volume in the engine to the clearance volume available at the end
of compression stroke.
Compression ratio = Total volume of air fuel mixture
Clearance volume
VOLUMETRIC EFFICIENCY :VOLUMETRIC EFFICIENCY :
VOLUMETRIC EFFICIENCY :VOLUMETRIC EFFICIENCY :
VOLUMETRIC EFFICIENCY :
Volumetric efficiency is the ratio between the volume of air fuel mixture that actually
enters the cylinder and Swept volume.
Volumetric Efficiency
= Volume of air fuel mixture inhaled during suction stroke
Swept volume
HORSE POWER (HP OR PS) :
HP : Horse Power
PS : PFERDESTARKE is German unit of power. Horse Power is the ability of the engine
to do a certain amount of work in a given time.
One Horse power is the power required for lifting a weight of 75 Kg. through vertical
distance of one meter in one second.
Conversion :
1PS = 0.986 HP = 0.735 KW
1 HP = 1.014 PS = 0.744 KW
1KW = 1.360 PS = 1.340 HP
Basic Terminology of IC Engines

02-5
IHP :
IHP stands for Indicated Horse Power. Indicated
Horse Power is the power actually developed inside
the engine cylinder by combustion process. It is
utilised to drive the piston.
FHP :
FHP stands for Frictionl Horse Power.
It is the amount of horse power used or lost to
overcome the friction between various moving
components of the engine.
BHP :
BHP stands for Brake Horse Power
Brake Horse Power is the amount of Power
actually available at the crankshaft or output
shaft. It is calculated by using dynamometer.
BHP = IHP - FHP
Mechanical Efficiency :
Mechanical Efficiency is the ratio between Brake horsepower and Indicated horse power.
Brake horsepower = BHP
Indicated Horse power IHP
TORQUE :
Torque is a twisting or turning force or effort. It is the product of a distance and force in
circular motion.
In the picture shown the torque-applied is the
product of distance (distance between the center
of the bolt and point where force is acting) and
the amount of force applied.
With the same force, if the distance is increased,
the torque will also increase and if distance is
reduced, torque applied will also be reduced.
CONVERSION :
1kg-m = 7.23 lb.ft = 9.81 N-m.
1lb.ft = 0.138 Kg-m = 1.356 N-m.
1 N-m = 0.102 Kg-m = 0.737 lb.ft
1HP (Horse
Power Available
after explosion)
FHP (Frictional
Losses)
BHP (Horse
Power Avaiable at
Crankshaft)
Basic Terminology of IC Engines