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

02-6
IGNITION TIMING :
Ignition timing is the timing in degrees of rotation
of crank shaft at which spark commences so that
the spark from the spark plug can ignite the
mixture in the combusion chamber at the end of
TDC during compression stroke.
If spark occurs earlier than specified ignition timing,
it is called “Advance” timing.
If spark occurs after the specified ignition timing,
it is called “Retard” timing.
IDLING SPEED :
It is the speed of the crankshaft (i.e. RPM) of the
engine when the throttle is in closed position.
Gear ratio :
The relative rotation between “Driven Gear” and
“Driving Gear” is known as the “Gear Ratio”. It is
determined by number of teeth on the respective
gears.
Gear Ratio = No. of teeth of Driven Gear
No. of teeth of Driving Gear
In Fig. 1, the Gear ratio is 20 ¸ 10 = 2 : 1
In Fig. 2, the Gear ratio is 20 ¸ 20 = 1 : 1
Gear ratios multiply the engine torque to fulfil
various demands for pulling the vehicle like.
- More effort is required during initial move-
ment of the vehicle.
- More effort is required to climb an elevation.
- More effort is required while driving in muddy
or sandy surfaces etc.
FINAL DRIVE RATIO :
It is a relative rotation between the engine sprocket
and the sprocket on the rear wheel. Both the
sprockets are connected through drive chain.
Final drive ratio further multiplies the torque
available at the output shaft of the gear box.
Basic Terminology of IC Engines
TDC Position
Ignition Timing
Ignition Timing

02-7
A. ENGINE AND ENGINE SYSTEMS
CLASSIC 500 CLASSIC 350
1. Engine Type 4 Stroke Single Cyl., Air cooled 4 Stroke Single Cyl. Air cooled
2. Bore 84mm 70mm
3. Stroke 90mm 90mm
4. Displacement 499cc 346cc
5. Compression ratio 8.5:1 8.5:1
6. Max Power @ rpm 27.2 HP @ 5250 rpm 19.6 HP @ 5250 rpm
7. Max Torque @ rpm 41.3 Nm @ 4500 rpm 28 Nm @ 4000 rpm
8. Idle rpm 1050 ± 200 rpm 1050 ± 200 rpm
9. Starting Kick & Electric Start Kick & Electric Start
10. Air filter element Paper element Paper element
11. Lubrication Forced Lubrication, Wet Sump Forced Lub., Wet Sump
12. Engine oil tank capacity 2.75 litres 2.75 litres
13. Engine oil grade MOTUL 3000 4T Plus 15W50 MOTUL 3000 4T Plus 15W50
API SL JASO MA API SL JASO MA
14. Cooling Natural air flow Natural air flow
B. TRANSMISSION
1. Clutch Wet multiplate (7 Friction Plates Wet multiplate(6 Friction Plates
& 6 Steel Plates) & 5 Steel Plates)
2. Primary drive 3/8” Duplex chain & sprocket 3/8” Duplex chain & sprocket
3. Primary ratio 2.15 : 1 2.15 : 1
4. Gear box 5 Speed Constant Mesh 5 Speed Constant Mesh
5. Overall Ratio
1st 3.063 : 1 3.063 : 1
2nd 2.013 : 1 2.013 : 1
3rd 1.522 : 1 1.522 : 1
4th 1.212 : 1 1.212 : 1
5th 1:1 1:1
6. Secondary drive 5/8” Chain & Sprocket 5/8” Chain & Sprocket
7. Secondary ratio 2.235 : 1 2.375 : 1
8. Drive Chain links 102 Links 100 Links
Technical Specifications

02-8
C. CHASSIS
CLASSIC 500 CLASSIC 350
1. Frame Tubular Tubular
2. Front Suspension Telescopic, hydraulic damping, Telescopic, hyd. damping,
Stroke 130 mm Stroke 130 mm
3. Rear Suspension Swing arm with gas Swing arm with gas
shock absorbers shock absorbers
4. Fr. Fork oil capacity 195 cc per leg 195 cc per leg
5. Front fork oil 1F Endurance Fork Oil 1F Endurance Fork Oil
6. Front Brake Hydraulic, Hand operated, Hydraulic, Hand operated,
280 mm dia ventilated disc 280 mm dia ventilated disc
7. Rear Brake Mechanical, Foot operated, Mechanical, Foot operated,
153 mm internal expanding 153 mm internal expanding
8. Brake Oil Capacity 60 ml 60 ml
9. Brake Oil Grade DOT 3 or DOT 4 DOT 3 or DOT 4
10. Tyre size : Front 90/90 - 18” - 51 P Front 3.25X19 - 4PR/6PR
Rear 110/90 - 18” - 61 P Rear 110/90 - 18” - 61 P
D. TYRE PRESSURE
1. Solo : Front 20 PSI (1.41 kg. / cm2) Front 20 PSI (1.41 kg. / cm2)
Rear 30 PSI (2.11 kg. / cm2) Rear 30 PSI (2.11 kg. / cm2)
2. With Pillion : Front 22 PSI (1.55 kg. / cm2) Front 22 PSI (1.55 kg. / cm2)
Rear 32 PSI (2.25 kg. / cm2) Rear 32 PSI (2.25 kg. / cm2)
3. Fuel tank capacity 13.5 litres 13.5 litres
4. Reserve / Low Fuel 2.5 litres 2 litres approx.
Warning
5. Dead Stock of Petrol 0.75 litres Not applicable
(Unusable petrol)
E. ELECTRICALS
1. Generation Alternator Alternator
2. System 12V - DC 12V - DC
3. Battery 12V - 14 AH MF 12V - 14 AH MF
Technical Specifications

02-9
4. Spark plug - primary Mico - WR7 DDC 4 Mico - WR5DC
5. Spark plug - secondary Super Bosch UR5DC Super Bosch UR5DC
6. Spark plug gap 0.7 to 0.8 mm 0.7 to 0.8 mm
7. Head lamp 12V, 60/55w 12V, 60/55w
8. Tail / Brake Lamp 12V 5 / 21W 12V 5 / 21W
9. Speedometer lamp 12V, 3.4W 12V, 3.4W
10. Hi beam indicator 12V, 2W 12V, 2W
11. Neutral lamp Tell tale 12V, 2W 12V, 2W
12. Turn Signal Tell Tale 12V, 2W 12V, 2W
13. Turn signal 12V, 10W 12V, 10W
14. Horn 12V DC 12V DC
15. Starter Motor 12V, 0.9 KW 12V, 0.7 KW
F. WEIGHTS
1. Kerb Weight 187 Kg. 182 Kg
2. Max pay load 178 Kg 168 Kg
G. DIMENSIONS
1. Length 2160 mm 2160 mm
2. Width 800 mm 800 mm
3. Height 1050 mm 1050 mm
4. Wheel base 1370 + 20 mm 1370 + 20 mm
5. Ground clearance 135 mm 135 mm
6. Saddle height 800 mm 800 mm
NOTE :
1. Values given above are for your guidelines only
2. In view of continuous improvements, specifications are likely to change with-
out notice
Technical Specifications

02-10
Identification of Chassis & Engine No.
ENGINENO.
CHASSIS NO.
TheenginenumberispunchedonthelefthandsideCrankcase-belowthe Cylinder barrel. It is the means of identification of the Engine and its productiondetails.Pleasedonottamperwiththenumberasitisprohibited by law.
Type of Engine Swept Volume Type of Start Type of Transmission Type of Fuel Feed Dummy No Year of Manufacturing Month Manufacturing Production Sl. No.
U 3 S 5 C O 9 A 00001
ENGINE NUMBER - DETAILS
The VIN is a 17 digit number punched on the right side steering head tube.
Manufacture’s Code Type of Engine Swept Volume Type of Start Type of Transmission Type of Fuel Feed Dummy No Year of Manufacturing Month Manufacturing Production Sl. No.
M E 3 X X X X X O 9 A 00001
VEHICLE IDENTIFICATION NUMBER -

02-11
1 ST-25118 - 4 Cylinder head nut tightening tool To remove and tightening of
cylinder head nut.
2 ST-25123 - 1 Valve spring compressor To compress the valve spring for
removal and fitting of valve.
3 ST-25612-4 Rotor tightening & loosening tool To hold magneto rotor while loosening
magneto nut.
4 ST-25128 - 2 Puller for magneto rotor Removal of magneto rotor assy.
5 ST-25592-4 Connecting rod locking tool To hold connecting rod in its top position.
6 ST-25151-4 Puller for chain case outer To remove Crankcase LH cover.
7 ST-25591-4 Sprocket & Clutch tightening tool To hold the clutch housing and sprag
sprocket while dismantling & assembly.
8 ST-25594-4 Clutch plate tightening tool To compress clutch springs while
dismantling & reassembling of clutch plates.
9 ST-25153 - 4 Extractor for gear box rocker Removal of rocker shaft spring top
pivot pin pivot pin and camplate pivot pin.
10 ST-25835-2 Front drive sprocket removing To remove FD sprocket on the sleeve
tool gear.
11 ST-25834-2 Front fork dismantling tool To hold pipe seat of front fork while
dismantling main tube with bottom case
(fork end assy.)
12 ST-25114-4 Extractor for fork oil seal To remove oil seal from front fork end
assy. (bottom case)
13 ST-25113 - 4 Mandrel for oil seal Fitment of oil seal in front fork end assy.
14 ST-25112-4 Expander for front fork Oil seal Expanding the oil seal lip while inserting
main tube into bottom case of front fork.
15 ST-25110-3 Gauge plate for tightening Alignment of swing arm while
chain stay mounting / tightening into chassis.
16 ST-25244 - 4 Special spanner adjuster To adjust gas filled shock absorber
spring load.
SL. PART NO. DESCRIPTION APPLICATION
NO.
List of Special Tools & Its Application

02-12
ST-25118-4
Cylinder head nut tightening tool Application : To remove and tightening of
cylinder head nut.
List of Special Tools & Its Application
Application : To compress the valve spring for
removal and fitting of valve.
ST-25123-1
Valve spring compressor
Rotor tightening & loosening Tool Application: To hold magneto rotor while
loosening of magneto nut.
ST-25612-4
ST-25128-2
Puller Magneto (Rotor Extractor) Application : Removal of magneto rotor assy.

02-13
List of Special Tools & Its Application
Application : To hold the connecting
rod in its top position.
ST-25592-4
Connecting rod locking tool
Puller for chain case outer Application :To remove Crank case LH cover.
ST-25151-4
Application : To hold Clutch housing & sprag sprocket
while dismantling / tightening the Clutch & Sprag Sprocket bolt.
Sprocket & clutch
tightening tool
ST-25591-4
ST-25594-4
Clutch plate tightening tool
Application : To compress clutch springs while
dismantling & reassembling of clutch plates.

02-14
List of Special Tools & Its Application
Application : To remove gear rocker shaft spring top
pivot pin and gear cam plate pivot pin.
ST-25153-4
Extractor for Gear box
rocker pivot pin
FD sprocket removing tool Application : To remove front drive sprocket
from Sleeve Gear.
ST-25835-2
Application : To hold pipe seat of front fork while
dismantling & tightening of front fork main tube with
bottom case (fork end assy.).
Front fork Dismantling tool
ST-25834-2
ST-25114-4
Extractor for Fork oil seal Application : To remove oil seal in front fork bottom case.

02-15
List of Special Tools & Its Application
Application : Fitment of oil seal into front fork
bottom case.
ST-25113-4
Mandrel for oil seal
Expander for front fork oil seal Application : Expanding the oil seal lip while
inserting main tube into bottom case of front fork
ST-25112-4
Application : Alignment of Swing Arm while
mounting / tightening into chassis.
Gauge plate for tightening chain stay
ST-25110-3
ST-25244-4
Application :To adjust gas filled shock
absorber spring load.
Special spanner adjuster