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ROYAL ENFIELD 500 SERVICE MANUAL PDF

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Download the official service manual for Royal Enfield Classic & UCE motorcycles in PDF format for all your maintenance needs. choose save as, mb in pdf format) Click here to download Royal Enfield Bullet workshop manual (right click and choose save as, mb in pdf format) Jan 3, #7. Can I get ECU manual for the RE Classic TECHNICAL SPECIFICATIONS cc & cc. We take pleasure in releasing this Maintenance Manual as a guide t. - senice. no liability can be accepted by Royal Enfield or the publisher for 10s or injury caused due to errors or omissions in the informations given. PRECAUTIONS AND GENERAt INSTRUCTIONS.


Royal Enfield 500 Service Manual Pdf

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HEAD 2. HEAD 3. Lubricate all moving parts prior to reassembly. While fixing bearings or bushes in the crankcases, it is necessary to heat the crankcase for ease of fixing. Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig. Ensure the rubber sealed face is facing the FD sprocket side, while assem- bling the bearing.

Check bearing seating position and for free rotation. Fix cam plate return spring, pawl cam plate with machined washer and nyloc nut Torque 1 KG- M.

Do not hammer directly over sleeve Gear. It is recommended to use arbor press. Please ensure the roller should be facing downwards during assembly. Ensure free rotation of kick pin- ion gear while pressing down the kick pawl and plunger.

Ensure kick pawl is seated over the trip plate in the Crank case RH. Ro- tate kick Gear and confirm free wheel movement. Then assemble spacer inside the spring as shown in Fig. Ensure striker spring both ends are seated on striker lever rocker shaft. Ensure oil seal is replaced before fixing kick shaft cover. Ensure bottom pivot bearing smooth machined surface are facing upwards.

It is recommended to tighten the upper pivot bearing first and then the bottom pivot bearing to avoid gear shifting problems. ST as shown in Fig. Apply thread lock sealant before fixing spring stop pin to avoid oil seepage.

Ensure 2nd gear selector fork groove side is facing towards MS 4th gear. Ensure special thrust washer profile is facing towards sleeve gear. Gently slide inside the crankcase RH. Ensure alignment of main shaft with sleeve gear hole, fork shaft with fork hole inside the Crank case RH and sliding gear with lay shaft. Check Gear shifting system by rotating Cam plate and Main shaft sub assy while rotating the shafts simultaneously.

Check for smooth gears engagement. Ensure special thrust washer profile facing towards Crank shaft bearing side on LH Crank case. Simultaneously holding self motor jack shaft carefully. Ensure cut portion of shaft is facing upwards. Insert rubber boot properly. This double stepped faceshould be inside. Crank the engine gently for ease of assembly. Ensure wide flanges face of the sprag clutch bearing must face outwards. Lubricate the needle bearing well before assembling on the sprag clutch.

Similarly follow the same to sub assemble all the clutch plates. ST - Clutch spring compressing tool to compress the clutch springs over spring holder and tighten with 2 long bolts.

Royal Enfield Classic 350/500 UCE Service Manual

Tighten bolts diagonally and evenly 5 threads each Torque 1 KG-M. Fix the 2 hex bolts. Mount on main shaft. Torque 4. ST Clutch centre holding tool to lock Clutch sprocket and engine sprag clutch assy. Ensure 2 Nos. Care to be taken while fixing the FD sprocket direction circular groove in- dex mark, facing outwards. Ensure "O" ring is located on the oil pump body outlet. Ensure spring eyelet is seated properly inside flyweight hole.

To reduce axial play in between Cam Gears outer surface and steady late, additional shim may be added as per need. Use special tool No. ST to lock connecting rod movement during tightening magneto nut. Replace the oil seal every 20, kms interval. Care must be taken while fix- ing cover due to spring force and gasket. Set each piston ring squarely into the Cylinder barrel at a point 25 mm from the bottom, pushing the ring by piston head and then measuring the end gap.

Measure outside dia of piston pin at 3 points. Second ring has a taper edge cross sec- tion and is hard chrome plated. After installation, the ring should rotate freely rotatable in the ring grooves. Top ring has rectangular cross section with black colour Nitride coat- ing.

Royal Enfield Classic / UCE Service Manual » Think Blog

Ensure the open end of any piston ring does not align with the pis- ton pin boss. Do not use any sharp objects to press piston rings against groove. Use thumb finger force to locate rings in its position properly. Do not allow the grinding paste to seep into the valve stem and valve guide. Keep the Cylinder head on a table. Fill petrol on top of the valves. Seepage of petrol past the valve seat indicates improper valve seating. Please ensure cleaning of the cyl- inder head with solvent and blow thor- ough all oil passages with compressed air.

Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring. Check for proper working of all electrical equipments. Align the rear wheel. It consists of an Electronic Control Unit ECU which constantly takes inputs like en- gine speed, engine temperature, throttle position, manifold air pressure, exhaust oxy- gen feed back etc, from the respective sensors, provided in the vehicle and determines both the ignition timing and the ideal amount of fuel to be injected, to optimize the air- fuel ratio.

It controls the output devices by giving pulses to the respective devices. Flash memory is an exclusive recording unit for controlling program and setting data. It collects different inputs from various sensors and calculates optimised values and gives outputs to the respective controlling devices. The main advantage is, the system is nonvolatile and stores the data even when the electricity is off. While in operation the other breakdown information gets recorded automatically.

Specification Operating Voltage: Sensor Supply Voltage: Operating temperature: Storage Temperature: Operating Voltage: Fuel Injection pressure: The injection system used is a timed injection system and the injection is done close to the inlet valve.

The injector operates based on the pulse width signal given by the ECU. The fuel injector is as- sembled in the inlet manifold located between the inlet port on the cylinder head and air filter. It is placed at an angle in the intake manifold so as to give maximum fuel spray and minimum wall wetting.

The Pump operation is determined by the ECU so that it gives exactly the required volume of fuel. The Pump maintains a uniform kPa fuel pressure. Any excess pres- sure is bypased back into the fuel tank so that the fuel hose, injector etc. The fuel pump module has an inbuilt micro fuel filter which filters even the most minute dust particles to prevent damage to the seat in the injector. The pump is located inside the fuel tank so that it is submerged in liquid and hence cannot ignite itself due to electrical sparks and cause an explosion.

Assembled in fuel tank bottom RH side Specification: Operating voltage: Fuel level in tank to switch ON: Lamp load: Tightening torque: Controlled Pressure Regulator: Inbuilt Filter Capability: Bulb Rating: It controls the amount of air flowing into the engine, in response to throttle opening. A throttle plate butterfly valve is used for regulating the airflow The throttle body also has a throttle position sensor TPS , a manifold pressure sensor MAP and a manual Bi Starter.

Out Put Voltage: Throttle Angle: Throttle Out Put Voltage at Idling: TPS is used to monitor the position of the throttle and is located on the butterfly spindle so that it can directly monitor the position of the butterfly throttle valve. The sensor is usu- ally a potentiometer and therefore provides a variable resistance depending upon the posi- tion of the butterfly valve and hence throttle position can be sensed by the ECU.

The sensor signal is used by the ECU as an input to its control system. The ignition timing and fuel injection timing and potentially other parameters are altered depending upon the position of the throttle, and also depending on the rate of change of the position. When the lever is pulled down, a cable pulls up the spring loaded piston in the throttle body. Helps in providing additional air into the engine during cold start, for better idling RPM, till the engine operating temperature is attained.

It senses the oil temperature and provides the input to the ECU which calculates the average engine temperature.

The ECU accordingly operates the injector to optimise the air fuel ratio. The engine temperature sensor is located in the cylinder head underneath the inlet manifold and on the oil passage. Resistance Value w. The crank position sensor sends an alternating voltage signal to the powertrain control module, which is used to determine engine speed and ignition timing.

Thus the speed of the engine at that instant is known by the ECU. If the engine runs beyond the maximum rated speed rpm , the ECU cuts off the fuel supply to the injector so that the engine will stall and the RPM will reduce to its rated operating RPM.

This is a safety aspect inbuilt to prevent damage to moving engine parts. Output voltage: The Rollover Sensor is located under the seat on the vehicle-mounting strip of the frame.

Operating Angle: Operating Temperature: Check for any sensor loose connections and plug in properly. By inserting a piece of wire into this connector and grounding it to an earth, the defective sensor can be identified by the following frequency of the MIL blinking. Engine will start but not perform to its potential. Engine will NOT Start but will crank. This will accu- rately determine the defective sensor and show the details on the diagnostic screen with the following respective codes as shown below.

Fuel flows at a very high pressure during these times. Use only a good, correctly charged battery to start OR check the motorcycle. Keep them well protected while washing the vehicle. Recharge battery Fuse blown. Check all fuses. Recharge battery Starter motor cables loose Check cable connections for A E Start related connection. Relay starter not working. Starter motor does not rotate Check for firm wire connections. Check if motor is jammed. Replace starter motor.

Check fuel pump relay C Fuel Pump resistance. Check fuel pump resistance. Replace pump if defective Fuel air mixture too rich due to Hold throttle fully open. Release cranking without using Manual throttle as soon as engine starts. Bi starter. Check proper working of position due to extreme cold Bi starter plunger. Correct as necessary.

Replace if faulty.

Top cover fixing screw 2. Diaphragm top cover 3. Piston valve spring 4. Jet Needle plate fix screw 5. Jet needle fixing plate 6. Jet needle retainer spring 7. Jet needle washer 8.

Jet needle E-ring 9. Jet needle ring Jet needle Piston valve assy. Diaphragm piston valve Diaphragm retainer ring Body CV carburetor Air vent hose Needle jet O-ring Jet holder Main jet Float Needle Valve assy. Float pin Screw O-ring Float chamber Float chamber body assy Washer screw mounting Screw assy. Hose drain Drain screw Packing washer Spring Idle screw Pilot jet Pilot air jet Clip Hose drain Choke Plunger assy.

Washer Spring Mixer Screw Cap It varies the air-fuel ratio according to the operating conditions and requirements of the engine. It produces a mixture which is properly atomized. Atomization is the mixing of air and fuel to form a fine spray or mist and to deliver the mixture to the engine. It regulates the amount of air - fuel mixture required by the engine.

P In order to meet requirements for the proper mixture ratio under various conditions the following systems are being used in Butterfly slide BS type carburetors. Disconnect fuel hose from carburetor by pressing clip. Loosen cable outer nut and lock nut by 10 mm spanner.

Slip the tip of the cable from the slot in the throttle pully. After following the above said pro- cedure for removal of carburetor from the motorcycle carefully.

Unscrew completly the drain screw from the float chamber body if nessasary. Remove strap from Air filter bellow. Loosen the clip screw from bellow and flange carburetor. Tilt and twist to remove the carburetor gently.

Jet Needle 2. Needle Jet 3. Main Air Jet 4. Diaphragm 5. Piston Valve 6. Buterfly Valve 7. Mixture 8. Petrol 9. Main Jet Air Inspect both hose pipes for clog. Clean thoroughly before fixing. By using the right size spanner to remove the choke plunger sub assy. In case of lever type choke plunger assy. Inspect choke piston and needle. Unscrew the top cover fixing screws and remove the diaphragm top cover, piston valve spring from the carburetor as shown in Fig.

Gently remove thorottle piston valve assembly as shown in Fig. Care to be taken while removing diaphragm top cover due to spring force. Unscrew the float toggle pin mounting screw and then remove the float body unit along with needle valve assy.

Remove the needle jet from the mixing body only if it is necessary. Unscrew the pilot air jet from the mixing body if required. Ensure that float body and needle valve are being removed before carrying out any other jobs. Spray carburetor cleaner in all passages to ensure that there is no blockage due to dust, dirt, gum or car- bon deposit, especially in the main air passage, pilot air passages, including by- pass holes and pilot outlet. Now clean all the carburetor components and apply compressed dry air in all passages of mixing body unit.

Unscrew the mixture control screw along with its spring, plate washer and o-ring. Assemble the pilot air jet to the mixing body if removed. Assemble the needle jet through Main jet hole and tap gently into the mixing body if removed. Ensure that the small dia face towards mixing body hole.

While fixing the needle jet ensure that the correct con- centricity to main jet holder hole is main- tained. Apply a coat of petroliem jelly over mix- ture screw thread portion before fixing into mixing body to avoid mixture screw jam problem. Pre set mixture screw position to 3 turns out from fully close position.

Check float level height specified If necessary adjust. Assemble float body along with needle valve assy. Tighten the float pin fixing screw gently. Inspect float needle valve spring cushion effect on clip side and rubber tip for worn out if any. Place the float needle valve assy. Ensure that float body swinging freely on float toggle pin. Recheck again float height after the adjustment. Inspect rubber diaphragm and retainer ring. In case of dust or carbon particals wipe with banian cloth carefully before assembling into mixing body.

Lubricate a thin film of engine oil on throttle pistion valve before fixing into mixing body. Assemble throttle piston sub assembly by locating rubber tip tab being seated on the mixing body. Fix pistion valve spring and top cover as shown in Fig.

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Royal Enfield Classic 500 - Service Manual

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