Table Of Contents; Engine Dismantling; Section Six; Section Two - Royal Enfield Classic 500 2009 Service Manual

Contents
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
01-3