Page 1 EURO IV - ENGINE SERVICE MANUAL...
Page 2 Engine Management System. In the event of non availability of any special tool or Royal Enfield NACS II Diagnosis tool, it is recommended that the motorcycle may please be taken a nearest Royal Enfield Authorised Service Station for a detailed investigation &...
Page 3: Table Of Contents
12.29 Cylinder Head Assembly .......... 138 8.25 Sleeve Gear ..............57 12.30 Engine Oil Filling ............140 8.26 Kick Starter ..............58 13. Trouble Shooting ..............141 8.27 Kick Starter Shaft ............59 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 4: Engine Views
(EXHAUST SIDE) Rocker Cover Cylinder Inlet manifold Head (Insulator) Exhaust port Lay shaft with gears Oil filler Kick Gear pedal Lever Main shaft with gears Kick starter pinion ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 5: Technical Specifications
Secondary ratio 2.235:1 2.12:1 Values / Dimensions mentioned above are for reference only.  In view of continuous improvements, the specifications are subject to change without prior notice.  ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 6: Exploded Views
Cover Plate, Breather Chamber Plug Dummy Hex Flange Bolt M6 X 1 X 20 Plug ID 2.3 mm Restrictor - LEE Plug Cap, Oil Filter - Buffed Circlip Oil Window ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 7 Liquid Gasket (Loctite 5699) 30 ML Lock Pin Spring, Clutch Operating Mech. Oil Seal INA G 12 X 18 X 5, Clutch Operating Lever Clutch Cable Assembly Oil Filler Plug ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 8 Hex Flange ‘u’ Nut M8 (new Type) > July 2012 Stud, Chain Tensioner Pad Spacer Jack Shaft - (applicable For Ks Version) Bush, C T Pad Chain Tensioner Pad ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 9 Starter motor assembly 0.9 kw Oil pump sub assembly 500 & 535cc Cover starter motor Dummy plug Hex socket, button head screw, m5x12 Oil pump assembly complete 500 & 535cc Dowel pin ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 10 (Common for 350, 500 & 535cc) Rocker Arm, Exhaust Copper Washer Gasket, Rocker Cover Inlet Pav Adaptor (applicable for 500 & 535cc) Rocker Cover - Inlet Pin Piston Washer - Seal ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 11: Gear Operating Positions
POSITIVE POWER FLOW- M5(Engages to M2) —>—> Change Camplate Plate Anti Skip M5 FD SPKT Cam Plate 5TH GEAR POSITION Pawl Bolt GEAR RATIO = 1:1 Gear Cam Plate Plate-Anti skip Changer Assy. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 12: Lubrication System
OIL FILTER ANTI BACKLASH GEAR ASSY. INLET OIL FILTER DECOMPRESSOR ASSY. COVER RH HYDRAULIC CON ROD BIG TAPPET END BEARING OIL PUMP OIL SUMP FLY WHEEL CHAMBER SUCTION SHAFT RH FLY WHEEL FILTER SCREEN ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 13 Trichoidal high flow oil pump type delivers 9.5 Lit./Min. of lubricating oil. This provides excellent lubrication to all the internal moving parts and enhances the life of the engine moving parts. Outer (driven) rotor Inner (driven) rotor Suction hole Discharge hole Discharge hole Suction hole ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 14: Periodical Maintenance Chart
The frequency of the maintenance must be shortened depending upon the severity of the driving condition OR if the motorcycle is used in a dusty environment, severe climatic conditions, bad roads, water logged areas etc., Contact a nearest Royal Enfield Authorized Dealer / Distributor for expert advice and to carry out the periodical maintenance.
Page 15: Special Tools Usage List
Extractor for Gear box To remove gear rocker shaft spring rocker pivot pin top pivot pin and gear cam plate pivot pin. ST-25835-2 FD sprocket removing tool To remove front drive sprocket from Sleeve Gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 16: Engine Dismantling Sequence
Crank case repair/replacement.  Crank shaft and main bearings replacement.  Roller Hydraulic Valve Lifter (RHVL) replacement.   Kick Starter Gear, Pawl, Spring, Plunger replacement. Transmission parts like Gears, Mainshaft, Layshaft, repair / replacement  ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 17: Engine Oil Drain
Plug M14 Socket spanner 22 mm  Remove the 2 Flanged Hex. flanged Bolt M5 hex bolts and the drain T spanner 8 mm cap with ‘O’ ring.  Remove suction filter. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 18: Cylinder Head
 Remove 4 bolts each on Hex Socket Plug M6 the rocker bearing inlet Allen Key 5 mm & exhaust.  Remove the inlet and exhaust rocker bearing complete with dowel and rocker arm.  Remove inlet exhaust pushrods. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 19  Remove the 6 flanged Hex. Bolt M8 hex nuts, securing the T spanner13MM cylinder head crankcase.  Gently tap the cylinder head from bottom & remove.  Remove the multi layer steel (MLS) head gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 20: Dismantling Inlet & Exhaust Valves
 Remove spring retainer top valve spring & collar bottom.  Remove valve from the valve guide from the inside of the cylinder head.  Remove Inlet Exhaust Valve stem seal from valve guides. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 21: Cylinder Barrel / Piston
 Remove piston along with ring & gudgeon pin.  Remove Cylinder barrel NOTE: bottom Gasket. Carefully remove the piston rings from the piston without deforming. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 22 Instructions Cylinder barrel / piston  Hold connecting rod by Special tool No. ST- 25592-4 using Special tool. NOTE: Support connecting rod by using special tool ST- 25592-4 to prevent damage to connecting rod. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 23: Starter Motor & Housing
Starter motor & housing  Loosen 2 hex screw holding starter motor to crankcase.  Loosen 4 hex screw holding starter motor to crankcase.  Gently pull out the starter motor along with housing. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 24: Removal Of Rh Cover
 Remove oil filter cap gasket, “O”ring & Spring.  Remove the 3 “O” rings, CAUTION: Oil filter element spring Care must be taken while cap, washer & Oil filter removing cover due to element. spring force. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 25 & 2 dowels. Remove the stator coupler from the wiring harness before removing Right Cover.  Remove Pulser coil by Hex. Socket Head Cap removing 2 screws. screw M5 Allen Key 4 mm ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 26 M5 screws. Allen Key 4 mm  Remove circlip, oil seal and jet crankshaft.  Remove oil filler cap and “O” ring.  Remove Ignition Timing check bolt and washer (if not removed earlier). ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 27 Hex Socket Head remove breather chamber Cap. Screw M5 cover. Allen Key 4 mm  Remove breather chamber gasket.  Remove the 2 oil seals OUTSIDE OIL SEAL INSIDE OIL SEAL from the Kick Shaft hole ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 28: Removal Of Rotor Assembly
Ensure threaded bolt in puller is fully loosened  Tighten threaded bolt till it released the magneto rotor from shaft.  Remove magneto rotor along with special tool  Remove the woodruff key. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 29: Cam Steady Plate & Cam Gears
It is important to reduce noise and axial play between the cam gear face and the cam steady plate.  Remove Cam gear inlet.  Remove gear Exhaust along with Auto decompressor assy. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 30: Auto Decompressor
Auto Decompressor  Remove hex socket Hex socket head cap screw on flyweight in Screw M4 exhaust cam. Allen Key 3 mm  Remove flyweight along with return spring.  Remove the actuating pin. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 31: Oil Pump
Observe short boss of pump drive gear should face outwards.  Remove the 4 allen screws to remove Oil pump assy. along with gasket / rubber ring.  Remove the Oil pump assembly with “O” ring. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 32: Gear Shift Assembly Removal
Screw M5 remove the rocker shaft upper pivot bearing with Allen Key 4 mm “O” ring.  Remove the 2 hex socket head cap screws holding the lower pivot bearing. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 33 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Gear Shift assembly 8.11 removal  Remove the rocker shaft assembly by gently tilting and twisting from crankcase RH ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 34: Sprocket
 Straighten lock tab and Socket Spanner 32mm Unlock the FD sprocket nut.  Remove nut and lock washer (A). Special tool No.ST-25612-4  Locate Special tool on FD Sprocket & remove from shaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 35 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions F.D. Sprocket 8.12  Gently Pull out Sleeve gear Spacer from the sleeve gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 36: Kick Starter
(B).  Remove Kick starter Flanged Hex Bolt M6 return spring locking Socket Spanner 10mm bolt with washer (A).  Remove Kick starter return spring from kick starter shaft (B). ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 37: Cover Lh
 It may be necessary to tap the cover slightly to remove from crankcase.  Remove lock pin and PULL LOCK PIN spring from clutch operating shaft.  Remove clutch operat- ing shaft assy from clutch cover. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 38 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Cover LH 8.14  Remove Clutch operat- ing shaft oil seal and 2 Nos. of Dowels.  Remove gear lever shaft bush and oil seal. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 39: Clutch Assembly
 Locate Special tool to Special tool No.ST-25591-4 lock Clutch outer sprocket and engine sprocket.  Loosen & remove nyloc Hex. Nut M16 nut & plain washer from Socket spanner 21mm clutch center. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 40  Remove collar on main shaft (distance collar from crankshaft LH).  Remove special distance Flanged U Nut M8 washer sprag clutch on Crankshaft drive side. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 41: Sprag Clutch Assembly
 Remove sprag clutch assy. from primary chian.  Holding drive gear gently rotate engine sprocket clockwise pull FLANGE FACE simultaneously seperate engine sprocket from sprag gear.  Remove spacer.  Remove sprag clutch from sprag gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 42: Dismantling Of Clutch Assembly
T Spanner 8 mm clutch assy.  Loosen the 2 screw of NOTE: the special tool slowly & Loosen bolts in diagonally simultaneously simultaneously 5 threads release spring each. tension.  Remove special tool. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 43 Fastener, Size, Tool Usage, Precautions, Photos Instructions Dismantling of 8.17 Clutch Assembly  Remove Spring retainer plate & 6 Springs  Remove clutch drum sprocket with washer.  Remove clutch hub, centre, friction and steel plates. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 44: Auto Chain Tensioner
8.18 Tensioner  Remove hex nut and Hex Socket Head Cap washer to remove chain Screw M6 tensioner pad. Allen Key 6mm  Remove Auto chain tensioner body assy. by removing the allen screws. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 45: Starter Double Gear
Starter Double 8.19 Gear  Remove double gear shaft and double gear from crankcase LH.  Remove circlip in jack NOTE: shaft. Ensure jack shaft is not  Remove gear. pushed into the crankcase. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 46: Crankcase Lh & Rh
LH so as to socket are recommended leave the gear & shaft in before splitting crankse. crankse RH.  Remove special thrust washer (lay shaft ) from Crank case Left & 2 Nos. Dowel pins. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 47 & bushes can drop out of the crankcase & turned upside down  Remove clutch ball bearing from crankcase Left.  Remove needle roller bearing for lay shaft from crankcase Left. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 48  Remove roller bearing NU 305 from crankcase Left.  Remove spacer, circlip, crank shaft bearing 6305 from crankcase Left.  Remove last circlip from crankcase Left.  Remove crank shaft needle roller bearing from crankcase Right. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 49 Right.  Remove nyloc nut, machined washer, pawl - camplate, return spring and bolt pawl from crankcase Right.  Gently pull out the 2 needle roller pins holding the inlet and exhaust hydraulic tappets. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 50 NOTE: exhaust and inlet hydraulic EX. Tappet Remove Inlet tappet first tappets carefully from and then the exhaust Crankcase RH top side. tappet. CAUTION: Store the tappets carefully in vertical direction always. INLET tappet ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 51: Gear Train Removal
 Locate special tool on Special tool No.ST 25153-4 cam plate pivot pin & gently pull out cam plate pivot pin with “O” ring from crankcase RH.  Remove Layshaft 1st gear and thrust washer from the Layshaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 52  Remove selector fork NOTE: sub assembly from main Take care not to drop the shaft & lay shaft sliding selector fork while gears to take out Right seperating the gear shafts. selector fork. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 53 Fastener, Size, Tool Usage, Precautions, Photos Instructions Gear Train Removal 8.21  Remove centre selector fork from the selector shaft and then Left selector fork.  Remove circlip from the selector shaft if required. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 54: Hydraulic Tappets
 Remove special thrust washer (Layshaft) from Crank case RH.  Remove the Allen screw, Hex Cap Screw M5 and the bracket on crankcase RH inside Allen Key 4mm from barrel sealing area. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 55: Layshaft
 Remove Double gear (Layshaft 3rd and 4th gear) from larger side of layshaft.  Remove the high gear from smaller side of lay shaft.  Remove 2nd gear and thrust washer from smaller side of layshaft ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 56: Mainshaft
 Remove the main shaft 2nd gear from opposite end.  Remove the main shaft 3rd gear from opposite end.  Remove circlip & 1st. thrust washer. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 57 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Mainshaft 8.24  Remove 4th gear and 2nd thrust washer from threaded end of main shaft ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 58: Sleeve Gear
Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Sleeve Gear 8.25  Gently pull out sleeve gear assy. from bearing in crankcase. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 59: Kick Starter
Allen Key 4mm  Remove oil trough.  Gently pull out kick starter sub assy. from crankcase RH by rotate clock wise to release kick pawl from its stop. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 60: Kick Starter Shaft
Fastener, Size, Tool Usage, Precautions, Photos Instructions Kick Starter Shaft 8.27  Remove circlip & thrust washer from kick starter end of shaft.  Remove the thrust washer.  Remove the Kick pinion gear.  Remove the thrust washer. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 61 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions Kick Starter Shaft 8.27  Remove the Kick pawl, plunger and spring from kickstarter shaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 62: Unidirectional Fittings List
Oil pump drive pinion - Short boss facing  outwards. Piston rings -”1 IP” and “2 IP” facing upwards.  Piston- “A” or “B” mark on the crown facing  towards throttle body / inlet side. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 63: Inspection
Ring to groove clearance : oil ring UCE 535 UCE 535 UCE 500 UCE 500 New Min. 0.095 0.095 New Min. 0.04 0.010 0.115 0.114 0.16 0.180 New Max. New Max. 0.30 0.30 0.21 0.44 Service Limit Service Limit ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 64 Small end bore inner diameter UCE 535 UCE 535 UCE 500 UCE 500 New Min. New Min. 0.00 0.00 20.007 20.007 New Max. New Max. 0.05 0.05 20.016 20.016 Service Limit Service Limit 0.08 0.08 20.046 20.046 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 65 Valve stem OD (Exhaust) UCE 535 UCE 500 UCE 535 UCE 500 New Min. New Min. 6.945 6.945 7.000 7.000 New Max. New Max. 7.015 7.015 6.960 6.960 Service Limit Service Limit 6.935 6.935 7.040 7.040 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 66 Hydraulic tappet to guide clearance UCE 500 UCE 535 UCE 535 UCE 500 New Min. 0.00 0.00 New Min. 0.012 0.012 New Max. 0.03 0.03 New Max. 0.051 0.051 Service Limit 0.05 0.05 Service Limit 0.060 0.060 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 67 Selector fork lug thikness UCE 535 UCE 500 UCE 535 UCE 500 12.995 3.90 3.90 12.995 New Min. New Min. 3.95 3.95 13.045 New Max. 13.045 New Max. 3.88 3.88 Service Limit 13.060 Service Limit 13.060 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 68 MS 4 UCE 500 UCE 535 UCE 500 UCE 535 New Min. 24.00 24.00 2.95 New Min. 2.95 New Max. New Max. 24.03 24.03 3.05 3.05 Service Limit Service Limit 24.06 24.06 2.60 2.60 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 69 Lobe Bush Lobe I.D. height I.D. height 15.884 38.079 15.884 New Min. 37.679 15.886 38.179 15.886 37.779 New Max. Service Limit 15.916 37.979 15.916 37.579 UCE 500, 535 New Min. New Max. Service Limit ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 70 Oil pump end clearance UCE 500, 535 UCE 500, 535 0.080 0.053 New Min. New Min. New Max. New Max. 0.200 0.10 Service Limit Service Limit NOTE : Tip clearance between rotors new 0.15mm Max. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 71 Do not use any sharp engine oil and then objects to press piston rings assemble over against groove. Use thumb piston by gently twisting finger force to locate rings in and tilting. its position properly. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 72  Check for piston wear, measure the outside diameter piston perpendicular to the piston pin hole.  Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 73 25 mm from the bottom, pushing the ring by piston head and then measuring the end gap.  Check the piston pin for wear. Measure outside dia of piston pin at 3 points. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 74  Check the valve guide for wear with small bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance.  Replace valve if the valve head is knife edged. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 75  Check inlet and exhaust valve stem for wear.  Check the valve seat to valve head seating as below.  Make pencil marks on the seating area of valve head as shown in Fig. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 76  Lift and turn the valve by half and grind valve on its seat.  Repeat the process of valve lapping as explained several times for ensuring perfect valve seating.  Clean the valve and valve seat thoroughly. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 77 Seepage of petrol past the valve seat indicates improper valve seating.  Check the free length of valve spring.  Pour solvent into exhaust port and check for valve seat leakage if any. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 78 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions ValveTiming 11.5  Bring piston to TDC so that the woodruf key in the timing shaft is at 12’ Clock position. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 79 Decarbonisation of cylinder  In case compression pressure less than 80 PSI, head / piston (combustion chamber). Also then refit spark plug & start again to warm-up the check for smoky exhaust problem. engine. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 80: Torque Chart
Hex Socket Head cap screw M5*25 Starter motor housing assy Hex Socket Head cap screw M5*45 Chain Pad nut assy Hex Nut M8 * 1.25 Engine Sprocket & Sprag gear assy Hex flange screw M12*1.25 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 81 Hex Socket head Head cap screw M5*40 Rear mounting bracket assy Hex Nut with Nyloc insert M8 Engine Front munting bracket assy Hex Nut with Nyloc insert M8 Clutch Clutch Assy Hex Nut with Nyloc insert M 16 *1.5 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 82: Engine Assembling Sequence
 Fix the clutch bearing Hex.Flange bolt M5 retainer plate with 2 Allen Key 4mm allen bolts ( Torque 0.60 KG-M/6 NM).  Insert 1st circlip in Crank case Left. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 83  Assemble 6305 - C3 bearing after 1st circlip. Insert 2nd circlip then bearing spacer in Crank case Left.  Assemble NU 305 big roller bearing after bearing spacer in Left Crank case crankshaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 84: Engine Bearings Crankcase Rh
FD sprocket side, while assembling 6007 bearing.  Insert circlip and then assemble crankshaft Right side needle roller bearing into Crank case.  Assemble closed end needle bearing inside sleeve Gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 85 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Engine Bearings 12.2 Crankcase RH  Assemble open end needle bearing. Check bearing seating position and for free rotation. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 86: Kick Starter Sub Assembly
 Insert the spring, plunger and pawl in the kick starter spindle.  Fix the thrust washer on kick spindle.  Assemble Kick pinion gear over kick pawl mechanism.  Insert the thrust washer above the kick spindle. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 87: Kick Starter Shaft
Torque 0.6 KG-M under the kickstarter Gear (Torque 0.6 KG-M).  Assemble Kick starter spring on kick starter stud that the inner lug is above & facing the stud & eyelet in facing down. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 88 Ensure oil seal is replaced then assemble kick before fixing kick shaft shaft Cover with oil seal cover. on Crank case Right by 4 screws. Hex. Flange Screws M5 Allen Key 4 mm Torque 0.6 KG-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 89: Layshaft Sub Assembly
 Assemble High gear.  Assemble Double gear (Layshaft 3rd and 4th gear).  Assemble thrust washer NOTE : and then Lay shaft 1st Ensure bottom pivot bearing gear. smooth machined surface are facing upwards ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 90 Fastener, Size, Tool Usage, Precautions, Photos Instructions Layshaft Sub 12.5 Assembly  Assemble rocker shaft Hex. Soc Hd Cap Screw M6 upper pivot bearing with Allen Key 5mm “O” ring with 2 bolts (Torque 1 KG-M). Torque 1 KG-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 91: Mainshaft Sub Assembly
 Smear oil on the 3rd & 4th gear with bush before assembly on Mainshaft.  Smear oil on the 3rd & 4th gear with bush before assembly on Mainshaft.  Assemble main shaft 3rd gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 92 Fastener, Size, Tool Usage, Precautions, Photos Instructions Mainshaft Sub 12.6 Assembly  Assemble main shaft NOTE : 2nd gear. Ensure 2nd gear selector fork groove side is facing towards Mainshaft 4th gear.  Assemble main shaft 1st gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 93  Assemble circlip on the selector shaft.  Assemble Left selector fork on the selector shaft and then insert centre fork so that the cut shoulders of both the forks are matched.  Assemble Right selector fork. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 94 & High gear with Lay shaft with sleeve gear hole, shaft mounted on the fork shaft with fork hole Crank case Right. inside the Crank case Right and sliding gear with lay shaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 95 Check Gear shifting system by rotating Cam plate and Main shaft sub assy while rotating the shafts simul- taneously. Check smooth gears engagement.  Assemble thrust washer and then Layshaft 1st gear on the Layshaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 96 Ensure the bearing inner Right. races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembl- ing in the crankcase Right. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 97 - all shaft holes are crankcase LH & RH. aligned - The jack shaft is in position and does not fall off. - The crankcase joints are perfectly matched. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 98 - Step face is facing LH inside. crankscase LH inside. - Locate proper ends on woodruff key. NOTE : Ensure smaller gear is facing crankcase LH inside & meshes with idler gear ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 99: Hydraulic Tappets
 Locate bracket pin over Hex socket screws M6 needle roller pin of Allen Key 45 mm hydraulic valve lifter and Torque 1 KG-M tighten with hex socket screw. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 100 Fastener, Size, Tool Usage, Precautions, Photos Instructions Hydraulic Tappets 12.7  Locate tappet cover on Hex Socket crankcase RH. CSK head Screw M5 Allen Key 4 mm  Tighten 4 hex socket csk head screws. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 101: Drain Plug
 Assemble magnetic drain DRAIN BOLT NOTE: plug assy with O ring on Apply LOCKTITE 542 thread crankcase Right. sealant before assembling the drain plug. Hex flange bolt M5 Socker Spanner 8mm Torque 2 KG-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 102: Gear Train
Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Gear Train 12.9  Insert sleeve Gear into NOTE: Crankcase Right. Do not hammer directly over sleeve Gear. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 103: Gear Rocker Shaft On Crankcase Rh Outer
Locate spacer inside the spring.  Assemble striker spring NOTE : on rocker shaft assy. Ensure striker spring both ends are seated on striker lever rocker shaft. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 104  Use Special tool to to avoid oil seepage. assemble rocker return spring stop pin along Special tool No. ST 25123-4 with ‘O’ ring. Hex Socket Head Cap Screw M5 Allen key 4mm ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 105 This double stepped face shown in Fig. Fix cam should be inside. plate return spring, pawl cam plate with Torque 2 KG-M Pawl Bolt machined washer and nyloc nut. Torque 1 KG-M Nyloc Nut ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 106: Crankcase Lh & Rh
Ensure the bearing inner Right. races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembl- ing in the crankcase Right. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 107 - all shaft holes are crankcase LH & RH. aligned - The jack shaft is in position and does not fall off. - The crankcase joints are perfectly matched. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 108 - Step face is facing LH inside. crankscase LH inside. - Locate proper ends on woodruff key. NOTE : Ensure smaller gear is facing crankcase LH inside & meshes with idler gear ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 109: Starter Double Gear
Fastener, Size, Tool Usage, Precautions, Photos Instructions Starter Double Gear 12.12  Locate the double gear in the crankcase LH and insert shaft.  Ensure cut portion of CUT PORTION shaft is facing upwards. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 110: Auto Chain Tensioner
2 allen screws (Torque1 KG-M).  Assemble chain tensioner Hex.Flange U Nut 8mm pad, washer and hex Ring Spanner 10mm nut. Torque 2.5 KG-M  Assemble collar on main shaft (distance collar on ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 111: Sprag Clutch Assembly
 Locate engine sprocket CAUTION : into sprag clutch & Lubricate the needle bearing gently press inside well before assembling on simultaneously rotating the sprag clutch. anticlockwise.  Assemble spacer (distance washer) on Crankshaft Left. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 112: Sub Assembly Of Clutch Plates
 Assemble clutch springs Special tool No. 6 Nos. on clutch sub ST-25594-4 assy. then place clutch spring holder. Hex. Bolt M6 Socket Spanner 8 mm ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 113 Fix the 2 hex bolts.  Locate clutch sprocket engine in primary chain, assembly as a set on the main shaft & crankshaft respectively .  Locate thrust washer in clutch sprocket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 114: Assembly Of Clutch
Hex Flange Bolt M17 washer on sprag clutch assy. Socket Spanner 24 mm Torque 4.8 Kg-M  Fix the washer and nyloc Nyloc Nut M20 hex nut over clutch Socket Spanner 24 mm assembly and tighten. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 115 Hex Flange Screw M5 with “O” ring for the auto Allen Key 4mm chain tensioner (Torque 1 KG-M).  Assemble clutch bearing cup, ball bearing (6001) & clutch push pad.  Assemble gear lever shaft bush. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 116: Cover Lh
Hex Flange bolt M6 cover Left and tighten. Allen Key 5mm Torque 1 Kg-M  Assemble clutch cable on Crank case cover Left and fix to clevis.  Assemble Sleeve gear Spacer over sleeve as. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 117  Assemble oil filler plug NOTE : with “O” ring. Ensure 2 Nos. dowel pins are located properly. Apply LOCKTITE 5699 RTV silicon liquid gasket.  Assemble the cover LH on Crank case LH. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 118 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Cover LH 12.17  Assemble gear lever oil seal on cover Left .  Assemble Clutch operating shaft oil seal. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 119: Fd Sprocket
Hex Flange U Nut washer and nut (Torque Socket Spanner 24 mm 7.5 KG-M). Torque 7.5 Kg-M  Lock the tab over the FD sprocket nut.  Fix Rear Chain master link, plate and lock clip. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 120: Gear Shift Assembly
& gently push the pivot pin into the Crankcase RH.  Locate Gear shift shaft Special Tool No : with spacer on RH side. ST-25123-4  Locate Gear change lever on gear shift shaft on LH side ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 121: Oil Pump
(Torque 0.35 to 0.6 KG-M).  Fix the woodruff key carefully on Crankshaft.  Assemble Gear lever shaft assembly into Right Crank case window and then fix gear shaft spacer. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 122: Auto Decompressor
 Assemble the flyweight along with return spring over activating pin and tighten with allen screw.  Lubricate and ensure NOTE : free movement of the Ensure spring eyelet is returning seated properly inside flyweight. flyweight hole. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 123: Assembly Procedure Of Cam Gears
 Fix Cam steady plate and Hex Socket ScreW M6 check for axial play of Allen Key 5 mm Cam Gears to avoid noise problem. Torque 1 Kg-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 124 ST 25592-4 4.8 KG-M) by using Special tool.  Fix oil seal 2 Nos. at Kick Shaft hole on Crank case Right cover. INSIDE OIL SEAL OUTSIDE OIL SEAL  Fix breather chamber gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 125 Timing inspection bolt with copper washer (if not assembled earlier).  Assemble jet Crankshaft, NOTE : oil seal Crank feed and Replace the oil seal every circlip on cover Right 20,000 kms interval. inside. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 126 KG-M).  Assemble 2 dowels and Right Crank case cover gasket.  Assemble cover Right carefully by aligning kickshaft and dowels.  Fix cover Right and tighten with 11 allen screws (Torque 1 KG-M). ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 127 Spring and gasket oil Care must be taken while filter cap. fixing cover due to spring force and gasket.  Assemble oil filter cover (Torque 0.60 KG-M).  Assemble kickstarter Torque 2.5 Kg-m lever (Torque KG-M). ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 128 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Assembly Procedure 12.22 of Cam Gears  Fix Cylinder barrel bottom Gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 129: Assembly Of Rotor Assembly
ST 25592-4 4.8 KG-M) by using Special tool.  Fix oil seal 2 Nos. at Kick Shaft hole on Crank case Right cover. INSIDE OIL SEAL OUTSIDE OIL SEAL  Fix breather chamber gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 130 Timing inspection bolt with copper washer (if not assembled earlier).  Assemble jet Crankshaft, NOTE : oil seal Crank feed and Replace the oil seal every circlip on cover Right 20,000 kms interval. inside. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 131  Assemble Pulser coil on Hex Soc. Hd.Cap Screw M6 cover Right and tighten Allen Key 5 mm with 2 screws (Torque 1 Torque 1 KG-M KG-M).  Assemble 2 dowels and Right Crank case cover gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 132: Assembly Of Rh Cover
 Assemble the “O” rings, Oil filter element, washer and plate as shown.  Assemble “O” ring, CAUTION : Spring and gasket oil Care must be taken while filter cap. fixing cover due to spring force and gasket. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 133 Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Assembly of RH 12.24 Cover  Assemble oil filter cover Torque 0.6 Kg-M  Assemble kickstarter Torque 2.5 Kg-m lever ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 134: Starter Motor & Housing
(Torque 1 KG-M) along sealant to mounting bolts to with earthing cable. avoid oil seepage if any. Hex Soc. Screw M6  Fix the E-Start motor Allen Key 5 mm cover. Torque 1 KG-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 135: Cylinder Barrel/Pistion
Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Cylinder Barrel/ 12.26 Piston  Assemble the multi layer steel (MLS) head gasket on the barrel & 2 Nos. dowels. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 136: Piston Ring Sub Assembly
Crank case  Fit the circlips on either neck by shop towel / side and ensure they are chamois cloth as shown in located properly in the Fig. grooves. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 137: Assembly Of Inlet /Exhaust Valves
 Locate valve in the valve guide on the inside of the cylinder head.  Locate spring retainer top valve spring & collar bottom.  Locate special tool till the spring is fully compressed ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 138 Exhaust special tool on the inlet valve valve when the bolt is seated on the valve, the Special Tool No : collar is seated on the valve spring retainer. ST-25123-1 ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 139: Cylinder Head Assembly
(MLS) head gasket.  Gently locate cylinder head on barrel.  Install 6 hex flanged nuts Hex Flange Bolt M8 securing the cylinder T Spanner 13mm head to crankcase. Torque 3 Kg-M  Locate Spark plug. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 140  Locate the Inlet & Exhaust Rocker cover, dowel & rubber gasket.  Install 2 Hex Plugs with Hex Socket Plug M7 rubber seals on Inlet and Allen Key 6 mm exhaust rocker covers. Torque 1.4 Kg-M ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 141: Engine Oil Filling
Aggregate to Assemble / Fastener, Size, Tool Usage, Precautions, Photos Instructions Engine Oil Filling 12.30  Fill recommended the engine oil to the correct level and tighten filler cap with “O” ring. ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 142: Trouble Shooting
The third most important aspect is a careful and visual inspection with a “careful eye for detail”, for any telltale signs of what could have caused the fault and then ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 143 Valve stem bent, seating area Check & replace burnt, excess carbon deposit on seating area, Valve springs broken Piston rings sticky/ worn-out Check & replace Cylinder barrel / Piston excess Check & replace clearance ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 144 Big end bearing seized in Crank Investigate cause of seizure, pin / connecting rod big end check & correct as required Crankshaft bearings in LH/RH Investigate cause of seizure, crankcases seized check & correct as required ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 145 Valve not seating properly (stem Check & replace bent. Heavy carbon deposit on seating surface) Piston rings worn out/ broken / Check & replace stuck in ring groove Cylinder / piston worn Check & replace ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 146 Check & correct Clutch plates worn out / warped / Check & correct sticky release / burnt Front / rear brakes jamming Check & correct E. Others Front / rear wheel bearing jammed Check & correct ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 147 Excessive Carbon in combustion Check & Clean chamber Piston ring bad (worn, weak, Check & Replace broken, or sticking) Piston rings clearance excessive Check & Replace Cylinder, piston worn Check & Replace ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 148 Check & correct C. Bluish / White smoke Excess clearance between valve Check & correct stem & guide Oil scrapper ring worn out Check & correct Cylinder barrel / piston clearance Check & replace high ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 149 Oil cooler fins dirty / blocked Check & clean oil cooler fins Clutch slipping Check & correct Front / Rear brakes jammed Check & correct Engine oil pressure less Check & correct Silencer choked Check & clean ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 150 Clutch housing gear / crank gear backlash Replace matched gears F. Transmission noise Drive / counter gears backlash Check & replace Drive / Countershaft bearings worn out Check & replace Gears / bushes seized in drive /counter shaft Check & replace ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 151 Selector drum grooves worn out Check & replace F. Gears overshifts Sliding Gear dogs worn out Check & replace Drive shaft/counter shaft splines worn out Check & replace Drive / counter shaft bearings wornout Check & replace ROYAL ENFIELD UCE ENGINE SERVICE MANUAL...
Page 152 Royal Enfield Support : 1800-2100-007 Email : support@royalenfield.com Twitter : @RoyalEnfieldSupport Web : www.royalenfield.com...