Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
Print this page
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Royal Enfield Manuals
Motorcycle
Classic 350 2009
Service manual
Royal Enfield Classic 350 2009 Service Manual
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
Table Of Contents
230
page
of
230
Go
/
230
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Important Notice
Preparation for Service
Safety
Use of Genuine Spare Parts
Table of Contents
Engine Dismantling
Section Four
Section Six
Section Three
Section Two
Section Two
General
Four Stroke Cycle Operation
Unit Construction Engine
Salient Features of the Unit Construction
Basic Terminology of IC Engines
Clearance Volume
Cubic Capacity / Displacement
Stroke
Total Volume
Compression Ratio
Volumetric Efficiency
Horse Power (Hp or Ps)
Ihp
Fhp
Bhp
Torque
Ignition Timing
Idling Speed
Gear Ratio
Final Drive Ratio
Technical Specifications
Engine and Engine Systems
Identification of Chassis & Engine No.
List of Special Tools & Its Application
Control Cables & Wiring Harness Routing
Under Tank and Seat Top View
Under Tank Lh View
Under Tank Rh View
General Vehicle Information
Harness Routing Steering Rh
Magneto Wires Routing
Plug Wire Routing
Handle Bar Instrument Panel & Cable Routing
Horn Wire Routing
Fuse Carriers Arrangement (Classic 500)
Fuse Carriers Arrangement (Classic 350)
Throttle Body Mounting
Tail Lamp & Trafficator Wires Routing
Ecu Mounting
Tci Unit Mounting
Section Three 03
Service Data
Section Three
Wear Limits
Service Limits of Components
New Min
New Min.
Clutch Spring Length
Lay Shaft 1St Gear Inner Diameter
Lay Shaft 2Nd Gear Inner Diameter
New Max.
Pivot Cam Plate Outside Diameter
Classic 500 Classic 350 New Min. 0.06
Clutch Cable -Free Play
Drive Chain : Slackness
Duplex Chain - Length Across 21 Pins
Rear Sprocket Chain Pull off
Brake Lining Thickness
Drive Chain Length Across 21 Pins
New Min.
Sprocket
Wheel Rim: Face out / Run out
Caliper Piston Outer Diameter
Front Fork Assembly Spring : Length
Main Tube - Run out
Master Cylinder Piston OD
New Max. 0.07
Service Limit
Spark Plug Gap
Swing Arm Bush & Spacer
Tyre Tread : Depth
Periodical Maintenance Chart
Air Filter Cleaning
Engine Oil
Oil Level Check
Spark Plug Cleaning
Draining Procedure
Fitting Procedure
Oil Change
Rear Wheel Chain Slackness Adjustment
Brake Cam Greasing
Brake Pedal Play Adjustment
Pedal Free Play 20 to 30 MM
Rear Brake Switch Adjustment
Front Fork
Rear Shock Absorbers Adjustment
Disc Brake Fluid Level Check
Steering Play Adjustment
Clutch Cable Free Play
Steering Ball Race Lubrication
Adjustment at Handle Bar End (Classic 500)
Primary Chain Tension Adjustment
Throttle Cable Assy Replacement (Classic 500)
Throttle Cable Play Adjustment
Checking Procedure of Throttle Position Sensor (Tps) Cable
Throttle Cable Assy Replacement (Classic 350)
CV Carburetor Drain and Tuning Procedure
Engine Compression Test
Float Height Adjustment
Decarbonising Cylinder Head
Cylinder Head and Valves
Inspect the Valve Seat Face
Service Limit
Valve Seat Inspection
Valve Seat Refacing
The Parts Detail of Cylinder Head Assembly
Valve Timing Cum Eccentric Cam Spindle
Eccentric Cam Spindle Adjustment
Battery Electrolyte Level Checking
Specific Gravity Checking
Terminal Cleaning
Section Four
Engine Lubrication System
Upper Cylinder Lubrication
Lower Cylinder Lubrication
Lubrication Oil
Oil Pump : Trochoid Type
What Is Hydraulic Tappet
Benefit of Hydraulic Tappet
Cut Section View of Rhvl
Working Principle
Precautionary Measures
Auto Decompressor
Auto Decompressor - Working Principle
Benefits of Auto Decompressor
Electric Starting System & Sprag Mechanism
Auto Chain Tensioner Assembly
Engine Breather System
Inlet Manifold & Throttle Body
Crankcase RH - Coverside View
Crankcase LH - Inside View
Crankcase RH - Inside View
Description Qty
Flange Hex Nut - M8
Stud, M8 X
Engine Cover RH
Crankcase LH - Coverside View
Hex Socket Head Cap Screw, M5 X
Jack Shaft
Needle Bearing
Stud M6 X 106
Engine Cover LH
Gear Train Assembly
Gear Shifting / Kick Starter
Cylinder Head, Barrel, Piston & Crankshaft
Crank Shaft Assy.
Piston Assy.
Damper Pad Position Details
Engine
Section Five
Engine Dismantling Procedure
Engine Disassembly
Dismantling Procedure
Clutch Cable Removal
Removal of Throttle Cable
Removal of Throttle Body
Removal of Silencer and Exhaust Pipe
Battery Removal
Removal of E-Start Motor
Removal of Drive Chain
Removal of Side Stand
Removal of Rear Brake Switch
Engine Oil Drain
Cylinder Head Assembly
Removal of Valves
Cylinder Barrel Sub Assy.
Removal of Cover Rh Sub Assembly
Components for Dismantling from Crankcase Rh
Removal of Rotor Assembly
Dismantling Procedure of Auto Decompressor
Dismantling Cover Lh Sub Assembly
Components for Dismantling from Crankcase Lh
Removal of Clutch Assy
Dismantling of Clutch Assembly
Gear Train Removal
Dismantling of Layshaft Sub Assembly
Layshaft Sub Assembly
Main Shaft Sub Assembly
Dismantling of Mainshaft Sub Assembly
Removal of Sleeve Gear Assembly
Removal of Sleeve Gear Sub Assembly
Removal of Kick Starter Assembly
Removal of Kick Starter Sub Assembly
Vital Parts
Bearings
Gears / Sprockets
Unidirectional Fittings List
Torque Specification - Engine
Engine Assembly
Assembly of Engine Bearings
Crankcase Lh
Crankcase Rh
Assembling of Gear Rocker Shaft Sub Assembly
Assembling of Layshaft Sub Assembly
Assembling of Mainshaft Sub Assembly
Assembly of Clutch
Assembling Procedure of Auto Decompressor
Valve Timing
Assembly Procedure of Cam Gears
Piston Sub Assembly
Cleaning
Cylinder Barrel
Cylinder Head
Valve Leakage Test
Engine Mangement System
Section Six
Engine Dismantling Inspection & Assembly
Section Six 06
Section Eight
Function of Components in EMS
Electronic Control Unit (Ecu)
Alternator
Throttle Body Assembly
Ecu Pin Configuration
Fuel Injector
The Advantages of Fuel Injection
Exploded View of Fuel Injector
Assembled between Throttle Body and Cylinder Head
Fuel Pump Module
Low Fuel Sensor
Malfunction Indicator Lamp (Mil)
Assembled on the Headlamp Casing
Throttle Body Module
Assembled between Air Filter and Inlet Manifold
Throttle Position Sensor (Tps)
The Ecu Uses the Throttle Valve Position to Know
Manifold Pressure Sensor (Map)
Manual Bi Starter
Engine Oil Temperature Sensor
Crank Position Sensor
Assembled on the Cylinder Head
Assembled on the Engine RH Cover
Roll over Sensor
Assembled under the Seat
Level 1 Visual
Level 2 Test Pin
Level 3 Dol
Instructions (Do’s & Don’ts) on EMS
Trouble Shooting - EMS
Engine Management System (EMS)
Engine Management System - Functional Diagram
Section Six 07
CV Carburetor
CV Carburetor - Exploded View
Function of Carburetor
Carburetor Performs Three Important Functions
Carburetor Removal
Dismantling Proceedure - Carburetor
Torque Specification
Assembling Proceedure - Carburetor
Installation of Carburetor
Carburetor Tuning Procedure
Carburetor Maintenance
Procedure for Setting Idling Speed and Co%
Maintenance Tips
Service Guidelines
Trouble Shooting
Chassis, Wheels & Brakes
Torque Specification - Chassis
Front Wheel Removal
Front Wheel Bearings Removal
Disc Brake
Draining Old Brake Fluid
General Instructions
Overhauling Caliper and Master Cylinder
Bleeding Procedure
Normal Method
Bleeding Proceedure
Reverse Bleeding Method
Disassembly of Master Cylinder
Reassembly of Master Cylinder
Disassembly of Wheel Caliper
Caliper Assembly
Wheel Disc Inspection
Rear Wheel Removal
Brake Drum Assembly
Suspension & Steering
Section Nine
Front Fork Disassembly
Removal of Fork Seals
Front Fork Assembly
Steering Disassembly
Reassembly of Steering
Gas Filled Shock Absorber
Section Ten
Removal and Assembly of Rear Shock Absorber
Swing Arm
Recharging of Shock Absorbers
Center Stand
Electricals
Advertisement
Quick Links
1
Engine Dismantling
Download this manual
Service Manual
Classic 500 & 350
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Table of Contents
Troubleshooting
Trouble shooting - EMS
167
Trouble Shooting
178
Trouble Shooting - Electricals
221
Trouble Shooting
222
Need help?
Do you have a question about the Classic 350 2009 and is the answer not in the manual?
Ask a question
Questions and answers
Related Manuals for Royal Enfield Classic 350 2009
Motorcycle Royal Enfield Bullet Electra 350 2006 Owner's Manual
(69 pages)
Motorcycle Royal Enfield Classic 350 2020 Owner's Manual
(68 pages)
Motorcycle Royal Enfield Classic 350 2019 Owner's Manual
(126 pages)
Motorcycle Royal Enfield Classic 350 2019 Owner's Manual
(68 pages)
Motorcycle Royal Enfield Bullet 500 2017 Manual
(144 pages)
Motorcycle Royal Enfield Classic 350 Owner's Manual
(108 pages)
Motorcycle Royal Enfield CLASSIC 350 2021 Owner's Manual
(68 pages)
Motorcycle Royal Enfield Classic 350 2008 Owner's Manual
(110 pages)
Motorcycle Royal Enfield Meteor 350 2023 Owner's Manual
(128 pages)
Motorcycle Royal Enfield Meteor 350 Owner's Manual
(102 pages)
Motorcycle Royal Enfield Classic 350 Owner's Manual
(100 pages)
Motorcycle Royal Enfield CLASSIC 350 Owner's Manual
(116 pages)
Motorcycle Royal Enfield Classic 350 Owner's Manual
(137 pages)
Motorcycle Royal Enfield Bullet Workshop Manual
Bullet (29 pages)
Motorcycle Royal Enfield Bullet 350-ES Owner's Manual
(105 pages)
Motorcycle Royal Enfield THUNDERBIRD 350 Owner's Manual
(123 pages)
Table of Contents
Save PDF
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL
Need help?
Do you have a question about the Classic 350 2009 and is the answer not in the manual?
Questions and answers