Royal Enfield Classic 500 2009 Manuals

Royal Enfield Classic 500 2009 Manuals

Manuals and User Guides for Royal Enfield Classic 500 2009. We have 1 Royal Enfield Classic 500 2009 manual available for free PDF download: Service Manual

Royal Enfield Classic 500 2009 Service Manual

Royal Enfield Classic 500 2009 Service Manual (230 pages)

Brand: Royal Enfield | Category: Motorcycle | Size: 8.5 MB

Table of Contents

Important Notice
3
Preparation for Service
3
Safety
3
Use of Genuine Spare Parts
3
Table of Contents
4
Engine Dismantling
4
Section Four
4
Section Six
4
Section Three
4
Section Two
4
Section Two

6
General

6
- Four Stroke Cycle Operation
  7
- Unit Construction Engine
  7
- Salient Features of the Unit Construction
  7
  - Basic Terminology of IC Engines
    8
  - Clearance Volume
    8
  - Cubic Capacity / Displacement
    8
  - Stroke
    8
  - Total Volume
    9
  - Compression Ratio
    9
  - Volumetric Efficiency
    9
  - Horse Power (Hp or Ps)
    9
  - Ihp
    10
  - Fhp
    10
  - Bhp
    10
  - Torque
    10
  - Ignition Timing
    11
  - Idling Speed
    11
  - Gear Ratio
    11
  - Final Drive Ratio
    11
- Technical Specifications
  12
  - Engine and Engine Systems
    12
  - Identification of Chassis & Engine No.
    15
  - List of Special Tools & Its Application
    16
  - Control Cables & Wiring Harness Routing
    21
  - Under Tank and Seat Top View
    21
  - Under Tank Lh View
    21
  - Under Tank Rh View
    21
  - General Vehicle Information
    22
  - Harness Routing Steering Rh
    22
  - Magneto Wires Routing
    22
  - Plug Wire Routing
    22
  - Handle Bar Instrument Panel & Cable Routing
    23
  - Horn Wire Routing
    23
  - Fuse Carriers Arrangement (Classic 500)
    23
  - Fuse Carriers Arrangement (Classic 350)
    23
  - Throttle Body Mounting
    24
  - Tail Lamp & Trafficator Wires Routing
    24
  - Ecu Mounting
    24
  - Tci Unit Mounting
    24
Section Three 03

25
Service Data

25
- Section Three
  25
- Wear Limits
  26
- Service Limits of Components
  26
  - New Min
    26
  - New Min.
    30
    
    Clutch Spring Length
    31
    
    Lay Shaft 1St Gear Inner Diameter
    31
    
    Lay Shaft 2Nd Gear Inner Diameter
    31
  - New Max.
    31
    
    Pivot Cam Plate Outside Diameter
    31
    
    Classic 500 Classic 350 New Min. 0.06
    32
    
    Clutch Cable -Free Play
    32
    
    Drive Chain : Slackness
    32
    
    Duplex Chain - Length Across 21 Pins
    32
    
    Rear Sprocket Chain Pull off
    32
    
    Brake Lining Thickness
    33
    
    Drive Chain Length Across 21 Pins
    33
  - New Min.
    33
    
    Sprocket
    33
    
    Wheel Rim: Face out / Run out
    33
    
    Caliper Piston Outer Diameter
    34
    
    Front Fork Assembly Spring : Length
    34
    
    Main Tube - Run out
    34
    
    Master Cylinder Piston OD
    34
    
    New Max. 0.07
    34
  - Service Limit
    35
    
    Spark Plug Gap
    35
    
    Swing Arm Bush & Spacer
    35
    
    Tyre Tread : Depth
    35
- Periodical Maintenance Chart
  36
  - Air Filter Cleaning
    37
  - Engine Oil
    37
  - Oil Level Check
    37
  - Spark Plug Cleaning
    37
  - Draining Procedure
    38
  - Fitting Procedure
    38
  - Oil Change
    38
  - Rear Wheel Chain Slackness Adjustment
    39
  - Brake Cam Greasing
    40
  - Brake Pedal Play Adjustment
    40
  - Pedal Free Play 20 to 30 MM
    40
  - Rear Brake Switch Adjustment
    40
  - Front Fork
    41
  - Rear Shock Absorbers Adjustment
    41
  - Disc Brake Fluid Level Check
    42
  - Steering Play Adjustment
    42
  - Clutch Cable Free Play
    43
  - Steering Ball Race Lubrication
    43
  - Adjustment at Handle Bar End (Classic 500)
    44
  - Primary Chain Tension Adjustment
    44
  - Throttle Cable Assy Replacement (Classic 500)
    44
  - Throttle Cable Play Adjustment
    44
  - Checking Procedure of Throttle Position Sensor (Tps) Cable
    45
  - Throttle Cable Assy Replacement (Classic 350)
    46
  - CV Carburetor Drain and Tuning Procedure
    47
  - Engine Compression Test
    47
  - Float Height Adjustment
    47
  - Decarbonising Cylinder Head
    48
  - Cylinder Head and Valves
    49
  - Inspect the Valve Seat Face
    49
  - Service Limit
    49
  - Valve Seat Inspection
    49
  - Valve Seat Refacing
    50
  - The Parts Detail of Cylinder Head Assembly
    51
  - Valve Timing Cum Eccentric Cam Spindle
    52
  - Eccentric Cam Spindle Adjustment
    52
  - Battery Electrolyte Level Checking
    53
  - Specific Gravity Checking
    53
  - Terminal Cleaning
    53
Section Four

54
- Engine Lubrication System
  55
  - Upper Cylinder Lubrication
    55
  - Lower Cylinder Lubrication
    55
  - Lubrication Oil
    56
  - Oil Pump : Trochoid Type
    57
  - What Is Hydraulic Tappet
    58
  - Benefit of Hydraulic Tappet
    58
  - Cut Section View of Rhvl
    58
  - Working Principle
    59
  - Precautionary Measures
    59
- Auto Decompressor
  60
- Auto Chain Tensioner Assembly
  62
- Engine Breather System
  63
- Inlet Manifold & Throttle Body
  64
  - Crankcase RH - Coverside View
    65
  - Crankcase LH - Inside View
    67
  - Crankcase RH - Inside View
    69
  - Description Qty
    70
  - Flange Hex Nut - M8
    70
  - Stud, M8 X
    70
    
    Engine Cover RH
    71
    
    Crankcase LH - Coverside View
    73
  - Hex Socket Head Cap Screw, M5 X
    74
  - Jack Shaft
    74
  - Needle Bearing
    74
  - Stud M6 X 106
    74
  - Engine Cover LH
    75
  - Gear Train Assembly
    77
  - Gear Shifting / Kick Starter
    79
  - Cylinder Head, Barrel, Piston & Crankshaft
    81
  - Crank Shaft Assy.
    81
  - Piston Assy.
    81
  - Damper Pad Position Details
    83
Engine

54
Section Five

84
- Engine Dismantling Procedure
  84
  - Engine Disassembly
    85
  - Dismantling Procedure
    86
  - Clutch Cable Removal
    87
  - Removal of Throttle Cable
    87
  - Removal of Throttle Body
    87
  - Removal of Silencer and Exhaust Pipe
    88
  - Battery Removal
    88
  - Removal of E-Start Motor
    89
  - Removal of Drive Chain
    90
  - Removal of Side Stand
    90
  - Removal of Rear Brake Switch
    90
  - Engine Oil Drain
    91
  - Cylinder Head Assembly
    91
  - Removal of Valves
    92
  - Cylinder Barrel Sub Assy.
    93
  - Removal of Cover Rh Sub Assembly
    94
  - Components for Dismantling from Crankcase Rh
    97
  - Removal of Rotor Assembly
    97
  - Dismantling Procedure of Auto Decompressor
    98
  - Dismantling Cover Lh Sub Assembly
    102
  - Components for Dismantling from Crankcase Lh
    103
  - Removal of Clutch Assy
    103
  - Dismantling of Clutch Assembly
    104
  - Gear Train Removal
    110
  - Dismantling of Layshaft Sub Assembly
    112
  - Layshaft Sub Assembly
    112
  - Main Shaft Sub Assembly
    113
  - Dismantling of Mainshaft Sub Assembly
    113
  - Removal of Sleeve Gear Assembly
    114
  - Removal of Sleeve Gear Sub Assembly
    114
  - Removal of Kick Starter Assembly
    114
  - Removal of Kick Starter Sub Assembly
    115
  - Vital Parts
    116
  - Bearings
    116
  - Gears / Sprockets
    116
- Unidirectional Fittings List
  117
- Torque Specification - Engine
  118
  - Engine Assembly
    120
  - Assembly of Engine Bearings
    120
  - Crankcase Lh
    120
  - Crankcase Rh
    121
  - Assembling of Gear Rocker Shaft Sub Assembly
    125
  - Assembling of Layshaft Sub Assembly
    126
  - Assembling of Mainshaft Sub Assembly
    127
  - Assembly of Clutch
    135
  - Assembling Procedure of Auto Decompressor
    140
  - Valve Timing
    141
  - Assembly Procedure of Cam Gears
    141
  - Piston Sub Assembly
    145
  - Cleaning
    145
  - Cylinder Barrel
    147
  - Cylinder Head
    147
  - Valve Leakage Test
    151
  - Engine Mangement System
    154
  - Section Six
    154
Engine Dismantling Inspection & Assembly

84
Section Six 06

155
Section Eight

155
- Function of Components in EMS
  156
- Electronic Control Unit (Ecu)
  156
- Alternator
  156
- Throttle Body Assembly
  156
- Ecu Pin Configuration
  157
- Fuel Injector
  158
- The Advantages of Fuel Injection
  158
- Exploded View of Fuel Injector
  158
- Assembled between Throttle Body and Cylinder Head
  158
- Fuel Pump Module
  159
- Low Fuel Sensor
  159
- Malfunction Indicator Lamp (Mil)
  159
- Assembled on the Headlamp Casing
  159
- Throttle Body Module
  160
- Assembled between Air Filter and Inlet Manifold
  160
- Throttle Position Sensor (Tps)
  161
- The Ecu Uses the Throttle Valve Position to Know
  161
- Manifold Pressure Sensor (Map)
  161
- Manual Bi Starter
  161
- Engine Oil Temperature Sensor
  162
- Crank Position Sensor
  162
- Assembled on the Cylinder Head
  162
- Assembled on the Engine RH Cover
  162
- Roll over Sensor
  163
- Assembled under the Seat
  163
- Level 1 Visual
  164
- Level 2 Test Pin
  164
- Level 3 Dol
  165
- Instructions (Do’s & Don’ts) on EMS
  166
- Trouble Shooting - EMS
  167
Engine Management System (EMS)

155
- Engine Management System - Functional Diagram
  155
Section Six 07

169
CV Carburetor

169
- CV Carburetor - Exploded View
  170
- Function of Carburetor
  171
  - Carburetor Performs Three Important Functions
    171
  - Carburetor Removal
    171
  - Dismantling Proceedure - Carburetor
    172
  - Torque Specification
    173
  - Assembling Proceedure - Carburetor
    174
  - Installation of Carburetor
    175
  - Carburetor Tuning Procedure
    176
- Carburetor Maintenance
  177
  - Procedure for Setting Idling Speed and Co%
    177
  - Maintenance Tips
    177
  - Service Guidelines
    177
  - Trouble Shooting
    178
  - Chassis, Wheels & Brakes
    179
  - Torque Specification - Chassis
    180
  - Front Wheel Removal
    182
  - Front Wheel Bearings Removal
    182
  - Disc Brake
    183
  - Draining Old Brake Fluid
    183
  - General Instructions
    183
  - Overhauling Caliper and Master Cylinder
    184
  - Bleeding Procedure
    185
  - Normal Method
    185
  - Bleeding Proceedure
    186
  - Reverse Bleeding Method
    186
  - Disassembly of Master Cylinder
    187
  - Reassembly of Master Cylinder
    189
  - Disassembly of Wheel Caliper
    191
- Caliper Assembly
  193
  - Wheel Disc Inspection
    196
  - Rear Wheel Removal
    196
  - Brake Drum Assembly
    197
  - Suspension & Steering
    199
Section Nine

199
- Front Fork Disassembly
  201
- Removal of Fork Seals
  201
- Front Fork Assembly
  202
- Steering Disassembly
  202
- Reassembly of Steering
  203
- Gas Filled Shock Absorber
  204
Section Ten

204
- Removal and Assembly of Rear Shock Absorber
  205
- Swing Arm
  205
  - Recharging of Shock Absorbers
    205
  - Center Stand
    208
  - Electricals
    209
Electricals

210
- Electrical Symbols
  210
  - Battery Construction
    210
  - Initial Charge (New Battery) Electrolyte
    211
  - Temperature of Electrolyte
    212
  - Soaking Period
    212
  - Charging a New Battery
    212
  - Recharging Used Batteries
    212
  - Maintenance
    213
  - Spark Plug Maintenance
    214
  - Specific Gravity
    214
  - Check Voltage with Voltmeter
    214
  - Measuring Instrument
    215
  - Starter Coil
    215
  - Pulsar Coil
    215
- Ignition Coil
  215
  - Checking Procedure of Electrical Components
    216
  - Suppressor Cap - M14
    216
  - Battery
    216
  - Relay Starter
    216
  - E- Starter Motor
    217
  - Rr Unit
    217
  - IC Flasher
    217
  - Electrical Parts Inspection
    218
  - Clutch Switch
    218
  - Starter Switch
    218
  - Starter Relay
    218
  - Complete Wiring Diagram - Classic 500
    219
  - Complete Wiring Diagram - Classic 350
    220
  - Trouble Shooting - Electricals
    221
- Trouble Shooting
  222
Section Eleven

222

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