FOREWORD - Royal Enfield · PDF file · 2014-05-07other Royal Enfield machine.€Also please€ensure the same for your pillion rider€as well. ... limb assy Front fork oil make

1

FOREWORD

Congratulations on your choice of the Thunderbird TwinSpark. Your motorcycle represents a breakthrough in engineeringtechnology. It’s Unit Construction Engine delivers greater power and torque, while brand new ergonomics ensureenhanced comfort and safety. Aesthetics have also been refined, resulting in a sleeker, more aerodynamic profile whilepreserving the classic lines of the Thunderbird.

This manual is designed to give you complete control over your bike. It contains important information on efficientoperation and maintenance. We’ve also put in tips on riding safely, as well as some suggestions as to how you canenhance your motorcycling experience.

Your safety is of prime concern to us and we urge you to be a responsible biker. Please make a careful selection ofriding gear in accordance with your application, style and weather conditions which will go a long way in providing youwith a feeling of confidence that goes on to enhance the riding and ownership pleasure that comes with this and everyother Royal Enfield machine. Also please ensure the same for your pillion rider as well. Respect the rules of theRoad and ride safely.

Best of all, your Thunderbird TwinSpark automatically makes you a member of the legendary Royal Enfield community.You can locate your nearest club or sign up for the next big ride at www.royalenfield.com

Enjoy the Trip!

We request you to carefully read the terms and conditions of warranty and other useful information given in this manualbefore you begin to cruise on your Thunderbird TwinSpark.

SERVICE HEADQUARTERSRoyal Enfield, Tiruvottiyur High Road, Tiruvottiyur, Chennai-600019. Phone: 044-4223 0400, Fax: 044-4201 1719

E-mail: [email protected] Website: www.royalenfield.com

www.royalenfield.com

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All information in this manual is based on the latest product information available at the time ofpublication. Due to continues improvements or other changes, there may be discrepanciesbetween information in this manual and your vehicle. Royal Enfield reserves the right to makeproduct changes at any time without prior notice and without incurring any obligation tomake same or similar changes to vehicles previously built or sold.

All images shown are for reference only and to explain. They need not to be exactly the sameon the model you own. Technical specifications are subject to change without prior notice.

“© Copyright 2006 Royal Enfield. All Rights Reserved. No part of this manual shall be copied,distributed or otherwise dealt, without the express permission in writing of Royal Enfield.

NOTICE

Part No. 580589/b /Qty. 500/Oct. ‘10

mailto:[email protected]

www.royalenfield.com2

3

Personal and vehicle information.............. 4

Free service record.................................. 5

Specifications.......................................... 6

Safety Definitions..................................... 9

Safe and happy riding ........................... 10

Vehicle identification numbers ............... 11

Location of key parts ............................. 12

Operation of controls ............................ 16

Pre-Operational Checks ........................ 22

Running in............................................ 23

Starting .................................................. 24

Gear Shifting, Riding & Stopping ........... 26

Parking .................................................. 27

Tools & First aid kit ................................. 28

Periodical maintenance chart...................29

Recommended lubricants ...................... 31

Do it yourself ......................................... 32

Washing procedure ............................... 42

CONTENTS

Storage precautions................................43

Long trip precautions.............................. 45

Caring for Mileage ................................ 46

Wiring diagram ...................................... 48

Trouble shooting .................................... 49

Warranty terms and conditions ............. 56

Emission Warranty ................................. 58

All india Road Signs ............................... 63

Regional & Area Offices ........................ 64

Log Book ............................................... 65

Free Service coupons ............................. 68

Paid Service/Maintenance Record ......... 77

Notes ..................................................... 85

ANNEXURESVehicle Installation Form

Pre-Delivery Inspection Report

Bike Installation Confirmation By Cutomer

Form 22

4

PERSONAL & VEHICLE INFORMATION

Name

Door No./Street

Locality

City State Pin

Contact Nos. Res: Off: Mobile : Email :

Engine No. Battery No.

Frame No. Battery make

Reg. No. Licence No.

Date of Sale Valid till dt.

Model Key No.:

Tyre make Colour

Sold by Dealer Code

Vehicle Installation Form (VIF) No.

5

It is our endeavour to provide excellent service to your Thunderbird Twinspark at all times.Towards this we provide four free services at specific Intervals.

Please avail these services at the specified time, in any of the Royal Enfield Dealerships /Authorised service centres nearest to you and as a token of satisfactory services, kindly returnthe free service coupon duly filled in and signed, to the service outlet.

Availing the free services in the specified time is a prerequisite to warranty consideration.

The cost of fuel, oil, grease etc. used for free service is chargeable to the customer.

FREE SERVICE RECORD

Note : Please ensure that the free service details are recorded in this sheet immediately after theservice is carried out.

Date of ServiceKms CoveredServicingDealer’s NameAddress

1ST Service 4th Service2nd Service 3rd Service

6

SPECIFICATIONS

Engine and Engine systems

Engine Type .................. 4 Stroke, air cooled,................................... single cylinder

Bore ............................ 70mm

Stroke .......................... 90mm

Swept volume ............... 346cc

Compression ratio ........ 8.5:1

Max Torque @ rpm ....... 28 Nm @ 4000 rpm

Idle rpm ....................... 1050±200 rpm

Starting ........................ E’Start

Air filter element ........... Paper element

Carburettor .................. Ucal - BS 29

Lubrication ................... Wet Sump................................... pressure lubrication

Engine oil capacity... ...... 2.75 lits

Engine oil grade ........... Motul 3000 4T Plus................................... 15W 50 API SL Grade

Cooling ....................... Natural air flow

Transmission

Clutch ......................... Wet multiplate (6plates)

Primary drive ................ 3/8” Duplex chain................................... & sprocket

Primary ratio ................. 2.15 : 1

Gear box ..................... Constant mesh 5 Speed

Gear ratio ................. 1st - 3.06 : 1

............................... 2nd - 2.01 : 1

................................3rd - 1.52 : 1

................................4th - 1.21 : 1

................................5th - 1 : 1

Secondary drive ........... 5/8” Chain & Sprocket

Secondary ratio ............ 2.53 : 1

Drive Chain links .......... 100 L

F.D. Sprocket ................ 15 T

7

SPECIFICATIONS

Chassis

Frame .......................... Tubular

Suspension : Front ...... Telescopic, hydraulic................................... damping, Stroke 130 mm

Rear ........ Swing arm with................................... gas shock absorbers

Fr. Fork oil capacity ..... 265 cc+ 2.5 cc per................................... limb assy

Front fork oil make ..... 1F Grade Gabr iel /........................................ Royal Enfield Fork Oil

Brakes : Front ..... Hydraulic 280 mm................................... ventilated disc

Rear ....... Foot operated 153 mm................................... single lead, internal................................... expanding

Brake Oil Capacity ..... 60ml

Brake Oil Grade ......... DOT 3 or DOT 4

Tyre size : Front ...... 3.25´´ ×19´´................................... - 4PR/6PR

Rear ....... 3.5´´ ×19´´................................... - 4PR/6PR

Tyre pressure

Solo : Front ..... 1.41 kg/cm2 (20psi)

Rear ....... 2.11kg/cm2 (30psi)

With Pillion : Front ..... 1.54 kg/cm2 (22psi)

Rear ....... 2.25 kg/cm2 (32psi)

Steering lock ................ In built

Fuel tank capacity ....... 13.5 litres (MIN)

Reserve ....................... 2 litres

Electricals

Generation ................. Alternator AC-3Phase

System ......................... 12V - DC

Ignition ....................... Digital Dual spark................................... Ignition TCI System

Battery .......................... 12V - 14AH

Spark plug ................... Mico-WR5DC - 1 No.

................................... Bosch-UR5DC - 1 No.

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Spark plug gap ........... 0.7 to 0.8 mm

Head lamp .................. 12V, 35 / 35WHalogen bulb

Tail lamp ..................... 12V, 5W

Brake lamp .................. 12V, 21W

Speedometer lamp ...... 12V, 3.4W - 1 No.

Hi beam indicator ........ 12V, 1.7W

Neutral lamp Tell tale .. 12V, 1.7W - 1 No.

Turn Signal Tell Tale ..... 12V, 1.7W - 2 Nos.

Turn signal .................. 12V, 10W - 2 Nos.

Horn ........................... 12V DC

Starter Motor .............. 0.7KW

Weights

Kerb weight ................. 182 Kgs.

Max. pay load ............. 168 Kgs.

Dimensions

Length ......................... 2120 mm

Width ........................... 780 mm

Height .......................... 1080 mm

Wheel base ................... 1370 mm

Ground clearance ......... 135 mm

Saddle height ............... 750mm

Performance

Max. speed ................... 120 Km/hr

SPECIFICATIONS

Values given above are for your guidance only.

In view of continuous improvements being done on our products, the specifications are likely tochange without prior notice.

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The information given under the titles : Warning, Caution and Note are for your safety and forthe care and safety to your motorcycle and others. Please read these carefully and if disregardedmay result in injury to yourself or others and damages to the motorcycle.

Warning :

Indicates a potentially hazardous situation. Disregarding this message may result in injury torider or other persons.

Cau t i o n :This message if disregarded may result in damage to the vehicle.

No te :

Indicates important and useful messages for clear understanding.

SAFETY DEFINITIONS

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SAFE AND HAPPY RIDING

Riding dress

A proper riding apparel

No te :

A light coloured shirt enables greater visibilityto other road users especially during nights.

Cau t i o n : Loose clothing may get caught on moving

parts of your motor-cycle.

A pair of riding boots or shoes.

Soft leather gloves.

Goggles or spectacles to safe guard eyes.

An ISI certified helmet. Affix light reflectingstrips of stickers at the front and rear.

Sitting posture

Correct sitting posture is a pre-requisite for stableand safe riding :

Sit Straight with your shoulders completelyrelaxed.

Keep your elbows close to your body.

Keep your toes in straight ahead direction.

Slightly press the petrol tank with the knees.

Hold the handle grip close to its inner end.

Look extensively, including rear view mirror,without turning the head.

Braking

Use both front and rear brakes togetherfor maximum braking efficiency.

Warning :

Applying any one of the brakes suddenly maycause the vehicle to skid.

The hydraulic disc brake, fitted on yourThunderbird Twinspark requires very lesseffort and high ef fort or suddenapplication may lock the wheel. Please useutmost caut ion whi le apply ing thehydraulic disc brake.

While r id ing on wet or bad roadconditions use brakes cautiously.

11

VEHICLE IDENTIFICATION NUMBERS

Frame Number

Punched on steering head tube RH side.

Engine Number

Punched on top of the engine LH side.

12

LOCATION OF KEY PARTS

1. Trip meter knob

2. Speedometer

3. High beam indicator

4. Neutral indicator

5. RPM meter

6. Fuel Gauge

7. Turn signal indicator RH

8. Turn signal indicator LH

N

1 2 3 4 5 6

78

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1. Clutch lever

2. Head lamp dimmer switch

3. Turn signal switch

4. Handle bar

5. Head light switch

6. Ignition Kill switch

7. Front brake lever

8. Throttle control

9. E-Start Button

10. Horn button

1

23

4 5

6

7

89

10

14


11. Horn

12. Rear brake pedal

13. Kick Starter lever

14. Silencer

15. Rear number plate

1. Rear Trafficator

2. Side panel RH

3. Side panel lock

4. Carburetor

5. Fuel tank

6. Fuel tank cap

7. Front Trafficator

8. Head light

9. Front number plate

10. Steering lock

1 2 3 4

5

6 7

8

9

1011121314

15

15


1 2 3 4 5 6

89101112

11. Rider foldable foot rest

12. Gear shift lever

6. Pillion back rest

7. Tail lamp

8. Pillion foot rest

9. Side Stand

10. Center Stand

1. Fuel tap

2. Side panel LH

3. Side panel lock

4. Seat

5. Side handle

7

16

Electric Start Switch

Depress gently to start Engine

OPERATION OF CONTROLS

Ignition switch

OFF

ON

17


Ignition Stop switch

OFF

ON

Head light switch

OFF

Pilot ON

Head lamp ON

18


Dimmer switch

High beam

Low beam

Day Flash

Turn signal switch

Left turn signal ON

OFF (Push to Cancel)

Right turn signal ON

19


Fuel tap

OFF

Main ON

Reserve ON

Fuel tank cap

Turn KeyClockwise toopen

Turn KeyAnti Clockwiseto close.

20

Steering lock

Unlock

No te :

Turn handle bar to extreme left, beforeattempting to lock steering.

Lock


Choke

ON

Pull the knob.

OFF

Push the knob.

Cau t i o n : Choke should be used only to start a cold

engine. Riding the motorcycle with thechoke ‘ON’ will result in engine runningerratic, high fuel consumption, loss ofpower & increased exhaust emission

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Horn

Depress


Side panel &Side decor

No te : Key is common for ignition, petrol tank cap,

steering lock, and side panel.

Key for fuel tank and side panel can beremoved from the lock only in lockedposition.

Cau t i o n : R o t a t e

t r i p m e t e rknob only inf o r w a r ddirection.

Tripmeter

N o t e :

The odometer records the total distancethe vehicle has been driven. The trip metercan be used to measure the distancetravelled on short trips or between fuelfillings.

Cau t i o n : Keep track of your odometer reading and

carry out the maintenance schedule regularlyfor appropriate services. Increased wear ordamages to certain parts can result in failureor loss in performance if the services are notadhered as per the schedule.

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Check for :

1. Adequate fuelava i labi l i t y asindicated by thefuel gauge.

2. Operation andfree p lay offront brakelever and rearbrake pedal.

3. Free play andsmoothness ofal l operat ingcables.

4. Free movementof steering

5. B a t t e r yelectrolyte level.

6. Any cuts, cracksin the tyre and correct tyre pressure.

PRE OPERATIONAL CHECKS

Min.

7. Brake fluid isabove theminimum levelin the mastercylinder

8. Oil levelbetween upper& lower markwhen engine iscold. Top up ifnecessary.

9. Operat ion ofal l e lect r icalparts.

Max.

23

RUNNING IN

The Thunderbird Twinspark, as you would beexperiencing, is capable of consistent highspeeds. However as with any new motorcycle,a “running-in” is essential during the first 2000kms to achieve opt imum performancesubsquently.

The following tips will help in proper beddingin of a new motorcycle.

1. During the first 2000Kms of run, do not

exceed the following speed limits.

2. Do not exceed maximum pay load asspecified.

3. Warm up the engine for a few minutes toallow oil for all engine parts before ridingthe bike.

4. Do not ride in constant throttle for longdistances. Vary the speed by 10%.

5. Avoid sudden revving and racing starts.

VehicleSpeed

GearFirst 500 kms 501 - 2000 kms

1 15 KMPH 20 KMPH

2 25 KMPH 30 KMPH

3 30 KMPH 40 KMPH

4 45 KMPH 55 KMPH

5 60 KMPH 70 KMPH

24

STARTING

Turn fuel tap to ‘ON’

Use choke if required (E.g. When startinga cold engine in winter when temperatureis below 20 degree centigrade).

Switch on ignition.

Ensure gears are in neutral

No te :

Neutral position is indicated by neutrallight on the cockpit.

To shift into neutral, move the motorcycleback and forth gently, while shifting thegear.

Cau t i o n : Attempting to shift gears without moving

the motorcyc le back and for th, maydamage gears.

25

STARTING

Using the Electric Start

Pull the clutchlever anddepress starterbut ton andre lease oncethe enginestarts.

No te :

1. It is recommended to “kick-start” the bikein cold weather, winter, or starting after along duration. This will enhance the life ofthe battery.

2. If the engine does not start, wait for 30seconds before depressing the starterbutton again.

Cau t i o n :

Please ensure that the gears are in neutralbefore starting the motorcycle.

Depress Starter button and release starterswitch once the engine starts.

A Clutch switch is provided in the systemfor the safety of the rider. When the vehicleis in gear, the vehicle cannot be started.Shift gear to neutral before attempting tostart the engine.If the engine has to be started with theMotorcycle in gear, depress clutch andthen depress the starter button to start theengine. Release starter button as soon asengine starts

Sl ight l y crankengine furthertill compressioneases over.

Start themotorcycle witha powerfulswinging kick.

Release thechoke, i fapplied.

Using Kick Start

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Warm up engine for 2 minutes - till idlingis consistent.

Release choke ifapplied

Pull clutch levertowards thehand grip.

Depress gearlever with toe toengage 1st gear.

GEAR SHIFTING, RIDING & STOPPING

Gently open throttle and release clutchsimultaneously. I f c lu tch i s re leasedsuddenly, the engine may stall and causethe motorcycle to move with a jerk.

To shift to 2 nd

and highergears, c loset h r o t t l e ,depress theclutch leverand press thegear lever withheel.

No te :

Gear shift lever is on the left side of themotorcycle.

To stop the vehicle, close throttle, apply frontbrake with right hand and rear brakes withright leg,gently. Shift gears into neutral beforethe motorcycle just comes to a complete stop.

Turn ignition switch to ‘OFF’ position.

Turn fuel tap ‘OFF’

27

PARKING

Parking vehicle on centre stand

Select a firm, flat surface.

Hold handle bar straight.

Lower centre stand, such that, both thelegs of the stand are rest ing on firmground.

Apply pressure on the fulcrum lever on thecentre stand and pull vehicle backward.

Parking vehicle on side stand

Select a firm, flat surface.

Extend side stand. Tilt the motorcycle tothe left, till it is supported firmly.

Warning :

Ensure both the stands are retracted fullybefore riding the motorcycle.

Please exercise extreme caution whenparking, and ensure the vehicle is parkedfirmly to avoid the motorcycle from fallingover which may cause injury to you andothers or damage to motor cycle parts.

28

1. Antiseptic cream 5 gms 1

2. Wash proof plaster 1.9 cm x 7.2 cm 2

3. Gauze bandage 5 cm x 2 cm 1

4. Sterilized Gauze Swab 5 cm x 5 cm 2

5. Sterilized elastic plaster 7 cm x 6 cm 1

6. Elastic Gauze bandage 8 cm x 1 mtr. 1

7. First aid kit pouch 1

TOOLS & FIRST AID KIT

1. Tool wallet 1

2. Tommy bar 1

3. Tubular spanner (16mm) 1

4. Tubular spanner (21 x 24mm) 1

5. Screw driver 1

6. Double end spanners :

(10 x 12 mm) 2

S.No. Description Qty.S.No. Description Qty.

1

57

2

4

36

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PERIODICAL MAINTENANCE

The maintenance schedule detailed here will help you maintain your Thunderbird Twinspark meticulously and to get a long trouble freeservice. The schedule provided herein is based upon average riding conditions and indicates the Kms at which regular inspections,adjustments, replacements and lubrications are to be carried out. The frequency of the maintenance must be shortened depending upon theseverity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorised servicecentre for expert advice and to carry out the required maintenance.

S.No. DESCRIPTION FREE SERVICE

Whichever is earlier PAID SERVICE

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30Months 1.5 3 6 9

1 Engine Oil R R R R R RCheck level every 500 Kms or earlier as required

2 Engine oil f i lter R C R C R C R C R C R3 Engine sump filter & Secondary drain magnet plug C C C C C C4 Spark plug - 2nos. A A A A A R A A A A R5 HT leads for crack I I I I I I I I I I I6 Air filter element C C C C R C C C R C C7 Carburetor Clean, Inspect and Tune8 Fuel Tap C C C C R C C C R C C9 Fuel tank C C C C C

10 Fuel hose I I I I R I I I R I I11 Accelerator cable play at throttle, TPS & Carburetor A A A A A A A A A A A12 Rubber hose, Air filter to Carburetor I I I I R I I I R I I13 Rubber hose, Inlet manifold I I I I R I I I R I I14 Inlet / Exhaust valve seating I I

30

PERIODICAL MAINTENANCE

S.No. DESCRIPTION FREE SERVICE

Whichever is earlier PAID SERVICE

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : ReplaceNote : For Maintenance after 30,000 Kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorised Service Centre.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30Months 1.5 3 6 9

15 Cylinder head D D16 Exhaust system D D17 Clutch free play Adjust every 1000 Kms or earlier as required18 Rear brake pedal pivot L L L L L L L L L L L19 Battery terminals (apply petroleum jelly) C C C C C C C C C C C20 Battery Electrolyte level I I I I I I I I I I21 Earth wire eyelet (behind battery carrier) I I22 Rear Drive Chain R R

Adjust every 1000 Kms. or earlier as requiredLubricate every 3000 Kms or earlier as required

23 Fork oil R RCheck level every 1000 Kms or earlier as required

24 Hand levers & kick starter pivot Lubricate every 1000 Kms or earlier as required25 Rear brake free play Adjust every 1000 Kms or earlier as required26 Rear brake cam L L L L L27 Steering ball races L L28 Spokes tightness I I I I I I29 Wheel rim run out I I I I I30 Tyre wear I I I I I I I I I I31 Hand levers & kick starter pivot Lubricate every 1000 Kms or earlier as required

31

RECOMMENDED LUBRICANTS

Caution : Use of Wrong grade oil can reduce the life of the moving parts and seriouslyaffect performance.

Note : Recommendation subject to change without notice.

* Common oil for Engine, Gear box & Clutch

Engine Oil

Grade MOTUL 3000 4 T Plus 15 W 50 API SL Grade

Capacity 2.75 Litres

Refil Qty 2.35 Litres

Front Fork Oil

Make 1F Grade Gabriel or Royal Enfield Fork Oil

Capacity 265ml/leg

Brake Fluid

Grade DOT 3 or DOT 4

Capacity 60ml

32

Cau t i o n : Use of wrong grade or spurious oil can

seriously affect motorcycle performance &damage to moving parts

DO IT YOURSELF

The following simple maintenance activities willhelp in maintaining your motorcycle. Howeverfor an elaborate maintenance, we recommendyou to get in done at a Royal Enfield AuthorisedService Centre.

Control Cables

Lubricate after usingthe motorcyc le inra in, af terwaterwash or if usedin dusty conditions.

Hand lever & Kickstarter pivots

Wipe the area free ofdirt / grease.

Apply a few drops ofoil on the pivots.

Centre / Side Stand Pivots

Apply a few drops of oil on the pivots aftercleaning the area of dirt.

Oil Level Inspection

Place motorcycle on its centre stand on afirm surface.

Warm upengine for afew minutes &swi tch offb e f o r echecking oi llevel.

The level iscorrect, i f theoi l level is inbetween the minimum & maximum markon cover RH.

Top up with recommended oil if required,top up as required.

Min.Max.

33

DO IT YOURSELF

Brake fluid

Check if oil is belowminimum level. Totop up, removecover anddiaphragm and topup with DOT 3 orDOT 4 as specified.

Inspection of tyres and wheels

Inspect the tyres periodically for tread wear,cracks and cuts.

Check and remove stone, splinters, nailsor other particles embedded in the tyretreads.

Bald spots / swelling may be caused byinternal damage. Replace the tyres, ifdefective.

Replace tyres when the tread depth hasreached the minimum as specified.

Periodically inspect wheels for spokesbreakage and wheel rim run out.

Check proper seating of the tyre beading onthe rim whenever the tyre is reassembled.

Whenever a new tyre is installed, ensure rimand spokes do not get damaged on accountof using wrong levers.

M i n i m u m t r e a d d e p t h :

Front tyre : 1mm Rear tyre : 2 mm

Spark plug

Cleaning and adjusting Plug gap

Two spark plugs (M10 & M14 sizes) areprovided in your vehicle

Remove spark p lug using the plugspanner and tommy bar which is providedin the tool kit.

Clean the insulator tip and electrodes ofthe plug carefully using a pointed scraperor spark plug cleaner.

Set the gap between 0.7 to 0.8 mm.

Refit the spark plug on the cylinder head.

Repeat the above procedure for thesecond sparkplug.

34

Remove the axlenut along withwasher.

Tap and removethe front wheelspindle

Tilt the vehicle toRH Side andtake out thewheel along with speedo drive and RH sidespacer.

Use only standard tyres & tubes inflatedto correct pressure.

Tyre pressure

Front

Solo 1.41 kg/cm2 (20PSI)

With Pillion 1.54 kg/cm2 (22PSI)

R e a r

Solo 2.11 kg/cm2 (30 PSI)

With Pillion 2.25 kg/cm2 (32 PSI)

DO IT YOURSELF

Front Wheel removal

Place the vehicle on center stand

Place a wooden block the front end ofengine tosuppor t thevehicle.

D i s c o n n e c tspeedo cable.

Loosen thepinch bolt on theRH fork guide.

35

ensuring that the brake disc is locatedbetween the brake shoes.

Insert and tap the front wheel axle gentlyinside.

Refit the washer and tighten the nut firmly.

No te :

Ensure that the speedo drive is correctlylocated such that the cable can beconnected without difficulty.

Tighten thepinch bolt on theRH fork guide.

Rotate the wheeland check forsmooth rotation.

Connec t thespeedo cable tospeedo driveand check for proper working of speedometer.

DO IT YOURSELF

Take out Speedo drive and bush on theRH side.

Place a 4 mm thick wooden piece orcardboard sheet between the brake shoesto avoid brake shoes getting locked.

Cau t i o n : Do not depress the front brake lever when

wheel is removed as this will result in brakeshoes getting locked.

Front Wheel Reassembly

Remove the wooden piece / card boardsheet placed between the brake shoes.

Place the speedo drive bush in positionand placespeedo driveover it.

Insert the wheelalong wi thspeedo driveand RH spacerbetween thefront fork ends

36

DO IT YOURSELF

Rear wheel removal

Place vehicle on center stand on a firmand flat surface.

Note and mark the position of the chainadjuster butting with the stopper on theright side.

Remove split pinand cast le nuton the RH side.

Remove wheelspindle from LHside along withchain adjuster,taking care notto drop thewheel collar and spacer from the LH sideof the wheel.

Tilt vehicle to RH side and slide out rearwheel.

Rear wheel reassembly Ensure the four cush rubbers are in

position inside the rear wheel hub. Ti l t vehic le to right and insert wheel

assembly between the swing arms.

Position the rear wheel with cush rubberon the rear chain sprocket.

Hold wheel collar and spacer in position.

Introduce the wheel spindle along withchain adjuster from the LH side of vehicleand gently tap it through the wheel.

Ensure that the mark on the chain adjusternotch butts with the stopper.

Tighten the castle nut firmly and ensurethat the hole on axle shaft and the slot oncastle nut are aligned to enable split pinfitment.

Fit the split pin.

Cau t i o n : Do not force the spindle into the wheel as

the threads may get damaged. Tap itthrough the wheel gently.

37

Check free play of 2-3 mm at clutch leveron handlebar end.

Tighten lock nut (A) after adjustment iscomplete.

DO IT YOURSELF

Adjustments

Clutch cable (play 2-3 mm)

a. Clutch Play Adjustment

Loosen lock nut(A)

Turn the nut (B) clockwise to reduce playOR anticlockwise to increase the play.

AB

Warning :

Please ensure brakes are adjusted to theirmaximum efficiency. Inefficient brakes cancause an accident.

b. Pedal Play adjustment (Play 25 - 30mm)

Turn in or out the adjuster nut for correctpedal play.

38

Adjustment of rear gas shock absorber

The rear gas shock absorber is ofadjustable type i.e., the spring tension canbe increased orreduced.

Increase thespr ing tens ionfor high loadoperation.

Reduce thespr ing tens ionfor low loadoperation.

The adjusterprovided on thebottom of the spring has five notches. Insert 8mm tommy bar into the eyelet

provided on the adjuster. Turn the adjuster such that the adjuster

moves up to increase the spring tensionand vice versa to reduce the spring tension.

Adjust both left hand and right hand shockabsorbers so that the same notch rests onthe pin in both.

Warning : Riding the motorcycle with the notches

adjusted in different positions can causeloss of control and may lead to onaccident.

DO IT YOURSELF

Drive Chain tension (play 25 - 30 mm)

Remove rear wheel split pin.

Loosen castle nut, spindle nut, anchor nutand brake rod nut.

Turn theadjuster camson both s ides,till 25 to 30 mmslackness isachieved.

Cau t i o n :

Please check and adjus t Drive chaintension for every 1000 kms.

Check and ensure that the number ofnotches from the punch mark on the camto the notch resting on the pin are equalon both sides.

Apply brake and tighten all nuts.

39

DO IT YOURSELF

Removal of Battery from the Vehicle

Remove the LH side panel.

Disconnect both the terminal wi res(negative and positive)

Remove bracket.

Take out battery.

Visually check for

Electrolyte level

Battery Maintenance

The vehicle isprovided wi th12V - 14 AHm a i n t e n a n c efree battery.

The bat terymust bep e r i o d i c a l l ychecked for

Cleanl iness and corrosion f reeterminals.

Electrolyte level

If electrolyte level is low, top up withdistilled water.

No te :

For checking the battery voltage andelect ro ly te speci f ic gravi t y, contactauthorised battery service centre.

40

Changing Electrical Components

Head Lamp bulb

Remove theh e a d l i g h tholding screw atthe bottom of thehead lamp andremove sealedbeam.

Disconnect thecoupler.

Remove the rubber grommet. Press and unlock the spring holder. Remove halogen bulb. Position new bulb inside the sealed beam such

that the projection on the bulb shoulderaligns with the slot on the sealed beam.

Position bulb holder on top of the bulbensuring that the 3 locators align with sealedbeam.

Press spring and lock its dip in the holder. Fit the rubber grommet. Fit the electrical coupler on the bulb. Position sealed beam on to the head lamp

shell and tighten the mounting screw.

DO IT YOURSELF

Reassembly of Battery on Vehicle

Position the battery in the battery carriersuch that the negative terminal of thebattery is towards fuel tap.

Connect the positive terminal (Red wire).

Connect the negative terminal (Black wire).

Smear the terminals with petroleum jelly.(Do not use grease).

Refit the bracket to hold the battery.

Refit LH side panel.

Cau t i o n : Do not use battery with low electrolyte level

as the battery internals will get damaged.

Do not overfill the battery electrolyte as itwill spill of through the over flow pipe andcause corrosion to vehicle parts.

Use only distilled water meant for use inbatteries to avoid damage to battery.

Clean the wire terminals free of corrosionand keep the terminals coated wi thpetroleum jelly.

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DO IT YOURSELF

Fuse

Open the LHSide panel

There are twofuse boxavailable. Fusebox with 15A isfor battery mainand 10A for TCIignition

Open the fusecarrier

Replace the required fuse with the sparefuse available in the fuse carrier and closethe LH side panel.

Tail Lamp bulb

Remove the tail lamp cover screws.

Depress and turn bulb anticlockwise toremove bulb.

Position the newbulb onto theholder ensuringthat the pins onthe bulb matchwith the holder

Press bulb andturn it clockwise.

Fit the tail lampcover.

Note: Please ensure to replace a spare fusein the holder at the earliest oppurtunity.

Trafficator bulb

Remove thescrews & take outtrafficator glasscover.

Press bulb gently& Turn ant i-clockwise to takeout the bulb.

Position the new bulb inside holder, ensuringthat the pins in the bulb, match with the slotsin the holder.

Gently press the bulb and turn clockwise tolock the bulb in the holder.

Refit the trafficator cover and screws,ensuring the lense slot / cut mark facingdownwards.

42

WASHING PROCEEDURE

Rinse vehicle thoroughly with plain waterto remove the detergent and wipe vehicledry.

If possible, use compressed air and blow offwater particles from the obscure areas of thevehicle, electrical connections, etc.

After washing

Ensure, the vehicle is thoroughly dry bywiping with a clean soft absorbent clothor chamois leather.

Remove all plastic bags and adhesive tapes.

Lubricate control cables, pivot and rear chainwith lube oil

Polish the painted and plated surfaces usingpolishing wax.

Start engine and allow to run at idling speedfor a few minutes to warm up engine.

Drive the motorcycle slowly, applying bothbrakes intermittently to dry up the brakeshoes.

Test brakes for full efficiency.

Precautions

Wash vehicle when the engine is cold.

Cover the silencer, tail pipe, carburetorand control switches with suitable plasticbags and tie it firmly to prevent water entryto them.

Remove ignition key and seal key hole usingadhesive tape.

Brush engine area with kerosene / diesel toremove dirt or grease.

Use low pressure jet of water to clean thevehicle or engine.

Never spray water with great force on headlamp, speedometer, flasher lights, front andrear wheel hubs, electrical connections andwires, control cables, carburettor, sparkplug,battery etc.

Do not apply kerosene or diesel on paintedparts or rubber parts.

Use luke warm water and mild detergent onthe painted components to remove dirt, etc.

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STORAGE PRECAUTIONS

Incase your Motorcycle is not going to be usedfor a month or more, we advice the followingprecautions to the taken.

Carryout required repair / adjustments onthe motorcycle.

Wash the motorcycle thoroughly andlubricate as per the maintenance chart.

Drain fuel tank, fuel line and carburettor.

Keep the fuel tap in closed position and spraymotor oil inside the fuel tank to preventrusting.

Remove spark plug. Pour in about 50ml ofclean engine oil through spark plug hole.Close the hole and crank engine severaltimes and refit sparkplug.

Clean rear chain thoroughly and apply athin film of lub oil.

Remove battery from the bike. Clean theterminals free of corrosion.

Maintain electrolyte level between max. ormin. mark, by adding distilled water andwipe the battery dry.

Store the battery in a cool, dry and wellventilated place.

Do not place the battery in direct sun light,near open flame or where temperature isabove 40oC or below 0oC

Cover the silencer with plastic bags to preventmoisture entry. Set the motorcycle on itscenter stand.

Apply a thin film of oil on the engine barrelfins, cylinder head fins and other paintedparts.

Apply anti-rust solutions on all platedparts. Take care not to apply this solutionon rubber or painted parts.

Store motorcycle in a clean covered area freeof moisture and keep it covered to preventdust settling on it.

44

STORAGE PRECAUTIONS

Preparing the motorcycle for reuse

Remove the anti-rust solution from allplated parts and clean the motorcyclewell.

Inflate the tyres to the correct tyre pressure.

Ensure battery is fully charged and properelectrolyte level is maintained.

Connect the battery.

Lubricate all control cables and pivots.

Check proper level of oil in engine.

Clean and remove the motor oil from tankand fill tank with fresh petrol.

Clean carburetor and air filter.

Remove plastic covering from the silencer.

Remove spark plug on cylinder head andpour in a few drops of engine oil. Crankengine a few times to lubricate cylinder wallsand piston. Clean spark plug and refit.

Switch on ignition switch.

Start vehicle and warm up engine for a fewminutes before riding the vehicle.

No te :

Do not raise the engine rpm the moment it isstarted, allow the engine to run at idlingspeed.

45

LONG TRIP PRECAUTIONS

Checks prior to the commencement of longjourney

Service the motorcycle thoroughly a RoyalEnfield authorised service centre as perperiodical maintenance chart.

Sufficient quantity of petrol in the fuel tankfor the journey planned.

Correct tyre pressure.

Checks after every 1500 kms of run

Tightness of all fasteners.

Tyre tread condition and wear of tyres.

Battery condition and electrolyte level.

Correct level of oil in engine, front forkand break.

Working of all lights and horn.

Proper chain tension.

Items to be carried

Tool kit

First aid kit.

Bulbs for headlight, trafficator light, reartail lamp and fuse (15Amps & 10Amps).

Accelerator, clutch, front brake.

Rear chain link lock assembly.

Spare tube, tyre puncture repair kit - coldvulcanising type.

Foot operated air pump.

Insulation tape.

Spark plug, spark plug cap, fuel hose.

46

CARING FOR MILEAGE

Stop the drop that leaks

Petrol leak at a rate of one drop per minuteaccumulates to 5,25,600 drops a YEAR!That is, 35 ltrs of Petrol.

Petrol leaks cause raw petrol smell. Get theleaks arrested immediately.

Use recommended fuels and oils only

Wrong grade or adulterated petrol doesnot burn fully and results in heavy smoke,high rate of carbon deposition in cylinderand exhaust system and low mileage.

Wrong grade and inferior quality oils donot lubricate well. The moving parts wearprematurely.

Always use recommended fuel (unleaded> 87 octane petrol) and oils only.

Ride at cost effective speed

Cost effective speed (in top gear) is 45 to50 Km per hour.

Both lower and higher road speeds causelow kilometers per litre of petrol.

Perform preventive Maintenance as perrecommendationsRegular preventive maintenance ensures :

Correctly inflated tyres.

Fasteners tightened to correct torques.

Freely moving engine & t ransmiss ioncomponents.

Properly tuned and adjusted engine.

Cut off needless low idlingTen minutes of low idling wastes 70 ml. ofpetrol. So cut off the engine when you knowyou have to wait for one minute or more.

Stop

Revving : Ten revvings wastes 20 ml.of petrol

47

Rac ing s ta r t s : Ten racing startswastes 150 ml. of petrol.

Sudden a cce le ra t ion : Tensudden accelerations wastes 100 ml. ofpetrol.

Stop brake riding

Brake riding pushes the brake shoes /pads to come in contact with revolvingdrum / disc. To overcome the resultingfrictional load, engine burns additionalpetrol.

Result : Low mileage, loss of power, fasterwear of brake shoes / pads and drum /disc.

Never clutch ride

Clutch riding slips the clutch & engine drivedoes not get totally transferred to the rearwheel. Besides low mileage, clutch ridingends up with burnt friction plates of clutch,loss of power and engine overheating.

Avoid frequent braking

Braking arrests the road speed. Motorcyclemomentum is reduced. Additional fuel isburnt for subsequent acceleration.

For better mileage, use front and rearbrakes only when absolutely needed.Control vehicle speed with throttle andgear like smart riders always do.

Avoid over loading

Over loading tires the engine, wears theparts faster and reduces mileage.

Park your vehicle in shade when not in use

Petrol is highly volatile. It evaporates undernormal atmospheric temperature. Theevaportion increases with temperature.Prevent this loss by always parking yourvehicle under shade.

Too few Kms. running per day allows moretime for evaporation affecting the mileage.

CARING FOR MILEAGE

48

Complete Circuit

WIRING DIAGRAM

49

TROUBLE SHOOTING

I. Engine fails to start

1) Ignition switch in ‘OFF’ Position .......................... Switch on ignition.

2) Stop switch in ‘OFF’ Position ............................... Push stop switch to ‘ON’ position.

3) Clogged fuel line / tap ........................................ Clean the fuel line / tap.

4) Vent hole clogged in fuel tank cap ..................... Clean vent hole.

5) Carburetor passage & jets blocked ................... * Dismantle carburetor & clean jets............................................................................ / passages

6) Carburetor float stuck in closed position ............ Ensure correct movement of float

7) Spark plug cap / lead not connected ................. Fix cap / lead firmly

8) Loose HT connections ......................................... Fix connections firmly

9) HT Lead Damaged ............................................. * Replace HT Lead

10) Spark plug electrode dirty / fouled ........................ Clean spark plug & Reset gap.

11) Spark plug insulation cracked ............................... Replace spark plug

12) Poor compression :

- Auto Decompressor not working .......................... * Ensure free motion of flyweight in exhaust............................................................................ cam gear assembly

- Loose spark plug ................................................ * Tighten spark plug.

13) Clutch slipping .................................................... * Adjust clutch cable free play

* Contact Dealer / Authorised Service Centre

Causes Remedies

50

TROUBLE SHOOTING


Causes Remedies

II. Engine misfiring

1) Water in petrol tank/carburetor ........................ * Clean carburetor / petrol tank. Filltank ..................................................................... with fresh petrol.

2) Leak through intake hose ................................... Tighten rubber hose suitably............................................................................. Replace if necessary

3) Loose spark plug cap .......................................... Fix cap / lead firmly

4) Spark plug fouled/insulation broken .................. Clean / reset gap or, replace.

5) Poor Compression ............................................. * Refer 1 - 12

III. Engine starts, but runs irregularly & stops

1) Faulty fuel supply ............................................... Clean the fuel line / tap / vent hole

2) Very low idling speed ........................................... Increase idling speed

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TROUBLE SHOOTING

IV. Poor pickup

1) Accelerator cable free play excessive .................. Adjust cable free play

2) Faulty fuel supply ................................................. Clean the fuel line / tap / vent hole

3) Choked air filter .................................................. Clean / Replace air filter

4) Loose carburetor mounting ................................. Tighten clamps firmly

5) Brakes adjusted too tight .................................. * Re-adjust properly

6) Rear chain adjusted too tight ............................ * Re-adjust properly

7) Clutch Slipping .................................................. * Adjust clutch cable free play

8) Under inflated tyres ........................................... * Inflate to correct pressure

V. White/blue smoke

1) Oil level in tank is above the max. mark in the .... * Check and drain excess oil

oil level window


Causes Remedies

52

TROUBLE SHOOTING


VI. Engine overheating

1) Cylinder fins not clean .......................................... Clean the cylinder fins at............................................................................ regular intervals

2) Clutch slipping ................................................... * Check and correct

3) Suction / intake air leakage .............................. * Check and correct

4) Incorrect carburetor adjustments ..................... * Check and correct

VII. Excessive fuel consumption

1) Fuel leakage ...................................................... * Check and rectify

2) Worn out carburetor jets ................................... * Change the defective jets

3) Incorrect carburetor adjustments ..................... * Check and adjust correctly

4) Choked air filter ................................................... Clean / Replace

5) Poor compression ................................................. Refer I - 12

6) Under inflated tyres .............................................. Inflate to correct pressure

Causes Remedies

53

VIII. Ignition knock

1) Carburetor adjusted too lean ........................... * Check and readjust

2) Suction leakage .................................................. * Check and correct

IX. Brakes poor

1) Not adjusted properly ......................................... * Adjust properly

2) Oil / grease on lining or disc ............................ * Clean and refit

3) Linings worn / Uneven wear .............................. * Replace linings

X. Vehicle wobbles

1) Wheel rim runout .............................................. * Rectify

2) Loose / Broken spokes ........................................ * Tighten / Replace spokes

3) Tyres not fitted correctly ....................................... * Refit tyres correctly

4) Wheels misaligned ............................................. * Ensure proper alignment

5) Under inflated tyres .............................................. Inflate to correct pressure

Causes Remedies

TROUBLE SHOOTING


54

TROUBLE SHOOTING


Causes Remedies

XI. Electricals

Bulbs do not light

1) Loose / improper connection ............................ * Check and correct

2) Bulb fused .......................................................... * Replace bulb

3) Fuse blown ......................................................... * Replace fuse

4) Switch defective .................................................. * Replace switch

Horn not working

1) Loose connections .............................................. * Check and correct

2) Requires tuning ................................................... * Tune horn

3) Switch Defective .................................................. * Replace

Trafficators not working

1) Loose / improper connections ............................... Check and correct

2) Bulb fused ............................................................ Replace

3) Switch defective .................................................. * Replace

4) Flasher defective ............................................... * Replace

55

Causes Remedies

TROUBLE SHOOTING


Brake light remains on

(1) Switch not adjusted properly ............................... * Adjust switch properly

(2) Switch sticky ....................................................... * Replace switch

XII. Electric Start

Vehicle not starting

(1) Neutral indicator not glowing ................................ Bring the vehicle in neutral

(2) If vehicle is without neutral indicator ...................... Press the clutch lever & start switch together

(3) Loose Connection ................................................. Check & Correct

(4) Starter relay not working ....................................... Check & Replace

(5) Malfunctioning of clutch switch ............................. Check & Replace

(6) Malfunctioning of Starter switch ............................. Check & Replace

(7) Battery discharge .................................................. Check & Recharge

(8) Motor not working ................................................ Check & Replace

(9) Battery not fully charged ....................................... Check & charge

(10)Failure of sprag clutch .......................................... Check & replace

56

WARRANTY TERMS AND CONDITIONS

Royal Enfield Motor Cycles are manufactured following best Quality practices in respect of thematerial and workmanship.

Royal Enfield (RE) warrants Thunderbird Twinspark motor cycle to be free from manufacturingand material defect under normal use subject to following conditions.

1. RE will replace or repair defective part / parts at their authorised Dealers, Service point,free of charge within a period of 12 months from the date of sale (date of Installation) or10,000 kms whichever occurs earlier.

2. The warranty is applicable only to first registered owner.

3. The warranty shall be applicable only if all the free services are availed at the respectiveperiod / kilometer range as per the schedule given in the owner’s manual from RE Dealers/authorised service points.

4. During the warranty period, RE’s obligations shall be limited to repairing / replacing freeof charge such part or parts of the vehicle, which on examination to have manufacturingdefect. Such defective part / parts which have been replaced become property of RE.

5. Cost of oil, oil filter, fuel and other consumables are chargeable to the customer.

6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken upwith respective manufacturer or their authorised agents in the area directly by customer.RE shall not be liable in any manner to replace them though their Dealers will provideassistance in preferring such claims on their manufacturer.

7. Warranty shall not apply to:

(a) Normal ageing, detoriation or rusting of plated parts paints coat, rubber parts, softitems, glass items, plastic parts etc.

57

WARRANTY TERMS AND CONDITIONS

(b) Components like fuel filter, oil filter element, control cables, brake pads, brake shoes,clutch plates, which are subjected to normal wear and tear.

(c) Damages due to use of lubricant / oil / grease etc. other than specified by RE.

(d) Damages due to use of non-genuine parts.

(e) Damages due to lack of proper maintenance of the vehicle.

(f) Damages due to incorrect driving or riding habits.

(g) Parts damaged due to accidents, collision, abuse etc.

(h) Irregularities not recognized as affecting the quality or function of the vehicle such asslight vibration, oil leakage, blue discoloration of exhaust bent pipe / silencer, soft /hard shock absorber etc.

(i) Defects arising from fitment of unauthorised / additional Electrical loads.

(j) Vehicle serviced / repaired at unauthorised service points.

(k) Vehicle used for competition / racing.

(l) Electrical component likes bulbs, fuses etc.

(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, enginetune up and other such adjustments

8. RE reserves the right to finally decide on all warranty claims

9. RE reserves the right to make changes in Design of the vehicle without any obligation toinstall these changes on previously supplied vehicles.

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In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, RoyalEnfield certifies that the following warranty is applicable to those components liable to affect theemission of the gaseous pollutants in its range of motorcycles, in normal use to which it may besubjected to.

This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000Kms. or 36 months, whichever occurs earlier, from the date of sale to the first customer and is inaddition to and parallel to the warranty policy, conditions and obligations laid down in the Owner’sManual.

Royal Enfield further warranty that if on examination by its authorised service center, the motorcyclefail to meet the specified emission standards, then the authorised service center shall take necessarycorrective measures and shall at its sole discretion, repair or replace free of charge such componentsof the emission control system to meet the required emission standards.

The method/s of examination to determine the warranty conditions of the emission warranty relatedcomponents will be at the sole discretion of Royal Enfield and / or our authorised service centersand results of such examination will be final and binding. If on examination the warranty conditionsof the part/s is/are not established, Royal enfield will have the right to charge all, or part of thecost of such examination to the customer in addition to the cost of the components.

In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace freeof charge, the component/s as required. However, the consumables like fuel, lubricants, solvents,etc shall be chargeable to the customer as per actuals.

In case any of the components covered under emission warranty or the associated parts, are notindependently replaceable, Royal Enfield will have the sole discretion to replace either the entireassembly or parts of the assembly, through suitable repairs.

EMISSION WARRANTY

59

EMISSION WARRANTY

Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycleor replace any part, in addition to the repair or replacement of the components covered underemission warranty, to establish compliance to in-use emission standards. Such repairs /replacements will be chargeable to the customer.

All parts removed for replacement under warranty will become the property of Royal Enfield.

Royal Enfield will not be responsible for the cost of transportation of the motorcycle to thenearest authorised service center OR for any loss due to non availability of the motorcycleduring the period of examination and repairs by Royal Enfield and / or their Authorised Servicecentres.

Royal Enfield will not be responsible for any penalties that may be charged by statuatoryauthorities on account of failure to comply with the in-use emission standards.

That cost’s incurred to check emission of the motorcycle will have to be borne by the customer.

Emission warranty will be applicable irrespective of the change of ownership of the vehicleprovided all the conditions as laid down in this document are met from the date of original saleof the motorcycle.

The warranty shall apply if the customer :

Observes all the important instructions and any other precautions listed in the owner’smanual.

Under all circumstances uses lubricants and fuel as recommended by Royal Enfield.

60

Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelinesand enters the details in the Log book.

Immediately approaches the nearest authorised service centre upon discovery of failure tocomply with the IN-USE emission standard inspite of having maintained and used the vehiclein accordance with the instructions in the owner’s manual and having carried out suchrepairs and adjustments as may be required with a view to establish such compliance.

Produces the ‘Pollution Under Control’ certificate valid for the period immediately precedingthe test during which the failure is discovered, the test having been carried out either forobtaining a new certificate or pursuant upon being directed by an officer as referred to insub rule (2) of rule 116 of the Central Motor Vehicles Rules.

Produces the owner’s manual and Log book for verification details.

Produces receipts covering maintenance of the motorcycle is specified in the owner’s manualfrom the date of original purchase of the vehicle.

Produces valid certificate of Insurance and R T O registration certificate.

The Emission warranty shall not apply IF :

A valid “Pollution under control” certificate is not produced.

The motorcycle is not serviced by authorised service centers as per the service scheduledescribed in the maintenance chart.

EMISSION WARRANTY

61

EMISSION WARRANTY

The motorcycle has been subjected to abnormal use, abuse, neglect and impropermaintenance or has met with an accident.

Replacement parts not specified and approved by Royal Enfield have been used.

The motorcycle, or parts thereof, has been altered, tampered with or modified or replacedin an unauthorised manner.

The odometer is not functioning or the odometer and / or its reading has been changed /tampered with, so that the actual distance covered cannot be readily determined.

The motorcycle has been used for competitions, races, and rallies or for the purpose ofestablishing records.

On examination by Royal Enfield or its authorised service centers, if the motorcycle showsthat any of the conditions stipulated in the Owner’s manual with regard to use andmaintenance have been violated.

The motorcycle has been run on adulterated / leaded fuel or lubricant other than thosespecified by Royal Enfield in the Owner’s manual or any other document given to thecustomer at the time of sale of the motorcycle.

The emission related components are tampered with.

All service and parts related bills and vouchers incurred during the tenure of the emissionwarranty is not produced.

All maintenance activities carried out on the vehicle during the tenure of the emission

62

warranty is not entered in the log book.

Tips to be on the right side of Law

Always get your vehicle checked to meet the emission regulations through and authorisedemission checking center.

Always carry a valid ‘Pollution Under Control’ certificate with you at all times during thevalidity of the emission warranty (30,000 Kms / 3 years from the date of first sale)

Tips to reduce pollution

1. Ensure that the periodical maintenance is carried out as stipulated in the owner’s manualthrough a Royal Enfield authorised service center.

2. Use only Unleaded fuel (> 87 octane petrol) from reputed fuel pumps.

3. Ensure the fuel used is not adulterated.

4. Use correct spark plug as recommended in the owner’s manual.

5. Use lubricants as per recommendations given on grade / brand in the owner’s manual.

EMISSION WARRANTY

Royal Enfield, A Unit of Eicher Motors Limited, Tiruvottiyur High Road, Tiruvottiyur, Chennai - 600 019.Ph :+91-44-4223 0400. Fax : +91-44-4201 1719 Website : www.royalenfield.com

Documents

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