ROYAL ENFIELD Classic 500&350 Illustrated Parts manual

Spare Parts Catalogue Classic 500 & 350

1 Foreword We take pleasure in releasing CLASSIC 500 & 350 Spare Parts Catalogue. The Catalogue has been specially designed for selection of correct part number to maintain the vehicle, for its optimum performance, longer life and for enjoying the best running condition. The Royal Enfield Spares are manufactured under stringent quality control to ensure ultimate riding experience. It is therefore important to use only Royal Enfield Genuine Spares. Due to continuous improvement on performance and efficiency of the vehicle, since this catalogue was printed, it is possible some illustration, designs etc., found within this catalogue may differ from those found on the vehicle. Such modification will be conveyed through our Technical Service Bulletins, you are requested to update with the correct part numbers in this catalogue. SERVICE HEADQUARTERS : SERVICE HEADQUARTERS : SERVICE HEADQUARTERS : SERVICE HEADQUARTERS : SERVICE HEADQUARTERS : ROYAL ENFIELD ROYAL ENFIELD ROYAL ENFIELD ROYAL ENFIELD ROYAL ENFIELD (A Unit of Eicher Motors Limited) Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India. Tel : +91-44-4204 3300, Fax : +91-44-4201 1719. Website : www.royalenfield.com E-mail : customerservice@royalenfield.com “ © Copyright 2006 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Service technical manual shall be copied, distributed or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of this manual .”

2 03-30 FUEL TANK A1 Key Nos. 17, 18, 19 Alpha-Numeric Key No. for assy. Key No. Which make up the assy. Numeric Key No. Group No. For easy reference and quick identification, the parts are grouped into relevant categories. Details are given in the illustrated Group index. Tips on usage of this catalogue ILLUSTRATION Helps in identifying the shape of the part in its relative assembly.

3 1 2 3 4 5 Key No. Part Number Description Qty. Remarks 1. KEY NUMBER (KEY NO.) The numeric key number is provided to serve as the identification of the part with its part number. Serviceable assemblies or kits in a particular group are identified by alpha-numeric key numbers. e.g. A1, A2 etc. In such cases, key numbers of individual items or group number which make up such assembly / kit are given in illustration. 500EFI 350cc Part Number List

4 2. PART NUMBER The Part number of the individual item, kit OR the assembly is given in this column for unique identification. The parts for which part numbers are not given, are not individually serviced. 3. DESCRIPTION The description of the part assigned to the individual item kit / assembly is mentioned in this column. 4. QUANTITY The number of individual items, kits or assemblies required for one vehicle is mentioned here. Though quantity is indicated for oversize (O/S) or undersize (U/S) of some items, it is to be understood that for a vehicle the sizes only is applicable, depending upon the repair / matching requirements. 6. REMARKS For Reference purpose. Part Number List

5 Group No. Description Page No. 01-10 ENGINE ..................................................................... 13 01-15 CRANK CASE LH - COVER SIDE ............................. 15 01-20 CRANK CASE RH - COVER SIDE ............................. 19 01-25 CRANK CASE LH ...................................................... 25 01-30 CRANK CASE RH ...................................................... 27 01-45 CYLINDER & HEAD ASSEMBLIES .......................... 31 02-10 ENGINE COVER LH ................................................. 35 02-20 ENGINE COVER RH ................................................. 37 02-30 CLUTCH ..................................................................... 41 02-40 GEAR TRAIN ASSEMBLY ........................................ 43 03-10 SILENCER & EXHAUST PIPE .................................. 45 03-20 EFI COMPONENTS IN CYLINDER HEAD ................ 47 03-30 TCI & IGNITION COMPONENTS .............................. 49 03-40 CV CARBURETOR .................................................... 51 03-50 FILTER BOX ASSEMBLY (CLASSIC 500) ................. 55 03-50 FILTER BOX ASSEMBLY (CLASSIC 350) ................. 57 03-60 FUEL TANK (CLASSIC 500) ..................................... 59 03-60 FUEL TANK (CLASSIC 350) ..................................... 61 04-10 FRAME & PAV COMPONENTS ................................ 63 04-20 SEAT ASSEMBLY ...................................................... 69 04-30 CENTER STAND ....................................................... 71 05-10 HANDLE BAR & CONTROLS ................................... 73 05-20 CONTROL CABLES ................................................... 75 05-30 CALIPER ASSEMBLY ............................................... 77 05-40 MASTER CYLINDER ASSEMBLY ............................. 79 06-10 HEAD LAMP CASING ............................................... 81 06-20 FRONT FORK ........................................................... 85 06-30 SWING ARM ASSEMBLY .......................................... 87 06-40 REAR SHOCK ABSORBER ....................................... 89 07-10 BRAKE PEDAL ......................................................... 91 07-20 REAR CHAIN ............................................................ 93 07-30 FOOT RESTS ............................................................. 95 08-10 FRONT WHEEL ......................................................... 97 08-20 REAR WHEEL ........................................................... 99 09-10 REAR BRAKE ......................................................... 103 10-10 FRONT MUDGUARD .............................................. 105 10-20 REAR MUDGUARD ................................................. 107 11-10 BATTERY AND HARNESS ..................................... 111 11-20 SWITCHES, HORN & RELAYS ............................... 113 11-30 WARNING INDICATOR, AMMETER & SPEEDOMETER 115 11-40 HEAD LAMP ........................................................... 117 11-50 TAIL LAMP ............................................................. 119 11-60 TRAFFICATOR LIGHTS .......................................... 121 12-10 TOOL BOX (ELECTRICALS BOX) LH ..................... 123 12-20 UTILITY BOX .......................................................... 125 12-20 RESONATOR BOX & COVER ................................. 127 12-30 BATTERY CARRIER ............................................... 129 13-10 TOOL KIT ................................................................ 131 14-10 SPECIAL TOOLS LIST ............................................. 133 Group No. Description Page No. Group Index

6 Group Index - Pictorial 01-10 ENGINE 01-15 CRANK CASE LH - COVER SIDE 01-20 CRANK CASE RH - COVER SIDE Page 12 01-25 CRANK CASE - LH 01-30 CRANK CASE RH 01-45 CYLINDER & HEAD ASSEMBLIES 02-10 ENGINE COVER - LH 02-20 ENGINE COVER - RH 02-30 CLUTCH Page 14 Page 18 Page 24 Page 26 Page 30 Page 34 Page 36 Page 40

7 Group Index - Pictorial 02-40 GEAR TRAIN ASSEMBLY Page 42 03-10 SILENCER & EXHAUST PIPE Page 44 03-20 EFI COMPONENTS IN CYL. HEAD Page 46 03-30 TCI & IGNITION COMPONENTS 03-40 CV CARBURETOR Page 48 Page 50 03-50 FILTER BOX ASSY. (CLASSIC 500) Page 54 03-50 FILTER BOX ASSY. (CLASSIC 350) 03-60 FUEL TANK (CLASSIC 500) Page 56 Page 58 03-60 FUEL TANK (CLASSIC 350) Page 60

8 Group Index - Pictorial 04-10 FRAME 04-20 SEAT ASSEMBLY Page 62 Page 68 04-30 CENTER STAND Page 70 05-10 HANDLE BAR & CONTROLS 05-20 CONTROL CABLES Page 72 Page 74 500 350 05-30 CALIPER ASSEMBLY Page 76 05-40 MASTER CYLINDER ASSEMBLY 06-10 HEAD LAMP CASING Page 78 Page 80 06-20 FRONTFORK Page 84

9 Group Index - Pictorial 06-30 SWING ARM ASSEMBLY 06-40 REAR SHOCK ABSORBER Page 86 Page 88 07-10 BRAKE PEDAL Page 90 07-20 REAR CHAIN 07-30 FOOT RESTS Page 92 Page 94 08-10 FRONT WHEEL Page 96 08-20 REAR WHEEL 09-10 REAR BRAKE Page 98 Page 102 10-10 FRONT MUDGUARD Page 104

ROYAL ENFIELD Classic 500&350 Illustrated Parts manual

You're Reading a Preview

Recently Viewed