2009-2021 Royal Enfield Classic 350/Classic 500 Service & Repair Manual
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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 ........................................ 15
Pre-Operational Checks ..................................... 20
Running in Period ............................................. 22
Starting ............................................................... 23
Starting & Gear Shifting .................................. 24
Riding, Stopping & Parking ............................. 25
Parking ............................................................... 26
Tools & First aid kit .......................................... 27
Periodical maintenance ..................................... 28
Recommended lubricants .................................. 31
Do it yourself ..................................................... 32
Washing procedure ............................................ 49
Storage precautions .......................................... 50
Long trip precautions ....................................... 52
Complete Wiring diagram ................................. 53
Trouble shooting ................................................ 54
Warranty terms and conditions ....................... 62
Emission Warranty ........................................... 64
Log Book ............................................................ 69
Free Service coupons ......................................... 70
Paid Service / Maintenance Record
All India Road Signs
Notes
Annexures
Vehicle Installation Form
Pre-Delivery Inspection Report
Bike Installation Confirmation By Customer
Form 22
Contents
4
Personal & Vehicle Information
Vehicle Installation Form (VIF) No.
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
5
It is our endeavour to provide excellent service to your Classic 350 at all times. Towards this we provide
4 free services at specific Intervals.
Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service
Point nearest to you and as a token of satisfactory services, kindly return the free service coupon duly
filled in and signed, to the service outlet.
Availing the free services in the specified time is a prerequisite for warranty consideration.
The cost of fuel, oil, grease etc. used for all free services are chargeable to the customer.
NOTE : Please ensure that the free service details are recorded in this sheet immediately after the service
is carried out.
Date of Service
Kms Covered
Servicing
Dealer’s Name
Address
1
st
Service 4
th
Service 2
nd
Service 3
rd
Service
Free Service Record
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
6
ENGINE
Engine Type ................... 4 Stroke, OHV, Dual
........................................ Spark Ignition, air
........................................ cooled, single Cylinder
Bore ................................ 70mm
Stroke ............................. 90mm
Swept volume ................. 346cc
Compression ratio ......... 8.5:1
Max Power @ rpm ......... 19.8 BHP @ 5250 rpm
Max Torque @ rpm ........ 28 Nm @ 4000 rpm
Idle rpm .......................... 1050±200 rpm
Starting .......................... E’Start / Kick Start
Air filter element ........... Paper element
Carburettor .................... Ucal - BS 29
Lubrication .................... Wet Sump
........................................ Forced lubrication
Engine oil capacity ....... 2.75 lits
Engine oil grade ............ Royal Enfield 15W50 API
........................................ SL Engine Oil (JASOMA)
FD Sprocket ................... 16 Teeth
Rear Wheel Sprocket ..... 38 Teeth
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 ....................... 1
st
- 3.06 : 1
........................................ 2
nd
- 2.01 : 1
........................................ 3
rd
- 1.52 : 1
........................................ 4
th
- 1.21 : 1
........................................ 5
th
- 1 : 1
Secondary drive ............. 5/8” Chain & Sprocket
Secondary ratio ............. 2.375 : 1
Drive Chain links .......... 100 links
Specifications
7
CHASSIS
Frame ............................. Tubular
Suspension : Front ........ Telescopic, hydraulic
........................................ damping 130mm
Rear ........... Swing arm with gas
........................................ filled shockabsorbers
Fr. Fork oil capacity ..... 195 ml per leg
Front fork oil ................ 1F (Endurance Fork Oil)
Brakes : Front ........ Hydraulic 280 mm
........................................ ventilated disc
Rear ......... Foot operated 153 mm
........................................ single lead, internal
........................................ expanding (drum)
Brake Oil Capacity ........ 60ml
Brake Oil Grade ............. DOT 3 or DOT 4
Tyre size : Front ......... 90/90 X 19” - 52P
Rear .......... 110/90 X 18” - 61P
TYRE PRESSURE
Solo : Front ...... 20 psi/1.41kg/cm
2
Rear ........ 30 psi/2.11kg/cm
2
With Pillion : Front ....... 22 psi/1.55kg/cm
2
Rear ........ 32 psi/2.20kg/cm
2
Fuel tank capacity ......... 13.5 litres***
Reserve ........................... 2 litres approx.
ELECTRICALS
Generation ..................... Alternator/magneto
System ............................ 12V - DC
Ignition .......................... Digital Dual Spark
........................................ Ignition, TCI System
Battery ........................... 12V - 14AH, MF
Spark plug ..................... Mico / W5DC (M14)
........................................ Super Bosch / UR5DC
........................................ (M10)
Spark plug gap .............. 0.70 to 0.80 mm
Head lamp ...................... 12V, 60 / 55W
Halogen
Specifications
8
Position Lamp ................ 12V, 4W
Brake / Tail lamp ........... 12V, 21 / 5 W
Speedometer lamp .......... 12V, 3.4W
Neutral lamp Tell tale ... 12V, 2W
Turn Signal Tell Tale .... 12V, 2W
Turn signal .................... 12V, 10W - 4 nos
Horn ............................... 12V DC
Starter Motor ................. 12V, 0.7KW
WEIGHTS
Kerb weight ................... 187 Kgs.
Max. pay load ................. 163 Kgs.
DIMENSIONS
Length ............................ 2160 mm
Width .............................. 800 mm
Height ............................ 1050 mm
Wheel base ..................... 1370 mm + 20 mm
Ground clearance .......... 135 mm
Saddle height ................. 800 mm
Rear Chain Slackness ...... 25-30 mm
NOTE :
Values / Dimensions given above are for your guidance only.
In view of continuous improvements being done on our products, the specifications are likely to
change without prior notice.
Specifications
***Fuel tank is not a measuring instrument. The capacity of
tank may vary slightly from specified value.
WARNING
Using bulbs / other electrical gadgets other than
specified rating may lead to over loading / erratic behaviour
/ premature failure of electrical system.
Modifications on the bike which are not approved by Royal
Enfield may not only disqualify for warranty, but also affects
performance of the bike.
9
The information given under the titles : Warning, Caution and Note are for your safety and for the
care and safety to your motorcycle and others. Please read these carefully and if disregarded may
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 to rider or
other persons.
CAUTION :
This message if disregarded may result in damage to the vehicle.
NOTE :
Indicates important and useful messages for clear understanding.
Safety Definitions
NOTE: BS III
This vehicle meets Emission Norms -
Bharat (Trem) Stage - III
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
Get your hands on the 2009-2021 Royal Enfield Classic 350/Classic 500 Service & Repair Manual. This comprehensive manual is an indispensable resource for both professional mechanics and DIY enthusiasts, specifically covering the 2009-2021 models of the Royal Enfield Classic 350 and Classic 500.
Compatible with all Windows and Mac versions, this manual is available in PDF format and requires Adobe Acrobat Reader for viewing. The file size is 28 MB.
Engine details covered in this manual include:
- 346 cc 1-cylinder, 4-stroke, air-cooled engine
- 499 cc 1-cylinder, 4-stroke, air-cooled engine
The manual includes detailed sections on:
- Introduction and general information
- Periodical maintenance and tightening torque
- Technical specifications and special service tools
- Engine lubrication system and hydraulic tappets
- Auto decompressor and electric starting system
- Sprag mechanical and auto chain tensioner assembly
- Engine breather system, inlet manifold & throttle body
- Blow up charts and engine dismantling
- Inspection, assembly, and management system
- Carburetor system and front wheel-disc brake
- Overhauling caliper & master cylinder and wheel disc-brake drum
- Suspension system, steering system, and shock absorber-swing arm
- Electrical system, battery system, and charging system
- Starter coil-pulsar coil, ignition coil-suppressor cap, and relay starter-IC flasher
- E-starter motor-RR unit, clutch & starter switch
- Troubleshooting and wiring diagrams
This electronic manual allows you to print out the necessary pages and dispose of them after use. It contains detailed illustrations, step-by-step written instructions, and diagrams, ensuring you have all the guidance needed for service, repair, and maintenance procedures.
Whether you are a DIY enthusiast or a seasoned mechanic, this manual provides the necessary depth and detail to keep your Royal Enfield Classic 350 or Classic 500 running at peak performance.
