Royal Enfield Classic 350 manuals

Royal enfield Classic 350 Service Manual (229 pages)

Brand: Royal-enfield | Category: Motorcycles | Size: 13.93 MB |

English

Table of contents

Service Manual

1

INTRODUCTION

2

Foreword

3

Contents

4

Management System

7

TOTAL VOLUME :

9

COMPRESSION RATIO :

9

HORSE POWER (HP OR PS) :

9

TORQUE :

10

CONVERSION :

10

IGNITION TIMING :

11

IDLING SPEED :

11

FINAL DRIVE RATIO :

11

Technical Specifications

12

ENGINE NUMBER - DETAILS

15

UNDER TANK AND SEAT TOP VIEW

21

UNDER TANK LH VIEW

21

UNDER TANK RH VIEW

21

General Vehicle Information

22

SERVICE DATA

25

THREE 03

25

WEAR LIMITS

26

O.D. I.D

35

Periodical Maintenance

36

Auto Chain Tensioner

44

SLOT POSITION

46

Engine Lubrication System

55

Lubrication System

56

WHAT IS HYDRAULIC TAPPET :

58

BENEFIT OF HYDRAULIC TAPPET :

58

CUT SECTION

58

VIEW OF RHVL

58

WORKING PRINCIPLE :

59

PRECAUTIONARY MEASURES :

59

Auto Decompressor

60

WORKING PRINCIPLE

61

Auto Chain Tensioner Assembly

62

Engine Breather System

63

Crankcase RH - Coverside View

65

Crankcase LH - Inside View

67

CRANK CASE LH

68

Crankcase RH - Inside View

69

CRANK CASE RH - INSIDE VIEW

70

Engine Cover RH

71

Crankcase LH - Coverside View

73

Engine Cover LH

75

Gear Train Assembly

77

Gear Shifting / Kick Starter

79

CRANK SHAFT ASSY

81

PISTON ASSY

81

Damper Pad Position Details

83

ENGINE DISMANTLING

84

INSPECTION & ASSEMBLY

84

DISMANTLING PROCEDURE

86

REMOVAL OF THROTTLE CABLE

87

REMOVAL OF THROTTLE BODY

87

CLUTCH CABLE REMOVAL

87

BATTERY REMOVAL

88

REMOVAL OF SILENCER AND

88

EXHAUST PIPE

88

REMOVAL OF E-START MOTOR

89

REMOVAL OF DRIVE CHAIN

90

REMOVAL OF SIDE STAND

90

REMOVAL OF REAR BRAKE SWITCH

90

CYLINDER HEAD ASSEMBLY

91

ENGINE OIL DRAIN

91

Magnetic Drain Bolt

91

REMOVAL OF VALVES

92

CYLINDER BARREL SUB ASSY

93

REMOVAL OF COVER RH SUB

94

ASSEMBLY :

94

ING FROM CRANKCASE RH

97

DISMANTLING PROCEDURE OF

98

DISMANTLING COVER LH

102

SUB ASSEMBLY :

102

COMPONENTS FOR DISMANTL

103

ING FROM CRANKCASE LH

103

FLANGE FACE

104

DISMANTLING OF CLUTCH

104

ASSEMBLY

104

LAYSHAFT SUB ASSEMBLY

112

DISMANTLING OF LAYSHAFT SUB

112

MAIN SHAFT SUB ASSEMBLY

113

DISMANTLING OF MAINSHAFT SUB

113

REMOVAL OF KICK STARTER SUB

115

VITAL PARTS

116

II. GEARS / SPROCKETS

116

UNIDIRECTIONAL FITTINGS LIST

117

TORQUE SPECIFICATION - ENGINE

118

ASSEMBLY OF ENGINE BEARINGS

120

CRANKCASE LH

120

ENGINE ASSEMBLY

120

CRANKCASE RH

121

EX. RHVL

122

INLET RHVL

122

ASSEMBLING OF KICK STARTER

123

SUB ASSEMBLY

123

DRAIN BOLT

123

TRIP PLATE

124

ASSEMBLING OF GEAR ROCKER

125

SHAFT SUB ASSEMBLY

125

ASSEMBLING OF LAYSHAFT SUB

126

ASSEMBLING OF MAINSHAFT SUB

127

3RD GEAR POSITION

129

NOTE :NOTE :

131

CUT PORTION

132

SPRAG CLUTCH ASSEMBLY

134

ASSEMBLY OF CLUTCH

135

ASSEMBLING PROCEDURE OF

140

AUTO DECOMPRESSOR

140

ASSEMBLY PROCEDURE OF CAM

141

VALVE TIMING

141

OUTSIDE OIL SEAL

142

INSIDE OIL SEAL

142

PISTON SUB ASSEMBLY

145

CLEANING

145

INSPECTION

145

EX IN

146

VALVE SEAT INSPECTION :

150

VALVE LEAKAGE TEST

151

ENGINE MANGEMENT

154

THE BENEFITS OF EMS ARE :

155

Function of Components in EMS

156

LEVEL 1 VISUAL

164

LEVEL 2 TEST PIN

164

LEVEL 3 DOL

165

Trouble Shooting (EMS)

167

CV CARBURETOR

169

SEVEN 07

169

CV Carburetor - Exploded View

170

Functions of Carburetor

171

TORQUE SPECIFICATION

173

MIXTURE SCREW

174

INSTALLATION OF CARBURETOR

175

CARBURETOR TUNING

176

PROCEDURE

176

Carburetor Maintenance

177

CHASSIS

179

WHEELS & BRAKES

179

EIGHT 08

179

Front Wheel Removal

182

Chassis, Wheels & Brakes

183

SUSPENSION & STEERING

199

3 FORK STROKE LENGTH : 130 MM

200

Suspension & Steering

201

REMOVAL AND ASSEMBLY OF

205

REAR SHOCK ABSORBER

205

RECHARGING OF SHOCK

205

ABSORBERS

205

SWING ARM

205

ELECTRICALS

209

ELECTRICAL SYMBOLS

210

Electricals

211

MEASURING INSTRUMENT

215

STARTER COIL

215

PULSAR COIL

215

IGNITION COIL

215

Resistance 4 to 5 ohms

216

E- STARTER MOTOR

217

IC FLASHER

217

ELECTRICAL PARTS

218

DO’S AND DON’TS

218

TROUBLE SHOOTING

222

ELEVEN 11

222

Trouble Shooting

223

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