PDI Checklist

the ENGINE code is as follows

U = ENGINE FAMILY
5 = ENGINE CAPACITY (500cc)
S = TYPE OF START (electric?)
5 = TRANSMISSION (5 speed?)
F = FUEL FEED (fuel injection?)
0 = BLANK FOR FUTURE USE (?)
B = YEAR OF MANUFACTURE (-9=2009, A=2010, B=2011, C=2012)
L = MONTH OF MANUFACTURE (A=JAN, B=FEB, C=MAR...L=OCT, N=DEC)
108227= PRODUCTION SERIAL NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Check func. Front & rear indicators, no plate lamp

Front fork sleeve shouldn't touch mudguard or fork. On pre delivery ride - hard brake to check.
Rust on Main frame - near welding joints - at the bottom, where the main stand mates with the frame
Leaks around kick start, and chain slackness
Full tool kit
RE Embossed Leather Document Pouch (if possible)
Funct. Of fuel sensor, check fuel level
Check fuel leaks under tank where sensor is inserted, and also petrol pump outlet
Battery electrolyte level
Check any paint surface, aluminium buffed surfaces for scratch/damage
Proper fit of various control cables wrt play
Proper working of electricals
Proper tyre pressure - Recommended?\
Test Ride - see if bike pulls towards left or right
Ask to open OVEL Tool Box - generally jammed
Check proper RETRACTION of main & side stands - sometimes hang midway due to spring
Check 10 AMP fuse - can get knocked off due to running in shocks

1. Start with visually inspecting the whole bike- from bodywork to rims tyres- anything hanging,
out of place, damaged, dented, rusting at the welding joints or repaired(transit
damaged) painted parts like fuel tank, mudguard .
2. Check the front fork sleeves(which covers the forks top length) clearance between the
front mudguard - needs to be equal b/w sleeves & mudguard - if not, then it will scuff and
damage the paint work on mudguard/sleeves.
3. Check for all the electrical parts .e.g. headlight high/low beam- high beam pass, indicators,
horns, brake light switch -front and rear, parking light, EStart. Also check the indication light in
the speedo- neutral light, high beam and indicator.

4. Apply the front and rear brake to check out the effectiveness and any odd noise from
front or rear brake while braking.
5. Check your tool kit if its complete or not.
6. Take the key and match the serial number on the key with the lock serial no of the rear LHS
electrical/storage box. The no will be on the outside where you insert the key into the lock.
Also check working of all the locks on the bike with same key.
7. Check the chain slack while sitting on centre stand and then off it. Should be no more then 1.5
inch while on the centre stand.
8. After starting the bike, check for any exhaust leaks at the head where the down pipe is
attached and at the exhaust/down pipe joint. Also for any white smoke from the exhaust.
9. Check for any oil leaks from the engine-rocker covers, side covers- rear shock
absorbers and front. Don't worry if you see a bit of oil under the RHS engine cover. It will be
from the chain.
10. After engine has warmed up for a couple of minutes- the tick tick noise of the auto decompressor should stop. Check the idling is not erratic(jumping up/down). Starting should be
smooth and not take more then one crank (not more the 3 seconds) to start
11. Take a ride on the bike with a pillion ride to see if you have rubbing issues of the rear
tyre with the mudguard. Thats due to the bad alignment of the mudguard and sometimes of the
rear tyre also.
12. While test riding, go through all the gears and brakes(F/R). Notice any abnormal noise or
any hesitation in the engine response. Do check the exhaust for any white smoke or black
while riding.
13. Check for any acid spill from the battery and check if drain pipe from the battery is
attached. First gen C5 use to come with exide batteries which had no drain pipe but new ones
come with exide or FIemm batteries which have the drain pipe. Look for any spill damage on the
engine cover under the battery
14. Check the accelerator cable- should not get stuck when turning left or right while on C
stand. Check the choke cable for proper engagement and clutch cable is not too tight or
too lose.
15. Check springs (2 nos) on the centre stand. Engage the center & side stand. Should not
take much effort to engage both the stands.
16. Check for any pre damage to the chassis front. Turn the handle bar left to right - should
turn equally to both the sides, and not more or less at one side to other.
17. Tight Handle Check: lean the handle to one side wee bit and if it comes down fully then its
fine. Loose Handle Check: Apply front brake and rock the bike forward and backward. You will
feel the play or noise if its too loose. You can also put it on C stand and while holding the handle
firmly, ask you friend to grab the front forks and rock it forward / backward. Any play will be felt
easily.

18. While on C stand, rotate the front wheel and check the run out of the tyre or at least any
abnormal noise. Wheel should rotate freely and also check for front speedo is tight at the
speedo hub and the SMOOTH movement of speedo needle.
19. To check the D.O.B of your bike, open up the LHS electrical box and you will find the green
non- pollution sticker with the D.O.B on it. You can cross check the month with the
chassis no.
20. By RE rule, your dealer should fill the fuel tank above reserve and the reserve light
should go off. But most of the dealers steal the petrol money and give you only .5L(even less) to
get you to the nearest petrol station. You can actually demand from him to fill up more then
reserve as per company policy or else you should inform RE about it. After you fill her up, if the
reserve light is still on then the fuel level indicator is faulty.

GENERAL OBSERVATIONS on Thunderbird

1. The rear mudguard will be misaligned and the number plate will be tilted to one side. This
is a trademark, do not fret
2. Sit on the bike and check the break pedal position. I have checked this on 4 different
thunderbirds and found the pedals in different positions on all of them. Either they are getting
mauled in transportation or the manufacturer is playing a game of hit and trial with us. Anyway,
just check that your foot is able to rest itself on the whole of the horizontal line of the
rubber, if not on the rubber itself, when you press the pedal. If it is not horizontal to your foot,
your foot will tend to slip off on application of pressure, especially when wet or in rain. Have it
corrected.
3. The meters will shake a bit. My guess is that they are designed this way, so as to absorb the
shocks better. Do not fret (again)
4. Take it for a ride, leave the handle bar at a speed of 45-55 and check if the handle bar shakes
from side to side. If it does, you need to get the wheels aligned.
5. Check the silencer bend pipe for any rust
6. Some people have complained that the black part at the end of the silencer is scratched or
falling. I have had no such issue

7. Casually, check the Speedo reading on the other bikes in the showroom (You will have to ask
for the keys). They should have very similar reading. If your bike has more KM reading, than it may
have been used for test rides, though RE does not allow this. My dealer had given me a test on a
Desert Storm, which I found later, was waiting for delivery. Also if you are asked to pick one of two
bikes, choose the dirtier one. The one that has been in the showroom longer will have been
cleaned more often, but is also susceptible to have been abused by test riders.
8. There will be a "Mosquito sound" when you apply the front break at speeds above 20 KPH.
This is normal and has to do with the flow of break oil.
9. Keep your patience, the staff does not understand your passion and eye for detail. Tip them
before you leave (Even better if you take some sweets along). It will make subsequent visits easier
for you.

20. Accessories A) If you intent to ride solo without the rear seat then get the rear LHS guard(stay)
B) Leg guard- as per your choice to what is available at your dealer.
c) Horns- You wont need changing as I feel the twin setup is awesome.
d) Alloys - If you want to kill the looks of a classic but each to its own..
e) RE embossed leather tool kit bag and side bags if you like them.

f) Bike cover- You can get one if you intent to ride your bike quite less. Cant use it w

G) Upswept exhaust - if you fancy the looks and heavier thump. It's attached to the

H) Indicator shades- I personally dont like them but some do. Just like the one on th

Congrats to you too sam_b! It would be good to have more T-Bird riders to share vie
I followed Randhawa's PDI routine and it worked pretty well for me, since the bikes
The rear mudguard will be misaligned and the number plate will be tilte
Sit on the bike and check the break pedal position. I have checked this o
The meters are put together in such a way that they will shake a bit. My
Take it for a ride, leave the handle bar at a speed of 45-55 and check if
Check the silencer bend pipe for any rust
Some people have complained that the black part at the end of the silen
Casually, check the Speedo reading on the other bikes in the showroom
There will be a "Mosquito sound" when you apply the front break at spe
Keep your patience, the staff does not understand your passion and eye
While I have read this often about REs, but it registers very differently, when you e

ything hanging,
d(transit

between the
n it will scuff and

ass, indicators,
ication light in

Front fork sleeve should not touch the mudguard or the fork. take a pre

Rust on the main frame, especially at the welding joints. (do check at th
Check for leaks around the kick-shaft, and chain slackness.
Full tool kit.
RE embossed leather document pouch if possible. ( although i never go
Fill adequate petrol and check for the proper working of fuel sensor.
Check for leaks under the tank where fuel sensor is inserted, and also th
Battery electrolyte level.
Check any damage to paint surface / or scratches on the buffed alumini
Proper fitment of various control cables wrt play
proper working of all electricals
proper tyre pressure
While taking a pre-delivery test ride, see if the bike is not pulling toward
Ask them to open the OVAL TOOL BOX and show you. in most cases its j
Check for proper retraction of main and side stand. sometimes they han

dd noise from

o of the rear LHS

key into the lock.

no more then 1.5

own pipe is
the exhaust.
shock
cover. It will be

of the auto deing should be

es of the rear
d sometimes of the

normal noise or
smoke or black

the battery is
e but new ones
l damage on the

right while on C
not too tight or

d. Should not

o right - should

wn fully then its

ckward. You will
ding the handle
play will be felt

re or at least any
is tight at the

ll find the green

h with the

reserve light
y .5L(even less) to
more then
l her up, if the

o one side. This

4 different
ey are getting
ith us. Anyway,
line of the
al to your foot,
n rain. Have it

as to absorb the

andle bar shakes

cer is scratched or

u will have to ask

ading, than it may
n me a test on a
to pick one of two
have been

eds above 20 KPH.

etail. Tip them

quent visits easier

ear LHS guard(stay) changed to single pipe one.

ite less. Cant use it when the bike is hot which it stays for hours at a stretch and not water proof. Has minimal d

p. It's attached to the down pipe and does not come with free flow down pipe anymore so you wont harm the en

ust like the one on the front head light.

ird riders to share views and comments with.

r me, since the bikes are essentially the same engine. Just a few things to add, that I can think of:
ber plate will be tilted to one side. This is a trademark, do not fret
I have checked this on 4 different thunderbirds and found the pedals in different positions on all of them. Either
y will shake a bit. My guess is that they are designed this way, so as to absorb the shocks better. Do not fret (ag
f 45-55 and check if the handle bar shakes from side to side. If it does, you need to get the wheels aligned.

at the end of the silencer is scratched or falling. I have had no such issue
kes in the showroom (You will have to ask for the keys). They should have very similar reading. If your bike has m
he front break at speeds above 20 KPH. This is normal and has to do with the flow of break oil.
your passion and eye for detail. Tip them before you leave (Even better if you take some sweets along). It will m
fferently, when you experience it first hand: The bike will not be perfectly ready due to various reasons, and you

the fork. take a pre delivery ride, brake hard a few times and observe.

oints. (do check at the bottom, where the main stand mates with the frame)

although i never got one) :(

ng of fuel sensor.
inserted, and also the petrol outlet pump.

n the buffed aluminium parts.

is not pulling towards left or right.

u. in most cases its jammed and difficult to open.
sometimes they hang mid-way as springs are faulty.

proof. Has minimal dust protection.

ou wont harm the engine during running in period.

on all of them. Either they are getting mauled in transportation or the manufacturer is playing a game of hit and
etter. Do not fret (again)
wheels aligned.

ing. If your bike has more KM reading, than it may have been used for test rides, though RE does not allow this.

eets along). It will make subsequent visits easier for you.

ous reasons, and you will get to know it better and take care of it. Lovely thing you have gifted yourself! You are

ng a game of hit and trial with us. Anyway, just check that your foot is able to rest itself on the whole of the hori

does not allow this. My dealer had given me a test on a Desert Storm, which I found later, was waiting for deliv

ted yourself! You are going to enjoy it more because of the subtle demands for attention that it will put on you

the whole of the horizontal line of the rubber, if not on the rubber itself, when you press the pedal. If it is not ho

was waiting for delivery. Also if you are asked to pick one of two bikes, choose the dirtier one. The one that has

at it will put on you

e pedal. If it is not horizontal to your foot, your foot will tend to slip off on application of pressure, especially whe

ne. The one that has been in the showroom longer will have been cleaned more often, but is also susceptible to

ssure, especially when wet or in rain. Have it corrected.

s also susceptible to have been abused by test riders.

customerservice@royalenfield.com
Team-BHP / xBHP / BCMT Data on Thunderbird Issues
Sl No

Problem Location
1
2
3
4
5
6
7
8
9
10

http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum

11
12
13
14
15
16
17
18
19

http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum

http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
Tire Protector Gel - Ride On

http://www.team-bhp.com/foru
http://www.team-bhp.com/foru
http://www.team-bhp.com/foru
http://www.team-bhp.com/foru
http://www.team-bhp.com/foru
http://www.team-bhp.com/foru
http://www.team-bhp.com/foru

http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum

http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
Loc-Tite for Loose Nut, Adjusting & lubricating clutch cable - ArizonaJim
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum
http://www.team-bhp.com/forum

@royalenfield.com

nderbird Issues
Problem Faced

Author

Side Stand Light not going off - PDI

Rear Brake Sometimes Squeaky
Clutch too tight - makes squeaky sound when released
Fuel indicator inaccurate - shows higher if on side stand
Minor metallic sound from engine - went away on its own
Rear Brake gettting Locked
Loose chain
Stuck Gear between 1st & Neutral
Starting Issues
Console Electrical Issues - select button not working, fuel gauge irratic

vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore
vrajaram- Bangalore

Dak Dak coming from the chain - during I st service

Difficulty in bringing to NEUTRAL
Rear brake not working well after puncture repair (took wheel off)
Service Spanner in MID when NOT DUE
RC - details of engine & weight incorrect - 350CC
Seats with cat nail marks
Peeling off paint inside petorl tank cap
Fuel Bars not showing when tank full (4 bars showing)
Cracked speedometer glass

J. Ravi
J. Ravi
J. Ravi
J. Ravi
J. Ravi
J. Ravi
J. Ravi
J. Ravi
J. Ravi

Peeling off of chrome plating

J. Ravi

rear wheel not rotating freely

Headlight misaligned
Chain rusting
2 nd to 3rd gear transition not smooth
Difficulty in finding neutral

jimmy_u
jimmy_u
jimmy_u
jimmy_u
jimmy_u

Catalytic Convertor discolouration

Smokeymist
Squeky sound - suspected from tank
vikivix
Instrument cluster - RPM needle jumping around, time not set, 1000 kmGetLife
Petrol Tank Paint - rough in some zones
GetLife

Delayed Delivery
sam_b
91 kms on ODO at time of delivery
sam_b
RHS mirror plastic scratched badly
sam_b
D missing in Enfield tank sticker
sam_b
air filter to throttle rubber hose was torn from the junction of sam_b
EFI MIL glows lightly, flickering on dig odo
sam_b
Rear brake non responsive
sam_b

Rear brake not functioning well

Head lamp not focussed well
Rear brake jammed due to rear axle nut NOT PROPERLY TIGHTENE
One screw on magneto cover (just below EFI) became Loose & fell
Trip meter not getting RESET
RHS rear view mirror loose
Minor cracks along the edges (like J.Ravi)

Kick stater not working - notified at Ist Service

Oil Leaks - first few drops - then a lot
Clock stuck - time not adjustable
Small chain guard nut gets loose on its own
Idle RPM just shot up to 1.5K
Not comfortable with clutch setting
e Nut, Adjusting & lubricating clutch cable - ArizonaJim

rajneeesh
rajneeesh
rajneeesh
rajneeesh
rajneeesh
rajneeesh
rajneeesh

harikrishnanm
harikrishnanm
harikrishnanm
harikrishnanm
harikrishnanm
harikrishnanm
http://www.team-bhp.com/forum/motorbikes/129727-ro

Softening suspension method

Arizonajim

Rear brake lever & foot rest not in correct line

Exhaust joint - pipe bend to end can - loose
Rubber glands near fins on engine loose

InSearch
InSearch
InSearch
InSearch
InSearch
InSearch
InSearch
InSearch

Solution

Solution Location

SAME - Fixed during Ist service

SAME - Fixed during Ist service
May need greasing

Air lock suspect

Every 100 kms or so noise
Cold Engine in the morning
Cold Engine - allow warm up for 1 min

Solved in Ist Service

Solved in Ist Service - lubrication
ASC fixed without any cost
Press Select & Set buttons together for more than 3 seconds. Then turn off ignition & turn on again, while keeping the buttons
Sent for correction - returned
Started covering the seats
Tank replaced under warranty with galvanized internals tank http://www.team-bhp.com/forum/motorbikes/135505-royal-enfield
Float valve replaced under warranty
Replaced entire console under warranty, protective shoe glued
New meter has NEW software
Re-plated by Quality Chennai

Should get alignment done at night

Should disappear after use - due to coastal environment / Spray WD 40
should get resolved with use

Expected. Check spark plug/plugged pipe - check back press http://www.team-bhp.com/forum/motorbikes/135505-royal-enfield

If from front brakes, it is expected- check at ASC
http://www.team-bhp.com/forum/motorbikes/135505-royal-enfield
No proper response from ASC - had to contact Regional
Service Mgr RE - noth parts to be replaced under warranty

Delivery delayed from dealer's end - wrote to RE - matter sorted

Wrote to RE, responsible free loader dealt with
Replaced at time of delivery
New sticker put after 8 days
replaced aunder warranty during Ist service
Gone after unit completely dried
Fine after 4 to 5 hrs

Sorted during Ist service

Sorted during Ist service
Fixed by local mechanic
Replaced
Will be replaced under warranty. Maybe few weeks. EDIT: Replaced
Not fixed.
Replaced both meters second time under warranty (although 13 months were over)

Replaced part after one month

Some bolts & nuts tightened - oil leak increased - then some oil seals replaced - then stopped
Whole unit replaced under warranty
Tightened periodically by the owner - ArizonaJim suggests BLUE Loc-Tite
Fixed by service center - not informed of cause
Adjust multiple times - not found the correct posn yet
bhp.com/forum/motorbikes/129727-royal-enfield-thunderbird-500-twinspark-ownership-report-5.html#post3356471

ASC heated & reshaped it slightly

on again, while keeping the buttons pressed.

um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-12.html#post3196402

um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-14.html#post3200224
um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-15.html#post3243768

http://www.team-bhp.com/forum/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-2.html
http://www.team-bhp.com/forum/motorbikes/133045-thumping-all-way-my-thunderbird-500-ownership-report.html
http://www.team-bhp.com/forum/motorbikes/129727-royal-enfield-thunderbird-500-twinspark-ownership-report.html
http://www.team-bhp.com/forum/motorbikes/130880-i-live-again-thunderbird-500-ownership.html
enfield_500
apachelongbow
ebonho
Majumdarda
http://www.xbhp.com/talkies/motorcycle-ownership-experiences/24607-royal-enfield-thunderbird-500-a-67.html
1 Spare clutch cable
2 Spare fuses
3 Tyre filled with tire-protector gel (against punctures)

https://www.google.co.in/#q=thunderbird+500+ownership+review

http://www.team-bhp.com/forum/motorbikes/140314-bikers-heart-thumps-again-re-thunderbird-500-a.html
http://www.team-bhp.com/forum/motorbikes/132561-my-retro-bullet-tbts-500-flicker.html
3833.333

15835.5
2639.25

p-report.html
hip-report.html

J. Ravi
sam b
rajneesh

2666.667