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Congratulations on your choice of the Thunderbird TwinSpark. Your motorcycle represents a breakthrough in engineering
technology. Its Unit Construction Engine delivers greater power and torque, while brand new ergonomics ensure
enhanced comfort and safety. Aesthetics have also been refined, resulting in a sleeker, more aerodynamic profile while
preserving the classic lines of the Thunderbird.
This manual is designed to give you complete control over your bike. It contains important information on efficient
operation and maintenance. Weve also put in tips on riding safely, as well as some suggestions as to how you can
enhance 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 of
riding gear in accordance with your application, style and weather conditionswhich will go a long way in providing you
with a feeling of confidence that goes on to enhance the riding and ownership pleasure that comes with this and every
other Royal Enfield machine.Also pleaseensure the same for your pillion rideras well. Respect the rules of the
Roadand 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 manual
before you begin to cruise on your Thunderbird TwinSpark.
SERVICE HEADQUARTERS
Royal Enfield, Tiruvottiyur High Road, Tiruvottiyur, Chennai-600019. Phone: 044-4223 0400, Fax: 044-4201 1719
E-mail: customerservice@royalenfield.com Website: www.royalenfield.com
NOTICE
All information in this manual is based on the latest product information available at the time of
publication. Due to continues improvements or other changes, there may be discrepancies
between information in this manual and your vehicle. Royal Enfield reserves the right to make
product changes at any time without prior notice and without incurring any obligation to
make 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 same
on 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.
CONTENTS
Personal and vehicle information.............. 4
Storage precautions................................43
Specifications.......................................... 6
46
Safety Definitions..................................... 9
48
10
49
11
56
12
58
16
63
22
64
65
68
77
Notes .....................................................
85
Running in............................................ 23
Starting ..................................................
24
26
Parking ..................................................
27
28
ANNEXURES
Vehicle Installation Form
31
Do it yourself .........................................
32
42
Form 22
3
State
Res:
Off:
Pin
Mobile :
Email :
Engine No.
Battery No.
Frame No.
Battery make
Reg. No.
Licence No.
Date of Sale
Model
Key No.:
Tyre make
Colour
Sold by
Dealer Code
2 nd Service
3 rd Service
4 th Service
Date of Service
Kms Covered
Servicing
Dealers Name
Address
Note : Please ensure that the free service details are recorded in this sheet immediately after the
service is carried out.
5
SPECIFICATIONS
Engine and Engine systems
Transmission
Clutch .........................
Bore ............................
70mm
Stroke ..........................
90mm
2.15 : 1
346cc
8.5:1
st
3.06
28 Nm @ 4000 rpm
nd
............................... 2
2.01
1050200 rpm
................................ 3rd -
1.52
Starting ........................
EStart
................................ 4
1.21
Paper element
................................ 5
Carburettor ..................
Ucal - BS 29
Lubrication ...................
...................................
Wet Sump
pressure lubrication
2.53 : 1
2.75 lits
100 L
15 T
Cooling .......................
th
th
SPECIFICATIONS
Chassis
Tyre pressure
Frame ..........................
Tubular
Telescopic, hydraulic
damping, Stroke 130 mm
Rear ........
...................................
In built
1F Grade Gabriel /
Royal Enfield Fork Oil
Reserve .......................
2 litres
Brakes :
Front .....
...................................
Hydraulic 280 mm
ventilated disc
Rear .......
...................................
...................................
60ml
DOT 3 or DOT 4
Tyre size :
Front ......
...................................
3.25 19
- 4PR/6PR
Front .....
Rear .......
2.11kg/cm 2 (30psi)
Rear .......
Electricals
Rear .......
...................................
Solo :
3.5 19
- 4PR/6PR
7
Generation .................
Phase
Alternator AC-3
System .........................
12V - DC
Ignition .......................
...................................
Battery ..........................
12V - 14AH
Mico-WR5DC - 1 No.
...................................
Bosch-UR5DC - 1 No.
SPECIFICATIONS
Spark plug gap ...........
0.7 to 0.8 mm
Weights
12V, 35 / 35W
Halogen bulb
182 Kgs.
12V, 5W
168 Kgs.
12V, 21W
12V, 1.7W
Dimensions
Length .........................
2120 mm
Width ...........................
780 mm
Height ..........................
1080 mm
1370 mm
135 mm
750mm
H or n ...........................
12V DC
Performance
0.7KW
120 Km/hr
In view of continuous improvements being done on our products, the specifications are likely to
change without prior notice.
8
SAFETY DEFINITIONS
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
Riding dress
Caution
Braking
Warning :
Sitting posture
Correct sitting posture is a pre-requisite for stable
and safe riding :
Sit Straight with your shoulders completely
relaxed.
road
Engine Number
11
4 5 6
1.
4.
Neutral indicator
7.
2.
Speedometer
5.
RPM meter
8.
3.
6.
Fuel Gauge
12
6
7
9
10
1.
Clutch lever
5.
2.
6.
3.
7.
4.
Handle bar
8.
Throttle control
13
9.
E-Start Button
2 3
8
9
15
13 12 11 10
14
1.
Rear Trafficator
6.
11. H or n
2.
Side panel RH
7.
Front Trafficator
3.
8.
Head light
4.
Carburetor
9.
14. Silencer
5.
Fuel tank
2 3
12
11 10
1.
Fuel tap
6.
2.
Side panel LH
7.
Tail lamp
3.
8.
4.
Seat
9.
Side Stand
5.
Side handle
OPERATION OF CONTROLS
Ignition switch
OF F
ON
16
OPERATION OF CONTROLS
Ignition Stop switch
OF F
OF F
Pilot ON
ON
Head lamp ON
17
OPERATION OF CONTROLS
Dimmer switch
High beam
Low beam
Day Flash
18
OPERATION OF CONTROLS
Fuel tap
OF F
Turn Key
Clockwise to
open
Main ON
Turn Key
Anti Clockwise
to close.
Reserve ON
19
OPERATION OF CONTROLS
Choke
Steering lock
ON
Lock
OF F
Unlock
Caution
Note
20
OPERATION OF CONTROLS
Horn
Tripmeter
Depress
Caution
N o t e :
Caution
Note
:
Key is common for ignition, petrol tank cap,
steering lock, and side panel.
R o t a t e
tripm eter
knob only in
f o r w a r d
direction.
total distance
The trip meter
t he d ist an ce
between fuel
Adequate fuel
availability as
indicated by the
fuel gauge.
2.
Operation and
free
play
of
front
brake
l ev e r a n d r ea r
brake pedal.
3.
Fr e e p l a y a n d
smoothness of
all operating
cables.
4.
Free movement
of steering
5.
B a t t e r y
electrolyte level.
6.
22
7.
Brake fluid is
above
the
minimum level
in t he ma st er
cylinder
8.
Oil
level
between upper
& lower mark
when engine is
cold. Top up if
necessary.
9.
Operation of
all electrical
parts.
Max.
Min.
RUNNING IN
The Thunderbird Twinspark, as you would be
experiencing, is capable of consistent high
speeds. However as with any new motorcycle,
a running-in is essential during the first 2000
kms to achieve optimum performance
subsquently.
3.
4.
5.
Vehicle
Speed
Gear
15 KMPH
20 KMPH
25 KMPH
30 KMPH
30 KMPH
40 KMPH
45 KMPH
55 KMPH
60 KMPH
70 KMPH
23
STARTING
Switch on ignition.
Caution
24
STARTING
A Clutch switch is provided in the system
for the safety of the rider. When the vehicle
is in gear, the vehicle cannot be started.
Shift gear to neutral before attempting to
start the engine.
If the engine has to be started with the
Motorcycle in gear, depress clutch and
then depress the starter button to start the
engine. Release starter button as soon as
engine starts
Slightly crank
e n g i n e fu r t h e r
till compression
eases over.
Caution
Start
the
motorcycle with
a
powerful
swinging kick.
Release
choke,
applied.
the
if
Note
Release choke if
applied
PARKING
Parking vehicle on centre stand
Warning :
27
2
S.No.
Description
S.No.
Qty.
Description
Qty.
1.
Tool wallet
2.
Tommy bar
3.
3. Gauze bandage 5 cm x 2 cm
4.
5.
Screw driver
6.
(10 x 12 mm)
2
28
PERIODICAL MAINTENANCE
The maintenance schedule detailed here will help you maintain your Thunderbird Twinspark meticulously and to get a long trouble free
service. 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 the
severity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorised service
centre for expert advice and to carry out the required maintenance.
S.
No.
FREE SERVICE
Whichever is earlier
DESCRIPTION
Kms (x 1000)
Months
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Engine Oil
Engine oil filter
Engine sump filter & Secondary drain magnet plug
Spark plug - 2nos.
HT leads for crack
Air filter element
Carburetor
Fuel Tap
Fuel tank
Fuel hose
Accelerator cable play at throttle, TPS & Carburetor
Rubber hose, Air filter to Carburetor
Rubber hose, Inlet manifold
Inlet / Exhaust valve seating
A : Adjust
C : Clean
D : De-carbonise
I : Inspect
29
0.5
1.5
R
3
3
6
6
R
Check level
R
C
R
C
C
A
A
A
I
I
I
C
C
C
C
I
A
I
I
I
A
I
I
C
C
I
A
I
I
9
9
PAID SERVICE
12
15
18
21
24
27
R
R
R
every 500 Kms or earlier as required
C
R
C
R
C
R
C
C
C
C
A
A
R
A
A
A
A
I
I
I
I
I
I
I
C
R
C
C
C
R
C
Clean, Inspect and Tune
C
R
C
C
C
R
C
C
C
C
I
R
I
I
I
R
I
A
A
A
A
A
A
A
I
R
I
I
I
R
I
I
R
I
I
I
R
I
I
L : Lubricate
R : Replace
30
R
R
C
R
I
C
C
C
I
A
I
I
I
PERIODICAL MAINTENANCE
S.
No.
FREE SERVICE
Whichever is earlier
DESCRIPTION
Kms (x 1000)
Months
15
16
17
18
19
20
21
22
Cylinder head
Exhaust system
Clutch free play
Rear brake pedal pivot
Battery terminals (apply petroleum jelly)
Battery Electrolyte level
Earth wire eyelet (behind battery carrier)
Rear Drive Chain
23
Fork oil
24
25
26
27
28
29
30
31
0.5
1.5
L
C
3
3
6
6
9
9
PAID SERVICE
12
15
18
21
D
D
Kms or earlier as
L
L
L
C
C
C
I
I
I
24
27
required
L
L
C
C
I
I
30
D
D
L
C
I
I
R
R
Adjust every 1000 Kms. or earlier as required
Lubricate every 3000 Kms or earlier as required
R
R
Check level every 1000 Kms or earlier as required
Lubricate every 1000 Kms or earlier as required
Adjust every 1000 Kms or earlier as required
L
L
L
L
L
L
L
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Lubricate every 1000 Kms or earlier as required
A : Adjust
C : Clean
D : De-carbonise
I : Inspect
L : Lubricate
R : Replace
Note : For Maintenance after 30,000 Kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorised Service Centre.
30
RECOMMENDED LUBRICANTS
Engine Oil
Grade
Capacity
2.75 Litres
Refil Qty
2.35 Litres
Capacity
265ml/leg
Brake Fluid
Grade
DOT 3 or DOT 4
Capacity
60ml
Caution : Use of Wrong grade oil can reduce the life of the moving parts and seriously
affect performance.
DO IT YOURSELF
The following simple maintenance activities will
help in maintaining your motorcycle. However
for an elaborate maintenance, we recommend
you to get in done at a Royal Enfield Authorised
Service Centre.
Control Cables
Caution
32
DO IT YOURSELF
Brake fluid
tread
depth
Spark plug
Cleaning and adjusting Plug gap
DO IT YOURSELF
Use only standard tyres & tubes inflated
to correct pressure.
Tyre pressure
Front
Solo
With Pillion
Di sc on ne ct
speedo cable.
Loosen
the
pinch bolt on the
RH fork guide.
R e a r
Solo
With Pillion
DO IT YOURSELF
Take out Speedo drive and bush on the
RH side.
Caution
:
Note
Tighten
the
pinch bolt on the
RH fork guide.
Connect
the
speedo cable to
speedo
drive
and check for proper working of speedo
meter.
35
DO IT YOURSELF
Rear wheel reassembly
Ensure the four cush rubbers are in
position inside the rear wheel hub.
Tilt vehicle to right and insert wheel
assembly between the swing arms.
Remove wheel
s p in d le fr om L H
side along with
chain ad juster,
taking care not
to
drop
the
wheel collar and spacer from the LH side
of the wheel.
Caution
36
DO IT YOURSELF
Adjustments
Warning :
DO IT YOURSELF
Drive Chain tension (play 25 - 30 mm)
Caution
DO IT YOURSELF
Removal of Battery from the Vehicle
Battery Maintenance
The vehicle is
provided with
12V - 14 AH
maintenance
free battery.
terminal
wires
The
battery
must
be
periodically
checked for
Cleanliness
terminals.
Electrolyte level
39
corrosion
free
Electrolyte level
Note
Remove bracket.
and
Fo r c h e c ki n g t he b a t te r y v ol t a g e a n d
e l e c t r o l y t e s p e c i f i c g r a v i t y, c o n t a c t
authorised battery service centre.
DO IT YOURSELF
Reassembly of Battery on Vehicle
Caution
DO IT YOURSELF
Position the new bulb inside holder, ensuring
Fuse
Open the LH
Side panel
There are two
fuse
box
available. Fuse
box with 15A is
for battery main
and 10A for TCI
ignition
Open the fuse
carrier
Replace the required fuse with the spare
fuse available in the fuse carrier and close
the LH side panel.
Remove
the
screws & take out
trafficator glass
cover.
WASHING PROCEEDURE
Precautions
STORAGE PRECAUTIONS
Incase your Motorcycle is not going to be used
for a month or more, we advice the following
precautions to the taken.
Wa s h t h e m o t o r c y c l e t h o r o u g h l y a n d
lubricate as per the maintenance chart.
43
STORAGE PRECAUTIONS
Remove spark plug on cylinder head and
pour in a few drops of engine oil. Crank
engine a few times to lubricate cylinder walls
and piston. Clean spark plug and refit.
Note
44
Items to be carried
Tool kit
Insulation tape.
45
Fr e e l y m o v i n g e n g i n e & t r a n s m i s s i o n
components.
Stop
50 Km per hour.
of petrol
46
R a c i n g s t a r t s : Te n r a c i n g s t a r t s
wastes 150 ml. of petrol.
Sudden
acceleration
:
Te n
sudden accelerations wastes 100 ml. of
petrol.
47
WIRING DIAGRAM
Complete Circuit
48
TROUBLE SHOOTING
Causes
Remedies
Switch on ignition.
Replace HT Lead
TROUBLE SHOOTING
Causes
Remedies
Refer 1 - 12
supply ...............................................
TROUBLE SHOOTING
Causes
Remedies
Re-adjust properly
Re-adjust properly
V. White/blue smoke
1) Oil level in tank is above the max. mark in the .... *
TROUBLE SHOOTING
Causes
Remedies
Clean / Replace
Refer I - 12
TROUBLE SHOOTING
Causes
Remedies
Adjust properly
Replace linings
X. Vehicle wobbles
1) Wheel rim runout .............................................. *
Rectify
TROUBLE SHOOTING
Causes
Remedies
XI. Electricals
Bulbs do not light
1) Loose / improper connection ............................ *
Replace bulb
Replace fuse
Replace switch
Tune horn
Replace
Replace
Replace
Replace
TROUBLE SHOOTING
Causes
Remedies
Replace switch
(j)
(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine
tune 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 to
install these changes on previously supplied vehicles.
57
EMISSION WARRANTY
In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal
Enfield certifies that the following warranty is applicable to those components liable to affect the
emission of the gaseous pollutants in its range of motorcycles, in normal use to which it may be
subjected to.
This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000
Kms. or 36 months, whichever occurs earlier, from the date of sale to the first customer and is in
addition to and parallel to the warranty policy, conditions and obligations laid down in the Owners
Manual.
Royal Enfield further warranty that if on examination by its authorised service center, the motorcycle
fail to meet the specified emission standards, then the authorised service center shall take necessary
corrective measures and shall at its sole discretion, repair or replace free of charge such components
of the emission control system to meet the required emission standards.
The method/s of examination to determine the warranty conditions of the emission warranty related
components will be at the sole discretion of Royal Enfield and / or our authorised service centers
and results of such examination will be final and binding. If on examination the warranty conditions
of the part/s is/are not established, Royal enfield will have the right to charge all, or part of the
cost 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 free
of 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 not
independently replaceable, Royal Enfield will have the sole discretion to replace either the entire
assembly or parts of the assembly, through suitable repairs.
58
EMISSION WARRANTY
Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle
or replace any part, in addition to the repair or replacement of the components covered under
emission 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 the
nearest authorised service center OR for any loss due to non availability of the motorcycle
during the period of examination and repairs by Royal Enfield and / or their Authorised Service
centres.
Royal Enfield will not be responsible for any penalties that may be charged by statuatory
authorities on account of failure to comply with the in-use emission standards.
That costs 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 vehicle
provided all the conditions as laid down in this document are met from the date of original sale
of the motorcycle.
EMISSION WARRANTY
Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines
and enters the details in the Log book.
Immediately approaches the nearest authorised service centre upon discovery of failure to
comply with the IN-USE emission standard inspite of having maintained and used the vehicle
in accordance with the instructions in the owner s manual and having carried out such
repairs and adjustments as may be required with a view to establish such compliance.
Produces the Pollution Under Control certificate valid for the period immediately preceding
the test during which the failure is discovered, the test having been carried out either for
obtaining a new certificate or pursuant upon being directed by an officer as referred to in
sub rule (2) of rule 116 of the Central Motor Vehicles Rules.
Produces the owners manual and Log book for verification details.
Produces receipts covering maintenance of the motorcycle is specified in the owners manual
from 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 schedule
described in the maintenance chart.
60
EMISSION WARRANTY
The motorcycle has been subjected to abnormal use, abuse, neglect and improper
maintenance 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 replaced
in 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 of
establishing records.
On examination by Royal Enfield or its authorised service centers, if the motorcycle shows
that any of the conditions stipulated in the Owner s manual with regard to use and
maintenance have been violated.
The motorcycle has been run on adulterated / leaded fuel or lubricant other than those
specified by Royal Enfield in the Owner s manual or any other document given to the
customer 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 emission
warranty is not produced.
All maintenance activities carried out on the vehicle during the tenure of the emission
61
EMISSION WARRANTY
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 authorised
emission checking center.
Always carry a valid Pollution Under Control certificate with you at all times during the
validity 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 owners manual
through 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 owners manual.
5. Use lubricants as per recommendations given on grade / brand in the owners manual.
62
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