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The Royal Enfield Continental GT is our lightest, fastest, and most powerful motorcycle in production. It’s a machine
with a story, a nod to motorcycling’s finest hour, the best expression yet of a cultural phenomenon that has simply
refused to fade away - the cafe racer.
Your meticulously re-engineered Continental GT debuts a twin downtube cradle frame chassis developed by the
renowned Harris Performance from UK. A new engine displaces 535cc and dollops of torque, when you need it. W ith
gas-charged rear shock absorbers from Paoli and Brembo disc brakes, you stay in charge. W ith an aerodynamic
seating position, Pirelli Sports Demon tyres and a remapped ECU, the new Continental GT is part homage, part
engineering tour-de-force.
This manual will help you to operate your motorcycle and guide you to wholly maintain it. W e have also provided tips
on safe riding and on minor adjustments for the care of your motorcycle. W e request you to carefully read the terms
and conditions of warranty and other useful information given in this manual before starting to use your Continental
GT. Log on to the exciting world of Royal Enfield on www.royalenfield.com to get to know more about the company,
its products and news from time to time.
W elcome to the world of the Rockers, and enjoy your burn-ups atop this spectacular machine.
Notice 2
All information in this manual is based on the latest product information available at the time of publication. Due to
continuous improvements or other changes, there may be discrepancies between information in this manual and your
vehicle. Royal Enfield reserves the right to make production 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 to explain and need not to be exactly the same on the model you own. Technical
specifications are subject to change without prior notice.
© Copyright 2013 Royal Enfield. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise
dealt without the express permission in writing from Royal Enfield.
If you believe your motorcycle has a defect which could cause a crash and result in serious injury or loss of life, you
should immediately contact the National Highway Traffic Safety Administration (NHTSA) in addition to notifying
Classic Motor works, 1405 Cannon Circle Suite 12, Faribault, MN 55021. Toll Free: 1 800 201 7472
If NHTSA receives similar complaints, it may open an investigation and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in any individual
problems between you, and your dealer or Classic Motor works.
To contact NHTSA you may call the Auto Safety Hotline toll-free within the United States on 1-800-424-
9393 or w rite to: NHTSA, 400 Seventh Street SW, Washington, DC 20590. You can also obtain other
information about motor vehicle safety from the hotline.
Important 4
United States Environment Protection laws, Federal Motor Vehicle Safety Standards and California Air
Resources Board (Applicable only for motorcycles sold within the state of California.) strictly prohibits
tampering with the Exhaust Emission Control, Noise Control and Evaporative Emission Control systems:
W e would like to emphasize that any repairs to the induction, emission, exhaust and evaporative systems must be
performed only by an Authorized Royal Enfield Dealer so that the motorcycle confirms to the United States Environment
Protection laws, Federal Motor Vehicle Safety Standards and California Air Resources Board regulation (Applicable
only for motorcycles sold within the state of California.)
It is the responsibility of the Owner / User of the motorcycle to read this manual carefully and to comply with the
safety guidelines, operating instructions, and periodical maintenance instructions given here. Keep this manual in a
convenient place for easy reference. DO NOT use the motorcycle until you have become familiar with this motorcycle
and after reading and understanding this manual completely. In case you need any further clarifications, please
contact an Authorized Royal Enfield Dealer, nearest to you, for assistance.
If your motorcycle is being used by a friend, relative, or any other person, it is your responsibility to make certain that
they have completely understood the operating procedures of the motorcycle, and the contents in this manual with
particular reference to the safety aspects, before riding your motorcycle.
This motorcycle is designed for NORMAL ON ROAD USE ONLY. Operation in off-road usage in some areas may be
illegal and could be dangerous. Please obey local laws and regulations.
In the event of your motorcycle being sold to another person, it is your responsibility to hand over this manual along
with the motorcycle to the new owner.
Contents 5
Name
Door No./St.
Locality
City Country Postal Code
Res: Off: Mobile: Email:
Contact Nos.
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 it may result in injury to yourself or others
and damages to the motorcycle
Statement in this manual preceded by the following words are with special significance.
Warning
Indicates a potentially hazardous situation, which if not avoided, could result in death, serious injury, or damage.
CAUTION :
Indicates a potentially hazardous situation , if not avoided, may result in minor or moderate injury and / or damage.
NOTE :
Indicates important and useful messages for clear understanding.
Technical Specification 10
ENGINE
Bore.......................................................... 87 mm
Stroke ....................................................... 90 mm
Engine Oil Grade ..................................... 15W 50 API SL, JASO MA ESTER Semi Synthetic Oil
IGNITION SYSTEM
TRANSMISSION
ELECTRICALS
WARNING
Generation ................................................ Alternator
U s ing b ulbs / ot her e le c tr ic al
System ..................................................... 12V DC gadgets other than specified rating may
lead to over loading / erratic behaviour /
premature failure of electrical system.
Battery ...................................................... 12V - 14 AH
Modifications on the bike which are not
Head lamp ................................................. 12V, 50 / 35 W, approved by Royal Enfield may not only
disqualify for warranty, but also affects
Brake / Tail lamp ....................................... 21/5 W performance of the bike.
CHASSIS
Frame ....................................................... Tubular steel double cradle
Tire size ................................................... Front: 100/90-18 M/C 56H
.......................................................... Rear: 130/70-18 M/C 63H
Tire pressure ........................................... Front- Solo: 1.41 Kg/cm2 (20 PSI)
.......................................................... Pillion: 1.55 Kg/cm2 (22 PSI)
Note:
.......................................................... Rear- Solo: 2.11 Kg/cm2 (30 PSI)
***Fuel tank capacity given
.......................................................... Pillion: 2.25 Kg/cm2 (32 PSI)
here is approximate. It can
Fuel tank capacity .................................... 13.5 Litres*** v ary ma rgin ally fr o m this
Low fuel warning ..................................... 3.00 Litres specified value.
Suspension .............................................. Front: Telescopic, Stroke 110mm
.......................................................... Rear: Twin - Gas Charged, Stroke 80 mm
Front fork oil capacity .............................. 430 ml per leg
Front fork oil ............................................. Gabriel Fork Oil 2W 35
Hydraulic Brakes ...................................... Front: 300 mm dia floating disc, twin piston floating caliper
.......................................................... Rear: 240 mm dia disc, single piston floating caliper
Brake oil grade ......................................... DOT 3 or DOT 4
Brake oil capacity ..................................... Front: 50 ml
.......................................................... Rear: 100 ml
Technical Specification 15
DIMENSIONS
Length ...................................................... 2060 mm
W idth ....................................................... 760 mm
Height ...................................................... 1070 mm
W heel base ............................................. 1360 mm
Saddle height .......................................... 800 mm
Ground clearance ................................... 140 mm
WEIGHTS
Kerb Weight (with 90% Fuel) ................. 184 Kg
Gross vehicle weight .............................. 365 Kg
NOTE :
1. Values / Dimensions given above are for your guidance only.
2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.
Safe Riding Tips / Guidelines 16
Know and respect the rules of the road. Be a safe Fuels containing methanol should not be used as it
rider for your own safety and for other road users. can cause damage to the fuel system components
Safe Riding Tips / Guidelines 17
immediately. Take care not to spill any fuel on the Failure to do so can lead to improper balance, poor
engine, exhaust pipes, rubber parts or any other part stability, poor handling, and abnormal tread wear.
of the motorcycle.
Please replace tires which are punctured or damaged.
Do not store motorcycle with gasoline in the tank, Small punctures in the tread area may be repaired
within your home or garage where open flames, pilot from within the tire. The motorcycle should not be
lights, spark or any appliance with a pilot light, electric driven over 40 MPH (60 Kmph) for the first 24 hours
motors are present. Inadequate safety precautions and over 55 MPH (90 Kmph) thereafter with a repaired
could cause an explosion or fire and could result in tire.
damage to property, serious injury or loss of life.
Warning
TIRES & SUSPENSION
In emergency situations, please ride slowly with least
Please inspect and ensure tires are seated evenly & possible load until the tire is permanently repaired or
properly in the rims. Maintain the recommended tire replaced. Failure to heed to this warning could result
pressures as it is very important for riding stability. in serious injury or loss of life.
Pay strict attention to loose and / or broken spokes
Regularly inspect front forks, rear shock absorbers
Ensure the front and rear wheels are correctly
and rear suspensions for any wear, looseness / side
aligned. Check spokes for correct tightness in the
play, oil leaks etc. Replace worn parts. Worn parts
rims and free movement of steering system.
can adversely affect stability and handling.
Inspect the tires thread condition periodically and
replace worn out tires with approved make only.
Safe Riding Tips / Guidelines 19
Roy al E nfield c annot tes t an d make s pecific add weight to the handlebars or front forks.
r ec om mend at ions conc er ning sp ec if ic or a DO not exceed 5 pounds (2.3 kgs) maximum
combination of accessories sold. Therefore, the rider hanging load on either side of the motorcycle at
mus t be respons ible for safe operation of the the rear end.
motorcycle when installing accessories or carrying
additional weight. Recheck the cargo periodically to be sure it is
s ec ur ed and w ill not s hift while riding .
Please adhere to the following guidelines when Accessories secured loosely may affect the
c ar ry in g a pillion, c ar go or w hen fitt in g an y riding of the motorcycle and affect the stability of
accessories. the motorcycle.
DO NOT exceed 70 MPH (110 km/h) when riding Large surfaces such as fairings, windshields,
solo. backrests and luggage racks can adversely
DO NOT exceed 55 MPH (90 Km/h) when carrying affect handling of the motorcycle.Only genuine
a pillion and/or cargo. Royal Enfield accessories, designed specifically
for the motorcycle model should be used with
Keep cargo weight concentrated close to the proper installation.
motorcycle and as low as possible; this minimizes
sudden shift in the motorcycle’s center of gravity. Warning
Distribute weight evenly on both sides of the DO NOT load weight or install accessories improperly
motorcycle. on t he m ot or cycle. D oing s o may af fect t he
DO not load bulky items too far behind the rider or motorcycle’s stability, handling characteris-tics, and
Safe Riding Tips / Guidelines 21
Warning
R oyal E nf ield c au tion s you against use of
nonstandard parts such as aftermarket and custom
made extended front forks which may adversely
aff ec t th e per form an ce and h and ling of the
motorcycle. Removing or altering original parts may
adversely affect the performance of the motorcycle,
causing an accident, which could result in serious
injury or loss of life.
Safe & Happy Riding 22
Please wear proper riding apparel. Hold the handle bar grips, close to its inner end
A pair of riding boots or shoes. Look extensively ahead, including rear view
Soft leather gloves. mirrors, without turning the head.
Goggles or spectacles to safe guard eyes.
An approved helmet. Affixed with light reflecting BRAKING
strips of radium stickers at the front and rear. Ap ply fr on t and r ear br ak es g ently an d
NOTE : simultaneously for maximum braking efficiency.
A light Colored shirt enables greater visibility to other
road users especially during nights. WARNING
CAUTION : Applying any one of the brakes suddenly may cause
Loose clothing may get caught on moving parts of your the vehicle to skid. The hydraulic disc brakes fitted
motorcycle. on your motorcycle require very less effort. High effort
or sudden application may lock the wheel. Please use
SITTING POSTURE utmost caution while applying the brakes.
Correct sitting posture is a pre-requisite for stable
and safe riding W hile riding on wet or bad road conditions use
Sit in lean forwarded position. brakes cautiously.
Rules of the Road 23
Be sure your number plate is installed in the Keep to the correct side of the road center line
position specified by law and it is clearly visible when meeting oncoming vehicle.
at all times.
Actuate your turn signals and exercise caution
Ride at a safe speed that is consistent with the when passing other vehicles going in the same
type of road surface you are on. Pay strict direction. Never try to pass another vehicle
attention to whether the surface is : g oing in th e same direct ion at s tr eet
intersections, on curves, or when going up/or
Dry
down a hill.
Oily
Icy At street intersection give the right-of-way to
the vehicle on your left or right . DO NOT
Wet
presume you have the right-of-way.
Watch for loose debris, such as leaves, slippery
Always signal when preparing to stop, turn or
substances or loose gravel that can hamper the pass.
stability of your vehicle.
W hile turning either right or left, watch for
DO NOT exceed the legal speed limit or drive
pedestrians, animals, as well as vehicles.
too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High All traffic signs, including manual controls at
speed inc reases the influence of any other intersections, should be obeyed promptly.
condition affecting stability and increases the SLOW DOW N at traffic signs near schools and
possibility of loss of control. CAUTION signs at railroad crossings.
Rules of the Road 24
W hen intending to turn, signal at least 100 feet SIDE VIEW MIRRORS
(30.5 meters) before reaching the turning. Be
c lose to the center line (unless local rules
require otherwise), slow down and then turn
carefully.
Never jump a traffic light. W hen a Red
c hange is imminent from GO to Your motorcycles is equipped with convex mirrors
STOP ( or v ic e vers a) at Yellow
and have a curved surface. This type of mirror is
intersections, slow down and wait designed to give a much wider view of the rear than
for the light to change to green. Green
a normal flat mirror. However, cars and ot her
Never run through a yellow or red
objects seen in this type of mirror will look smaller
traffic light.
and farther away than when seen in a flat mirror.
DO NOT leave the curb or parking area without
signalling. Be sure your way is clear to enter Use care when judging the size or distance of
moving traffic. A moving line of traffic always objects seen in these mirrors.
has the right-of -way. NOTE :
W hen parking the motorcycle, park on a firm To help you to establis h the relative dis tanc e of
and flat surface to prevent it from falling over. vehicles behind your motorcycle, adjust each mirror
Protect your motorcycle against theft. After in such a way, that a small portion of your shoulder is
parking your motorcycle, ensure that steering visible and a large portion behind your motorcycle is
head is locked and then remove the Ignition key. seen clearly.
Vehicle Identification Number - Details 25
The VIN is a 17 digit number punched on right side of the steering head tube and in the information plate rivetted to the frame
down tube.
Decipherable information
Check digit No
Year of Manufacture
Place of Manufacture
Code for 535cc
Frame Sl. No.
Vehicle Identification Number - Details 26
CAUTION :
It is illegal of tamper with the VIN / information plate as it is the only means of identification of the motorcycle.
Engine Number - Details 27
The engine number is punched on the left hand side top of the LH Crankcase. It is the means of identification of the
Engine and its production details. Please do not tamper with the number as it is prohibited by law.
U 6 S 5 F 0 D G XXXXXX
Engine Family
Engine Capacity
Type of Start
Transmission
Fuel Feed
Assembly Factory
(0-Chennai, 1-Kanchipuram)
Year of Manufacture
( 2009-9, 2010-A, 2011 -B,....)
Production Month
(A - Jan., h - Aug., K - Sep., N - DEC.)
1. RH Trafficator front
RIGHT SIDE VIEW
2. Brake Pedal
3. Kick Start Lever
4. Starter Motor
5. Horn
7
1 6. RH Side Panel
7. RH Trafficator Rear
6 2 34 5
Key Parts Location 29
1. Trafficator front LH
LEFT SIDE VIEW
2. Spark plug
6 3. Gear Change Pedal
4. Centre stand
5. Side Stand
6. Side Panel LH / Battery Cover
1 7. Trafficator rear LH
2 3 5
4
Key Parts Location 30
TOP VIEW 4 56 7 8 9 10 11
2 12
13
1 14
1. Turn signal switch 6. Manual Bistarter / Choke 11. Engine Kill switch
2. Horn button 7. Speedometer 12. Park / head light switch
3. Clutch lever 8. Ignition switch 13. Electric Start Switch
4. Day flash switch 9. Malfunction Indicator Lamp 14. Fuel tank cap
5. Head lamp dip switch 10. Tacho Meter
Operation of Controls 31
IGNITION SWITCH
ON OFF
Insert ignition key and turn clockwise direction Turn the ignition key in anticlockwise direction
to “ON”. Once you turn on the ignition key all to “OFF”. Once you turn off, all the electrical
the indicating lights in instrument cluster starts s ys tems g oes off . Now th e k ey c an b e
glowing on for few seconds and the engine will removed.
get ready to start. The key cannot be removed
from “ON” possition.
Operation of Controls 32
Turn the handle bar to extreme left or right position. Push the key in steering lock Position, and turn
Push the key inside in “OFF” position, press clockwise direction to unlock the steering.
and further turn to anticlockwise direction to The key can be removed from the lock in this
lock the steering system. position.
The key can be removed from the lock in this
position.
CAUTION : CAUTION :
Protect your motorcycle against theft. After parking Do not lubricate barrel locks with petroleum based
your Motorcycle and lock the steering, then remove lubricants or graphite. Inoperative locks may result in
the key from combination switch. damage to your vehicle.
Operation of Controls 33
FUEL TANK CAP (WITH KEY LOCKING FEATURE) FUEL TANK CAP (CALIFORNIA MODELS)
TO OPEN:
Turn key clockwise to open. Press the cap to Turn Cap anticlockwise
lock with key in position.
TO CLOSE:
NOTE :
Locate cap and turn clockwise till click sound is
Key can be removed only in locked position. heard.
Operation of Controls 34
LOW BEAM
HIGH BEAM
Operation of Controls 38
PRESS
Apply choke in cold start condition while starting the Bike
Pre Operational Checks 40
A careful check of the following must be carried out 6. Engine oil level.
every time before riding and especially after long
periods of storage to determine if any additional 7. W heel spokes for proper tightness and no
maintenance is necessary. breakage.
1. Adequate fuel in the tank. 8. Headlamp, tail lamp, brake lamp and indicator
lamps for proper functioning.
2. Tires for correct pressure, abrasions or cuts.
California Air Resources Board, Emissions Owner’s Manual. Royal Enfield recommends that you
Regulations (Applicable for motorcycles sold in the retain all receipts covering maintenance on your
State of California) motorcycle. It is also your responsibility to present / take
your motorcycle to a Royal Enfield dealer, if a problem in
Your Royal Enfield motorcycle is equipped with an the evaporative emission system. As the vehicle owner,
evaporative emission control system consisting of a you should also be aware that Royal Enfield may deny
Canister, rubber hoses and connectors to comply with your warranty coverage if your vehicle or a part has
the stringent California Air Resources Board (CARB) failed due to abuse, neglect, improper maintenance or
emissions regulations, anti-smog standards. unapproved modifications. If you have
The equipment does not have any serviceable parts for any questions regarding your
the user to service. However in order to ensure that the warranty rights and responsibilities or
motorcycle is compliant, it is necessary to periodically if an authorized Royal Enfield dealer
inspect the rubber tubes and connections for any leaks, cannot repair your motorcycle or
cracks, cuts or damage. In case any of the above is honor your claim within a reasonable
noticed, the motorcycle should be taken immediately to a period of time, contact Royal Enfield
nearest Authorized Royal Enfield dealer for inspection for assistance@ 312-569-1075. If you
and necessary correction are not satisfied with the way in which
a warranty claim is resolved by Royal
The evaporative emission control system is covered Enfield, you may write directly to:
under warranty for 18,641 miles (30,000 Kms) OR 5
Years from the date of sale of the motorcycle to the first
customer. Director of Field Operations OR California Air Resources
BoardSupport Division (EI4-397F) 9480 Telstar Ave. Suite 4
As the vehicle owner, it is your responsibility to ensure Environmental Protection Agency El Monte, CA 91731
that the motorcycle is taken to the nearest Royal Enfield 401 M Street, S.W. Washington,
dealer to carry out the required maintenance listed in the D.C. 20460
Electronic Fuel Injection (EFI) 43
CAUTION :
Do not force the gear lever while attempting to shift to
neu tral . Move t he m otor c yc l e bac k & f or th and
simultaneously press gear lever to come to neutral.
Ensure neutral Indicator light glows in the Speedometer.
NOTE :
If the engine does not start on the first attempt
in cold climate, release the starter button, wait Ensure the side
for 30 s ec onds before pressing the starter and main stands
button again. are in released
Press starter button and release starter switch position
once the engine starts.
A clutch switch is provided in the system for Ensure that gears
the safety of the rider. This is to prevent the are in neutral and
vehicle from starting when the vehicle is in gear. neutral lamp is
To start the engine when it is in gear, pull clutch glowing
lever, press the starter button and release
slowly after the engine starts.
Starting 46
Press Starter
Button and NOTE :
release as It may be necessary to operate and hold the manual
soon as engine bi starter, when starting the engine for the first time in
starts cold mornings, temperatures below 10°C or at high
altitudes, to prevent the stalling and to keep the idling
RPM steady.
Starting 47
Warning
Always park the motor cycle on a firm and flat surface. Parking in a soft ground may cause stand to sink and the
motorcycle to fall, causing injury to you or to others and damage to the motorcycle parts.
Tools & Spares Kit 50
Warning
DO NOT switch oil brands indiscriminately because some oil interact chemically when mixed. Use of interior oils or
non-detergent oils can damage the engine.
DO NOT Mix DOT 3 & DOT 4 brake fluid together.
Periodical Maintenance 52
The maintenance schedule detailed here will help you to maintain your Royal Enfield motorcycle meticulously
and to get a long trouble free service. The schedule provided herein is based upon average riding conditions
and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must 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, severe climatic cold and hot conditions, bad roads,
stagnant water etc., Contact a nearest Royal Enfield Dealer for expert advice and to carry out the periodical
maintenance.
Warning
For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of
regular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the motorcycle
to malfunction and stall abruptly resulting in an accident and cause serious injury.
Periodical Maintenance 53
S.
No. DESCRIPTION SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
1 Engine Oil R R R R R R
Check level every 500 Kms or earlier as required
2 Engine oil filter R R R R R R
3 Engine sump filter C C C C C C
4 Magnetic drain plug under gear box on crankcase RH C C C C C C
5 Spark plug C&A C&A C&A C&A C&A R C&A C&A C&A C&A R
6 HT lead I I I I I I I I I I I
7 Fuel hose I I I I R I I I R I I
8 Fuel Pump Check for screw tightness in all services
9 Accelerator cable play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold I I I I R I I I R I I
12 Air filter element C C C C R C C C R C C
Periodical Maintenance 54
S.
No. DESCRIPTION SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
13 Inlet / Exhaust valve seating I
14 Cylinder head D
15 Exhaust pipe D
16 Clutch free play Adjust every 1000 Kms (600 Miles) or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L
18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet contact I I
Adjust every 1000 Kms (600 Miles) or earlier as required
21 Rear Chain
Lubricate every 3000 Kms (1800 Miles) or earlier as required
22 Fork oil R R
23 Steering ball races A L A L A
24 Spokes tightness I I I I I I
Periodical Maintenance 55
S.
No. DESCRIPTION SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
25 Wheel rim run out I I I I I
26 Tire wear I I I I I I I I I I
27 Hand levers & Kick starter pivot Lubricate every 1000 Kms or earlier as required
28 Brake Oil level check / Replacement I I I I I I I R I I I
29 Pivot-Side Stand L L L L L L L L L L L
30 Center Stand pivot L L L L L L L L L L L
31 Pillion Foot rest pivot L L L L L L L L L L L
32 Swing arm bearings L L
33 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I
A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace
Applicable only for Motorcycles sold in the State of California.
NOTE :
For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in
consultation with a Royal Enfield Service Station.
Minor Maintenance Tips 56
Secondary
Primary Drain Plug
Drain Primary
Plug Filter Cap
(Refer Periodical Maintenance Chart for frequency) Remove the secondary drain plug with its
Place the motorcycle on its centre stand on a washer and allow the oil to drain.
firm flat surface. Allow the oil to drain by tilting the motorcycle to
Start and warm up the engine for 2 minutes. both sides.
Keep a clean tray below the engine. W ash the drain plugs and the suction filter
Remove the primary drain plug with its washer thoroughly and refit on the crankcase after all
and allow the oil to drain in to the tray. the oil is drained out.
Remove the primary filter cap and then remove Soak a new oil filter paper element in the oil and
the primary filter. refit on the Crankcase Cover RH.
Minor Maintenance Tips 58
Max
Cleaning and adj usting gap (Refer Periodical
NOTE : Min Maintenance Chart for frequency)
Replace oil filter paper element whenever oil is being Remove HT Lead and the spark plug from the
replaced. cylinder head using the plug spanner and
Tommy bar.
CAUTION : Clean the insulator tip and electrodes of the
plug carefully using a pointed scraper or spark
Do not fill oil over MAX mark. It may cause the engine plug cleaner.
to smoke and result in loss of power. Do NOT use the
motorcycle if the oil is at the MIN mark. Doing so will Set the gap between 0.8 to 0.9 mm.
cause serious damage to the moving parts inside the Refit the spark plug on the cylinder head and
engine and result in an engine lock up. connect H.T. Lead.
Minor Maintenance Tips 59
FRONT BRAKE REAR BRAKE Bald spots / swelling may be caused by internal
damage. Replace the Tires, if defective.
Check if oil is below ‘MIN’ level. To top Up, remove Replace Tires when the tread depth has reached
cover and diaphragm, then top up with DOT 3 or the minimum as specified.
DOT 4 as specified. Periodically inspect wheels for spokes breakage
CAUTION : and wheel rim run out.
Check proper seating of the Tire beading on the
Brake fluid is highly corrosive and can cause damage
rim whenever the Tire is reassembled.
to painted parts. Please ensure that brake fluid does
not spill on any part of the motorcycle. In the event of W henever a new Tire is installed, ensure rim
a spill, please clean the area immediately with a soft and spokes do not get damaged on account of
cloth (preferably a wet cloth) to avoid damage. wrong handling.
Minor Maintenance Tips 60
Use only standard Tires & tubes inflated to FRONT WHEEL REMOVAL
correct pressure. Place the vehicle on center stand
CAUTION :
Do not press the rear brake pedal when wheel is
removed as this will result in the brake pads coming
too far out of the brake caliper.
REAR WHEEL REASSEMBLY Align the caliper bracket, wheel and swing arm
holes in-line and ensure distance collar is
Remove the wooden piece / card board sheet placed in hub dust seal.
placed between the brake pads.
Insert and tap the rear wheel axle gently.
Ensure the four Cush
r ub bers are in Ensure the index marks alignments on both
position in side t he sides of the swing arm are in same position
rear wheel hub. for proper wheel alignment.
Tilt vehicle to right Tighten the axle nut firmly.
and ins er t wh eel
Ensure that swing arm end plate is seated
ass em bly between
the swing arms. prop erly and the chain adj us ter nuts are
correctly tightened and Locked.
Position t he r ear
wheel with c us h
rubber on t he r ear CAUTION :
driven flange. Do not force the spindle into the wheel as the threads
may get damaged. Tap it through the wheel gently.
In sert t he caliper
assembly by pushing
in t he p roj ect ion
g iven ins ide th e Warning
swing arm. Ensure Ensure the vehicle do not come out of center stand
the brake disc is
located in between wh ile dis mant ling and as semb ling the wheel
the brake pads. assembly.
Minor Maintenance Tips 65
Clutch Lever (free play 2 - 3 mm) If above are alright, then do the adjustment as
mentioned below:
1. Turn the brake light switch adjustment nut while
Loosen the cable outer lock nut (A). holding the rear brake light switch body in
position.
Turn the Nut (B) Clockwise to reduce the play 2. If the brake light do not glows after pressing
the pedal for approximately 25mm,turn the
or Anticlockwise to increase the free play. adjusting nut in clockwise direction by 2 to 3
threads and check for brake light function.
Check free play 2 to 3 mm at Clutch lever pivot
3. If the brake light continuously glows,turn the
on handle bar end. adjusting nut in anti clockwise direction by 2
to 3 threads so as to get the positions in which
Tighten lock nut (A) after adjustment is done. the light goes off.
Minor Maintenance Tips 66
ADJUSTMENT OF GAS SHOCKABSORBER Adjust both the rear shock absorbers to the
same thread possitions.
Warning
Riding the motorc ycle with the s hock abs orbers
adjusted in dif ferent positions can caus e loss of
control.
The rear gas shock absorber is an adjustable Regularly inspect shock absorbers and front forks
type.The spring tension can be increased or for any leaks.
decreased.
R educ e th e s pr in g tens ion f or low load NOTE :
operation by turning the adjuster nut in the Ensure accessories, fitted if any, do not foul with
direction as shown above by using a suitable rear s hock absorb ers. C heck f or suf f ic ient gap
C - spanner. between the shock absorbers and the attachments
Inc reas e t he spring tension f or high load in a condition that the rear end of the Motorcycle is
operation by turning the adjuster nut in oposite fully loaded and the shock absorbers are maximum
direction. compressed.
Minor Maintenance Tips 69
(-) (+)
TERMINAL TERMINAL
Remove t he s eat
Assemble back the
assembly by pulling
tail lig ht in th e
seat lock cable.
r ever se ord er of
dismantling.
Remove t he t ail
light g lass by
u ns cr ew ing it s
mounting screw
Minor Maintenance Tips 73
AIR FILTER PAPER ELEMENT Takeout air filter paper element and check
CLEAN AND REFIX : EVERY 3000 KMS for dirt. Gently tap it as shown in fig and fix it
back.
Remove the screw from the side cover bottom
side and then take out RH side cover.
NOTE :
It is adviceable to replace air filter paper element once
in 10,000 KMS. In case of vehicle running in dusty /
Remove the air filter
mud road condition it may be replaced as earlier as
cover screws and required.
then takeout air filter
Us age of h igh pres sure com pres sed air is n ot
box cover.
recommended to clean air filter paper element.
Fitment of air filter paper element is reverse order of
removal process.
Washing Procedure 76
Cover the silencer tail end and control switches Use Luke warm water and mild detergent on the
with suitable plastic bags and tie it firmly to painted components to remove dirt, etc.
prevent water entry into them.
Rinse vehicle thoroughly with plain water to
Remove ignition key and seal key hole using remove the detergent and wipe vehicle dry.
adhesive tape.
If possible, use compressed air and blow off
Use a suitable engine degreaser, available with water particles from the obscure areas of
your local parts store, to remove dirt or grease t he vehic le, elect rical connect ions , EFI
from the engine external parts if required. components etc.
Follow the direct ions in the label carefully
before using the degreaser.
AFTER WASHING
Use low pressure jet of water to clean the entire
Ensure the vehicle is thoroughly dry by wiping
vehicle.
with a clean soft water absorbent cloth or
Never spray water with great force on head chamois leather.
lamp, Meter/cluster unit, trafficator lights, front
Remove all plastic bags and adhesive tapes.
Washing Procedure 77
Incase your Motorcycle is not going to be used for terminals and apply petroleum jelly on the
a m on th or mor e, w e advise th e following terminals to avoid corrosion.
precautions to be taken Maintain electrolyte level between max and
Carryout required repair/adjustments on the min marks, by adding distilled water and wipe
motorcycle. the battery dry.
Wash the motorcycle thoroughly and lubricate St ore the bat tery in a cool, dry and well
as per the maintenance chart. ventilated place.
Start the engine, warm up for a few minutes Do not place the battery in direct sun light, near
and switch off. open flame or where temperature is above
40°C or below 0°C
Drain out the fuel completely from the fuel tank
and fuel lines. Cover the silencer with plastic bags to prevent
moisture entry. Set the motorcycle on its center
Remove the spark plug. Pour in about 20ml of
stand.
clean engine oil through spark plug hole. Close
the hole and crank engine few times and refit Apply anti rust solution on all chrome plated
the sparkplug. parts. Take care not to apply this solution on
rubber or painted parts.
Clean the rear chain thoroughly and apply
lubrication oil on it. Store motorcycle in a clean covered area free
of moisture and keep it covered to prevent dust
Remov e battery from t he bik e. C lean its
settling on it.
Storage Precautions 79
PREPARING THE MOTORCYCLE FOR REUSE Remove spark plug on cylinder head and pour in
a few drops of engine oil. Crank engine a few
Remove anti rust solut ion from all chrome times to lubricate cylinder walls and piston. Clean
plated parts and clean the motorcycle. spark plug and refit.
Inflate the Tires to the correct Tire pressure. Switch “ON” the ignition switch.
Ensure battery is fully charged and electrolyte Start vehicle and warm up engine for a few
level is properly maintained. minutes before riding the vehicle.
Connect the battery.
CHECKS PRIOR TO THE COMMENCEMENT OF LONG CHECKS AFTER EVERY 1500 KMS (930 MILES) OF
JOURNEY RUN
Tightness of all fasteners.
Service the motorcycle thoroughly at Royal
Tire treads condition and wear pattern of Tires.
Enfield Dealer / Authorised Service Point as
per periodical maintenance chart. (Ref. Page Battery condition and electrolyte level.
No. 46 to 49) Correct oil level in engine.
W orking of all lights and horn.
Sufficient quantity of petrol in the fuel tank for
Proper drive chain tension.
the planned journey.
ITEMS TO BE CARRIED
Check and correct Tire pressure if necessary.
Tool kit.
Correct the oil levels in Engine, brake master First aid kit.
cylinders. Bulbs for Headlight, Trafficator light and mini
Check for good battery condition and proper Blade Fuses (15 & 10 Amps).
electro lyte level. Accelerator and Clutch cable.
Rear chain master link lock assembly.
Pr oper dr ive ch ain ten sion and corr ect ly Spare tubes.
adjusted rear brakes.
Foot operated Air Pump.
Check for proper functioning of all lights & horn Insulation tape.
etc., Spark plugs (M14).
Complete Wiring Diagram 81
NOTE :
Complete W iring Diagram is attached on this page.
Trouble Shooting 82
Warning Warning
The trouble shooting section of this Owner’s Manual Please get the electrical system of your Motorcycle
is intended solely as a guide for diagnosing problems. chec ked thoroughly and get the f aults c orrected
Carefully read the appropriate sections of this manual immediately after experiencing any fuse failure. Not
before performing any work. Repair and maintenance doing this can result into repeated fuse failures.
operations not listed in this Owner’s Manual should
be perf ormed by your Royal Enf ield Dealer only. Usage of f us es oth er than spec if ied rat ing will
Improper repair / maintenanc e could result in the damage the complete electrical system.
motorcycle not functioning properly or injury seriously.
CAUSES REMEDIES
I. ENGINE FAILS TO START
1) Stop switch in ‘OFF’ Position ............. Push stop switch to ‘ON’ position.
2) Side stand not retrieved .................... Retrieve side stand.
3) Vent hole clogged in fuel tank cap .... Clean vent hole.
4) Spark plug cap / lead not connected . Fix cap / lead firmly
5) Spark plug electrode dirty / fouled .... Clean spark plug
6) Spark plug insulation cracked ........... Replace spark plug
7) Clutch slipping ................................... *Adjust clutch cable free play
8) Main or EFI Fuse failed................... .. Replace with new fuse
* Contact Dealer / Authorised Service Point
Trouble Shooting 83
CAUSES REMEDIES
CAUSES REMEDIES
V. ENGINE OVERHEATING
1) Low engine oil level .......................... Check and top-up if necessary
2) Clutch slipping ................................... * Check and correct
3) Cylinder fins not clean ...................... Clean the cylinder fins at regular intervals
CAUSES REMEDIES
IX. ELECTRICALS
Bulbs do not glow
1) Bulb fused ........................................ * Replace bulb
Royal Enfield warrants its Motorcycle to be free from manufacturing and materials defects, under normal use subject to following conditions.
1. Warranty shall be in force until the expiry of a period of 24months from the date of sale.
2. The above warranty is applicable only to the first registered owner of the Motorcycle and is not extended to subsequent owner’s - if the
motorcycle sold as second hand.
3. Warranty repairs, if any and periodical servicing requirements should be availed only at the Authorized Royal Enfield distributor’s service
facility OR at their authorized dealership.
4. During the warranty period, Royal Enfield’s obligation is limited to repair or replacing free of charge, such part or parts of the vehicle, which
in examination shall be deemed defective in opinion of Royal Enfield and / or their distributors / authorized dealers. Such defective part /
s, which have been replaced, shall become the property of Royal Enfield.
5. Cost of consumables like fuel, Oils etc., Labour, shipping charges of replacement parts for any warranty replacement are chargeable to
the customer.
6. Warranty is not applicable for the following parts:
Normal ageing of parts like rubber parts, tires & tubes, hand grips, glass, plastic, soft items like seat rexene, cushion etc.
Dullness of chrome plated parts, discolorisation of chromed exhaust pipe / silencer, buffed parts, painted surfaces etc
Normal wear & tear items such as control cables, brake pads/ shoes, clutch plates etc
Electrical items like bulbs, wiring harness, switches, battery, fuses, electric start motor etc.
7. Warranty will become void under the following conditions:
Damages due to lack of proper maintenance, periodic services not carried out as per Royal Enfield recommendation etc.
Damages caused by any unauthorized repairs carried out in any part of the motorcycle
Warranty 88
The following warranty applies to the emission control system and is in addition to the LIMITED WARRANTY, NOISE
CONTROL SYSTEM WARRANTY & CALIFORNIA AIR RESOURCES BOARD REGULATIONS. EVAPORATIVE EMISSION
CONTROL SYSTEM WARRANTY. (Applicable only for motorcycles sold within the state of California.)
Royal Enfield Motors warrants the first owner and each subsequent owner, that this motorcycle is designed and built
so as to conform, at the time of sale, with applicable regulations specified by the U.S. Federal Environmental
Protection Agency and California Air Resources Board Regulations, that the Emission control system related parts
fitted to this motorcycle are free from defects in materials and workmanship which may cause this motorcycle not to
meet the U.S. Federal Environmental Protection Agency standards for a period of 5 years OR 18,641 Miles (30,000
Kms.), whichever occurs first, from the date of first use of the motorcycle.
The W arranty period shall begin, on the date the motorcycle is delivered to the first retail purchaser OR from the first
date the motorcycle is used as a demonstrator OR as a display and/or trial motorcycle.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE EMISSION CONTROL SYSTEM WARRANTY:
1. Failures which may arise as a result of misuse, alterations, accidents OR non performance of routine maintenance,
as specified in the Owner’s Manual.
Emission Control System Warranty 90
2. Replacement of parts such as Spark plugs, Air filter, fuel filter, Oil filter, fuel injector, lubricating oils etc that are
required to be replaced during routine maintenance at specified intervals as mentioned in this Owner’s Manual.
3. Loss of time, inconvenience, loss of motorcycle use or any other consequential loss or damages.
4. Any motorcycle in which the Odometer has been tampered with, OR the speedo cable has been disconnected for
any reason Or is broken and not replaced immediately, due to which the exact distance covered cannot be
determined.
IT IS RECOMMENDED THAT THE ROUTINE MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED
INTERVALS AND ANY MAINTENANCE TO THE EMISSION CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN
AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USING ONLY GENUINE ROYAL ENFIELD SPARE PARTS.
REPAIRS TO THE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE OUTLET
OR INDIVIDUAL AND USE OF PARTS OTHER THAN GENUINE ROYAL ENFIELD SUPPLIED PARTS IS PERMISSIBLE,
ONLY IF SUCH AGENCY OR INDIVIDUALS AND THE NON GENUINE PARTS USED, ARE CERTIFIED TO COMPLY WITH
THE U.S. ENVIRONMENTAL PROTECTION AGENCY STANDARDS.
Noise Control System Warranty 91
The following warranty applies to the noise control system and is in addition to the LIMITED WARRANTY, EMISSION
CONTROL SYSTEM WARRANTY & CALIFORNIA AIR RESOURCES BOARD REGULATIONS. EVAPORATIVE EMISSION
CONTROL SYSTEM WARRANTY. (Applicable only for motorcycles sold within the state of California.)
Royal Enfield Motors warrants the first owner and each subsequent owner, that this motorcycle is designed and built
so as to conform, at the time of sale, with applicable regulations specified by the U.S. Federal Environmental
Protection Agency and California Air Resources Board Regulations, that the Noise control system emission related
parts fitted to this motorcycle are free from defects in materials and workmanship which may cause this motorcycle
not to meet the U.S. Federal Environmental Protection Agency standards for a period of 5 years OR 18,641 Miles
(30,000 Kms.), whichever occurs first, from the date of first use of the motorcycle.
The W arranty period shall begin, on the date the motorcycle is delivered to the first retail purchaser OR from the first
date the motorcycle is used as a demonstrator OR as a display and/or trial motorcycle.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE NOISE CONTROL SYSTEM WARRANTY:
1. Failures which may arise as a result of misuse, alterations, accidents OR non performance of routine maintenance,
as specified in the Owner’s Manual.
Noise Control System Warranty 92
2. Replacing OR removing OR modifying any portion of the NOISE CONTROL SYSTEM (consisting of Exhaust, Air
intake/cleaner assembly) with parts not certified to be genuine and noise legal in the USA for street use.
3. Loss of time, inconvenience, loss of motorcycle use or any other consequential loss or damages.
4. Any motorcycle in which the Odometer has been tampered with, OR the Speedo cable has been disconnected for
any reason or is broken and not replaced immediately, due to which the exact distance covered cannot be
determined.
IT IS RECOMMENDED THAT THE ROUTINE MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED
INTERVALS AND ANY MAINTENANCE TO THE NOISE CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN
AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USING ONLY GENUINE ROYAL ENFIELD SPARE PARTS.
REPAIRS TO THE NOISE CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE OUTLET OR
INDIVIDUAL AND USE OF PARTS OTHER THAN GENUINE ROYAL ENFIELD SUPPLIED PARTS IS PERMISSIBLE, ONLY
IF SUCH AGENCY OR INDIVIDUALS AND THE NON GENUINE PARTS USED, ARE CERTIFIED TO COMPLY WITH THE
U.S. ENVIRONMENTAL PROTECTION AGENCY STANDARDS.
Evaporative Emission Control System Warranty 93
The following warranty applies to the evaporative emission control system and is in addition to the LIMITED WARRANTY,
EMISSION CONTROL SYSTEM WARRANTY & NOISE CONTROL SYSTEM WARRANTY.
Royal Enfield Motors warrants the first owner and each subsequent owner, that this motorcycle is designed and built
so as to conform, at the time of sale, with applicable regulations specified by the California Air Resources Board AND
that the evaporative emission control system related parts fitted to this motorcycle are free from defects in materials
and workmanship which may cause this motorcycle not to meet applicable regulations of the California Air Resources
Board standards, for a period of 5 years OR 18,641 Miles (30,000 Kms.), whichever occurs first, from the date
of first use of the motorcycle.
The Warranty period shall begin either on the date the motorcycle is delivered to the first retail purchaser OR from the
first date the motorcycle is used as a demonstrator OR as a display and/or trial motorcycle.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY:
1. Failures which may arise as a result of misuse, alterations, accidents OR non performance of routine maintenance,
as specified in the Owner’s Manual.
Evaporative Emission Control System Warranty 94
2. Replacing OR removing OR modifying any portion of the EVAPORATIVE EMISSION CONTROL SYSTEM (consisting
of Fuel tank, fuel tank cap, Canister, purge valve, throttle body, vapor hoses, fuel hoses and hose connectors)
with parts not certified to be genuine and approved by California Air Resources Board.
3. Loss of time, inconvenience, loss of motorcycle use or any other consequential loss or damages.
4. Any motorcycle in which the Odometer has been tampered with, OR the Speedo cable has been disconnected for
any reason OR is broken and not replaced immediately, due to which the exact distance covered cannot be
determined.
5. Normal ageing of parts such as fuel hoses, vapor hoses, gaskets & rubber components.
REPAIRS TO THE EVAPORATIVE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED
SERVICE OUTLET OR INDIVIDUAL AND USE OF PARTS OTHER THAN GENUINE ROYAL ENFIELD SUPPLIED PARTS IS
PERMISSIBLE, ONLY IF SUCH AGENCY OR INDIVIDUALS AND THE NON GENUINE PARTS USED, ARE CERTIFIED TO
COMPLY WITH THE CALIFORNIA AIR RESOURCES BOARD.
Service Maintenance Record 95