Royal Enfield Classic 500 350 Illustrated Parts Manual – DOWNLOAD

Spare Parts Catalogue Classic 500 & 350

Foreword We take pleasure in releasing CLASSIC 500 & 350 Spare Parts Catalogue.

The Catalogue has been specially designed for selection of correct part number to maintain the vehicle, for its optimum performance, longer life and for enjoying the best running condition.

The Royal Enfield Spares are manufactured under stringent quality control to ensure ultimate riding experience. It is therefore important to use only Royal Enfield Genuine Spares.

Due to continuous improvement on performance and efficiency of the vehicle, since this catalogue was printed, it is possible some illustration, designs etc., found within this catalogue may differ from those found on the vehicle.

Such modification will be conveyed through our Technical Service Bulletins, you are requested to update with the correct part numbers in this catalogue.

SERVICE HEADQUARTERS : ROYAL ENFIELD (A Unit of Eicher Motors Limited) Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. India.

Tel : +91-44-4204 3300, Fax : +91-44-4201 1719. Website : www.royalenfield.com E-mail : customerservice@royalenfield.com “ © Copyright 2006 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this Service technical manual shall be copied, distributed or otherwise dealt without the express permission in written from the Eicher Motors Limited, Royal Enfield Unit who remains the sole owner of this manual .”

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For easy reference and quick identification, the parts are grouped into relevant categories. Details are given in the illustrated Group index. Tips on usage of this catalogue

ILLUSTRATION Helps in identifying the shape of the part in its relative assembly.

03-30 FUEL TANK Group No.

Alpha-Numeric Key No. for assy.

A1 Key Nos. 17, 18, 19

Key No. Which make up the assy.

Numeric Key No.

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Part Number List

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2

Key Part Number No. 500EFI 350cc

1.

3

4

Description

Qty.

5 Remarks

KEY NUMBER (KEY NO.) The numeric key number is provided to serve as the identification of the part with its part number.

Serviceable assemblies or kits in a particular group are identified by alpha-numeric key numbers. e.g. A1, A2 etc. In such cases, key numbers of individual items or group number which make up such assembly / kit are given in illustration.

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Part Number List 2. PART NUMBER The Part number of the individual item, kit OR the assembly is given in this column for unique identification. The parts for which part numbers are not given, are not individually serviced.

3. DESCRIPTION The description of the part assigned to the individual item kit / assembly is mentioned in this column.

4. QUANTITY The number of individual items, kits or assemblies required for one vehicle is mentioned here.

Though quantity is indicated for oversize (O/S) or undersize (U/S) of some items, it is to be understood that for a vehicle the sizes only is applicable, depending upon the repair / matching requirements.

6. REMARKS For Reference purpose.

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Group Index Group No. 01-10 01-15 01-20 01-25 01-30 01-45 02-10 02-20 02-30 02-40 03-10 03-20 03-30 03-40 03-50 03-50 03-60 03-60 04-10 04-20 04-30 05-10 05-20 05-30 05-40

Description

Page No.

ENGINE .....................................................................

CRANK CASE LH - COVER SIDE .............................

CRANK CASE RH - COVER SIDE .............................

CRANK CASE LH ......................................................

CRANK CASE RH......................................................

CYLINDER & HEAD ASSEMBLIES ..........................

ENGINE COVER LH .................................................

ENGINE COVER RH .................................................

CLUTCH .....................................................................

GEAR TRAIN ASSEMBLY ........................................

SILENCER & EXHAUST PIPE ..................................

EFI COMPONENTS IN CYLINDER HEAD................

TCI & IGNITION COMPONENTS ..............................

CV CARBURETOR ....................................................

FILTER BOX ASSEMBLY (CLASSIC 500).................

FILTER BOX ASSEMBLY (CLASSIC 350).................

FUEL TANK (CLASSIC 500) .....................................

FUEL TANK (CLASSIC 350) .....................................

FRAME & PAV COMPONENTS ................................

SEAT ASSEMBLY ......................................................

CENTER STAND .......................................................

HANDLE BAR & CONTROLS ...................................

CONTROL CABLES ...................................................

CALIPER ASSEMBLY ...............................................

MASTER CYLINDER ASSEMBLY.............................

Group No.

13 15 19 25 27 31 35 37 41 43 45 47 49 51 55 57 59 61 63 69 71 73 75 77 79

06-10 06-20 06-30 06-40 07-10 07-20 07-30 08-10 08-20 09-10 10-10 10-20 11-10 11-20 11-30 11-40 11-50 11-60 12-10 12-20 12-20 12-30 13-10 14-10 5

Description

Page No.

HEAD LAMP CASING ............................................... 81 FRONT FORK ........................................................... 85 SWING ARM ASSEMBLY .......................................... 87 REAR SHOCK ABSORBER ....................................... 89 BRAKE PEDAL ......................................................... 91 REAR CHAIN ............................................................ 93 FOOT RESTS ............................................................. 95 FRONT WHEEL......................................................... 97 REAR WHEEL ........................................................... 99 REAR BRAKE ......................................................... 103 FRONT MUDGUARD .............................................. 105 REAR MUDGUARD ................................................. 107 BATTERY AND HARNESS ..................................... 111 SWITCHES, HORN & RELAYS ............................... 113 WARNING INDICATOR, AMMETER & SPEEDOMETER 115 HEAD LAMP ........................................................... 117 TAIL LAMP ............................................................. 119 TRAFFICATOR LIGHTS .......................................... 121 TOOL BOX (ELECTRICALS BOX) LH ..................... 123 UTILITY BOX .......................................................... 125 RESONATOR BOX & COVER ................................. 127 BATTERY CARRIER ............................................... 129 TOOL KIT ................................................................ 131 SPECIAL TOOLS LIST ............................................. 133

Group Index - Pictorial 01-15 CRANK CASE LH - COVER SIDE

01-10 ENGINE Page 12

01-25 CRANK CASE - LH

Page 14

01-30 CRANK CASE RH Page 24

02-10 ENGINE COVER - LH

01-20 CRANK CASE RH - COVER SIDE Page 18

01-45 CYLINDER & HEAD ASSEMBLIES Page 26

02-20 ENGINE COVER - RH Page 34

02-30 CLUTCH Page 36

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Page 30

Page 40

Group Index - Pictorial 02-40 GEAR TRAIN ASSEMBLY

03-10 SILENCER & EXHAUST PIPE

Page 42

03-30 TCI & IGNITION COMPONENTS

Page 44

03-40 CV CARBURETOR

Page 48

03-50 FILTER BOX ASSY. (CLASSIC 350)

03-60 FUEL TANK (CLASSIC 500) Page 58

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Page 46

03-50 FILTER BOX ASSY. (CLASSIC 500) Page 50

Page 56

03-20 EFI COMPONENTS IN CYL. HEAD

Page 54

03-60 FUEL TANK (CLASSIC 350) Page 60

Group Index - Pictorial 04-10 FRAME

04-20 SEAT ASSEMBLY Page 62

04-30 CENTER STAND Page 70

Page 68

05-10 HANDLE BAR & CONTROLS

05-20 CONTROL CABLES

Page 72

05-30 CALIPER ASSEMBLY Page 74

500

Page 76

350

05-40 MASTER CYLINDER ASSEMBLY

06-10 HEAD LAMP CASING

Page 78

06-20 FRONTFORK Page 80

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Page 84

Group Index - Pictorial 06-30 SWING ARM ASSEMBLY

06-40 REAR SHOCK ABSORBER Page 86

07-20 REAR CHAIN

Page 90

Page 88

07-30 FOOT RESTS Page 92

08-20 REAR WHEEL

07-10 BRAKE PEDAL

08-10 FRONT WHEEL Page 94

09-10 REAR BRAKE Page 98

10-10 FRONT MUDGUARD Page 102

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Page 96

Page 104

Group Index - Pictorial 10-20 REAR MUDGUARD

11-10 BATTERY AND HARNESS Page 106

11-30 WARNING INDICATOR, AMMETER & SPEEDOMETER

Page 110

11-40 HEAD LAMP

Page 114

11-60 TRAFFICATOR LIGHTS

11-20 SWITCHES, HORN & RELAYS Page 112

11-50 TAIL LAMP Page 116

12-10 TOOL BOX (ELE. BOX) LH Page 120

Page 122

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Page 118

12-20 UTILITY BOX Page 124

Group Index - Pictorial 12-20 RESONATOR BOX & COVER

12-30 BATTERY CARRIER

Page 126

14-10 SPECIAL TOOLS LIST

13-10 TOOL KIT Page 128

14-10 SPECIAL TOOLS LIST Page 132

Page 134

DOL

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Page 130

01-10 Engine

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2

12

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