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EURO IV - HIMALAYAN LS410 SERVICE MANUAL KS MOTORCYCLES - http://ksmotorcycles.com

EURO IV - HIMALAYAN LS410 SERVICE MANUAL...ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 5 EXPLODED VIEWS CYLINDER HEAD COVER ASSEMBLY 1 Cover - Tappet Inlet 2 Hex Flange Bolt-M6 X

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EURO IV - HIMALAYAN LS410 SERVICE MANUAL

KS MOTORCYCLES - http://ksmotorcycles.com

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 1

“FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction.

Royal Enfield is committed to upgradethe skills and knowledge of technicians so that they follow scientific repair

techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy

trouble free performance at all times.

This manual will help in complete understanding of systematic procedures for dismantling, inspection, diagnosis and

reassembly of the new range of Royal Enfield, LS 410Single Cylinder, 4 Stroke, Overhead Cam, Air Cooled with Oil

cooler Engine, in a simple and scientific manner.

While this manual is updated with latest Information and Specifications, at the time of going to print, due to continuous

improvements being done to improve performance, some of the data, illustrations etc., in this manual may differ

from the actual parts fitted in the engine.

Please do feel free to write to us at [email protected], if you have any queries, clarification,

suggestions or feedback.

With warm regards

SERVICE HEAD QUARTERSRoyal Enfield, A Unit of Eicher Motors Limited,Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019.Phone: 044 - 4223 0400, Fax: 044 - 4201 1719E-mail: [email protected]: www.royalenfield.com

“ © Copyright 2017 Royal Enfield (A Unit Eicher Motors Limited). All Rights Reserved. No part of this Service Manualshall be copied, distributed or otherwise dealt without the express permission in written from the Royal Enfield whoremains the sole owner of this manual .”

Part No: / Oct. ’17

PREFACE

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 01

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 4102

CONTENTS

SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.

1. Engine Views LH & RH ........................................ 3

2. Technical Specifications .................................... 4

3. Exploded Views ................................................. 5

4. Gear Operating Positions - LS 410 .................... 17

5. Oil Circulation ................................................... 19

6. Periodical Maintenance Chart - LS 410 ............ 20

7. Servicing / Overhauling .................................... 21

8. Components Dismantling Sequence .............. 22

9. Special Tools Usage List ................................... 23

10. Importance Notice Before Dismantling .......... 24Engine From Frame

11. Engine Dismantling Procedure Sequence ...... 25

12. Wear Limits - LS 410 ......................................... 66

13. Torque Values - LS 410 ..................................... 67

14. Precautions Before Engine Reassembly ......... 69

15. Trouble Shooting ........................................... 117

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41002

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 3

ENGINE VIEWS LH & RH

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 03

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 4104

TECHNICAL SPECIFICATIONS

ENGINE& ENGINE SYSTEMSA. ENGINE LS 4101 Type Single Cylinder, 4 Stroke SOHC, Air cooled, Fuel Injection2 Bore 78 mm3 Stroke 86 mm4 Displacement 411 cc5 Compression ratio 9.5 : 16 Max Power @ RPM 24.5 BHP(18.02 Kw @ 6500 RPM7 Max Torque @ RPM 32 Nm @ 4000 RPM8 Idle RPM 1250 + 50 RPM @ EOT 80 deg9 Starting Electric Start10 Air filter element Paper element11 Lubrication Forced Lubrication, Wet Sump

12Engine oil tank capacity (1st Dry fill/ fill after 2.3 litrescomplete Engine Overhaul)Engine oil tank capacity(Routine Oil change/ 2.0 litresSubsequent refills)

13 Engine oil grade SAE 15W 50 API SL Grade JASO MA 214 Cooling Forced Air Cooled with Oil CoolerB. TRANSMISSION  1 Clutch Wet, Multiplate2 Primary drive Gear3 Primary ratio 2.312: 14 Gear box 5 Speed Constant Mesh

5

Gear Ratios    1st Gear 2.916:1  2nd Gear 1.833:1  3rd Gear 1.428:1  4th Gear 1.173:1  5th Gear 1:000:16 Secondary drive 5/8” Chain & Sprocket7 Secondary ratio 2.533:1C. FUEL1 Fuel PetrolD. IGNITION Digital Spark Ignition - TCI System1 Ignition Advance / Ignition System 5 – 30O / Electronic Ignition, ECU/Variable2 Spark plug Bosch - UR5CC3 Spark plug gap 0.7 to 0.8 mmE. ELECTRICALS1 System 12V - DC2 Generation Alternator3 Alternator Output 170W @ 1500 RPM

ROYAL ENFIELD SERVICE MANUAL LS 41004 ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41004

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 5

EXPLODED VIEWS

CYLINDER HEAD COVER ASSEMBLY

1 Cover - Tappet Inlet

2 Hex Flange Bolt-M6 X 21

3 ‘O’ Ring - Camshaft Hole

4 Plug - Camshaft Hole

5 Hex Flange Bolt - M6 X 16

6 Hex Flange Bolt - M6 X 55

7 Hex Flange Bolt - M6 X 60

8 Gasket Washer – 6.2 X 14 X 1

9 Cover - Tappet Exhaust

S. NO. DESCRIPTION

10 O’ Ring - Tappet

11 Hex Flange Bolt - M6 X 40

12 Nut - Tappet Adjusting

13 Screws Tappet Adjusting

14 Arm comp valve Rocker

15 Shaft Valve Rocker Arm

16 Copper Washer

17 Plug - Rocker Shaft

18 Hex Flange Bolt - M6 X 45

S. NO. DESCRIPTION

2

1

10

2

18

1213

14

15

16

17

17

16

15

2

1011

2

8

777

6

6

6

5

43

14

13

12

ROYAL ENFIELD SERVICE MANUAL LS 410 05

9

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 05

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 4106

CYLINDER HEAD ASSEMBLY

1 Cylinder Head & Cover Box Assembly2 Hollow Dowel (OD 9 X12), Cover cylinder3 Seat Valve Spring4 Seal Valve Stem - Intake5 Seal Valve Stem - Exhaust6 Spring Valve Inner7 Spring Valve Outer8 Retainer Valve Spring9 Cotter Valve10 Spark Plug11 Bolt Cylinder Head M10 X 17012 Washer Cyl Head Bolt

S. NO. DESCRIPTION S. NO. DESCRIPTION

13 Cover- Cam Center14 Hex Flange Bolt - M6 X 1615 Hex Flange Bolt - M6 X 3016 Valve Exhaust17 Valve Inlet18 Nut M8 X 1.2519 Stud Exhaust20 Damper Pad - Cylinder Head Front21 Damper Pad RH - Cylinder Head22 Damper Pad - Cylinder Head Back23 Damper Pad LH - Cylinder Head

1

1918

17 1615 14

356

7

8

912

12

11

11

2

20

21

22

23

13

10

8

9

7

64

3

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41006

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 7

CYLINDER BARREL & PISTON ASSEMBLY

1 Gasket - Cylinder Head MLS2 Hollow Dowel (OD 13X18) - Cylinder Barrel3 Hex Flange Nut – M6 X 1, Cylinder Barrel4 Gasket - Cylinder Barrel5 Pin Piston

S. NO. DESCRIPTION S. NO. DESCRIPTION

1

2

3

4

5

67

8

9

6

2

10

A1

6 Circlip - Piston Pin7 Ring – Piston 1st8 Ring – Piston 2nd9 Ring – Piston oil10 Damper Pads Cylinder barrel

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 07

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 4108

CAM CHAIN ASSEMBLY

1 Pin, Control Arm Pivot

2 Pin Assy Decomp

3 Arm, Decompression Control

4 Spring, Control Arm

5 Cam Shaft Assy

6 Pin, Camshaft Sprocket

7 ‘C’ Ring, Camshaft

8 Lock Washer, Camshaft Sprocket

9 Bolt – M6 X 12, Camshaft Sprocket

S. NO. DESCRIPTION

10 Sprocket- cam shaft

11 Cam Chain

12 Guide pad

13 Tensioner Pad

14 Gasket - Chain Tensioner

15 Auto Chain Tensioner Assy

16 Hex. Socket Head. Cap Screw, M6 X 25

17 Bolt Stepped M6 X 14, Cam Chain Tensioner

18 Washer - 6 X 18 X 1, Cam chain Tensioner Bolt

S. NO. DESCRIPTION

21

7

610

8

9 11

12

13

14 15 16

1817

4

3

5

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41008

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 9

CRANK TRAIN

1 Crank Shaft with Balancer Shaft Assembly

2 Washer 10.5 X 28 X 2.5, Crank Balancer

3 Washer Belleville, Crank Balancer Lock

4 Hex Flange Bolt - M10 X 20

5 Sprocket – Oil pump Driven

6 Chain oil pump

7 Sprocket – Oil pump Drive

S. NO. DESCRIPTION

8 Nut- LH- M18, Oil Pump Drive Gear

9 Washer, Oil Pump sprocket Lock

10 Washer-22X4X1.5, Primary Drive GearThrust

S. NO. DESCRIPTION

5

89

6

710

43

2

1

ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 09

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41010

8

7

6

3

A125

4

1

9

E-START SYSTEM

A1 Starter Clutch Assembly

1 Gear, Starter Idle No.2

2 Spacer - Idler Gear

3 Gear, Starter Idle No.1 (Double Gear)

4 Shaft Starter Idle Gear No.2

5 Shaft Starter Idle Gear No.1

S. NO. DESCRIPTION S. NO. DESCRIPTION

6 ‘O’ Ring Starter Motor

7 Starter Motor Assy

8 Hex Flange Bolt - M6 X 30

9 Hex Soc. Head Screw - M6 X 20

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 11

8

7

6

3

A1

3

45

3

2

1

3

9

10

11

COVER LH

A1 Magneto Assembly

1 Cover LH

2 Hollow Dowel - OD13 X 18, Cover LH

3 Hex Flange Bolt M6 X 35

4 Copper Washer, Oil Check Plug

5 Plug, Oil Check– M14 X 12

6 Hex Socket Head Screw M5 X 30

S. NO. DESCRIPTION

7 Hex Socket Head Screw M5 X 15

8 Clamp Starter Wire

9 Hex Flange Bolt M6 X 55

10 O Ring

11 Cover Crankshaft Center

12 Hex Socket Head Screw M6 X 14

13 Gasket, Cover LH

S. NO. DESCRIPTION

13

12

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41012

A1 Magneto AssemblyA2 Starter Clutch Assembly1 Hex Flange Nut - M12 X 1.25P X 11(W), Magneto2 Key Woodruff3 Hex Soc. Head Screw - M6 X 204 Hex Flange Bolt-M6X16 Gear Position Switch5 Terminal Gear Position Switch6 Pin, Gear Position7 Spring, Gear Position Pin8 Oil Seal, Gear Shift Shaft9 Hex Flange Bolt - M6 X 20, Oil Strainer Cover10 Plug M14 X 12, Oil Drain11 Copper Washer Drain plug12 Cover, Strainer13 O-Ring, Oil Strainer Cover14 Strainer Comp. Engine Oil15 Hex Flange Bolt M8 X 12, Oil Gallery16 Gasket Washer - 8.2 X 16 X 1, Oil Gallery Bolt17 Hex Soc. Head Screw - M6 X 1218 Jet Comp, Starter Clutch Oil19 O-Ring - 4 X 1.2, Oil Jet

S. NO. DESCRIPTION S. NO. DESCRIPTION

20 Jet Comp, Piston Oil21 Bearing (#6204),Crank Balancer22 Bearing (#6203LU),COUNTER SHAFT,LH23 Stud M6 X 37, Cylinder Barrel24 Hollow Dowel - Od13 X 18, Crankcase Lh25 Bearing (#6305LU), Drive shaft LH26 Oil Seal, Drive Shaft27 O-Ring, Spacer Engine Sprocket28 Spacer, Engine Sprocket29 Sprocket Comp - Final Drive Engine 15T (#525)30 Tab Washer M20, Engine Sprocket Lock31 Nut M20, Engine Sprocket32 Retainer, Drive Shaft Oil Seal33 Bolt M6 X 10, Drive Shaft Oil Seal Retainer34 Sprocket Cover35 Hex Flange Bolt - M6 X 3536 Hex Flange Bolt - M8 X 10037 Hex Flange Bolt- M8 X 7038 Hex Flange Bolt – M6 X 6039 Hex Flange Bolt - M6 X 85

39

CRANKCASE LH

2224

2123

19

20

15 16

15 16 19 18 17 16 15

2414

1312 9 1110

6 978

54

2627 28

29

3031 32

33 35

34

A2

25

39383736

38

3

2

1A1

3738 393837

17

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 13

1112

1110

8

9 8 65

3 4

3

32

2 1

24

22

23

1819

2021

13

1819

8 9

14

15

13

16 17

CRANKCASE RH

1 Circlip Oil Pump Shaft2 Washer 8 X 16 X 0.5 Oil pump sprocket3 Hex Flanged Bolt – M6 X 304 Pump Assy, Oil5 Gasket6 Stopper, Gear Shift Arm7 Bearing -#16005 , Gear Shift Drum RH8 Hex socket head screw - M6 X 129 Retainer, Counter Shaft Bearing10 Circlip 17 X 1, Kick Idle Gear.11 Washer - 17 X 28 X 1, Kick Idle Gear Thrust12 Spacer Drive Shaft

S. NO. DESCRIPTION S. NO. DESCRIPTION

13 Hollow Dowel (Od13X18), Cover-RH14 Bearing - 6304, Counter Shaft RH15 Bearing - 6203, Drive Shaft RH16 Bearing - 6306, Crankshaft RH17 Bearing - 6204,Crank Balancer18 Oil jet19 O-Ring - 4 X 1.2, Oil Jet20 Copper Washer Drain plug21 Plug oil check M1422 Sprocket – Oil pump Drive23 Chain oil pump24 Sprocket – Oil pump Driven

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41014

COVER RH

8

76

54 2

3

2

12

2411 23

22

21

20

11

19

113

9

2

1110

1213

18

1716

1415

1

9

11

1 Cover RH Assembly2 Hex Flanged Bolt M6 X 1 X 303 Hollow Dowel (OD13X18), Cover-RH4 Oil Filter5 Spring Oil Filter6 O Ring Oil Filter7 Cap Oil Filter8 Hex Flange Bolt - M6 X 709 Hex Flanged Bolt M6 X 1 X 2010 Bracket, Clutch Release11 Hex Flange Bolt - M6 X 3712 O Ring Oil Filler

S. NO. DESCRIPTION S. NO. DESCRIPTION

13 Plug Oil Filler14 Seal Clutch Release15 Washer Clutch Release16 Spring Clutch Release17 Hex flange bolt M6 X 718 Shaft Clutch19 Gasket Cover RH20 Hex Socket Head Screw M6 X 1221 Plate Retainer22 Oil Seal Crankshaft RH23 Jet, Crank Shaft RH24 Lens Oil Level Check

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 15

911

12

13

14

1516

17

2

3

4

65

1

10

CLUTCH

1 Friction Plate

2 Plate Clutch

3 Wheel Clutch

4 Thrust Washer

5 Housing Assembly

6 Belleville Spring (Jadder spring)

7 Plain Washer (Jadder washer)

8 Hub Clutch With Ring

9 Compression Spring

10 Holder Clutch

S. NO. DESCRIPTION S. NO. DESCRIPTION

11 Hex Bolt M6

12 Washer, Clutch Sleeve Hub Lock

13 Nut M20 - Clutch Sleeve Hub

14 Bearing Cup

15 Bearing 17X35X10

16 Pin, Clutch Release

8

7

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41016

TRANSMISSION

1 Washer - 17 X 28 X 1, Drive Shaft thrust2 Bush, 1st Driven Gear3 Gear, 1st Driven4 Washer - 20 X 30 X 1, 1st Driven Gear thrust5 Gear, 5th Driven6 Circlip 25 X 1.2, 5th Drive Gear7 Washer, 3rd & 4th Driven Gear8 Bush, 3rd & 4th Driven Gear9 Gear, 4th Driven10 Washer, thrust Washer Lock11 Washer,3rd & 4th Driven Gear thrust12 Gear, 3rd Driven13 Wheel, Sliding Dog14 Bush, 2nd Driven Gear15 Gear, 2nd Driven16 Shaft Comp, Drive17 Gear, 2nd Driven18 Gear, 3rd & 4th Drive19 Washer - 25 X 34 X 1, 5th Drive Gear thrust20 Gear, 5th Drive21 Bush, 5th Drive Gear

S. NO. DESCRIPTION S. NO. DESCRIPTION

22 Shaft Comp, Counter23 Spacer primary drive24 Fork, Gear Shift No.125 Shaft, Gear Shift Fork26 Fork, Gear Shift No.227 Fork, Gear Shift No.328 Cam Comp, Gear Shift29 Star Index, Gear Shift Cam30 Stepped Bolt Hex Soc. Hd , Star Index31 Bolt Stepped, Gear Shift Cam Stopper32 Arm Stopper Comp, Gear Shift Cam33 Washer - 6 X 18 X 1, Tensioner Bolt34 Spring, Gear Shift Cam Stopper35 Circlip-14 X 1, Gear Shift Shaft36 Washer 14 X 25 X 0.8, Gear Shift Shaft Thrust37 Shim, Gear Shift Shaft38 Spring, Gear Shift Shaft Return39 Shaft Comp, Gear Shift40 Plate, Gear Shift Cam Drive41 Spring, Gear Shift Cam Drive Plate

3

56

4

7 8

910 11 8

127 6

13

6 13

15 16

35 37 4140

39 3835 37 36 35

3132

33 3430

292825

24

2322

21 2019

18 6 17 1

2627

61 2

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 17

OIL COOLER

6

5

4

3

2

1

1 2

7

8

7

5

4

1 Copper Washer

2 Bolt - Union Crankcase

3 Pipe Comp Engine Oil No 1

4 Hexagonal Nut M6

S. NO. DESCRIPTION S. NO. DESCRIPTION

5 O Ring Oil Coole

6 Oil Cooler

7 Hex.Socket Head Cap Screw M6 X 25

8 Pipe Comp Engine Oil No 2

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41018

GEAR OPERATING POSITIONS - LS 410

1ST GEAR

2ND GEAR

Clutch

Drive Shaft Gears1st 5th 4th 3rd 2nd

Final DriveSprocket

Counter Shaft Gears

1st 5th 4th 3rd 2nd

Clutch

Drive Shaft Gears1st 5th 4th 3rd 2nd

Final DriveSprocket

Counter Shaft Gears

1st 5th 4th 3rd 2nd

Clutch

Drive Shaft Gears1st 5th 4th 3rd 2nd

Final DriveSprocket

Counter Shaft Gears

1st 5th 4th 3rd 2nd

3RD GEAR

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 19

4TH GEAR

5TH GEAR

Clutch

Drive Shaft Gears1st 5th 4th 3rd 2nd

Final DriveSprocket

Counter Shaft Gears

1st 5th 4th 3rd 2nd

Clutch

Drive Shaft Gears1st 5th 4th 3rd 2nd

Final DriveSprocket

Counter Shaft Gears

1st 5th 4th 3rd 2nd

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41020

OIL CIRCULATION

ENGINE-OIL FLOW

LH VIEW RH VIEW

Oil Pump Oil FilterOil Strainer screen

Counter shaftMain shaft

Cam shaft

Oil Gallery

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 21

The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates theIntervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintainyour Himalayan motorcycle meticulously

If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads /stagnant water etc., the maintenance will need to be done earlier as may be required.

Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and forany expert advice.

PERIODICAL MAINTENANCE CHART - LS 410

A : A d j u s t C : C l e a n I : I n s p e c t L : L u b r i c a t e R : R e p l a c e

* Refer Service Manual.

# Check every time after vehicle is used for off road riding

For maintenance after 50,000 Kms. , please repeat same frequency specified above, in consultation with a RoyalEnfield Authorised Dealer / Service Center.

S.No. DESCRIPTION FREE SERVICE

Whichever is earlierPAID SERVICE

Whichever is earlierKms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50

Months 1.5 6 12 18 24 30 36 42 48 54 60

1 Engine Oil (Level check / Replace)R I R I R I R I R I R

Check level at every 1000 Kms or earlier as required

2 Oil Filter Element R R R R R R

3 Engine oil strainer on crankcase LH C C C C C C

4 Inlet / Exhaust Tappet setting I&A I&A I&A I&A I&A I&A I&A I&A I&A I&A I&A

5 Rubber hose, Inlet manifold * I I R I R I R I R I R

6 Oil cooler inlet & outlet pipes * I I I R I I R I I R I

7 Spark plug C&A C&A C&A R C&A C&A R C&A C&A R C&A

8 Accelerator Cable I I R I R I R I R I R

9 Clutch Plates R R R

10 Cam Chain / Chain Pads / Auto chain Tensioner I I I I I I I I I I I&R

11 Inlet / Exhaust valve seating (compression test) * I I

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41022

SERVICING / OVERHAULING POSSIBLEWITHOUT DISMANTLING ENGINE FROMFRAME Inlet & Exhaust Tappet adjustments

Auto Chain Tensioner, Cam shaft assembly, Camchain, pads

Cylinder Head assembly

Cylinder Barrel, Piston&Rings

Clutch assembly

Oil pump assembly

Gears operating mechanism/ gear shift shaft oil seals

Magneto Stator / Rotor Assembly

Starter Clutch Assembly

Starter Motor replacement

Gear position sensor switch ,

Final Drive sprocket.

SERVICING / OVERHAULING FORWHICH ENGINE HAS TO BE REMOVEDFROM FRAME Crankcases opening

Crank shaft / Balancer Shaft / Main Shaft / CounterShaft / Gears / Gear Operator forks / Gear SelectorDrum.

Crank case bearings.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 23

COMPONENTS DISMANTLING SEQUENCE

COMPONENTS DISMANTLING SEQUENCE TO REMOVE ENGINE FROM FRAME

Skid Plate on Frame bottom.(Himalayan models)

Engine oil (Drain when warm. Remove drain plug /oil strainer cover on crankcase LH & Oil filter on CoverRH)

Oil Cooler along with inlet & outlet pipes.

Fuel hose & Pulse Air valve connections

Battery connections

TPS/Magneto/Gear position/ Side stand switch:couplers dismantle

Starter motor connections

Spark plug suppressor cap

Engine steady bracket

Control Cables (Clutch / Accelerator)

Exhaust pipe & Silencer

Gear shift linkage

Starter motor

Cover LH

Gear position indicator sensor

Magneto rotor assembly including Starter clutch

Starter idler gears with bush & spindles

Rear Chain (Remove from FD sprocket)

FD sprocket nut (loosen )

Cover RH

Oil pump gears / Oil pump

Crank shaft Nut (LEFT HAND THREADED)

Balancer shaft Bolt

Clutch center nut & Clutch assembly

Gear shift shaft assembly (Remove circlip & washeron shift shaft from LH crankcase side first)

Cam shaft covers / Cylinder head cover

Automatic chain tensioner

Cam shaft gear & cam shaft Assembly

Cylinder Head Sub Assembly

Chain Tensioner Pads

Cylinder Barrel Sub Assembly

Cradle frame top mountings (with connector)mounting to frame

Cradle frame bottom mounting LH& RH on frame

Rear top engine mounting on frame (support enginefrom bottom suitably)

Four mounting studs of Engine to cradle frame

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41024

SPECIAL TOOLS USAGE LIST

ST-27527-2 Tappet Adjusting Tool To adjust Tappets Clearance

ST-27528-2 Valve Spring Compressor For removal of Inlet/ Exhaustvalves from cylinder head

ST-27529-2 Piston Support Plate

To support Piston duringassembly / Dismantlingcylinder barrel & for removal/installation of circlips in piston

ST-27530-2 Magneto Rotor PullerTo remove Magneto rotorfrom Crankshaft

ST-27531-2 Clutch Locking PlateTo compress Clutch springsduring dismantling/assemblyof clutch plates

ST-27532-2 Piston Circlip Installer For installing Piston pin circlips

ST-27533-2 Crank Gears locking ToolTo lock Crankshaft /Clutch gearfor removing/ tighteningCrankshaft / clutch nut

ST-27534-2 Magneto rotor & FD To lock Magneto rotor/FD sprocket locking Tool sprocket for removing

tightening nut.

Part No. Description Photo Usage purpose

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 25

1. Engine oil should always be drained when the engine is warm and before engine is dismantled from the frame..

2. Ensure oil cooler pipes are dismantled from engine and Oil cooler is removed from the frame.

IMPORTANT NOTES BEFORE DISMANTLING ENGINE FROM FRAME

4. Remove pillion & rider seat

5. Remove fuel tank mounting fasteners at the rear end, Lift up tank slightly and disconnect fuel level sensorconnection coupler to wiring harness.

6. Slide fuel tank towards the rear and gently pull out fuel tank from frame. Take care not to damage fuel tank whilelifting up or while sliding towards the rear.

7. Remove side panel RH, Remove the battery holding strap, Disconnect battery connections.

8. Remove pulse air valve -inlet & outlet pipe connections from inlet manifold and cylinder head.

9. Remove exhaust pipe & silencer.

10. Disconnect all electrical connections& couplers: spark plug suppressor cap, magneto, pulsar coil, E start motor,throttle position switch, gear position indicator, side stand switch& earth terminals.

11. Remove engine steady plate from cylinder head &frame

12. Remove gear shift linkage from gear shaft on frame LH side

13. Remove clutch & accelerator cable connections from engine.

14. Remove rear chain.

15. Remove the bolts & studs mounting cradle frame to main frame at the front, rear & bottom after suitablysupporting the engine at the bottom.

16. Remove the bolts & nuts mounting engine to cradle frame.

3. E nsur e pi ston i s at T DC oncompression stroke:

Remove inspection bolt on cover LH tovisually check if the timing mark on themagneto rotor is aligned with thereference mark on cover LH.

If the marks are not aligned, removecover- crankshaft centerfromcover LH&rotate magneto rotor nut ONLY INCLOCKWIS E di rection , till the “+”reference mark on magneto rotor alignswith the mark on cover LH.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41026

ENGINE DISMANTLING SEQUENCE

S.No.

1. Oil cooler Remove Inlet & Outlet

Banjo union bolts fromLH& RH Crankcaserespectively & allow oilto drain.

Ensure the 4 washersare removed from the oilpipes / banjo Union

Remove oil cooler alongwith inlet & outlet pipes.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Bolt Union: M17Socket Spanner:23mm

NOTE:Ensure Oil cooler mountingbolts are removed fromframe bracket beforeremoving oil cooler.

Hex Plug: M14 X 12Socket Spanner: 21 mm

2. Oil drain plug Remove hex plug with

copper washer from oilstrainer housing oncrankcase LH.

CAUTION:Dispose drained oil onlythrough an authorizedrecycling agency to preventenvironment pollution.

Hex flange bolt: M6 X 20Hex Socket: 8 mm

3. Oil strainer Remove 2 hex flange

bolts from strainercover.

Remove cover with ‘O’ring.

Pull out the strainergently from crankcase

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 27

S.No.

4. Oil Filter Remove 1 long Hex

flange bolt from thebottom of il filter cover.

Remove 2 Hex flangebolts from the top of theoil filter cover.

Gently pull out of the oilfilter element.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolt: M6 X 70Hex socket: 8mm

Hex flange bolt: M6 X 30Socket spanner: 8mm

5. Starter motor Remove 2 Hex flange

bolts from Crankcase RHside.

CAUTION:Remove bolts evently &slowly since cover is springloaded.

Ensure ‘O’ ring is removedfrom cover.

Hex flange bolts: M6 X 20Hex socket: 8mm

NOTE:The filter element will betight in cover RH, due to therubber seal on the inside ofthe element seating on thespout.

NOTE:Ensure Earth terminal isdisconnected from the Hexflange bolt.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41028

5. Starter motor Gently pull out starter

motor from the spigot incrankcase LH& remove.

Hex flange bolt: M6 X 35Socket Spanner– 8mm

6. Sprocket cover Remove 2 hex flange

bolts, holding sprocketcover to crankcase LH.

Remove cover.

Hex socket hd. screw:M6 X 14Allen Key: M5

7. Cover crankshaftcenter Remove 2 hex socket

head screws, from thecover crankshaft center

Remove cover.

NOTE:Remove ‘O’ ring if stuck tocover LH.

Hex flange bolt: M6 X 55:3 Nos.Hex flange bolt: M6 X 35:8 Nos.Socket Spanner– 8mm

8. Cover LH Remove 3 long hex

flange bolts from therear side of cover LH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure the Magneto & Gearposition sensor wire couplersare disconnected beforeremoving cover LH

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 29

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

8. Cover LH Remove 8 short hex

flange bolts from thefront & center of coverLH.

Gently tap on the tabs incover LH to release:

- Stator from

magneto rotor.

- From the locating

dowel at the

bottom of

crankcase LH.

Remove gasket.

Special Tool-ST-27534-2, MagnetoRotor & FD sprocketlocking Tool

9. Final drive sprocketnut: Straighten locking tab

overhex U nut, using asuitable chisel.

Locate special tool on FDsprocket & remove hex“U” nut.

Remove lock washer &sprocket.

Hex “U” Nut: M20Hex Socket: 32mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41030

10. Gear positionindicator Remove 2 hex flange

bolts.

Gentlyrotate &pull outfrom crankcase LH.

Remove the pin & springfrom counter shaft.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolt: M6 X 16Hex Socket: 8mm

NOTE:Ensure ‘O’ ring is removedalong with gear positionindicator.

11. Starter Idle gears Remove 2 bushes from

idle gear spindles.

Remove idle gear(middle).

Remove double gear(top).

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 31

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

12. Magneto Rotor Locatethe special tool

on 3 hex socket headscrews inside magnetorotor to prevent it fromrotating while looseninghex nut.

Remove nut & locatemagneto rotor remov-ing special tool on thethreaded portion of therotor.

Tighten center bolt toremove magneto rotor,along with starter clutchassembly from LH shaft.

Special Tool-ST-27534-2,Magneto rotor & FDsprocket locking Tool

Hex nut: M15 XHex Socket: 18mm

Special Tool: ST-27530-2,Magneto Rotor Puller

NOTE:Ensure special tool is fullythreaded on the magnetodamage to the rotor.rotorcenter, to prevent

NOTE:Ensure woodruff key isremoved from LH shaft.

11. Starter Idle gears Remove the 2 spindles.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41032

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

15. Cover RH Remove 2 Hex flange

bolts holding clutchbracket to cover RH

Hex flange bolt: M6 X 30Hex flange bolt: M6 X 37Hex Socket: 8mm

13. Starter ClutchAssembly Gently rotate outer gear

anticlockwise & removefrom starter clutch.

Hex socket hd screw: M6 X 20Allen Key: M5

14. Starter ClutchAssembly Remove 6 hex socket

head screws from insidemagneto rotor andremove outer ring alongwith starter clutch.

Remove starter clutchfrom outer ring.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 33

15. Cover RH Remove small Hex flange

bolt (fully threaded)from front of cover RH.

Remove balance 11 Hexflange bolts.

Gently tap cover torelease the same fromthe locating dowels oncrankcase RH whiles i m u l t a n e o u s l yactivating the clutchlever to remove cover RH

Remove RH covergasket.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure the clutch push paddoes not fall off whileremoving Cover RH

Hex flange bolt: M6 X 20

Hex Socket: 8mm

Hex flange bolts: M6 X 37Hex Socket: 8mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41034

16. Jet-Crankshaft,Cover RH: Remove hex socket

head screw with retainerplate.

Remove oil seal& jet fromcover RH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

18. Balancer shaft bolt Locate special tool

between crankshaftgear & clutch housinggear at the bottom tolock crankshaft.

Loosen & remove theFlanged hex bolt

Remove big & small blackthrust washers.

Special Tool- ST-27533-2,Crank Gears locking Tool

Hex socket hd screw:M6X12Allen key: M5

17. Oil jet in crankcaseRH Gently pull out the Oil Jet

located in the oil gallerynear the oil pump gear inCrankcase RH.

Hex flange bolt: M10 X 20Hex Socket: 14mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 35

19. Crank shaft nut Locate special tool

between crankshaftgear & clutch housinggear at the bottom tolock crankshaft.

Loosen hex nut byrotating it “CLO CK-WISE” & remove.

Remove small thrustwasher.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

20. Clutch Nut Remove clutch bearing

with collar.

Locate special toolbetween clutch gear &crank shaft gear at thebottom to lock clutchhousing.

Loosen hex nut.

Special Tool: ST-27533-2,Crank Gears locking Tool

CAUTION:LH thread nut. Loosen byrotating

Nut LH thread: M18Hex Socket: 24mm

Special Tool: ST-27533-2,Crank Gears locking Tool

Hex nut: M20Hex Socket: 27mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41036

21. Oil pump sprocket& chain assembly Remove circlip on oil

pump shaft.

Remove thrust washer

Remove pump sprocketalong with the small gearon crankshaft assembly& chain

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

22. Oil pump assembly Remove 4 hex flange

bolts holding oil pump &remove pump.

Remove pump gasket.

Hex flange bolts: M6 X 30Hex Socket: 8mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 37

23. Clutch Remove splined washer

from clutch main shaft.

Remove clutch assemblyfrom clutch housing

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

24. Clutch plates Remove 2 hex screwsat

diagonally oppositeends of the clutchholding plate.

Position special toolover clutch holding platesuch that the mountingholes of the tool isaligned with the 2 holeson clutch holding plate.

Assemble 2 long M6screws over the tool&tighten till the specialtool rests firmly on theclutch holding plate.

Loosen & remove the 4hex screws from theclutch holding plate.

Loosen the 2 screwsslowly & remove specialtool.

Hex Screw: M6 X 10Hex Socket: 10mm

Special tool: ST-27531-2,Clutch locking plate

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41038

24. Clutch plates Remove clutch holding

plate and the 6 springs.

Remove clutch hubalong with the clutchplates.

Remove the clutchpressure plates, steelplates, Belleville & steelwashers.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 39

25. Clutch housing Remove washer from

main shaft.

Remove clutch housingwith bush from mainshaft.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

27. Gear Shift Shaft Remove circlip and

blackened washer fromgear shift shaft on LHside.

Outside circlip plier

26. Crank shaft Gear Remove thrust washer.

Remove splined gear &bush.

CAUTION:Gear shift shaft cannot beremoved if circlip &washerare not removed from shafton LH side.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41040

27. Gear Shift Shaft Remove circlip from gear

shift shaft on RH side.

Remove washer, spring& gear selector.

Remove gear shift leverwith spring & washer.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

28. Gear Star Indexstopper Remove stepped bolt

holding arm stopper toCrankcase.

Stepped Bolt: M8Hex Socket: 10mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 41

28. Gear Star Indexstopper Remove arm stopper

along with washer &spring

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

30. Drive shaft Spacer Remove circlip on drive

shaft.

Remove 1st thrust washer,spacer & 2nd thrust washer.

Outside Circlip Player

Hex socket Hd screw: M6Allen key: M5

29. Gear Star Index Remove stepped hex

Socket Head bolt,holding star index toselector drum.

Remove star index

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41042

31. Auto chaintensioner Remove hex bolt with

spring from the center ofauto chain tensionerbody.

Remove 2 hex sockethead screws &gentlypull out auto chaintensioner assembly.

Remove gasket.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolt: M8Hex Socket: 12mm

CAUTION:Open slowly &carefully sincespring loaded bolt.

NOTE:Ensure ‘O’ ring is removedfrom housing.

Hex Socket Hd screw:M6 X 25Allen Key: M5

32. Inlet manifold Remove 2 hex socket

head screws.

Remove inlet manifoldwith “O” ring

Hex Socket HdScrew:M6X25Allen key: M5

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 43

33. Cover- Cam Center Remove 2 hex flange

bolts & remove cover

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

35. Tappet cover inlet Remove 2 hex flange

bolts & remove coverwith O ring.

Hex flange bolts: M6X21Hex Socket: 8mm

Hex flange bolts: M6 X 16Hex Socket: 8mm

34. Plug - CamshaftHole Remove hex flange bolt.

Rotate plug clock-wise gently. DO NOTATTEMPT to removeplug forcefully from thecylinder head cover.

Hex flange bolt: M6 X 16Hex Socket: 8mm

NOTE:The plug will be tight incylinder head cover.

Do not attempt to removebefore loosening all thecylinder head cover bolts.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41044

36. Tappet coverexhaust Remove 2 hex flange

bolts & remove coverwith O ring.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

38. Cylinder head cover Remove 2 long hex

flange bolts withaluminum washers fromthe top RH side.

Remove 3 long hexflange bolts from the topLH side

Hex flange bolts: M6X21Hex Socket: 8mm

37. Plugs rocker shafts Loosen 2hex socket

head plugs from cylinderhead cover RH side.(Donot remove plugs fully)

Hex Socket plug: M14 X 12Allen key: M8

Hex flange bolt: M6 X 60Hex Socket: 8mm

Hex flange bolt: M6 X 60Hex Socket: 8mm

NOTE:Aluminum washers areprovided to prevent oil leakthrough the bolts.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 45

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

38. Cylinder head cover Remove 3 medium Hex

flange bolts from the LHside.

Remove 2 long Hexflange bolts from RHside.

Remove 2 fully threadedHex flange bolts frominlet & Exhaust tappetsopening.

39. Plug camshaft hole Remove small cam shaft

cover.

Hex bolt: M6X55HexSocket: 8mm

Hex flange bolt: M6 X 40 EXHex flange bolt: M6 X 45 INHex Socket: 8mm

Hex bolt: M6X16Hex Socket: 8mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41046

40. Cylinder head cover Remove cylinder head

cover by gently tappingon the pegs provided.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

42. Shaft - Rocker arms Locate 2 long suitable

M8 hex screws into therocker shaft threads &pull out the shafts.

41. Rocker Shaft Plugscrews Remove the 2 hex socket

plug screws (Loosenedearlier) with their copperwashers from thecylinder head cover.

Hex flange bolts: M8Hex Socket: 10mm

43. Rocker arms Remove inlet & exhaust

rocker arms.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 47

44. Spark plug Remove spark plug from

cylinder head.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

45. Cam shaft assembly Rotate cam shaft such

that the half lock washerwill come up from thecylinder head slot.

Remove the half washer.

Rotate Cam shaft ifnecessary such that Onehex bolt can be accessedfor loosening.

Straighten lock tab &remove 1st hex bolt.

Hex bolt: M6 X 12Hex Socket: 10mm

Spark plug M10Deep Hex Socket 16mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41048

45. Cam shaft assembly Rotate Cam shaft to

access the 2nd hex bolt.

Straighten lock tab &remove hex bolt, alongwith lock plate.

Release sprocket fromthe dowel in cam shaft toincrease chain slack.

Release cam chain fromthe Sprocket by liftingand pushing it behindthe sprocket.

Lift cam shaft andremove sprocket.

Remove cam shaft.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

CAUTION:Ensure the Lock tab andwasher does not drop intothe cam chain

NOTE:Hold chain securely, toprevent it from droppinginto cylinder head.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 49

46. Cylinder headassembly Remove 4 Long hex

bolts from insidecylinder head

Remove 2 hex flangebolts from the LH side ofthe cylinder head cover.

Gently tap and lift upcylinder head, takingcare not to drop the camchain into cylinderbarrel.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

47. Cylinder headgasketRemove cylinder head

gasket.

NOTE:2 dowels are provided incylinder barrel to locate thecylinder head.

Hex bolt: M10 X 170Hex Socket: 12mm

NOTE:Take care not to dropthefour thick washers fromthe bolts.

Hex flange bolts: M6 X 30Double end spanner: 8mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41050

48. Valves in CylinderHead Locate valve spring

compressor tool on inletvalve such that thesleeve with screw isresting on the retainervalve spring & thebottom of the tool iscentrally located on thevalve.

Tighten special tool tillsprings are compressedfully & the cotters arefree from the valvestem.·

Remove both cotters &loosen special tool tillsprings are fullyexpanded & tool can beeasily removed.

Remove special tool,retainer, outer spring,inner spring & springseat from the cylinderhead.·

Remove inlet valve bypulling it from bottom ofcylinder head.

Remove Valve stem sealsfrom the valve guidetop.

Repeat above procedureto dismantle exhaustvalve.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

49. Chain guide pads Remove chain guide pad

located in the front onthe cylinder head, bypulling it from the top.

Special Tool: ST-27528-2Valve Spring CompressorTool

CAUTION:Ensure special tool iscorrectly located beforeattempting to compressvalve springs.

NOTE:Ensuresplit collars areremoved before releasingsprings

NOTE:The valve guides & valveseat inserts should not beremoved from cylinderhead OR reworked as it willaffect engine performance.In the event of any wearout, complete cylinderhead assy. should only bereplaced

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 51

49. Chain guide pads Release the cam chain

from the sprocket oncrankshaft and removefrom the engine.

RemoveBolt- Stepped,holding chain tensionerpad to crankcase LH.

Remove fixed chainguide pad from the top.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

50. Cylinder barrelassembly Remove 2 hex flange

nuts on LH side ofcylinder barrel.

Gently lift cylinder barrelup to remove frompiston.

Remove cylinder basegasket.

Locate special tool onconnecting rod belowpiston on inlet side, tosupport piston

Hex flange nut: M6Double end spanner:8mm

Bolt Stepped: M6 X 14Allen Key: 5

CAUTION:Take care to remove thewasher behind the chaintensioner pad.

NOTE:Ensure the 2 dowels areremoved from crankcaseLH. / cylinder barrel

Special Tool: ST-27529-2Piston support specialtool.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41052

51. Piston Pin Remove circlip from one

side of piston & push outgudgeon pin fromopposite side.

Remove Piston fromConnecting rod

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

53. Oil Jet Cylinderbarrel seating area Remove oil jet from RH

Crankcase / barrelseating area.

52. Piston rings Remove piston rings by

expanding the rings attheir open ends slightly &lifting towards the top ofthe piston.

54. Oil Jet - CrankcaseLH (outside) RemoveHex socket head

screw from CrankcaseLH

Special Tool: ST-27529-2Piston support specialtool.

NOTE:Do not expand rings toomuch since they will break!

The oil control ring is a 3piece set.

Hex Socket Hd Screw:M6 X 12Allen Key: M5

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 53

54. Oil Jet - CrankcaseLH (outside) Gently pull out & remove

oil jet.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure the small ‘O ’ring isremoved from seating areain crankcase / behind oil jet.

55. CrankcaseFastenersRemove Hex socket head screw

from crankcase LHfront.

3 hex bolts from crank-case LH magneto area.

1 Hex flange bolt from LHcrankcase near startermotor housing.

Hex Socket Hd Screw:M6X 12Allen Key: M5.

Hex bolt: M8 X 70Hex Socket: 12mm

Hex bolt: M6 X 60Hex Socket: 8mm

NOTE:8 Hex Bolts (1 near Startermotor housing, 4 in front &3 at bottom are shorter &same length.)

6 Hex bolts on rear end arethe longest

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41054

55. CrankcaseFastenersRemove 4 Hex flange bolts from

LH crankcase front.

6 Hex bolts (Longest)from LH crankcase rear.

3 Hex bolts from crank-case LH bottom

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

56. Crankcases splitting Split crankcases by

locating 2 suitable shortHex bolts with nuts,between the front & reartabs on the crankcases.

Unscrew nuts evenlysuch that the crank-cases separate.

Gently tap on the tabsusing small plastic malletto separate crankcasesfurther.

Hex bolt: M6 X 60Hex Socket: 8mm

Hex Flange bolt: M6 X 85Hex Socket: 10mm

Hex bolt: M6 X 60Hex Socket: 8mm.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 55

57. Crankcase RHremoval Remove Crankcase RH

from the shafts by gentlytapping on the shaftssimultaneously, using asmall plastic mallet

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

59. Crank shaftAssembly Remove crank shaft

assembly by slightlyrotating & tapping fromLH side (magneto side).

NOTE:The LH shaft main bearingis integral with the crankshaft assembly, henceshould NOT be removed orserviced separately.

NOTE:Please ensure thrustwasher on counter shaftdoes not fall off

58. Balancer shaftassembly Gently tap balancer

shaft out of the bearingfrom the CrankcaseLH.(Partial blind hole)

NOTE:The gear has a highinterference fit in balancershaft and hence cannot beseparated from the shaft.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41056

60. Oil Jet -crankcaseLH(inside) RemoveHex socket head

screw from CrankcaseLH.

Gently pull out & removeoil jet.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Socket Head Screw:M6X12Allen Key: M5

NOTE:Ensure the small ‘O ’ring isremoved from seating areain crankcase / behind oil jet.

61. Gear OperatorForks Remove the 2 spindles

holding the operatorforks to the gear drumassembly.

Remove three operatorforks from the gears.

NOTE:Both the long operatorforks are located towardsthe rear end of crank case &the small operator fork atthe center.

The forks are numbered 1,2 & 3 for easy identification.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 57

62. Gear shifter drum Remove gear shifter

drum from crankcase LH

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

63. Drive shaftassembly Remove thrust washer

· Remove 1st gear withfloating bush.

Remove thrust washer

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41058

63. Drive shaftassembly Remove 5thgear.

Gently tap drive shaftfrom the LH side &remove from crankcaseLH.

Remove drive shaftspacer from crankcaseLH outside.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Caution:The bush will be tight ondrive shaft, due to the ‘O’ring inside the bush.

Gently tap the shaft toremove from crankcase LH.

Take care not to damagethe threads while tappingon the shaft.

64. Gears in drive shaft Remove circlip.

External circlip pliers

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 59

64. Gears in drive shaft Remove thrust washer

with 3 lugs.

Remove 4th gear

Remove bush withinternal splines.

Remove splined washerwith outside tabs.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41060

64. Gears in drive shaft Rotate thrust washer

with internal splinessuch that the splines arefree to move in the shaft& remove washer fromshaft.

Remove 3rd gear.

Remove splined bush.

Remove thrust washer.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 61

·

64. Gears in drive shaft Remove circlip.

Remove sliding bush.

Remove circlip

Remove collared bush.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Externalcirclip pliers

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41062

64. Gears in drive shaft Remove 2nd gear.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

CAUTION:Ensure thrust washer onmain shaft does not getmisplaced while removingmain shaft

65. Counter shaftassembly Pull out main shaft with

gears from crankcaseLH.

External circlippliers

66. Gears in countershaft Remove 2ndgear.

Remove circlip.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 63

66. Gears in countershaft Remove 3rd& 4thsliding

gears.

Remove thrust washer.

Remove circlip.

Remove 5th gear.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Externalcirclip pliers

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41064

66. Gears in countershaft Remove bush.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:1st gear is integralwith main shaft

Hex bolt: M6 X 10Hex Socket: 10mm

67. Crankcase LH oilseals Open lock tabs and

remove 2 Hex boltsalong with lock platefrom crankcase LHouter side.

Remove drive shaft oilseal from the crankcaseLH outer side.

Remove gear shift shaftdouble lipped oil sealfrom crankcase LHouter side.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 65

68. Crankcase RHbearingsA. Selector drum bearing:

· Remove 2 hex sockethead screws withretainer plates fromcrankcase RH outer side.

Using a suitable drift,drive out the ball bearingfrom the inner side ofcrankcase RH.

B. Drive shaft bearing:

· Using a suitable drift,drive out the ball bearingfrom the outer side ofcrankcase RH.

C. Counter shaft bearing:

Remove hex sockethead screw along withretainer platefrom theinner side of crankcaseRH.

Using a suitable drift,drive out the ball bearingfrom the outer side ofcrankcase RH.

D. Crankshaft bearing:

Using a suitable drift,drive out the ball bearingfrom the outer side ofcrankcase RH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Socket Hd. Screw:M6 X 12Allen Key: M5

Bearing drift & plasticmallet.

Hex Socket Head Screw:M6 X 12Allen Key: M5

Bearing drift & plasticmallet.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41066

68. Crankcase RHbearingsE. Balancer shaft bearing:

Use a suitable drift todrive the ball bearing outfrom the outer side ofcrankcase RH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Bearing drift & plasticmallet.

69. Crankcase LHbearingsA. Drive shaft bearing:

Using a suitable drift,drive out the ball bearingfrom the outer side ofcrankcase LH.

B. Counter shaft bearing:

· Use a suitable two jawpuller to pull out the ballbearing from the blindhole inside crankcaseLH.

C. Balancer shaft bearing:

Using a suitable drift,drive out the ball bearingfrom the outer side ofcrankcase LH.

Bearing drift & plasticmallet.

Two Jaw puller.

Bearing drift & plasticmallet.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 67

WEAR LIMITS - LS 410

New components must be within the limits specified. Components within service limits may be reused after carefulinspection. Use of parts beyond service limit can reduce the operating life of the component and affect the motorcycleperformance seriously. (All units in mm unless specified)

Cylinder Bore ID Top, Middle & Bottom of Piston working area 78.000 78.030 78.100Piston OD Top, Middle & Bottom of piston 77.940 77.970 77.870Cylinder Bore/Piston Clearance 0.015 0.040 0.20Piston ring top 1 Rings End Gap in Bore at the topmost ring 0.15 0.30 0.60Piston ring top 2 working area in bore. 0.20 0.40 0.70Top ring Clearance between Piston ring 0.03 0.07 0.10Middle ring groove & piston rings in 0.03 0.07 0.10Oil scrapper ring assembled condition 0.03 0.07 0.10Balancer Shaft Run out - 0.03 0.05Crankshaft Assembly Crankshaft assembly run out - 0.05 0.09Crankshaft Assembly Big End Axial Play - - 0.065Piston Pin Piston Pin Diameter 19.992 19.997 19.977Connecting rod Connecting rod small end ID 20.010 20.019 20.050Cylinder head / cover Warpage - - 0.01Cylinder head / barrel Warpage - - 0.01Valve guide Inlet

Internal ID7.000 7.015 7.070

Valve guide Exhaust 7.000 7.015 7.100Valve stem Inlet

Stem OD6.960 6.975 6.945

Valve stem Exhaust 6.945 6.960 6.920Valve / Guide Inlet

Valve stem to Guide Clearance0.01

Valve / Guide Exhaust 0.14Valve seat/valve Contact area 1.00 1.50Valve Spring Inner

Overall Length36.70 34.70

Valve Spring Outer 43.90 41.90Cam shaft Run out 0.02 0.05Camshaft Journal Dia 21.959 21.980 21.930Camshaft Journal Bore Dia 21.988 22.025 22.088Camshaft Journal Oil groove clearance - - 0.05Cam Lobe Lobe Height 36.92 36.96 36.76Clutch Spring Free Length 33.60 32.60Clutch Steel Plate Thickness 1.550 1.650 1.533Clutch Friction Plate Thickness 2.950 3.050 2.830Clutch Steel/

Distortion 0.10 0.30Friction PlatesShifter Drum Groove width 6.05 6.20 6.30

Shifter ForksGuide Pin Dia 5.85 5.95 5.75Lug Thickness 5.30 5.40 5.20

Component Where / What to Measure Minimum Maximum Service Limit

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41068

TORQUE VALUES - LS 410

Aggregate Component Fastener Qty Torque Range (Nm) (Kg. M)

Piston Oil Jet Hex Socket Head Screw M6 X 12 1 8 - 12 0.8 – 1.2

Starter Clutch Oil Jet Hex Socket Head Screw M6 X 12 1 8 - 12 0.8 – 1.2

Cam Chain Tensioner Pad Bolt Stepped - M6 X 14 1 10 - 12 1.0 – 1.2

Gear Position Switch Hex Flange Bolt - M6 X 16 2 6.8Max 0.68Max

Crankcase LH Side Oil Strainer Cap Hex Flange Bolt - M6 X 20, 2 8 - 12 0.8 – 1.2

Oil Passage Hex Flange Bolt - M8 X 12 3 20 - 24 2.0 – 2.4

Crankcase Drain Plug M14 X 12 1 20 - 25 2.0 – 2.5

Drive Shaft Oil Seal Retainer Hex Bolt - M6 X 10 2 8 - 12 0.8 – 1.2

Final Drive Sprocket Hex Nut M20 1 130 - 160 13 - 16

Sprocket Cover Hex Flange Bolt - M6 X 35 2 8 - 12 0.8 – 1.2

MagnetoRotor Ring Assembly Hex Socket Head Screw M6X20 6 10 - 12 1.0 – 1.2

Magneto Rotor Hex Flange Nut M12 X1.25 X 11 1 70 - 80 70 – 8.0

Clamp, Stator Wire Hex Socket Head Screw M5 X 15 2 8 - 10 0.8 – 1.0

Stator Coil Screw Hex Socket Head Screw M5 X 30 3 8 - 10 0.8 – 1.0

Cover LH TDC Inspection Plug Plug – M14 X 12 1 20 - 25 2.0 – 2.5

Cover LH MountingHex Flange Bolt - M6 X 35 8 8 - 12 0.8 – 1.2

Hex Flange Bolt - M6 X 55 3 8 - 12 0.8 – 1.2

Cover LH Logo Hex Socket Head Screw M6 X 21 2 8 - 12 0.8 – 1.2

Hex Socket Head Screw M8X 100 1 20 - 24 2.0 – 2.4

Crankcase boxingHex Flange Bolt- M8 X 70 3 20 - 24 2.0 – 2.4

Crankcase LH & RH Hex Flange Bolt - M6 X 85 6 8 - 12 0.8 – 1.2

Hex Flange Bolt – M6 X 60 8 8 - 12 0.8 – 1.2

Starter Motor Hex Flange Bolt - M6 X 30 2 10 - 12 1.0 – 1.2

Cam Drum Bearing Retainer Hex Socket Head Screw M6 X 12 2 8 - 12 0.8 – 1.2

Oil Pump Hex Flange Bolt - M6 X 30 4 7 - 9 0.7 – 0.9

Crankcase RH Stopper, Gear Shift Arm Hex Flange bolt M8 1 10 - 12 1.0 – 1.2

Pump Drive Gear Nut (LH Thread) M18 1 85 - 90 8.5 – 9.0

Balancer Shaft Hex Flange Bolt - M10 X 20 1 40 - 60 4.0 – 6.0

Clutch Center Hex Nut M20 1 40 - 60 4.0 – 6.0

Gear shiftingStar Index Hex Socket Head, Stepped Bolt 1 10 - 12 1.0 – 1.2

Gear Shift Cam Stopper Hex Bolt Stepped 1 10 - 12 1.0 – 1.2

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 69

Aggregate Component Fastener Qty Torque Range (Nm) (Kg. M)

Cover Oil Jet Seal Retainer Hex Socket Head Screw M6 X 12 1 8 - 12 0.8 – 1.2

Clutch shaft spring. Hex Flanged Bolt– M6 X 10 1 10 - 12 1.0 – 1.2

Hex Flange Bolt - M6 X 37 8 8 - 12 0.8 – 1.2

Cover RHCover RH Hex Flange Bolt M6 X 30 5 8 - 12 0.8 – 1.2

Hex Flange Bolt – M6 X 20 1 8 - 12 0.8 – 1.2

Cap – Oil FilterHex Flange Bolt - M6 X 70 1 8 - 12 0.8 – 1.2

Hex Flange Bolt - M6 X 20 2 8 - 12 0.8 – 1.2

Plug, Oil Check Plug– M14 X 12 1 20 - 25 2.0 – 2.5

Cylinder Head Special Hex Bolts - M10 X 170 4 40 - 45 4.0 – 4.5

Camshaft & Sprocket Lock Hex Bolt – M6 X 12 2 10 - 12 1.0 – 1.2

Cylinder Head Side Mount Hex Flange Bolt – M6 X 2 8 - 12 0.8 – 1.2

Cylinder Head De Compressor Fly Weight Hex Socket Head Screw 1 3 - 5 0.3 – 0.5

PAV Pipe Mounting Hex Socket Head Screw M X 2 8 - 12 0.8 – 1.2

Spark Plug Spark Plug (M10) - CR8E 1 10 - 15 1.0 – 1.5

Adapter Carb To Cyl Head Hex Socket Head Screw- M6 2 8 - 12 0.8 – 1.2

Cylinder barrel side Mount Hex Flange Nut M6 X 1 2 8 - 12 0.8 – 1.2

Cylinder Barrel Auto Chain Tensioner Mtg Hex Socket Head Screw M6 X 25 2 10 - 12 1.0 – 1.2

& Spring bolt Special Hex Bolt M 8 1 8 - 10 0.8 – 1.0

Hex Flange Bolt - M6 X 60 5 10 - 14 1.0 – 1.4

Hex Flange Bolt - M6 X 55 3 10 - 14 1.0 – 1.4

Cylinder Head CoverHex Flange Bolt - M6 X 45 1 10 - 14 1.0 – 1.4

Cylinder Head Cover Hex Flange Bolt - M6 X 40 1 8 - 12 0.8 – 1.2

Hex Flange Bolt - M6 X 20 6 8 - 12 0.8 – 1.2

Hex Flange Bolt - M6 X 21 2 8 - 12 0.8 – 1.2

Tappet Cover Hex Flange Bolt-M6 X 21 4 8 - 12 0.8 – 1.2

Plug, Camshaft Hole Hex Flange Bolt - M6 X 16 1 8 - 12 0.8 – 1.2

Cam CoverRocker Shaft Plugs Hex Socket Head Plug-M14 X 12 2 25 - 30 2.5 – 3.0

Cover- Cam Center Hex Flange Bolt - M6 X 16 2 8 - 12 0.8 – 1.2

Oil CoolerOil Cooler Pipe banjo Bolt, Union M 2 35 - 38 3.5 – 3.8

Oil Cooler pipe Mtg Hex Socket Head Screw M 4 8 - 12 0.8 – 1.2

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41070

PRECAUTIONS BEFORE ENGINE REASSEMBLY

Please ensure all parts are thoroghly cleaned and stored in a sequence for inspection

and reassembly.

Lubricate all moving parts prior to reassembly.

Replace parts like: Gaskets, “O” Rings, Oil seals, Dust seals, Rubber items, Aluminum

washers, Circlips whenever they are removed OR during a complete engine overhaul.

NOTE:

While fixing bearings, bushes or oil seals, it is NOT necessary to heat theCrankcase.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 71

1. Crankcase LHBearingsA. Balancer shaft

Bearing:·

Locate bearing inCr ankc ase LH frominnerside & gently tapusing a suitable drift andplastic mallet

.

B. Counter shaft bearing:

· Locate bearing in theblind hole in CrankcaseLH fromi nner side &gently tap using asuitable drift and plasticmallet

C. Drive shaft bearing:

Locate bearing in Crank-case LH from innerside& gently tap using asuitable drift and plasticmallet

Bearing drift & plasticmallet.

NOTE:Ensure bearing outer raceis flush with housing incrank case after pressingthe bearings.

ENGINE ASSEMBLY SEQUENCE

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41072

2. Crankcase RHBearingsA . Balancer shaft

bearing:

Locate bearing incr ankc ase RH frominner side & gently tapusing a suitable drift andplastic mallet.

B. Crankshaft bearing:

Locatebearing inc rankcase RH frominner side & gently tapusing a suitable drift andplastic mallet.

C. Counter ShaftBearing:

Locate bearing in crank-case RH from inner side& gently tap using asuitable drift and plasticmallet.

Position retainer platebetween the slots incrankcase RH & tightenwith Hex Socket Headscrew.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Bearing drift & plasticmallet.

NOTE:Ensure bearing outer raceis flush with housing incrank case after pressingthe bearings.

Hex socket hd. screw:M6X12Allen Key: 5mmTorque: 0.8-1.2Kg.M(8-12 Nm)

NOTE:Ensure retainer plate isproperly located overbearing outer race, beforetightening screw.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 73

2. Crankcase RHBearingsD . Drive Shaft Bearing:

Locate bearing incr ankc ase RH frominner side& gently tapusing a suitable drift andplastic mallet.

E. Gear selector drumbearing.

Locate bearing inCr ankc ase RH fromouter side& gently tapusing a suitable drift andplastic mallet.

Position two retainerlatesbetween the slots incrankcase RH & tightenwith Hex Socket Headscrews.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

3. Crankcase LH OilsealsA . Gear shift shaft oil

seal.

Locate double lip oil sealin Crankcase LH fromouter side& gently tapusing a suitable drift andplastic mallet.

Bearing drift & plasticmallet.

Hex socket hd screw:M6 X 12Allen Key: 5mmTorque: 0.8-1.2Kg.M(8-12 Nm)

Bearing drift & plasticmallet.

NOTE:Ensure retainer plate isproperly located overbearing outer race, beforetightening screw.

NOTE:Ensure oil seal outer face isfacing outside & is flushwith housing in crank case.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41074

3. Crankcase LH OilsealsB. Drive shaft oil seal: Locate oil seal on crankcase

LH from outer side& gentlytap using a suitable drift andplastic mallet.

Locate retainer plate over oilseal & tighten in positionwith 2 Hex bolts.

Bend the retainer plate locktabs over the hex bolts, toprevent them fromloosening

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure oil seal outer face isfacing outside & is flushwith housing in crank case.

NOTE:Apply grease on ‘O’ ring tohold it in place.

Hex Socket Hd Screw:M6 X 12Allen key: 5mmTorque: 0.8-1.2Kg M (8-12Nm)

4. Piston Oil Jet Locate ‘O’ ring in crank-

case LH inside.

Locate oil jet in crank-case LH inside with itsspout facing upwards

Tighten with Hex SocketHead screw.

Hex Bolt: M6 X 10Hex Socket spanner: 8mmTorque: 0.8-1.2Kg.M (8-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 75

5. Starter Clutch OilJet. Locate ‘O’ ring in Crank-

case LH outside.

Locate oil jet in Crank-case LH outside with itsspoutfacing downwards.

Tighten with Hex SocketHead screw.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

6. Sub Assembly ofgears in Drive Shaft Insert 2nd gear on the

shaft such that the smallrecess in the machinedside of the gear is seatedon the collar of the shaft.

Hex Socket Hd Screw:M6 X 12Allen key: 5mmTorque: 0.8-1.2KgM (8-12Nm)

NOTE:Apply grease on ‘O’ ring tohold it in place.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41076

6. Sub Assembly ofgears in Drive Shaft Insert collared bush on

the shaft, such that thebush will enter into thegear and the collar isfacing outside andseated flush with thegear.

Assemble 1st circlip.

Insert bigger side of thesliding dog on the shaft,such that it is facing 2ndgear.

Assemble 2nd circlip.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

OutsideCirclip Plier

OutsideCirclip Plier

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 77

6. Sub Assembly ofgears in Drive shaft Assemble thrust washer

with three internalsplines on the shaft.

Align oil hole in thesplined bush with the oilhole in shaft and lower itfully.

Assemble 3rd gear on theshaft with its slot facingthe sliding dog.

Assemble thrust washerwith internal andexternal splines on theshaft, align the internaltabs with the groove inshaft, just above the 3rd

gear and rotate washersuch that the washerlocks in the shaft andcannot be removed.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

CAUTION:Ensure oilhole in bushis alignedwith oil holein shaft.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41078

6. Sub Assembly ofgears in Drive Shaft Assemble thrust washer

with outside tabs suchthat the tabs in thewasher locks into theslots in the thrustwasher.

Align oil hole in thesplined bush with the oilhole in shaft and lower itfully.

Insert 4thgear on theshaft, with the slot in thegear facing outside andlocate it on the splinedbush.

Assemble 2nd thrustwasher with the threeinternal splines.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

CAUTION:Ensure oilhole in bushis alignedwith oil holein shaft.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 79

6. Sub Assembly ofgears in Drive shaft Assemble 3rd Circlip.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

OutsideCirclip plier

7. Sub Assembly ofgears in countershaft Assemble bush on

counter shaft, from thenon-threaded end ofthe shaft.

Assemble 5thgear suchthat the lugs of the gearare towards the non-threaded end of thecounter shaft.

Assemble 1st thrustwasher.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41080

7. Sub Assembly ofgears in countershaft Assemble 1st circlip.

Assemble3rd& 4thslidinggear on the shaft suchthat the larger gear isfacing the 5th gear.

Assemble 2nd circlip.

Assemble2ndgear.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Larger gearmust betowards the1st gear.

OutsideCirclip plier

OutsideCirclip plier

NOTE:Collar in thegear shouldface towards1stgear.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 81

8. Counter shaftthrust washer Place thrust washer over

counter shaft bearing inCrankcaseLH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Apply grease on thrustwasher to preventit fromfalling off when locatingmain shaft.

NOTE:Ensure threaded end ofcounter shaft is facingupwards & threaded end ofmain shaft is inserted intoCrankcase LH.Gently tap both shafts intobearings simultaneouslyfor proper seating.

9. Counter shaft &Drive shaft inCrankcase LH Locate the shafts in their

respective locations inCrankcaseLH, ensuringthe gears in both shaftsare aligned.

10. Sub Assembly ofgears in Drive shaft Assemble5thgear such

that the gear side isfacing towards 1stgear.

Assemble thrust washer.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41082

10. Sub Assembly ofgears in Drive shaft Assemble1stgear bush.

Assemble 1st gear overthe bush such that thedeep groove in 5th gear isfacing towards 1st gear.

Assemble thrust washerover 1st gear

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure gears in bothcounter shaft & drive shaftare aligned.

11 Selector Forks Locate selector fork

No.2, inside sliding dogof on drive shaft, withthefork lug facingabove.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 83

11. Selector Forks Locate operator fork

No1 in the recess in driveshaft 5thgear.

Locate operator forkNo.3 in counter shaft on4thgear.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

12. Gear Shift DrumAssembly Insert long end of Shift

Drum Assembly intoCrankcase LH. (thetwooffset pegs in the drumassy must be facingoutside.)

Lock selector forks inposition by locating thespindles in CrankcaseLH.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41084

13. Crank shaftAssembly Locate bearing in the

housing in Crankcase LHand press crankshaftgently till the bearing isseated completely.

Rotate Crankshaft suchthat the crank webs areat their lowest position &the dot mark on the gearin crankshaft is facingtowards the front.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure dot marks oncrankshaft gear & balancershaft gear are matchedcorrectly.

NOTE:Smear oil on bearing outerrace.

Hold crankshaft vertically& ensure bearing enterscrankcase LH squarely.

14. Balancer shaftAssembly Position balancer shaft

such that the dot markon balancer shaft gearaligns with dot mark oncrankshaft gear andgently press balancershaft into the bearing incrankcase LH

NOTE:Apply Loctite No 5699 onthe mating surface of crankcase LH.

15. Crankcase Boxing Ensure Gasket sealant is

applied evenly anduniformly on the matingsurface of crankcase LH

Ensure dowels arelocated in crankcase LH.

Locate Crankcase RHover crankcase LH andgently tap it in whilegently rotating theshafts

Ensure Crankcase RH isfully seated over crank-case LH & all shafts arerotating freely.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 85

16. CrankcaseFastenersAssemble

Hex Socket Head screwin Crankcase LH belowBarrel seating area.

3 hex bolts in magnetoarea in crankcase LH.

1 Hex flange bolt incrankcase LH nearstarter motor housing

4 Hex flange bolts incrankcase LHfront.

6 Hex bolts (Longest) incrankcase LHrear.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Socket Hd Screw:M8 X 100Allen key: M6Torque: 2-2.4KgM (20-24Nm)

Hex Flange Bolt- M8 X 70Socket spanner: 12mmTorque: 2-2.4KgM (20-24Nm)

Hex Flange Bolt- M6 X60 Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

Hex Flange Bolt- M6 X60 Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

Hex Flange Bolt- M6 X 85Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41086

16. CrankcaseFastenersAssemble

3 Hex bolts from crank-case LH bottom

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Flange Bolt- M6 X 60Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

NOTE:Ensure the words “TOP” 2in 2nd compression ring &“TOP 1” in 1st compressionring are facing towards thetop of the piston.

Lubricate rings well &position ring end gaps at120o to each other, for easyassembly of cylinder barrel.

NOTE:Ensure stiffener ring iscorrectly located betweenthe 2 oil Control rings.

17. Piston RingsAssembly Assemble Oil control ring

with stiffener ring in the3rd groove.

Assemble 2nd compressionring in the middlegroove.

Assemble 1st compressionring in the top mostgroove.

NOTE:Tighten all fasteners evenly &diagonally, for proper sealingof the crankcase joints

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 87

18. Oil Jet Locate oil jet in Crank-

case RH, barrel seatingarea with its slotted endfacing up and press intocrank-case gently.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure ‘O’ ring does not getdamaged during assembly.

Ensure slotted end of jet isfacing outside.

NOTE:Apply grease on gasketseating surface.

19. Cylinder BarrelGasket Locate the two dowels

on Crankcase LH.

Locate gasket on Crank-case ensuring the recessfor the oil jet is correctlypositioned.

Caution:Gasket is unidirectionalhence ensure it is fittedcorrectly.

CAUTION:Ensure circlip locks in placeand does not fall intocrankcase.

Remove cloth afterassembling circlip.

20. Piston Assembly onConnecting Rod Assemble circlip on

piston, on one side &insert piston pin fromthe other side. Ensurethe pin is pressed justsufficiently into thepiston and notprotruding into piston

Support connecting rodusing special tool tohold it vertically forassembling piston.

Special Tool: ST-27529-2,Piston Support.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41088

20. Piston Assembly onConnecting Rod Position piston on

connecting rod, ensuringthe piston pin holes inboth piston & connectingrod are aligned.

Lubricate piston pin &gently insert into pistontill it rests on the circlip

Cover crankcase spigotsuitably & assemble theother circlip on thepiston.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure marking, “EX” on thepiston is facing towardscrankcase front.

CAUTION:Ensure circlip locks in placeand does not fall intocrankcase.Remove cloth after assembl-ing circlip.

21. Cylinder Barrel onpiston Lubricate piston rings,

piston & cylinder barrel,with oil, for easy entry ofpiston into cylinderbarrel.

Ensure Piston issupported vertically.

Gently lower barrelover piston whiles i m u l t a n e o u s l ycompressing rings foreasy entry.

Remove piston support-ing tool & lower barrelfully into Crankcase.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 89

21. Cylinder Barrel onpiston Rotate Crank Shaft

Assembly to bringpiston to TDC.

Tighten barrel toCrankcase using 2Flanged Hex nuts on theLH side.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Flange Nut: M6 X 1D E Spanner: 8 mmTorque: 0.8-1.2KgM (8-12Nm)

NOTE:Apply grease on cylinderhead gasket for properseating.

22. Cylinder headGasket Locate 2 dowels on

cylinder barrel top LHside.· Locate cylinderhead gasket over thecylinder barrel.

Stepped Hex socketBolt: M6X14Allen Key: M5Torque: 1.0 - 1.2KgM (10-12Nm)

23. Cam Chain Pads Insert chain tensioner

pad through cylinderbarrel.

Apply grease on thethrust washer to hold itin place over the threadedlocation in crankcase LH.

Position chain pad overthrust washer & tightenwith hex socket Headstepped bolt.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41090

23. Cam Chain Pads Insert the cam chain

through the cylinderbarrel & locate it on thecrank shaft gear.

Ensure chain is properlysupported at the top toprevent it from droppinginto the crankcase.

Insert fixed cam chainpad through cylinderbarrel & locate it in thecrankcase LH

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Apply grease on the gear &chain to hold the chain inplace.

24. Valves in CylinderHead Insert inlet valve into

valve guide from insidecylinder head.

Assemble spring seat,inner spring, outerspring &retainer, fromthe top of cylinder head.

Locate valve springcompressing tool overthe retainer & compressspring till the valve stemcomes out through theretainer.

NOTE:Ensure fixed chain pad islocked in position in cylinderbarrel.as well as crankcaseLH.

NOTE:Ensure stem seals are fittedon the valve guide.

Ensure denser coils of thespring are seated on thespring seat in cylinder head.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 91

24. Valves in Cylinderhead. Insert split collars on

retainer. Ensure they areseated correctly againstvalve stem and retainer& release puller slowly.

Repeat above procedureto assemble exhaustvalve.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Special tool: ST-27528-2,Valve spring compressor.

NOTE:Apply grease on crankshaftsprocket & chain to hold itin place.

Secure chain from top toprevent it from droppinginto crankcase.

25. Cylinder HeadAssembly Position cylinder head

assembly over cylinderbarrel.

Holding the cam chainfrom the top, route itthrough the slot incylinder head bottomand locate the cylinderhead on the barrelcorrectly.

CAUTION:Ensuresplit collars arecorrectly locked betweenretainer & valve stem.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41092

25. Cylinder HeadAssembly Locate 4 special Hex

bolts with washer &tighten diagonally.

Locate 2 Hex flange boltson cylinder head LHsideand tighten.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Special Hex Bolts:M10X170Hex Socket: 12mmTorque: 4-4.5KgM (40-45Nm)

26. Cam Chain &Sprocket Assembly Locate cam shaft along

with sprocket on cylinderhead.

Ensure sprocket is freeon cam shaft & locatechain on sprocket withmarking “T” on sprocketfacing up.

Rotate cam shaft,without disturbing thesprocket till the dowel inthe shaft aligns with thehole in the sprocket.

Ensure chain has noslack & Insert cam shaftinto sprocket such thatthe dowel locates intothe sprocket.

Hex flange bolts: M6X30D E Spanner: 8mmTorque: 0.8-1.2KgM(8-12Nm)

NOTE:Ensure Key way in crankshaftis facing up so that piston is atTDC on compression stroke.

CAUTION:- Ensure reference lines on

cam sprocket & camshaft are parallel &aligned.

- Crankshaft keyway is atTDC position.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 93

26. Cam Chain &Sprocket Assembly Fix 1 hex bolt with lock

plate on sprocket &tighten just sufficiently.

Rotate camshaft slowly& tighten 2nd Hex bolt,through the lock plate.

Tighten both bolts &bend lock plate over thebolts.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Bolt: M6X12Hex Socket: 8 mmTorque: 1-1.2KgM (10-12Nm)

27. Cam Shaft Lock“C”washer. Align slot in cam shaft

with the groove incylinder head.

Insert “C” washer intocylinder head to lockaxial movement of thecam shaft

NOTE:Ensure “C” washer is locatedcorrectly into the slot incylinder head failing whichthe cylinder head covercannot seat properly

28. Auto Chain TensionerAssembly Ensure center bolt with

spring is removed fromassembly.

Release lock on chaintensioner body &depress pad completely.

NOTE:Ensure gasket is assembledon the Auto chain tensionerAssembly.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41094

28. Auto Chain TensionerAssembly Locate chain tensioner

assembly in cylinderbarrel& tighten with 2Hex socket head screws.

Locate ‘O’ ring in thechain tensioner body.

Insert spring into chaintensioner and tightenwith special Hex bolt.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure lock in chaintensioner assembly is facingdownwards

29. Spark Plug Assemble spark plug on

cylinder head.

Hex Socket Hd Screw:M6X25Allen Key: 5mmTorque: 1-1.2KgM (10-12Nm)

NOTE:Ensurespark plug gap is set0.7 - 0.8 mm

Special Hex bolt: M8Hex socket: 10mmTorque: 0.8-1.0KgM (8-10Nm)

30. Inlet Manifold Assemble Inlet manifold

with the PAV inlet nipplefacing downwards.

Tighten with 2 Hexsocket head screws withcopper washers.

NOTE:Ensure ‘O’ ring is located inthe Inlet manifold.

Hex Socket Hd screw:M6X25Allen key: 5mmTorque: 0.8-1.2KgM (8-12Nm)

Socket Spanner: 16mmTorque: 1-1.5KgM (10-15Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 95

31. Inlet Rocker arm &shaft in Cylinderhead cover Position inlet rocker arm

inside cover such thatthe tappet adjustmentscrew on the rocker armis facing outside &roller isfacing inside.

Assemble rocker shaft inthe cylinder head coversuch that the slot andthe internal threads inthe shaft are facingoutside.

Ensure the slot in therocker shaft is per-pendicular to the topmounting hole in thecylinder head cover suchthat the cover mountingbolt can pass throughthe slot in the rockershaft.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

32. Exhaust Rocker arm& shaft in Cylinderhead cover Position exhaust rocker

arm inside cover suchthat the tappet adjust-ment screw on therocker arm is facingoutside &roller is facinginside.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41096

32 Exhaust Rocker arm& shaft in Cylinderhead cover Assemble rocker shaft in

the cylinder head coversuch that the slot andthe internal threads inthe shaft are facingoutside.

Ensure the slot in therocker shaft isperpendicular to the topmounting hole in thecylinder head cover suchthat the cover mountingbolt can pass throughthe slot in the rockershaft.

Assemble 2 Hex Socketpre coated plugs withcopper washers in thecylinder head cover.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Socket Hd plug:M14X12Allen key: 8mmTorque: 2.5-3.0KgM (25-30Nm)

33. Cylinder HeadCover Apply Loc tite 590 0

gasket sealant on cylinderhead mating surface.

Locate cylinder headcover on the cylinder headand ensure proper seating.

Assemble 2 long Hexflange bolts withaluminum washers inthe top RH side.

NOTE:- Ensure the 2 dowels are

located in cylinder head.

- Aluminum washers areprovided to prevent oilleak through the bolts.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 97

33. Cylinder HeadCover Assemble 3 long Hex

flange bolts in the top RHside.· Assemble 2 longHex flange bolts withaluminium washers inthe centre RH side.

Assemble 3 long Hexflange bolts in the top LHside.

Assemble mediumlength Hex flange bolt inthe RH side rear.

Assemble small Hexflange bolt in RH sidefront.

Assemble 2 fullythreaded Hex flangebolts inside the inlet &Exhaust tappet housingareas.

Ti ghten al l the bo l tsjust sufficiently. Do nottorque tighten fully

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolts: M6X55Socket Spanner: 8mm

Hex flange bolts: M6X60Socket Spanner: 8mm

NOTE:Aluminium washers areprovided to prevent oil leakthrough the bolts.

Hex flange bolts: M6X60Socket Spanner: 8mm

Hex flange bolts: M6X45Socket Spanner: 8mm

Hex flange bolts: M6X40Socket Spanner: 8mm

Hex flange bolts: M6X21Socket Spanner: 8mm

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 41098

34. Camshaft Coversmall. Locate ‘O’ ring in cam

shaft cover small.

Locate cam shaft coverin cylinder head & alignfixing hole.

Assemble Hex flangebolt (fully threaded).

Tighten Hex flange bolton cam shaft coversmall AND the 12 boltson cylinder head cover,diagonally using 8mmsocket spanner torespective torque values.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Apply Loctite 5900 gasketsealant on seating facebefore locating on cylinderhead cover

35. Cam Shaft CoverBig Assemble cover and

tighten with 2 Hex flangebolts (fully threaded)

NOTE:Tappets MUST be adjustedONLY WHEN:

- Engine is cold

- Pi ston i s at T DC onCompression stroke.

Hex flange bolt: M6X16Socket spanner: 8mm

Hex flange bolts: M6X60,M6X55, M6X45& M6X40Torque: 1.0-1.4KgM (10-14Nm)Hex flange bolts:M6X21Torque: 0.8-1.2KgM (8-12Nm)

Hex flange bolt: M6X16Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

36. Tappets Adjustment If Magneto rotorNOT

fitted on crankshaft:- Ensure key way oncrankshaft is facing up &piston is at TDC

If Magneto rotor is fittedon crankshaft- Rotate magneto rotor“CLOCKWISE ONLY”suchthat the reference mark onthe rotor aligns with theinspection hole on cover LH/Reference mark onCrankcase LH.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 99

36. TappetsAdjustment Locate special tool &

loosen adjuster lock nutby turning the long leveranticlockwise.

Using a pointed feelerstrip, set the specifiedgap by rotating theknurled head of thespecial tool:- Clockwise to reduce

gap.- A ntic lockwi se to

increase gap. Hold the knurled head

firmly so that the tappetadjustment does not getgets disturbed & lock thetappet locknut firmly byturning long lever clock-wise.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Special Tool: ST-27527-2,Tappet adjusting tool &pointed, long feeler strip.

Tappet Setting:Inlet: 0.08 - 0.10mmExhaust: 0.23 - 0.25mm

CAUTION:DO NOT adjust the tappetstoo tight as it will result inheavy load coming on therocker shafts and damagingthe bore in the cylinder headcover.

37. Tappet AdjusterCover Inlet Locate O Ring in cover

inlet & position coverover cylinder headcover.· Ti g h t e nwith 2 Hex bolts.

Hex flange bolts: M6X21Socket Spanner: 8mmTorque: 0.8-1.2KgM (8-12

38. Tappet AdjusterCover Exhaust Locate O Ring in cover

exhaust & positioncover over cylinder headcover.

Tighten with 2 hex bolts.

Hex flange bolts: M6X21Socket Spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410100

39. Starter ClutchAssembly Assemble starter clutch

such that the startershoulder is seated in thegroove in the ringbearing.

Locate ring gear withstarter clutch onmagneto such that therecess in the ring bearingis seated on themagneto.

Tighten ring gear tomagneto with 6 HexSocket Head screws.

Assemble Big ring gearinto starter clutch byrotating anti clock wise &pressing gently, to allowfor starter clutch toexpand and allow flushseating of big ring gear

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex SocHd screw: M6X20Allen key: M5Torque: 1.0-1.2KgM (10-12Nm)

CAUTION:Do not force or hammerstarter bearing into ring gearas it will damage the starterbearing.

Apply oil & gently press thebearing into the ring gear.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 101

40. Magneto rotor Ensure the crankshaft is

in TDC position andlocate woodruff key onshaft.

Locate Magneto rotorwith starter clutch onthe shaft ensuring thewoodruff key slot iscorrectly aligned withthe woodruff key andgently tap magnetorotor till it is seated fullyin the shaft

Locate rotor holdingspecial tool in themagneto rotor

Ensure the 3 lugs of thespecial tool are firmlyseated on 3 hex sockethead screws insidemagneto rotor toprevent it from rotatingwhile tightening.

Assemble Hex Flangenut and tighten.

Remove the magnetorotor holding special tool

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex nut: M12X1.25X11Socket spanner: 19mmTorque: 7-8KgM (70-80Nm)

Special Tool: ST-27534-2,Magneto rotor & FDsprocket locking tool

41. Idler gears onCrankcase LH Insert the 2 idler gear

spindles into crankcaseLH

Assemble double gearwith the smaller gearfacing outwards.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410102

41. Idler gears onCrankcase LH Assemble spacer bush.

Assemble idler gear.

Assemble spacer bush.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

42. Starter Motor Insert starter motor into

LH case spigot ensuringcorrect engagement ofstarter motor shaft withdouble gear.

NOTE:Ensure wire terminal ofstarter motor is facingupwards.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 103

42. Starter Motor Tighten starter motor to

crankcase with 2 hexflange bolts.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

43. Drive Shaft Spacer Fix ‘O’ ring inside the

spacer.

Assemble spacer ondrive shaft.

NOTE:Ensure earth terminal islocated on the outside hexflange bolt of the startermotor before tighteningboth bolts.

Hex flange bolt: M8Socket Spanner: 10mmTorque: 0.8-1.2KgM (10-12Nm)

NOTE:The spacer has to beassembled on the shaft suchthat the 4 slots are facinginside.

44. FD Sprocket Assemble FD sprocket

on drive shaft.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410104

44. FD Sprocket Assemble lock washer.

Tighten Hex nut totorque& lock tab washerover Hex nut by bendingat opposite ends.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Special Tool: ST-27534-2,Magneto rotor & FDsprocket locking tool

Hex U nut: M27Socket spanner: 32mmTorque: 13-16KgM (130-160Nm)

45. Gear PositionIndicator Locate switch on

crankcase LH ensuringthe offset holes matchwith the threads incrankcase LH.

Tighten with 2 Hexflange bolts.

NOTE:Ensure ‘O’ ring is locatedproperly on the gearposition indicator switch.

Hex flange bolt: M6Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

46. Cover LH Ensure dowel is located

on Crankcase LH.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 105

46. Cover LH Locate gasket on

crankcase LH.

Locate cover LH on thedowel& tap it in gently.

Assemble 3 long Hexflange bolts on coverrear side.

Assemble 8 short HexFlange bolts on the fronttop, Centre & bottomsides..

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Apply grease on gasket tohold it in position.

NOTE:Take care to ensure statorassembly is correctly locatedinto magneto rotor and thewire grommet is seatedproperly on cover LH

Hex flange bolt: M6X35 &M6X55Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

47. Timing markInspection plug Assemble plug with

copper washer on coverLH and tighten.

Hex Plug: M14X12Socket spanner: 17mmTorque: 2.0-2.5KgM (20-25Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410106

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolts: M6X35Socket Spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

50. Gear Star Index Locate star index on the

cam comp. gear shiftcorrectly such that the 2pegs are fully locked instart index.

Tighten star index to camcomp. gear shift withstepped bolt hex sockethead screw.

NOTE:Ensure the offset holes inthe star index are seatedcorrectly on the 2 pegs oncam comp. gear shift

Stepped bolt hex soc HdscrewAllen key: M4Torque: 1-1.2KgM (10-12 Nm)

51. Gear Star IndexStopper Locate blackened thrust

washer behind starindex stopper.

Locate spring on starindex stopper such thatthe curved end of springis seated in the grooveprovided.

Tighten with Hex bolt.

49. FD Sprocket Cover Locate FD sprocket

cover over crankcaseLH& tighten with 2 Hexflange bolts.

Hex bolt: M8Socket spanner: M10Torque: 1-1.2 KgM (10-12Nm)

48. RE Logo cover oncover LH Ensure “O” ring is

correctly located in thegroove in logo cover LH.

Position logo cover oncoverLH and tightenwith 2 hex socket headscrews.

Hex Soc Hd. Screw:M6X14Allen key: 5mmTorque: 0.8-1.2KgM (8-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 107

52. Gear Shift Shaft Insert gear shift shaft

assembly, fromCrankcase RH.

Assemble black thrustwasher on LH side ofshaft.

Assemble circlip on LHside of gear shift shaft.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

NOTE:Ensure spring legs arecorrectly positioned on thestopper in crankcase RH.

Ensure circlip is properlyseated.

54. Gear Selector· Assemble spring &

washer.

NOTE:Ensure lugs of the gearselector are located on thestar index.

The peg in the shift shaft islocated in the selector.

53. Gear Shift Shaft· Locate gear selector

assembly on shaft suchthat the lugs arecorrectly located in thestar index and the peg inthe gear shift shaft islocated into selectorassembly.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410108

54. Gear Selector Compress spring &

assemble circlip on gearshift shaft on RH side.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

External Circlip Plier

56. Clutch PlateAssembly Assemble beveled steel

washer with the bevelfacing upwards, in thegroove in clutch hub.

55. Drive shaft Spaceron RH side Assemble blackened

washer, spacer &blackened washer.

Assemble circlip on geardrive shaft.

External Circlip Plier

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 109

56. Clutch PlateAssembly Assemble plain steel

washer over beveledsteel washer.

Assemble 1st steel plate.·Assemble 1st frictionplate with its lugs in linewith the lugs on theclutch hub, to locate inthe clutch housing.

Assemble the balancesteel plates & frictionplates on the clutch hubensuring the lugs of thefriction plate are in astraight line andbetween the lugs of theclutch hub.

Assemble clutch backplate assembly over theclutch plates, with itslugs passing throughthe holes in the clutchhub.

Carefully turn theassembly over to installthe springs & pressureplate.

Compress springs &pressure plate by fixing2 long Hex bolts & specialtool to the clutch backplate assembly.

Locate 4 Hex flange boltsand tighten evenly.

Remove the 2 long Hexbolts & special tool & fixthe balance 2 Hex flangebolts.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Special Tool: ST-27531-2,Clutch Locking Plate

Hex bolt: M8Socket spanner: M10Torque: 1-1.2 KgM (10-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410110

57. Collared Bush onCounter shaft Assemble collared bush

on counter shaft with itscollar facing the bearingon crankcase RH.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

59. Clutch Assembly onCounter shaft Assemble clutch housing

on bush.

Assemble big metalwasher on main shaft.

58. Gear Primary Driveon Crank shaft Locate gear on the

crankshaft splines.·Locate thrust washer.

NOTE:The gear primary drive is amatched set with the clutchhousing gear.

Do not interchange the gearwith any other clutch assyOR vice versa, as it will resultin gears mismatch noise

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 111

59. Clutch Assembly onCounter shaft Locate clutch assembly

into clutch housing suchthat the offset frictionplate lug is seated on therecess in the clutchhousing.

Assemble splined washeron main shaft.

Locate Hex nut M20 oncounter shaft. Do nottighten fully.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex Flange Bolt - M6 X 30Socket spanner: M8Torque: 0.7- 0.9KgM (7-9Nm)

60. Oil pump assembly Position pump gasket

correctly on crankcaseRH with a little grease tohold it in place.

Ensure the holes in thegasket are alignedcorrectly to the holes incrankcase RH.

Locate Pump correctlyover the gasket, withoutdisturbing its seatingand ensuring the 4mounting holes arealigned to the threadedportion in crankcase RH.

Tighten Pump tocrankcase RH using 4hex flange bolts.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410112

61. Oil pump sprocket& chain assembly Locate small and big

drive gears in the oilpump chain.

Locate small gear oncrankshaft and slot inbig gear on the oil pumpshaft, duly ensuring it isseated correctly.

Assemble circlipover thebig gear in the groove inthe oil pump shaft&ensure it is seatedproperly.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

63. Clutch Nut Locate special tool

between clutch gear &crankshaft gear to lockclutch assembly whiletightening.

Locate Hex nut M20 andtighten clutch assemblyto counter shaft.

62. Crank shaft nut Assemble small thrust

washer and special LHthread hex nut oversmall gear on crankshaft.

Locate special toolbetween crankshaftgear & clutch housinggear at the top to lockcrankshaft.

Rotate “AN TI CLO CK-WISE” to tighten nut.

CAUTION:LH thread nut. Tighten byrotating Anti Clockwise.

Special Tool:ST-27533-2,Crank Gears locking Tool

Nut LH thread: M18Socket spanner:24mmTorque: 8.5- 9.0 KgM (85-90 Nm)

Hex Nut: M20Socket Spanner 27mmTorque: 4-6 KgM (40-60Nm)

Special Tool: ST-27533-2,Crank Gears locking Tool

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 113

64. Clutch bearing withcollar Assemble clutch bearing

with collar on the clutch.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

66. Oil jet in CrankcaseRH Locate ‘O’ ring in oil Jet.

Insert Oil Jet intocrankcase RH such thatthe slotted end of the jetis facing inside.

65. Balancer shaft bolt Locate small &big black

thrust washers on thebolt· Locate specialtool between crankshaftgear & clutch housinggear at the top to lockcrankshaft.

Locate Flanged hex bolton balancer shaft andtighten

67. Jet crankshaft incover RH Locate jet crankshaft in

cover RH such that thecup end is facing outside.

Position oil seal in coverRH such that the lip isfacing towards the jetcrankshaft and tap it ingently till its outer surfaceis flush with cover RH.

Special Tool- ST-27533-2,Crank Gears locking Tool

NOTE:Ensure jet crankshaft iscorrectly located in coverRH.

Wrong fitment will affect oilflow into crankshaft andcause serious damage toengine.

Hex flange bolt: M10 X 20Socket Spanner 14mmTorque: 4-6 KgM (40-60Nm)

NOTE:Ensure ‘O’ ring is correctlylocated in the groove in oiljet.

Ensure Oil jet is correctlyinserted such that theslotted end is insidecrankcase.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410114

67. Jet crankshaft incover RH Position the plate

retainer over the oil seal,align the mounting holeand tighten with hexsocket head screw.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex socHd screw: M6X12Allen Key: M5Torque: 0.8-1.2KgM (8-12Nm)

68. Cover RH Locate the 2 dowels in

crankcase RH.

Position gasket on crank-case.

Ensure clutch push padis located in Cover RH.

Note:Apply only grease on gasketto hold it in position.

DO NOT APPLY anyadhesive or gasket sealanton the gasket to stick it tothe crankcase RH as it mayblock the oil galleries &seriously affect lubricationof engine parts.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 115

68. Cover RH Locate cover RH,on the

dowels in crankcase RHand gently tap it in toseat against the gasket.

Locate clutch cableguide on top of cover RH& fix 1 Hex flange bolt(M6X37) at the rear ofthe cable guide.

Fix 1 Hex flange bolt(M6X30) at the fr ontend of cable guide.

Fix 1 Hex flange bolt(M6X20) at the fronttop ( at the r ec ess) ofcover RH.

Fix 6 Hex flangebolts(M6X37) at the rear& bottom of cover RH.

Fix 4 Hex flange bolts oncover RH front.

Fix 1 Hex flange bolt atfront bottom of coverRH.

Tighten all the 14 flangebolts diagonally tospecified torque

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolts: M6X30

NOTE:Ensure gasket does not getdisturbed while fixing coverRH.

Ensure cable guide is locatedcorrectly with its longer sidefacing forward

Hex flange bolt: M6X37

Hex flange bolt: M6X30

Hex flange bolt: M6X20

Hex flange bolts: M6X37

Hex flange bolt: M6X37

Socket Spanner: 8mmTorque: 0.8-1.2 KgM (8-12Nm)

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410116

69. Oil Filter Assembly Locate Oil filter element

in cover RH such that therubber seal of theelement seats correctlyin the spigot in cover RH.

Assemble spring insidefilter cover.

Assemble ‘O’ ring on oilfilter element cover.

Locate filter elementcover over cover RH&tighten with:

- 1 long Hex flange boltat the bottom.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Note:Rubber seal in filter elementshould seat on the spigot incover RH.

Note:Ensure proper seating ofspring in the cover.

Ensure ‘O’ ring is properlyseated in the cover.

Hex flange bolt: M6X70

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 117

69. Oil Filter Assembly- 2 small Hex flange

bolts at the top.

Tighten all the three hexflange bolts uniformly totorque.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolts: M6X20

Socket Spanner: 8mmTorque: 0.8-1.2 KgM(8-12Nm)

70. Oil Strainer oncrankcase LH Locate strainer in

crankcase LH, ensuringthe thinner edge of thestrainer is inserted intothe crankcase.

NOTE:The Oil strainer has a largertapered faceat one end as amistake proofing forassembly.Ensure the thinner side ofthe strainer is inserted intocr ankc ase for corr ec t &proper seating.

71. Oil Strainer cover Ensure ‘O’ ring is

correctly positioned inoil strainer cover.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410118

71. Oil Strainer cover Assemble cover such

that the drain pluglocation is at the bottom& tighten with 2 hexflange bolts.

S.No.

Fastener, Size, Tool Usage, Precautions, PhotosAggregate to Assemble /Instructions

Hex flange bolts: M6X20Socket spanner: 8mmTorque: 0.8-1.2KgM (8-12Nm)

72. Oil Drain Plug Assemble drain plug

with copper washer onoil strainer cover.

73. Engine Oil Cooler Ensure the oil cooler is

located correctly in thebracket in vehicle framewith 2 Hex flange bolts·

Route the Inlet & Outletpipes between the frame& engine and tighten tocrankcase LH & RHrespectively with the 2Banjo union bolts & 4washers.

Plug Hex: M14X12Socket spanner: 21mmTorque: 2-2.5KgM (20-25Nm)

Banjo Union bolts: M17Socket Spanner: 23mmTorque: 3.5-3.8 KgM(35-38Nm

NOTE:Ensure washers are locatedon both sides of the banjounions of inlet & outlet pipesbefore tightening.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 119

TROUBLE SHOOTING

It is very important for a competent and successfultechnician to be able to diagnose a fault correctly andfirst time right.

If the symptom is not diagnosed systematically andcorrectly, it will not only result in expensive and timeconsuming repairs BUT will end up with an unsatisfiedcustomer as well. Also the fault will not be rectified, andwill result in repetitive repairs.

In order to accurately troubleshoot and correctly a fault,the technician should be very thorough with:

Each and every component of the motorcycle, itsfunction and the effect it has on the overallperformance of the motorcycle.

Typical failures or symptoms that will occur in theevent a component fails or is in the process of failure

The second most important aspect to be able tocorrectly troubleshoot a fault is to understand theexact nature of failure, conditions under which thefailure occurs etc. Towards this it is very importantto ask meaningful and correct questions to the riderof the motorcycle about the circumstances whichcaused the failure.

For Eg. If a motorcycle comes with a fault of enginemisfiring, the technician should ask the correctquestions to the rider such as

Did the misfiring start immediately after fuel wasrefilled?

Did the misfiring occur immediately after themotorcycle was water washed, used in water loggedarea etc.

Was the motorcycle out of use for a prolongedperiod of time.

Was the motorcycle attended to by anyunauthorized / inexperienced free lance technicalperson/s

This will help analyze and pinpoint the most likely causeof the misfiring and help in rectifying the fault.

The third most important aspect is a careful and visualinspection with a “careful eye for detail”, for any telltalesigns of what could have caused the fault and thennarrow down to the assembly/subassembly/ suspectedpart.

It is also very essential to be able to analyze andunderstand the nature of failure as:

Failure due to not adhering to the periodicalmaintenance service schedule.

Failure due to improper servicing by anunauthorized person

Failure due to misuse/abuse of the motorcycle.

Consequential failure (part failed due tomalfunctioning of another part).

New or unique failure (One off in nature)

Premature failure of a part

Finally, a detailed and systematic inspection of thesuspect assembly/subassembly/ part will help rectifythe fault correctly and accurately.

The following table details symptoms, possible causeand remedy for some of the common faults that arise ina motorcycle engine. The list is not exhaustive andintended to be used only as a guide to help trouble shootfaults.

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410120

A. Ignition spark weak

Battery voltage low Recharge/ replace batterySpark plug cap / high tension wire Check & correctloose / shorted / defectiveSpark plug incorrect Replace with correct spark plugSpark plug sooty / wet Check &clean spark plugSpark plug gap incorrect Correct spark plug gapSpark plug insulator cracked Replace spark plugNo spark from Ignition coil Check & Replace Ignition coilPulsar coil defective Check & ReplaceTCI Unit defective Check & Replace

B. No Ignition spark

Battery dead Recharge/ replace batterySpark plug cap / high tension wire Check & correctshorted / defective / disconnectedSpark plug insulator cracked Replace spark plugNo spark from Ignition coil Check & Replace Ignition coilPulsar coil defective Check & ReplaceTCI Unit defective Check & Replace

C. Fuel related

No Fuel in fuel tank Fill fuel tank.Stale / adulterated fuel Clean fuel tank

Fill with fresh fuelAir vent blocked in fuel cap/carb. Clean air vent/sFuel filter clogged Clean fuel filterFuel line pinched Check & correct fuel lineExcess fuel going into induction Check & correct Float levelchamber setting

D. Compression related

Spark plug loose Tighten spark plug to torqueTappets adjusted too tight Check & adjust tappets to specnCylinder head gasket blown Check & replaceCylinder head nuts loose Check & tighten to torqueCylinder head warped Check & replaceValve stem bent, seating area Check & replaceburnt, excess carbon deposit onseating area, Valve springs brokenPiston rings sticky/ worn-out Check & replaceCylinder barrel / Piston excess Check & replaceclearance

Symptom Probable Cause Remedy1. ENGINE CRANKS BUT DOES NOT START

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 121

Ignition key not in ON position Switch ON ignition keyEngine Kill switch in OFF position Switch ON engine Kill switch

Gears not in neutral (neutral lamp Depress clutch / shift to correctnot glowing) neutral & start

Battery voltage low Check battery. Rechargereplace battery

Starter circuit Fuse blown Check all fuses & replace blownA. Starter motor does not rotate fuse

Starter motor connections loose Check & tighten connections

Starter relay connections loose Check & tighten connections

Ignition Switch defective Check & replace Ignition switch

Starter button defective Check & replace RH switch.

Starter relay failed Check & replace starter relay

Starter motor failed Check & replace starter motor

Major short in Wiring harness Check & correct wiring harness

Motor rotates slowly due to low Check & correct battery /B. Starter motor rotates battery / worn out starter motor starter motor

BUT engine does brush

not crank Magneto rotor woodruff key broken Check & replace woodruff key

Starter clutch assembly slipping Check & replace starter clutchassy

Inlet/ Exhaust rocker arm seized in Investigate cause of seizure,rocker shaft check & correct as required

Cam shaft seized in cylinder Investigate cause of seizure,head/cover check & correct as required

Cam chain jammed in sprocket Investigate cause of seizure,gears check & correct as required

C. Engine does not crank and Piston Seized in cylinder barrel Investigate cause of seizure,sounds locked. check & correct as required

Piston Pin seized in connecting Investigate cause of seizure,rod small end check & correct as required

Big end bearing seized in Crank Investigate cause of seizure,pin / connecting rod big end check & correct as required

Crankshaft bearings in LH/RH Investigate cause of seizure,crankcases seized check & correct as required

Symptom Probable Cause Remedy2. ENGINE DOES NOT CRANK

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410122

A. Ignition related

Battery voltage low Recharge/ replace batterySuppressor cap/ H T lead loose Check & correct as requiredSuppressor cap/ H T lead defective Check & correct as requiredSpark plug fouled / wet Replace / clean spark plugElectrode gap too less/excessive Check and correct electrode gapSpark plug wrong specifications Replace with correct spark plugIgnition coil defective Check & replacePulsar coil / Magneto defective Check & replace

B. Fuel / Induction related

Adulterated / Bad fuel Clean fuel tank.Fill with fresh fuel

Air vent holes in Fuel tank cap Check & clean air vents

Fuel flow partially blocked Check & clean fuel filter

Air filter dirty / clogged Check & clean / replace

Inlet manifold loose Check & correct

Pilot Jet loose / partially blocked Check & correct

Pulse air valve pipe connections Check & correctloose / cracked

C. Compression related

Spark plug loose Check & tighten to torque

Inlet / Exhaust tappets adjusted Check & correctwrongly

Cylinder head gasket blown Check & correct

Cylinder head studs loose Check & tighten to torque

Cylinder head seating area warped Check & replace

Cam shaft sticky rotation /seized Check & correctin cylinder head

Valve spring broken or weak Check & replace

Valve not seating properly (stem Check & replacebent. Heavy carbon deposit onseating surface)

Piston rings worn out/ broken / Check & replacestuck in ring groove

Cylinder / piston worn Check & replace

Attribute Probable Cause Remedy3. IDLING ERRATIC / ENGINE MISFIRING AT LOW RPM

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 123

A. Ignition related

Suppressor cap/ H T lead defective Check & correct as requiredSpark plug fouled / wet Replace / clean spark plugElectrode gap too less/excessive Check and correct electrode gapSpark plug wrong specifications Replace with correct spark plugIgnition coil defective Check & replacePulsar coil / Magneto defective Check & replace

B. Fuel / Induction related

Adulterated / Bad fuel Clean fuel tank.Fill with fresh fuel

Air vent holes in Fuel tank cap Check & clean air ventspartially blockedFuel flow partially blocked Check & clean fuel filterAir filter dirty / clogged Check & clean / replaceFuel level bowl too high or too low Check & correct float levelInlet manifold loose Check & correctPilot Jet loose / partially blocked Check & correctMain jet clogged / wrong size Check & replaceJet needle / needle jet worn out Check & replaceDiaphragm damaged Check & replacePulse air valve pipe connections Check & correctloose / cracked

C. Compression related

Spark plug loose Check & tighten to torqueInlet / Exhaust tappets adjusted wrongly Check & correctCylinder head gasket blown Check & correctCylinder head studs loose Check & tighten to torqueCylinder head seating area warped Check & replaceCam shaft sticky rotation /seized Check & correct in cylinder headValve spring broken or weak Check & replaceValve not seating properly (stem Check & replacebent. Heavy carbon deposit onseating surface)Piston rings worn out/ broken / Check & replacestuck in ring grooveCylinder / piston worn Check & replace

D. Transmission related

Rear chain tension too slack / tight Check & correctNo free play in clutch / clutch release sticky Check & correctEngine oil quantity too high Check & correctEngine oil wrong grade/ high viscosity Check & correctClutch plates worn out / warped / Check & correctsticky release / burnt

E. Others Front / rear brakes jamming Check & correctFront / rear wheel bearing jammed Check & correct

4. PICKUP POOR / SLUGGISHAttribute Probable Cause Remedy

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410124

A. Ignition related

Spark plug electrode gap too less/ Check and correct electrode gapexcessive

Spark plug wrong specifications Replace with correct spark plug

Spark plug insulator cracked Check & replace

Suppressor cap/ H T lead loose Check & correct as required

Suppressor cap/ H T lead defective Check & correct as required

Ignition coil defective Check & Replace

TCI defective Check & replace

Pulsar coil / Magneto defective Check & replace

B. Fuel / Induction related

Adulterated / stale fuel / water Check, Clean fuel tank/content in fuel Fill with fresh fuel

Air vent holes in Fuel tank cap Check and clean air vents

Fuel flow partially blocked Check & clean fuel filter

Inlet manifold loose / cracked Check & tighten / replace

Fuel level bowl too high or too low Check & correct float level

Main jet clogged / wrong size Check & replace

Jet needle / needle jet worn out Check & replace

C. Compression Related

Spark plug loose Tighten spark plug to torque

Tappets adjusted too tight Check & adjust tappetscorrectly

Cylinder head bolts loose Check & tighten to torque

Cylinder head gasket damaged Check & Replace

Cylinder head warped Check & Replace

Valve spring broken or weak Check & Replace

Valve not seating properly (valve Check & Replacebent, worn, carbon accumulationon the seating surface.)

Excessive Carbon in combustion Check & Cleanchamber

Piston ring bad (worn, weak, Check & Replacebroken, or sticking)

Piston rings clearance excessive Check & Replace

Cylinder, piston worn Check & Replace

5. ENGINE MISFIRING AT HIGH SPEEDS/ HIGH RPM.Attribute Probable Cause Remedy

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 125

A. Black smoke

Adulterated / Bad fuel Clean fuel tank.Fill with fresh fuel

Spark plug Electrode gap too less Check and correct electrode gap

Spark plug wrong specifications Replace with correct spark plug

Fuel level bowl too high Check & correct float level in(overflowing)

Air Filter element clogged Check & Clean

Pulse air valve pipe connections Check & correctloose / cracked

Main jet loose / too large Check, correct / replace

Jet needle worn out/ wrong size Check & replace

Ignition coil defective Check & replace

B. Brown smoke

Adulterated / Bad fuel Clean fuel tank.Fill with fresh fuel

Fuel level bowl too low Check & correct

Air filter box poorly sealed / Check & correctelement partially clogged

Main jet too small Check & replace

C. Bluish / White smoke

Engine oil level too high Check & Maintain Oil level asRecommended

Valve stem seal damaged Check & correct

Excess clearance between valve Check & correctstem & guide

Oil scrapper ring worn out Check & correct

Cylinder barrel / piston clearance Check & replacehigh

Symptom Probable Cause Remedy6. EXHAUST SMOKE EXCESS

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410126

Prolonged driving in low gear at High Ride in appropriate gear asspeeds / High gear at Low speeds required by traffic conditionsEngine in Idling RPM for prolonged Switch off Engine if required toperiods be in standstill traffic for more

A. Driving / traffic related than 2 minutes.Vehicle in standstill with gear engaged and Shift to neutral & release clutchclutch depressed for prolonged periodsEngine RPM high when vehicle at Allow engine to run in idlingstandstill position RPM when in neutralRiding in traffic with brakes partially Release both brakes and driveengaged for prolonged periods at appropriate speedsSpark plug electrode gap too less/excessive Check and correct electrode gapSpark plug wrong specifications Replace with correct spark plug

B. Ignition RelatedSpark plug insulator cracked Check & replaceSuppressor cap/ H T lead loose Check & correct as requiredSuppressor cap/ H T lead defective Check & correct as requiredIgnition coil defective Check & ReplaceTCI defective Check & replacePulsar coil / Magneto defective Check & replaceAdulterated / Bad fuel Clean fuel tank.

Fill with fresh fuelAir filter dirty / clogged Check & clean / replaceImproper fuel level Check & correct

C. Fuel / Induction related Inlet manifold loose Check & correctMain jet clogged / wrong size Check & replaceJet needle / needle jet worn out Check & replacePulse air valve pipe connections Check & correctloose / cracked

D. Compression Related

Spark plug loose Tighten spark plug to torqueTappets adjusted too tight Check & adjust tappets correctlyExcessive Carbon in combustion chamber Check & CleanPoor compression due to cyl. head gasket Check & correctblown, Valve seating improper, Piston ringsworn out / broken, Piston/Cyl. worn out

E. Others

Engine oil less viscous / wrong Check & correctspecification / level too lowOil cooler fins dirty / blocked Check & clean oil cooler finsClutch slipping Check & correctFront / Rear brakes jammed Check & correctEngine oil pressure less Check & correctSilencer choked Check & clean

Attribute Probable Cause Remedy7. ENGINE HEAT EXCESSIVE

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410 127

A. Knocking noise

Prolonged driving in low gear at High Ride in appropriate gear asspeeds / High gear at Low speeds required by traffic conditionsExcessive Engine heat Check & correctAdulterated / Bad fuel Clean fuel tank.

Fill fresh fuelIncorrect plug gap. Wrong spec spark plug Check & correct gap

Excessive carbon in combustion chamber Check & correctPulse air valve pipe connections loose / Check & correctcrackedExhaust pipe & cylinder head joint not Check & tighten exhaust flangesealed correctly nuts / replace gasket

B. Lubrication relatedEngine oil less viscous/wrong specification Check & correct / level too lowOil filter element blocked Replace filter elementOil pressure low Check & correct

C. Top End noise

Tappets clearance excessive Check & adjust tappetscorrectlyCamshaft sticky rotation Check & correctCam lobes in camshaft uneven wear Check & replaceCylinder head gasket blown Check & replaceValve spring broken / weak Check & replaceValve stem squeaky noise Replace stem sealsValve stem to guide clearance high Check & replace

D. Cylinder barrel / central

Piston rings broken Check & replace

portion noise

Cylinder / Piston scored Check & replace. Check air filter/ housing also for damagesExcess clearance between piston / barrel Check & replace(Piston slap)Cam chain pads worn out Check & replaceAuto chain tensioner jammed Check & replaceExcessive clearance between Cam chain / Check & replacesprocketsConnecting rod small end / piston pin Check & replaceclearance excess

E. Bottom end noise

Connecting rod bent Check & replace crankshaftExcess clearance between connecting rod Check & replace crankshaftbig end / crank pinCrankshaft / balancer shaft support Check & replacebearings wornCrankshaft run out excessive Check & replaceBalancer shaft / crankshaft gears backlash Check & correct

F. Transmission noise

Clutch housing/friction plate clearance Check & replaceexcessiveClutch housing gear / crank gear backlash Replace matched gearsDrive / counter gears backlash Check & replaceDrive / Countershaft bearings worn out Check & replaceGears / bushes seized in drive /counter shaft Check & replace

Attribute Probable Cause Remedy8. ENGINE NOISY

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ROYAL ENFIELD EURO IV - SERVICE MANUAL LS 410128

A. Clutch cable related

Routing improper Check & correct

Strapped too tight to frame Check & correct

Inner cable sticky Check & replace

Inner/outer cable damaged Check & replace

Free play excess Correct free play to 2-3mm

B. Oil related Oil less / more viscous. Wrong specification Check & correct

Oil level too high / too low Check & correct

Gear lever position incorrect Check & correct

Shift lever sticky / jammed on pivot pin Check, clean & lubricate pivot pin

C. Shift lever / linkage / Gear shift linkage ball joint stuck/worn out Check & correct

shifting Mechanism Return spring weak / broken Check & replace

related Indexing pawl pins worn out Check & replace

Shift forks sticky in pin / selector drum Check & correct

Shift forks / pins worn out Check & replace

Selector drum grooves worn out Check & replace

Clutch pad sticky / worn out Check & replace

Clutch plates movement sticky Check & correct

D. Clutch assembly related Springs weak / broken Check & replace

Friction plates worn out / burnt Check & replace

Steel plates warped Check & replace

No end float of clutch assembly in shaft Check & correct

E. Gears does not engage

Shift forks sticky in pin / selector drum Check & correct

Selector drum rotation sticky Check & correct

Sliding gear movement sticky in shaft Check & correct

Gears / bushes partially seized in shaft Check & correct

F. Gears overshifts

Shift forks / pins worn out Check & replace

Selector drum grooves worn out Check & replace

Sliding Gear dogs worn out Check & replace

Drive shaft / counter shaft splines worn out Check & replace

Drive / counter shaft bearings wornout Check & replace

Attribute Probable Cause Remedy9. GEAR SHIFTING HARD / SLIPS

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Twitter : @RoyalEnfieldSupportWeb : www.royalenfield.com

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