Royal Enfield Thunderbird 500 - Pdi Checklist Troubleshooting Guide

7/25/2019 Royal Enfield Thunderbird 500 - Pdi Checklist Troubleshooting Guide

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PDI Checklist

the ENGINE code is as follows

U = ENGINE FAMILY

5 = ENGINE CAPACITY (500cc) = TYPE !F TA"T (elect#ic$)

5 = T"ANMII!N (5 s%eed$)

F = FUEL FEE& (f'el iectio$)

0 = *LAN+ F!" FUTU"E UE ($)

* = YEA" !F MANUFACTU"E (,-=.00-/ A=.00/ *=.0/ C=.0.)

L = M!NT1 !F MANUFACTU"E (A=2AN/ *=FE*/ C=MA"333L=!CT/ N=&EC)

04..= P"!&UCTI!N E"IAL NUM*E"

1 Check func. Front & rear indicators, no plate lamp

2 Front fork sleeve shouldn't touch mudguard or fork. On pre delivery ride - hard rake to check.

! "ust on #ain frame - near $elding %oints - at the ottom, $here the main stand mates $ith the frame

eaks around kick start, and chain slackness

( Full tool kit

) "* *mossed eather +ocument ouch if possile

/ Funct. Of fuel sensor, check fuel level

0 Check fuel leaks under tank $here sensor is inserted, and also petrol pump outlet

attery electrolyte level

13 Check any paint surface, aluminium uffed surfaces for scratch4damage

11 roper fit of various control cales $rt play

12 roper $orking of electricals

1! roper tyre pressure - "ecommended56

1 7est "ide - see if ike pulls to$ards left or right1( 8sk to open O9* 7ool o: - generally %ammed

1) Check proper "*7"8C7;O< of main & side stands - sometimes hang mid$ay due to spring

1/ Check 13 8# fuse - can get knocked off due to running in shocks

1. Start with visually inspecting the whole bike- from bodywork to rims tyres- anything haout of place, damaged, dented, rusting at the welding joints or repaired(transitdamaged)painted parts like fuel tank, mudguard .

2. Check the front fork sleeves(which covers the forks top length clearance betweenfront mudguard - needs to be equal b/w sleeves & mudguard - if not,then it will scdamage the paint work on mudguard"sleeves.

#. Check for all theelectrical parts.e.g. headlight high"low beam- high beam pass, indichorns, brake light switch -front and rear, parking light, $Start. %lso check the indication lithe speedo- neutral light, high beam and indicator.


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&. %pply the front and rear braketo check out the eectiveness and an odd noiseffront or rear brake while braking.

'. Check yourtool kitif its complete or not.

. )ake the key and match the serial number on the kewith the lock serial no of the reelectrical/storagebo*. )he no will be on the outside where ou insert the keinto t%lso check working of allthe locks on the bike with same key.

+. Check the chain slack while sitting on centre stand and then o! it. Should be no more tinchwhile on the centre stand.

. %fter starting the bike, check for any e'haust leaksat the headwhere the down pipe iattached and at the e'haust/down pipe joint. %lso for any white smokefrom the e*ha. - , -

absorbers and front. on/t worry if you see a bit of oil under the "# engine cover. 0t

from the chain.

1. %fter engine has warmed up for a couple of minutes- the tick tick noiseof the autcompressor should stop. Check the idling is not erratic(umping up"down. Starting shoulsmooth and not take more then one crank (not more the seconds) to start

11. )ake a ride on the bike with a pillion ride to see if you have rubbing issues of thetre with the mudguard. )hats due to the bad alignment of the mudguard and sometimrear tyre also.

. , .an hesitation in the engine response. o check the e*haust for any white smoke o

while riding.1#. Check for any acid spill from the batterand check if drain pipe from the batteattached. 5irst gen C' use to come with e*ide batteries which had no drain pipe but newcome with e*ide or 50emm batteries which have the drain pipe. 6ook for any spill damagengine coverunder the battery

1&. Check the accelerator cable- should not get stuck when turning left or right whstand. Check the choke cable for proper engagementand clutch cable is not too titoo lose.

1'. +heck springs ( nos) on the centre stand. $ngage the center 7 side stand. #houldtake much eortto engage both the stands.

1. Check for any pre damage to the chassis front. )urn the handle bar left to right - sturn equallto both the sides, and not more or less at one side to other.

1+. ight"andle +heck8 lean the handle to one side wee bit and if it comes down fully t9ne. !oose "andle +heck8 %pply front brake and rock the bike forward and backward. :ofeel the play or noise if its too loose. :ou can also put it on C stand and while holding the h9rmly, ask you friend to grab the front forks and rock it forward " backward. %ny play will beasily.


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GENERAL OBSERVATIONS on Thunderbird

1. 3hile on C stand, rotate the front wheeland check the run out of the tre or at leabnormal noise. 3heel should rotate freel and also check for front speedo is tightspeedo hub and the #." movement of speedo needle.

1. )o check the .;.< of your bike, open up the !"# electrical bo'and you will 9nd thenon- pollution sticker with the 0%%1on it. :ou cancross check the month with thchassis no%

2.


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2. %ccessories -

% 0f you intent to ride solo without the rear seat then get the rear 6?S g


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Congrats to you too samIbJ 0t would be good to have more )-


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5ront fork sleeve should not touch the mudguard or the fork.

=ust on the main frame, especially at the welding oints. (do

Check for leaks around the kick-shaft, and chain slackness. 5ull tool kit.

=$ embossed leather document pouch if possible. ( although

5ill adeAuate petrol and check for the proper working of fuel s

Check for leaks under the tank where fuel sensor is inserted,


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rom

ar !"#e lock.

hen $%

sst.

ill be

de-be

eares of the

black

r isneson the

ile on +ght or

not

ould

en itsu willndlefelt


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ast anyt the

green

ghtless to

f the

e. )his

ingway,

eoot,e it

b the

hakes

tched or


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ard(stay changed to single pipe one.

nt use it when the bike is hot which it stays for hours at a stretch and not water proof. ?as

hed to the down pipe and does not come with free Dow down pipe anymore so you wont h

one on the front head light.

to askn it mayt on aof two

2 FH?.

hems easier


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o share views and comments with.

the bikes are essentially the same engine. Eust a few things to add, that 0 can think of8

hen you e*perience it 9rst hand8 )he bike will not be perfectly ready due to various reaso

ill be tilted to one side. )his is a trademark, do not fret

cked this on & di!erent thunderbirds and found the pedals in di!erent positions on all of th

e a bit. @y guess is that they are designed this way, so as to absorb the shocks better. ocheck if the handle bar shakes from side to side. 0f it does, you need to get the wheels ali

of the silencer is scratched or falling. 0 have had no such issue

showroom (:ou will have to ask for the keys. )hey should have very similar reading. 0f you

ak at speeds above 2 FH?. )his is normal and has to do with the Dow of break oil.

n and eye for detail. )ip them before you leave ($ven better if you take some sweets alon


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ake a pre delivery ride, brake hard a few times and observe.

heck at the bottom, where the main stand mates with the frame

i never got one 8(

ensor.

and also the petrol outlet pump.

d aluminium parts.

ing towards left or right.

cases its ammed and diMcult to open.

s they hang mid-way as springs are faulty.


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minimal dust protection.

rm the engine during running in period.


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s, and you will get to know it better and take care of it. 6ovely thing you have gifted yours

m. $ither they are getting mauled in transportation or the manufacturer is playing a game

ot fret (again ned.

bike has more F@ reading, than it may have been used for test rides, though =$ does not

. 0t will make subseAuent visits easier for you.


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lfJ :ou are going to enoy it more because of the subtle demands for attention that it will p

of hit and trial with us. %nyway, ust check that your foot is able to rest itself on the whole

allow this. @y dealer had given me a test on a esert Storm, which 0 found later, was waiti


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t on you

of the hori>ontal line of the rubber, if not on the rubber itself, when you press the pedal. 0f i

g for delivery. %lso if you are asked to pick one of two bikes, choose the dirtier one. )he on


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it is not hori>ontal to your foot, your foot will tend to slip o! on application of pressure, esp

e that has been in the showroom longer will have been cleaned more often, but is also sus


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cially when wet or in rain. ?ave it corrected.

eptible to have been abused by test riders.


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Tea!B"P # $B"P # BC%T Data on Thunderbird Is

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ues

Proble &aced Author

@ide @tand ight not going off - +; vra%aram- angalore"ear rake @ometimes @Aueaky vra%aram- angalore

Clutch too tight - makes sAueaky sound $hen released vra%aram- angalore

Fuel indicator inaccurate - sho$s higher if on side stand vra%aram- angalore

#inor metallic sound from engine - $ent a$ay on its o$n vra%aram- angalore

"ear rake gettting ocked vra%aram- angalore

oose chain vra%aram- angalore

@tuck >ear et$een 1st & etife

etrol 7ank aint - rough in some ones >etife

+elayed +elivery samD

1 kms on O+O at time of delivery samD

"E@ mirror plastic scratched adly samD

+ missing in *nfield tank sticker samD

ai# filte# to th#ottle #'66e# hose was to# f#o7 the 'ctio of samD

*F; #; glo$s lightly, flickering on dig odo samD

"ear rake non responsive samD

com
mailto:[email protected]:[email protected]


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"ear rake not functioning $ell ra%neeesh

Eead lamp not focussed $ell ra%neeesh

"ear rake %ammed due to rear a:le nut E7*


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Solution Solution Location

@8#* - Fi:ed during ;st service@8#* - Fi:ed during ;st service

#ay need greasing

8ir lock suspect

*very 133 kms or so noise

Cold *ngine in the morning

Cold *ngine - allo$ $arm up for 1 min

@olved in ;st @ervice

@olved in ;st @ervice - lurication8@C fi:ed $ithout any cost

ress @elect & @et uttons together for more than ! seconds. 7hen turn off ignition & turn on again, $h

@ent for correction - returned

@tarted covering the seats

7ank replaced under $arranty $ith galvanied internals tank http=44$$$.team-hp.com4forum4motori

Float valve replaced under $arranty

"eplaced entire console under $arranty, protective shoe glued


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@orted during ;st service

@orted during ;st service

Fi:ed y local mechanic

"eplacedJill e replaced under $arranty. #aye fe$ $eeks. *+;7= "eplaced


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ile keeping the uttons pressed.

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#a%umdarda
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B. "avi

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Royal Enfield Thunderbird 500 - Pdi Checklist Troubleshooting Guide

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Transcript of Royal Enfield Thunderbird 500 - Pdi Checklist Troubleshooting Guide