Royal Enfield Meteor 350 - Service Repair Manual - Owners Manual

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ROYAL ENFIELD METEOR 350 - WORKSHOP, SERVICE, REPAIR MANUAL - OWNERS MANUAL

- English Service Manual / Repair Manual and Owners Manual, for motorcycles Royal Enfield Meteor 350.

 
CONTENTS:

SERVICE MANUAL

1. General Information
1.3 Important Information
1.4 General Precautions
1.5 Prior to Service
3_PMS_PERIODIC MAINTENANCE SCHEDULE (PMS)
5. ENGINE
- 5.1 Components Removal from Engine
- 5.1.1. Drain Plug
- 5.1.2. Oil Filter
- 5.1.3. Throttle Body
- 5.1.4. Injector
- 5.1.5. Spark Plug
- 5.1.6. Engine Oil Temperature Sensor
- 5.1.7. Starter Motor
- 5.1.8. Breather Hose Connections
- 5.1.9. Gear Position Sensor
- 5.1.10. Clutch Actuating Lever
- 5.1.11. Cover RH
- 5.1.12. Clutch Actuating Shaft
- 5.1.13. Oil Level Window
- 5.1.14. OIl Bypass Seal
- 5.1.15. Transmission Jet
- 5.1.16. Oil Pump
- 5.1.17. Balancer Shaft Bolt
- 5.1.18. Crankshaft Nut
- 5.1.19. Clutch Assembly
- 5.1.20. Gear Shifter Shaft
- 5.1.21. Star Index Stopper
- 5.1.22. Star Index
- 5.1.23. FD Sprocket
- 5.1.24. Plug-Crankshaft Hole
- 5.1.25. Cylinder Head Cover
- 5.1.26. Auto Chain Tensioner
- 5.1.27. Rocker Carrier
- 5.1.28. Rocker Arm From Rocker Carrier
- 5.1.29. Camshaft, Sprocket and Chain
- 5.1.30. Cover LH
- 5.1.31. Stator Assembly
- 5.1.32. Magneto Rotor Bolt
- 5.1.33. Idler Gear
- 5.1.34. Starter Clutch From Magneto Rotor
- 5.1.35. Cylinder Head
- 5.1.36. Components From Cylinder Head
- 5.1.37. Guide Pad-Chain
- 5.1.38. Pistons
5.2 Engine Removal from Main Frame
- 5.2.1. Engine Oil
- 5.2.2. Oil Filter
- 5.2.3. Side Panel RH
- 5.2.4. Side Panel LH
- 5.2.5. Pillion Backrest and Seat from Frame
- 5.2.6. Rider Seat from Frame
- 5.2.7. Battery Connections
- 5.2.8. Clutch Cable
- 5.2.9. Fuel Tank
- 5.2.10. Fuel Pump Connector
- 5.2.11. Fuel Hose (Fuel Pump to Injector)
- 5.2.12. EVAP Connections to Fuel Tank
- 5.2.13. Drain Hose
- 5.2.14. Throttle Cable
- 5.2.15. Secondary Air Valve Connection
- 5.2.16. Air Filter Housing to Throttle Body
- 5.2.17. Throttle Body
- 5.2.18. Hego/Oxygen Sensor Connectors
- 5.2.19. Exhaust Pipe and Silencer
- 5.2.20. Magneto/Gear Position/Side Stand
- 5.2.21. Starter Motor Connection
- 5.2.22. Spark Plug Suppressor Cap
- 5.2.23. Breather Hose Connection
- 5.2.24. Gear Shift Linkage
- 5.2.25. FD Sprocket Cover and FD Sprocket
- 5.2.26. Rear Wheel (Increasing chain slack)
- 5.2.27. Remove Rear Chain from FD Sprocket
- 5.2.28. Gear Position Sensor
- 5.2.29. Cradle Frame Mountings
5.3 Engine Assembly to Frame
- 5.3.1. Engine to main frame
- 5.3.2. Engine Mounting Final Torque
- 5.3.3. Cradle Frame Mountings
- 5.3.4. Gear Position Indicator Sensor
- 5.3.5. FD Sprocket
- 5.3.6. FD Sprocket Cover
- 5.3.7. Gear Shift Linkage
- 5.3.8. Breather Hose Connection
- 5.3.9. Spark Plug Suppressor Caps
- 5.3.10. Starter Motor Connections
- 5.3.11. Magneto/Side Stand Switch Connectors
- 5.3.12. Exhaust Pipe on Cylinder Head
- 5.3.13. Hego/Oxygen Sensor Connectors
- 5.3.14. Throttle Body
- 5.3.15. Air Filter Housing to Throttle Body
- 5.3.16. Reed Valve Connection
- 5.3.17. Injector Connections
- 5.3.18. Throttle Cable
- 5.3.19. Fuel Tank
- 5.3.20. Drain Hose
- 5.3.21. EVAP Connections to Fuel Tank
- 5.3.22. Fuel Hose (Fuel Pump to Injector)
- 5.3.23. Fuel Pump Connector
- 5.3.24. Battery Connections
- 5.3.25. Rider Seat Assembly on Frame
- 5.3.26. Pillion Backrest and Seat Assembly on Frame
- 5.3.27. Side Panel LH
- 5.3.28. Side Panel RH
5.4 Engine Dismantling
- 5.5.1. Drain Plug
- 5.5.2. Oil Filter
- 5.5.3. Throttle Body
- 5.5.4. Injector
- 5.5.5. Spark Plugs
- 5.5.6. Engine Oil Temperature Sensor
- 5.5.7. Starter Motor
- 5.5.8. Breather Hose
- 5.5.9. Gear Position Sensor
- 5.5.10. Clutch Actuating Lever Assembly
- 5.5.11. Cover RH
- 5.5.12. Clutch Actuating Shaft
- 5.5.13. Oil Level Window
- 5.5.15. Transmission Jet
- 5.5.16. Oil Pump
- 5.5.17. Balancer Shaft Bolt
- 5.5.18. Crankshaft Nut
- 5.5.19. Clutch Assembly
- 5.5.20. Gear Shifter Shaft
- 5.5.21. Star Index Stopper
- 5.5.22. Star Index
- 5.5.24. Plug - Crankshaft Hole
- 5.5.25. Cylinder Head Cover
- 5.5.26. Auto Chain Tensioner
- 5.5.27. Rocker Carrier
- 5.5.28. Rocker Arms from Rocker Carriers
- 5.5.29. Cam Shaft, Sprocket & Chain
- 5.5.30. Cover LH
- 5.5.31. Stator Assembly
- 5.5.32. Magneto Rotor Bolt
- 5.5.33. Idler Gear
- 5.5.34. Starter Clutch from Magneto Rotor
- 5.5.35. Cylinder Head
- 5.5.36. Components from Cylinder Head
- 5.5.38. Cylinder Barrel
- 5.5.39. Pistons
- 5.5.40. Crankcase Fasteners
- 5.5.41. Splitting Crankcase
- 5.5.42. Balancer Shaft
- 5.5.43. Crankshaft Assembly
- 5.5.44. Gear Selector
- 5.5.46. Driveshaft
5.6.2 Cylinder Barrel
- 5.6.3 Crankcase
- 5.6.5 Shifter Forks
5.8 Engine Assembly
- 5.8.1. Components Sub Assembly in Crankcase
- 5.8.2. Crankshaft Assembly
- 5.8.3. Balancer Shaft
- 5.8.4. Countershaft Components
- 5.8.5. Driveshaft Components
- 5.8.6. Transmission Selector Drum
- 5.8.7. Dowel pins
- 5.8.8. Crankcase Closing
- 5.8.9. Crankcase Bolts Tightening Procedure
- 5.8.10. Piston and Piston Rings
- 5.8.11. Cylinder Barrel
- 5.8.12. Valves and Springs
- 5.8.13. Timing chain on Crankshaft
- 5.8.14. Woodruff Key on Crankshaft
- 5.8.15. Magneto Rotor on Crankcase
- 5.8.16. Cylinder Head
- 5.8.17. Camshaft Assembly
- 5.8.18. Rocker Carrier in Cylinder Head
- 5.8.19. Tappet Clearance Adjustment
- 5.8.20. Cylinder Head Cover
- 5.8.21. Spark Plug
- 5.8.22. Star Index
- 5.8.23. Star Index Stopper
- 5.8.24. Gear Shifter Shaft
- 5.8.25. Clutch assembly (LH thread)
- 5.8.26. Crank gear (LH Thread)
- 5.8.27. Balancer Shaft Bolt
- 5.8.28. Oil Pump
- 5.8.29. Transmission Jet
- 5.8.30. Oil Level Window
- 5.8.31. Oil Bypass seal
- 5.8.32. Clutch Actuating Shaft
- 5.8.33. Clutch Actuating Lever Assembly
- 5.8.34. Cover RH
- 5.8.35. Starter Idler Gear
- 5.8.36. Cover LH
- 5.8.37. Gear Position Sensor
- 5.8.38. Plug-Crankshaft Hole
- 5.8.39. Starter motor
- 5.8.40. Oil Strainer
- 5.8.41. Breather Hose
- 5.8.42. FD sprocket
- 5.8.43. Throttle Body
- 5.8.44. Engine Oil Temperature/EOT sensor
5.9 Engine Troubleshooting
Dismantling
- 6.1.1. Air Filter Element
- 6.1.2. Air Filter Box
- Inspection
- Assembly
- 6.1.3. Air Filter Box Assembly
Troubleshooting
6.2.3. Throttle Cable
- 6.2.4. Throttle Cables Free Play Adjustment
- 6.2.5. Clutch Cable
Inspection
6.2.1. Clutch Cable
- 6.2.2. Throttle Cable
Assembly
- 6.6.9. Rear Mudflap
- 6.6.11. Rear Mudguard
- 6.6.12. Reflector
- 6.6.13. Rear Number Plate (For Indian Market)
- 6.6.15. Front Mudguard
6.6.6. Rear Mudguard
6.6.5. Reflector Rear
6.6.4. Rear Fender
Dismantling
- 6.7.1. Side Panel RH
- 6.7.2. Side Panel LH
- 6.7.4 Rider Seat from Frame
- Assembly
- 6.7.5. Rider Seat Assembly on Frame
- 6.7.6. Pillion Backrest and Seat Assembly on Frame
- 6.7.7. Side Panel LH
Assembly
- 6.8.11. Tyre Assembly on Wheel Rim
- 6.8.10. Drive Chain Free Play Adjustment
- 6.8.9. Rear Wheel into Swing Arm
- 6.8.8. Rear Wheel and Brake Disc
Inspection
- 6.8.5. Front Wheel and Brake Disc
- 6.8.6. Rear Wheel and Brake Disc
Dismantling
- 6.8.1. Front Wheel Assembly
- 6.8.2. Front Wheel and Brake Disc
- 6.8.3. Rear Wheel from Swing Arm
6.9.13. Swingarm
- 6.9.14. Subframe
- 6.9.15. Shock Absorber
- 6.9.15. Steering Stem Assembly into Frame Head Tube
- 6.9.17. Steering Stem on Frame Head Tube
- 6.9.18. Top Yoke on steering stem
- 6.9.19. Front Fork Sub Assembly LH and RH
- 6.9.20. Front Fork LH and RH Assembly on Motorcycle
- 6.9.21. Steering Stem Play Adjustment
6.9.7. Front Fork Leg
- 6.9.8. Front Fork Air Gap Setting
- 6.9.9. Steering Stem
- 6.9.10. Shock absorber
- 6.9.11. Swingarm
- 6.9.12. Top Yoke
6.9.6. Swingarm
6.9.6. Sub Frame
6.9.5. Shock absorber
6.9.3. Steering Stem Assembly from Frame Head Tube
6.9.2. Front Fork Sub Assembly LH and RH
7.1.9. Fuel Float
- 7.1.10. Fuel Pump
- 7.1.11. Fuel Filter
7.1.1. Fuel Tank
- 7.1.2. Fuel Pump Connector and Fuel Level Sensor
- 7.1.3. Fuel Hose (Fuel Pump to Injector)
- 7.1.4. EVAP Connections to Fuel Tank
- 7.1.7. Fuel Pump
- 7.1.6. Fuel Level Sensor
- 7.1.6. Fuel Filter
7.1.12 Fuel Filter
- 7.1.13. Fuel Level Sensor
- 7.1.14. Fuel Pump
- 7.1.15. Fuel Tank
- 7.1.16. Drain Hose
- 7.1.17. EVAP Connections to Fuel Tank
- 7.1.18. Fuel Hose (Fuel Pump to Injector)
8.1.3. Charcoal Canister
- 8.1.4. Purge Valve
- 8.1.5. Hoses
- 8.1.6. Hose Connectors
- 8.1.7. EVAP System Leak Test Procedure
EVAP Components
- 8.1. Evaporative (EVAP) Emission Control System
General Description
8.1.1. Charcoal Canister
- 8.1.2. EVAP Purge Valve
8.1.8. EVAP Purge Valve
9.3.11 ABS DTC Codes
- 9.4. Preparation ( Front Disc Brake)
- 9.5. Reassembly
- 9.6. Preparation ( Rear Disc Brake)
- 9.8. Brake Bleeding
- 9.8.1. Front Brake Bleeding
- 9.8.2. Front Brake Fluid Leakage
- 9.8.3. Front Brake Fluid Top up
- 9.8.4. Rear Brake Bleeding
- 9.8.5. Rear Brake Fluid Leakage
- 9.8.6. Rear Brake Fluid Top Up
Assembly
- 9.3.6. Toner Ring – Front
- 9.3.7. Toner Ring –Rear
- 9.3.8. Wheel Speed Sensor - Rear
- 9.3.9. Wheel Speed Sensor - Front
- 9.3.10. Modulator
Dismantling
- 9.3.1. Modulator
- 9.3.2. Wheel Speed Sensor - Front
- 9.3.3. Wheel Speed Sensor - Rear
- 9.3.4. Toner Ring – Front
- 9.3.5. Toner Ring –Rear
Functions and Specifications of the ABS Aggregates
Typical Motorcycle Braking Distance
Working Principle
Brake - Front
- 9.2.7. Brake Disc - Front
- 9.2.8. Brake Caliper - Front
- 9.2.9. Master cylinder - Front
- 9.3 Anti-lock Braking System (ABS)
Rear Brake pedal
Brake - Rear
- 9.2.4. Brake Disc - Rear
- 9.2.5. Brake Caliper Assembly - Rear
Assembly
Inspection
Dismantling
- 9.1. Brake - Front
- 9.1.1. Master Cylinder Assembly - Front
- 9.1.2. Brake Caliper - Front
- 9.1.3. Brake Disc - Front
- 9.2. Brake - Rear
- 9.2.1. Master Cylinder Assembly - Rear
- 9.2.2. Brake Caliper Assembly - Rear
- 9.2.3. Brake Disc - Rear
10. Engine Management System (EMS)
- EMS Components
- Functional Specifications
- 1. Electronic Control Unit (ECU) Integrated with Throttle Body
- Functional Diagram
- 2. Fuel Injector
- 3. Fuel Supply Module
- 4. Throttle Position Sensor
- 5. Manifold Absolute Pressure Sensor (MAP)
- 6. Canister Purge Valve
- 7. HEGO Sensor/Oxygen Sensor (HEGO / O2)
- 8. Idle Air Control Valve (IAC)
- 9. Secondary Air Injection Solenoid (SAI)
- 10. Engine Oil Temperature Sensor (EOT)
- 11. Intake Air Temperature Sensor (IAT)
- 12. Clutch Switch
- 13. Side Stand Switch
- 14. Gear Position Sensor (GPS)
- 15. Roll Over Sensor
- 16. Crank Position Sensor (CPS)
- 17. Starter Motor Relay
- 10.1 Engine Management System (EMS)
- Dismantling
- 10.1.2. Fuel Pump
- 10.1.3. Throttle Body Assembly
- 10.1.4. Fuel Injectors
- 10.1.5. Engine Oil Temperature Sensor (EOT)
- 10.1.6. HEGO/Oxygen (O2) Sensor
- 10.1.7. Secondary Air Injection Unit (Solenoid) (SAI)
- 10.1.8. Purge Valve
- 10.1.9. Ignition Coil
- 10.1.10 Crank Position Sensor
- 10.1.17. Gear Position Sensor
- 10.1.18. Clutch Switch
- 10.1.19. Side Stand Switch
- 10.1.20. Starter Motor Solenoid
- Assembly
- 10.1.21. Engine Control Unit (ECU)
- 10.1.22. Fuel Pump
- 10.1.23. Fuel injectors
- 10.1.28. Engine Oil Temperature Sensor (EOT)
- 10.1.29. HEGO (O2) Sensor
- 10.1.31. Secondary Air Injection Unit (SAI) (Solenoid)
- 10.1.32. Purge Valve
- 10.1.34. Ignition Coil
- 10.1.35. Crank Position Sensor
- 10.1.36. Gear Position Sensor
- 10.1.37. Clutch Switch
- 10.1.38. Side Stand Switch
- 10.1.39. Starter Motor Solenoid
- 10.1.39 Actuator
10.2 EMS DTC Codes
11.1 Headlamp and Cluster Dismantling
- 11.1.1 Headlamp Reflector from Housing
- 11.1.3 Headlamp Bulb from Reflector
- 11.1.4 Connectors and Sensors from Headlamp Housing
- 11.1.5 Headlamp Housing from Holder LH & RH.
- 11.1.6 Direction Trafficators from Headlamp Holder
- 11.1.7 Cluster Dismantling
- 11.1.7 Ignition Switch
- 11.1.8 Headlamp Housing Holders from Fork Legs
11.2 Tail Lamp Dismantling
- 11.2.1 Tail Lamp
11.3 Brake Lamp Connectors Dismantling
- 11.3.1 Brake Lamp Connector - Rear
- 11.3.2 Brake Lamp Connector - Front
11.4 Trafficators Dismantling
- 11.4.1 Direction Trafficators - Rear
- 11.4.2 Trafficator bulb - Front
11.5 Battery Dismantling
- 11.5.1 Battery Terminals
- 11.5.2 Battery Tray
- 11.5.3 Starter Solenoid
- 11.5.4 RR Unit
11.6 Horn Dismantling
Inspection
Assembly
11.7 Horn Assembly
11.8 Battery Assembly
- 11.8.1 RR Unit
- 11.8.3 Battery Tray
- 11.8.4 Battery Terminals
11.9 Trafficators Assembly
- 11.9.1 Direction Trafficator Bulb - Front
- 11.9.2 Direction Trafficators - Rear
11.10 Brake Lamp Connectors Assembly
- 11.10.1 Brake Lamp Connector - Rear
- 11.10.2 Brake Lamp Connector - Front
11.11 Tail Lamp Assembly
- 11.11.1 Tail Lamp
11.12 Headlamp and Cluster Assembly
- 11.12.1 Headlamp Housing Holders into Fork Legs
- 11.12.2 Cluster Assembly
- 11.12.3 Direction Trafficators into Headlamp Holder
- 11.12.5 Connectors and Sensors into Headlamp Housing
- 11.12.6 Headlamp Bulb into Reflector
- 11.12.7 Pilot Bulb into Reflector
- 11.12.8 Headlamp Reflector into Housing
12.1 Index
12.2 Glossary


OWNERS MANUAL

- Safety Definitions
- Personal and Motorcycle Information
- Safe Riding Tips/ Guidelines
- Rules of the Road
- Accessories and Luggage
- Technical Specifications
- Recommended Lubricants
- Motorcycle Identification Numbers
- Engine Number Details
- Location of Key Parts
- Operation of Controls
- Warning Indications and Safety Systems
- Pre-Operational Checks
- Running in Period
- Starting
- Gear Shifting, Riding and Stopping
- Parking
- Tools
- Minor Maintenance Tips
- Rear Suspension Setting
- Long Trip Precautions
- Washing Procedure
- Storage Precautions
- Environment Care
- Periodical Maintenance Chart
- Warranty Terms and Conditions
- Emission Warranty
- EVAP
- Service/ Maintenance Record
- Notes