PDI CHECKLIST

FOR
ROYAL ENFIELD
CLASSIC

Engine Number :Chassis Number:-

Date:

Decoding (key-in the chassis number vertically in the first

column with the last 6 digits in the last cell)

Engine Family
Engine Capacity
Type of start
Transmission
Fuel feed
Blank
Year of Manufacture

-------------

Month of Manufacture
Production serial number

Engine C apacit y = 35 0cc / 500cc

Type of start = Self / Kick
Transmissio n = No. of gears
Fuel feed = Fuel injec tion / Carburetor
Year of Manufacture = A-2010, B-2011, C-2012, D-2013,....
Month of Manufacture = A-Jan, B-Feb,.. . L -Oct, M-Nov, N-Dec [ I & J not used]

*I prepared this checklist referencing many internet sources and consulting some mechanic friends.

Checklist
PHYSICAL CHECK (Outer)
Check for any damage or irregular paint works

check all the welded edges under the tank, look

for any minute scratches in the obvious visible

No scratches?

Equal

High beam

Low beam

It is bright

Right

Left

Front-Right indicator

Front-Left indicator

Rear-Right indicator

Rear-Left indicator

No difference?

body
Check the front fork sleeve length

both should be equal

PHYSICAL CHECK (Electrical parts)

Check the effective functioning of the headlights

should be bright & glowing continuous

Check the functioning of the High beam pass

should be bright

Check the functioning of the parking lights

should be bright & glowing continuous

Check the functioning of the Indicators

check whether the indicators are blinking with

equal intervals

check while the bike is idling and then raise the

accelerator

all the times the indicators should be working

in the same manner as said above

Check the functioning of the horn

check by continuously pressing the horn button

for 5 seconds & check for any difference

Rear

Fuel indicator is off?

Speedometer light

Fuel indicator light

Idle

Driving

Idle

Driving

cooling condition

normal condition

Front

Rear

Front brake

Gradual

Less

Rear brake

Less

check the front & rear brake lights

Front

Gradual

Immediate

Check the functioning of the brake lights

Immediate

PHYSICAL CHECK (Electrical parts)

Check the functioning of the fuel indicator

Fuel should be above reserve level and check

the reserve light fuel indicator should be off

Check the functioning of the speedometer light

check the speedometer, fuel indicator lights

Check the functioning of the neutral light

check in both idle and driving conditions

Check the functioning of the indicator notifiers

check in both idle and driving conditions

check for any delay in the response item

Check the functioning of the e-Start

check in cooling conditions & normal conditions

Brakes
Braking

check the effectiveness & check for any odd

noise while braking

Brake Response

Apply both the brakes at various speeds & check

the brake response

Starting the Bull

Starting

Starting should be smooth should not take

Expected time to start?

Front

Rear

No leak at engine cover

No leak at shock absorbers

Expected noise stoppage?

No ups & downs?

No rubbing sound?

No lack in engine response?

No abnormal noise?

No white smoke?

No acid spills?

more than 3 seconds to start

Exhaust leaks

No leaks at the exhaust (both ends)

Oil leaks

No oil leaks at the engine rocker cover & shock

absorbers

Decompressor Noise

after 2 minutes noise from the decompressor

should stop

Idling

check Idling is stable with no ups & downs

Riding the Bull

Rubbing Issues

Ride with a pillion rider & check for any

rubbing issues at the rear

Engine Response

Drive at all the gears and check for any lack in

engine response & noise

Exhaust

Check for white smoke from the exhaust

Battery

Check for acid spills in the battery and over the

battery cover

Other miscellaneous checks

Clutch

Clutch cable should not be too tight or too loose

Accelerator

Choke
Choke cable should be properly engaged

Stands

Not too tight or too loose?

Turn right

Turn left

Properly engaged

Accelerator cable should not stuck when

turning the head while standing

Engage both the stands

Springs properly working?

No much effort required engaging the stands?

Handle Bar

Turn the handle bar & it should turn equally to

Turns equally

No difficulty in rotating?

Chain slack is within the

both the sides

Front wheel

Simply rotate the front wheel and check

alignment, difficulty in rotating & any noise

Chain Slack

Measure the chain slack should not be more

expected range

than 1.5 inch (38mm)

Date Sync

Check the date in the green non-pollution

sticker in the left electrical box with the date

Dates are in Sync

Key number & lock

obtained by decoding the chasis no.

Keys

Match the key number with the numbers in all

numbers are in Sync

the locks
Kits

Check both the first aid box & toolkit

Kits are available and new

Kindly check with your showroom or the sales guy if any of the above mentioned points are not as expected

Study your Bull completely before investing your hard earned money on this everlasting
mighty beast.
I hope this checklist helps you all in selecting your masculine partner without any flaws.
- Your fellow bulletian

Muralikrishna

(krish.v88@gmail.com)
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if you have any suggestions regarding this checklist kindly mail me your comments