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PDI Checklist

the ENGINE code is as follows
U = ENGINE FAMILY
5 = ENGINE CAPACITY (500cc)
S = TYPE OF START (electric?)
5 = TRANSMISSION (5 speed?)
F = FUEL FEED (fuel injection?)
0 = BLANK FOR FUTURE USE (?)
B = YEAR OF MANUFACTURE (-9=2009, A=2010, B=2011, C=2012)
L = MONTH OF MANUFACTURE (A=JAN, B=FEB, C=MAR...L=OCT, N=DEC)
108227= PRODUCTION SERIAL NUMBER
1
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5
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Check func. Front & rear indicators, no plate lamp
Front fork sleeve shouldn't touch mudguard or fork. On pre delivery ride - hard brake to check.
Rust on Main frame - near welding joints - at the bottom, where the main stand mates with the frame
Leaks around kick start, and chain slackness
Full tool kit
RE Embossed Leather Document Pouch (if possible)
Funct. Of fuel sensor, check fuel level
Check fuel leaks under tank where sensor is inserted, and also petrol pump outlet
Battery electrolyte level
Check any paint surface, aluminium buffed surfaces for scratch/damage
Proper fit of various control cables wrt play
Proper working of electricals
Proper tyre pressure - Recommended?\
Test Ride - see if bike pulls towards left or right
Ask to open OVEL Tool Box - generally jammed
Check proper RETRACTION of main & side stands - sometimes hang midway due to spring
Check 10 AMP fuse - can get knocked off due to running in shocks

1. Start with visually inspecting the whole bike- from bodywork to rims tyres- anything hanging,
out of place, damaged, dented, rusting at the welding joints or repaired(transit
damaged) painted parts like fuel tank, mudguard .
2. Check the front fork sleeves(which covers the forks top length) clearance between the
front mudguard - needs to be equal b/w sleeves & mudguard - if not, then it will scuff and
damage the paint work on mudguard/sleeves.
3. Check for all the electrical parts .e.g. headlight high/low beam- high beam pass, indicators,
horns, brake light switch -front and rear, parking light, EStart. Also check the indication light in
the speedo- neutral light, high beam and indicator.

4. Apply the front and rear brake to check out the effectiveness and any odd noise from
front or rear brake while braking.
5. Check your tool kit if its complete or not.
6. Take the key and match the serial number on the key with the lock serial no of the rear LHS
electrical/storage box. The no will be on the outside where you insert the key into the lock.
Also check working of all the locks on the bike with same key.
7. Check the chain slack while sitting on centre stand and then off it. Should be no more then 1.5
inch while on the centre stand.
8. After starting the bike, check for any exhaust leaks at the head where the down pipe is
attached and at the exhaust/down pipe joint. Also for any white smoke from the exhaust.
9. Check for any oil leaks from the engine-rocker covers, side covers- rear shock
absorbers and front. Don't worry if you see a bit of oil under the RHS engine cover. It will be
from the chain.
10. After engine has warmed up for a couple of minutes- the tick tick noise of the auto decompressor should stop. Check the idling is not erratic(jumping up/down). Starting should be
smooth and not take more then one crank (not more the 3 seconds) to start
11. Take a ride on the bike with a pillion ride to see if you have rubbing issues of the rear
tyre with the mudguard. Thats due to the bad alignment of the mudguard and sometimes of the
rear tyre also.
12. While test riding, go through all the gears and brakes(F/R). Notice any abnormal noise or
any hesitation in the engine response. Do check the exhaust for any white smoke or black
while riding.
13. Check for any acid spill from the battery and check if drain pipe from the battery is
attached. First gen C5 use to come with exide batteries which had no drain pipe but new ones
come with exide or FIemm batteries which have the drain pipe. Look for any spill damage on the
engine cover under the battery
14. Check the accelerator cable- should not get stuck when turning left or right while on C
stand. Check the choke cable for proper engagement and clutch cable is not too tight or
too lose.
15. Check springs (2 nos) on the centre stand. Engage the center & side stand. Should not
take much effort to engage both the stands.
16. Check for any pre damage to the chassis front. Turn the handle bar left to right - should
turn equally to both the sides, and not more or less at one side to other.
17. Tight Handle Check: lean the handle to one side wee bit and if it comes down fully then its
fine. Loose Handle Check: Apply front brake and rock the bike forward and backward. You will
feel the play or noise if its too loose. You can also put it on C stand and while holding the handle
firmly, ask you friend to grab the front forks and rock it forward / backward. Any play will be felt
easily.

18. While on C stand, rotate the front wheel and check the run out of the tyre or at least any
abnormal noise. Wheel should rotate freely and also check for front speedo is tight at the
speedo hub and the SMOOTH movement of speedo needle.
19. To check the D.O.B of your bike, open up the LHS electrical box and you will find the green
non- pollution sticker with the D.O.B on it. You can cross check the month with the
chassis no.
20. By RE rule, your dealer should fill the fuel tank above reserve and the reserve light
should go off. But most of the dealers steal the petrol money and give you only .5L(even less) to
get you to the nearest petrol station. You can actually demand from him to fill up more then
reserve as per company policy or else you should inform RE about it. After you fill her up, if the
reserve light is still on then the fuel level indicator is faulty.

GENERAL OBSERVATIONS on Thunderbird

1. The rear mudguard will be misaligned and the number plate will be tilted to one side. This
is a trademark, do not fret
2. Sit on the bike and check the break pedal position. I have checked this on 4 different
thunderbirds and found the pedals in different positions on all of them. Either they are getting
mauled in transportation or the manufacturer is playing a game of hit and trial with us. Anyway,
just check that your foot is able to rest itself on the whole of the horizontal line of the
rubber, if not on the rubber itself, when you press the pedal. If it is not horizontal to your foot,
your foot will tend to slip off on application of pressure, especially when wet or in rain. Have it
corrected.
3. The meters will shake a bit. My guess is that they are designed this way, so as to absorb the
shocks better. Do not fret (again)
4. Take it for a ride, leave the handle bar at a speed of 45-55 and check if the handle bar shakes
from side to side. If it does, you need to get the wheels aligned.
5. Check the silencer bend pipe for any rust
6. Some people have complained that the black part at the end of the silencer is scratched or
falling. I have had no such issue

7. Casually, check the Speedo reading on the other bikes in the showroom (You will have to ask
for the keys). They should have very similar reading. If your bike has more KM reading, than it may
have been used for test rides, though RE does not allow this. My dealer had given me a test on a
Desert Storm, which I found later, was waiting for delivery. Also if you are asked to pick one of two
bikes, choose the dirtier one. The one that has been in the showroom longer will have been
cleaned more often, but is also susceptible to have been abused by test riders.
8. There will be a "Mosquito sound" when you apply the front break at speeds above 20 KPH.
This is normal and has to do with the flow of break oil.
9. Keep your patience, the staff does not understand your passion and eye for detail. Tip them
before you leave (Even better if you take some sweets along). It will make subsequent visits easier
for you.

20. Accessories A) If you intent to ride solo without the rear seat then get the rear LHS guard(stay)
B) Leg guard- as per your choice to what is available at your dealer.
c) Horns- You wont need changing as I feel the twin setup is awesome.
d) Alloys - If you want to kill the looks of a classic but each to its own..
e) RE embossed leather tool kit bag and side bags if you like them.

f) Bike cover- You can get one if you intent to ride your bike quite less. Cant use it w

G) Upswept exhaust - if you fancy the looks and heavier thump. It's attached to the

H) Indicator shades- I personally dont like them but some do. Just like the one on th

check the Speedo reading on the other bikes in the showroom          There will be a "Mosquito sound" when you apply the front break at spe          Keep your patience. leave the handle bar at a speed of 45-55 and check if          Check the silencer bend pipe for any rust          Some people have complained that the black part at the end of the silen          Casually. I have checked this o          The meters are put together in such a way that they will shake a bit. since the bikes          The rear mudguard will be misaligned and the number plate will be tilte          Sit on the bike and check the break pedal position. but it registers very differently. the staff does not understand your passion and eye While I have read this often about REs. when you e .Congrats to you too sam_b! It would be good to have more T-Bird riders to share vie I followed Randhawa's PDI routine and it worked pretty well for me. My          Take it for a ride.

         Check for leaks under the tank where fuel sensor is inserted. (do check at th          Check for leaks around the kick-shaft. take a pre          Rust on the main frame. ( although i never go          Fill adequate petrol and check for the proper working of fuel sensor.          Full tool kit. see if the bike is not pulling toward          Ask them to open the OVAL TOOL BOX and show you. d(transit between the n it will scuff and ass. especially at the welding joints.          Check any damage to paint surface / or scratches on the buffed alumini          Proper fitment of various control cables wrt play          proper working of all electricals          proper tyre pressure          While taking a pre-delivery test ride.ything hanging. in most cases its j          Check for proper retraction of main and side stand. sometimes they han . indicators. ication light in          Front fork sleeve should not touch the mudguard or the fork. and also th          Battery electrolyte level. and chain slackness.          RE embossed leather document pouch if possible.

no more then 1.should wn fully then its ckward. You will ding the handle play will be felt . Should not o right .dd noise from o of the rear LHS key into the lock. It will be of the auto deing should be es of the rear d sometimes of the normal noise or smoke or black the battery is e but new ones l damage on the right while on C not too tight or d. shock cover.5 own pipe is the exhaust.

if the o one side. line of the al to your foot.5L(even less) to more then l her up. This 4 different ey are getting ith us. Anyway. Have it as to absorb the andle bar shakes cer is scratched or .re or at least any is tight at the ll find the green h with the reserve light y . n rain.

Cant use it when the bike is hot which it stays for hours at a stretch and not water proof. It's attached to the down pipe and does not come with free flow down pipe anymore so you wont harm the en ust like the one on the front head light.u will have to ask ading. etail. Has minimal d p. . than it may n me a test on a to pick one of two have been eds above 20 KPH. ite less. Tip them quent visits easier ear LHS guard(stay) changed to single pipe one.

If it does. My guess is that they are designed this way. Either y will shake a bit. since the bikes are essentially the same engine. Just a few things to add. It will m fferently. I have had no such issue kes in the showroom (You will have to ask for the keys). do not fret I have checked this on 4 different thunderbirds and found the pedals in different positions on all of them. so as to absorb the shocks better. If your bike has m he front break at speeds above 20 KPH. and you . Do not fret (ag f 45-55 and check if the handle bar shakes from side to side. This is a trademark. at the end of the silencer is scratched or falling. Tip them before you leave (Even better if you take some sweets along).ird riders to share views and comments with. that I can think of: ber plate will be tilted to one side. r me. your passion and eye for detail. you need to get the wheels aligned. when you experience it first hand: The bike will not be perfectly ready due to various reasons. This is normal and has to do with the flow of break oil. They should have very similar reading.

u.the fork. . where the main stand mates with the frame) although i never got one) :( ng of fuel sensor. sometimes they hang mid-way as springs are faulty. is not pulling towards left or right. in most cases its jammed and difficult to open. (do check at the bottom. oints. take a pre delivery ride. and also the petrol outlet pump. brake hard a few times and observe. n the buffed aluminium parts. inserted.

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proof. . ou wont harm the engine during running in period. Has minimal dust protection.

and you will get to know it better and take care of it. If your bike has more KM reading. Lovely thing you have gifted yourself! You are . Either they are getting mauled in transportation or the manufacturer is playing a game of hit and etter. ing. It will make subsequent visits easier for you.on all of them. ous reasons. though RE does not allow this. eets along). Do not fret (again) wheels aligned. than it may have been used for test rides.

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Anyway. was waiting for deliv ted yourself! You are going to enjoy it more because of the subtle demands for attention that it will put on you .ng a game of hit and trial with us. My dealer had given me a test on a Desert Storm. just check that your foot is able to rest itself on the whole of the hori does not allow this. which I found later.

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The one that has at it will put on you . if not on the rubber itself. when you press the pedal.the whole of the horizontal line of the rubber. Also if you are asked to pick one of two bikes. choose the dirtier one. If it is not ho was waiting for delivery.

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your foot will tend to slip off on application of pressure. but is also susceptible to . If it is not horizontal to your foot.e pedal. especially whe ne. The one that has been in the showroom longer will have been cleaned more often.

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Have it corrected. s also susceptible to have been abused by test riders. . especially when wet or in rain.ssure.

com/forum http://www.com/forum Tire Protector Gel .team-bhp.com/forum http://www.com/forum http://www.team-bhp.com/forum http://www.com/forum http://www.team-bhp.team-bhp.team-bhp.com/forum http://www.team-bhp.team-bhp.com/foru .team-bhp.team-bhp.team-bhp.com/forum http://www.team-bhp.com/forum http://www.com/foru http://www.team-bhp.team-bhp.team-bhp.team-bhp.team-bhp.com/forum http://www.com/forum http://www.com/forum http://www.team-bhp.team-bhp.com/forum http://www.team-bhp.com Team-BHP / xBHP / BCMT Data on Thunderbird Issues Sl No Problem Location 1 2 3 4 5 6 7 8 9 10 http://www.com/forum http://www.com/forum http://www.team-bhp.com/foru http://www.team-bhp.com/forum 11 12 13 14 15 16 17 18 19 http://www.com/foru http://www.Ride On http://www.team-bhp.team-bhp.team-bhp.team-bhp.team-bhp.com/forum http://www.customerservice@royalenfield.team-bhp.com/foru http://www.com/forum http://www.com/forum http://www.team-bhp.team-bhp.team-bhp.com/forum http://www.team-bhp.com/forum http://www.team-bhp.team-bhp.com/forum http://www.com/forum http://www.com/foru http://www.team-bhp.com/forum http://www.com/forum http://www.com/forum http://www.com/forum http://www.com/foru http://www.com/forum http://www.com/forum http://www.team-bhp.team-bhp.

team-bhp.team-bhp. Adjusting & lubricating clutch cable .com/forum http://www.team-bhp.team-bhp.com/forum http://www.team-bhp.com/forum http://www.team-bhp.team-bhp.com/forum http://www.com/forum http://www.com/forum http://www.team-bhp.com/forum .team-bhp.com/forum http://www.com/forum http://www.team-bhp.team-bhp.team-bhp.team-bhp.com/forum http://www.team-bhp.ArizonaJim http://www.com/forum http://www.team-bhp.com/forum http://www.team-bhp.http://www.team-bhp.com/forum http://www.com/forum Loc-Tite for Loose Nut.com/forum http://www.com/forum http://www.com/forum http://www.

rough in some zones GetLife Delayed Delivery sam_b 91 kms on ODO at time of delivery sam_b RHS mirror plastic scratched badly sam_b D missing in Enfield tank sticker sam_b air filter to throttle rubber hose was torn from the junction of sam_b EFI MIL glows lightly. time not set.Bangalore vrajaram. Ravi J. Ravi J.Bangalore vrajaram.Bangalore vrajaram.Bangalore vrajaram.Bangalore vrajaram. Ravi J.Bangalore vrajaram.350CC Seats with cat nail marks Peeling off paint inside petorl tank cap Fuel Bars not showing when tank full (4 bars showing) Cracked speedometer glass J. Ravi J. Ravi J. Ravi J. Ravi J. fuel gauge irratic vrajaram. flickering on dig odo sam_b Rear brake non responsive sam_b .Bangalore vrajaram.RPM needle jumping around.suspected from tank vikivix Instrument cluster .@royalenfield. Ravi rear wheel not rotating freely Headlight misaligned Chain rusting 2 nd to 3rd gear transition not smooth Difficulty in finding neutral jimmy_u jimmy_u jimmy_u jimmy_u jimmy_u Catalytic Convertor discolouration Smokeymist Squeky sound .Bangalore Dak Dak coming from the chain .PDI Rear Brake Sometimes Squeaky Clutch too tight .during I st service Difficulty in bringing to NEUTRAL Rear brake not working well after puncture repair (took wheel off) Service Spanner in MID when NOT DUE RC .shows higher if on side stand Minor metallic sound from engine . 1000 kmGetLife Petrol Tank Paint . Ravi J.Bangalore vrajaram.Bangalore vrajaram.makes squeaky sound when released Fuel indicator inaccurate .details of engine & weight incorrect .went away on its own Rear Brake gettting Locked Loose chain Stuck Gear between 1st & Neutral Starting Issues Console Electrical Issues .select button not working. Ravi Peeling off of chrome plating J.com nderbird Issues Problem Faced Author Side Stand Light not going off .

Ravi) Kick stater not working .first few drops .com/forum/motorbikes/129727-ro Softening suspension method Arizonajim Rear brake lever & foot rest not in correct line Exhaust joint .ArizonaJim rajneeesh rajneeesh rajneeesh rajneeesh rajneeesh rajneeesh rajneeesh harikrishnanm harikrishnanm harikrishnanm harikrishnanm harikrishnanm harikrishnanm http://www.loose Rubber glands near fins on engine loose InSearch InSearch InSearch InSearch InSearch InSearch InSearch InSearch .notified at Ist Service Oil Leaks .time not adjustable Small chain guard nut gets loose on its own Idle RPM just shot up to 1.team-bhp.5K Not comfortable with clutch setting e Nut. Adjusting & lubricating clutch cable .then a lot Clock stuck .Rear brake not functioning well Head lamp not focussed well Rear brake jammed due to rear axle nut NOT PROPERLY TIGHTENE One screw on magneto cover (just below EFI) became Loose & fell Trip meter not getting RESET RHS rear view mirror loose Minor cracks along the edges (like J.pipe bend to end can .

com/forum/motorbikes/135505-royal-enfield No proper response from ASC .team-bhp.noth parts to be replaced under warranty Delivery delayed from dealer's end . Then turn off ignition & turn on again. it is expected.Solution Solution Location SAME .team-bhp. protective shoe glued New meter has NEW software Re-plated by Quality Chennai Should get alignment done at night Should disappear after use .com/forum/motorbikes/135505-royal-enfield Float valve replaced under warranty Replaced entire console under warranty. while keeping the buttons Sent for correction . Check spark plug/plugged pipe . responsible free loader dealt with Replaced at time of delivery New sticker put after 8 days replaced aunder warranty during Ist service Gone after unit completely dried Fine after 4 to 5 hrs .matter sorted Wrote to RE.team-bhp.allow warm up for 1 min Solved in Ist Service Solved in Ist Service .check at ASC http://www.had to contact Regional Service Mgr RE .due to coastal environment / Spray WD 40 should get resolved with use Expected.lubrication ASC fixed without any cost Press Select & Set buttons together for more than 3 seconds.returned Started covering the seats Tank replaced under warranty with galvanized internals tank http://www.wrote to RE .com/forum/motorbikes/135505-royal-enfield If from front brakes.Fixed during Ist service May need greasing Air lock suspect Every 100 kms or so noise Cold Engine in the morning Cold Engine .Fixed during Ist service SAME .check back press http://www.

Replaced both meters second time under warranty (although 13 months were over) Replaced part after one month Some bolts & nuts tightened . Maybe few weeks.Sorted during Ist service Sorted during Ist service Fixed by local mechanic Replaced Will be replaced under warranty.oil leak increased .com/forum/motorbikes/129727-royal-enfield-thunderbird-500-twinspark-ownership-report-5.then stopped Whole unit replaced under warranty Tightened periodically by the owner .not found the correct posn yet bhp.not informed of cause Adjust multiple times .then some oil seals replaced .ArizonaJim suggests BLUE Loc-Tite Fixed by service center . EDIT: Replaced Not fixed.html#post3356471 ASC heated & reshaped it slightly .

html#post3200224 um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-15. um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-12.html#post3243768 . while keeping the buttons pressed.html#post3196402 um/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-14.on again.

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5 2639.co.25 .html 1 Spare clutch cable 2 Spare fuses 3 Tyre filled with tire-protector gel (against punctures) https://www.com/forum/motorbikes/140314-bikers-heart-thumps-again-re-thunderbird-500-a.com/forum/motorbikes/135505-royal-enfield-thunderbird-500-my-motorcycle-diaries-2.com/forum/motorbikes/132561-my-retro-bullet-tbts-500-flicker.com/forum/motorbikes/129727-royal-enfield-thunderbird-500-twinspark-ownership-report.com/talkies/motorcycle-ownership-experiences/24607-royal-enfield-thunderbird-500-a-67.team-bhp.html 3833.team-bhp.team-bhp.com/forum/motorbikes/133045-thumping-all-way-my-thunderbird-500-ownership-report.333 15835.team-bhp.html enfield_500 apachelongbow ebonho Majumdarda http://www.html http://www.com/forum/motorbikes/130880-i-live-again-thunderbird-500-ownership.xbhp.html http://www.in/#q=thunderbird+500+ownership+review http://www.html http://www.http://www.html http://www.team-bhp.google.team-bhp.

p-report. Ravi sam b rajneesh 2666.667 .html hip-report.html J.