S.

Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
27. Gear Shift Shaft
 Remove circlip from gear
shift shaft on RH side.

 Remove washer, spring

& gear selector.

 Remove gear shift lever

with spring & washer.

28. Gear Star Index

Stepped Bolt: M8
stopper Hex Socket: 10mm
 Remove stepped bolt
holding arm stopper to
Crankcase.

40 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
28. Gear Star Index
stopper
 Remove arm stopper
along with washer &
spring

29. Gear Star Index

Hex socket Hd screw: M6
 Remove stepped hex Allen key: M5
Socket Head bolt,
holding star index to
selector drum.

 Remove star index

30. Drive shaft Spacer

Outside Circlip Player
 Remove circlip on drive
shaft.
 Remove 1st thrust washer,
spacer & 2nd thrust washer.

ROYAL ENFIELD SERVICE MANUAL LS 410 41

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
31. Auto chain Hex flange bolt: M8
tensioner Hex Socket: 12mm
 Remove hex bolt with
spring from the center of CAUTION:
auto chain tensioner
body. Open slowly &carefully since
spring loaded bolt.

NOTE:
Ensure ‘O’ ring is removed
from housing.

 Remove 2 hex socket

head screws &gently Hex Socket Hd screw:
pull out auto chain M6 X 25
tensioner assembly. Allen Key: M5

 Remove gasket.

32. Inlet manifold

Hex Socket HdScrew:
 Remove 2 hex socket M6X25
head screws. Allen key: M5

 Remove inlet manifold

with “O” ring

42 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
33. Cover- Cam Center
Hex flange bolts: M6 X 16
 Remove 2 hex flange Hex Socket: 8mm
bolts & remove cover

34. Plug - Camshaft

Hex flange bolt: M6 X 16
Hole Hex Socket: 8mm
 Remove hex flange bolt.

 Rotate plug clock-

wise gently. DO NOT NOTE:
ATTEMPT to remove The plug will be tight in
plug forcefully from the cylinder head cover.
cylinder head cover.
Do not attempt to remove
before loosening all the
cylinder head cover bolts.

35. Tappet cover inlet

Hex flange bolts: M6X21
 Remove 2 hex flange Hex Socket: 8mm
bolts & remove cover
with O ring.

ROYAL ENFIELD SERVICE MANUAL LS 410 43

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
36. Tappet cover
Hex flange bolts: M6X21
exhaust Hex Socket: 8mm
 Remove 2 hex flange
bolts & remove cover
with O ring.

37. Plugs rocker shafts

Hex Socket plug: M14 X 12
 Loosen 2hex socket Allen key: M8
head plugs from cylinder
head cover RH side.(Do
not remove plugs fully)

38. Cylinder head cover

 Remove 2 long hex
flange bolts with
aluminum washers from
the top RH side.
Hex flange bolt: M6 X 60
Hex Socket: 8mm
NOTE:
Aluminum washers are
provided to prevent oil leak
through the bolts.

 Remove 3 long hex Hex flange bolt: M6 X 60

flange bolts from the top Hex Socket: 8mm
LH side

44 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
38. Cylinder head cover
Hex bolt: M6X55Hex
 Remove 3 medium Hex Socket: 8mm
flange bolts from the LH
side.

 Remove 2 long Hex Hex flange bolt: M6 X 40 EX

flange bolts from RH Hex flange bolt: M6 X 45 IN
side. Hex Socket: 8mm

 Remove 2 fully threaded Hex bolt: M6X16

Hex flange bolts from Hex Socket: 8mm
inlet & Exhaust tappets
opening.

39. Plug camshaft hole

 Remove small cam shaft
cover.

ROYAL ENFIELD SERVICE MANUAL LS 410 45

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
40. Cylinder head cover
 Remove cylinder head
cover by gently tapping
on the pegs provided.

41. Rocker Shaft Plug

screws
 Remove the 2 hex socket
plug screws (Loosened
earlier) with their copper
washers from the
cylinder head cover.

42. Shaft - Rocker arms Hex flange bolts: M8

 Locate 2 long suitable Hex Socket: 10mm
M8 hex screws into the
rocker shaft threads &
pull out the shafts.

43. Rocker arms

 Remove inlet & exhaust
rocker arms.

46 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
44. Spark plug
Spark plug M10
 Remove spark plug from Deep Hex Socket 16mm
cylinder head.

45. Cam shaft assembly

 Rotate cam shaft such
that the half lock washer
will come up from the
cylinder head slot.

 Remove the half washer.

 Rotate Cam shaft if

necessary such that One Hex bolt: M6 X 12
hex bolt can be accessed Hex Socket: 10mm
for loosening.
 Straighten lock tab &
remove 1st hex bolt.

ROYAL ENFIELD SERVICE MANUAL LS 410 47

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
45. Cam shaft assembly
CAUTION:
 Rotate Cam shaft to
Ensure the Lock tab and
access the 2nd hex bolt.
washer does not drop into
the cam chain
 Straighten lock tab &
remove hex bolt, along
with lock plate.

 Release sprocket from

the dowel in cam shaft to
increase chain slack.

 Release cam chain from

the Sprocket by lifting
and pushing it behind
the sprocket.
NOTE:
Hold chain securely, to
prevent it from dropping
into cylinder head.

 Lift cam shaft and

remove sprocket.
 Remove cam shaft.

48 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
46. Cylinder head
Hex bolt: M10 X 170
assembly Hex Socket: 12mm
 Remove 4 Long hex
bolts from inside
cylinder head NOTE:
Take care not to drop
thefour thick washers from
the bolts.

 Remove 2 hex flange

bolts from the LH side of
the cylinder head cover.

 Gently tap and lift up

Hex flange bolts: M6 X 30
cylinder head, taking
Double end spanner: 8mm
care not to drop the cam
chain into cylinder
barrel.

47. Cylinder head

NOTE:
gasket
2 dowels are provided in
Remove cylinder head
cylinder barrel to locate the
gasket.
cylinder head.

ROYAL ENFIELD SERVICE MANUAL LS 410 49

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
48. Valves in Cylinder
Special Tool: ST-27528-2
Head Valve Spring Compressor
 Locate valve spring Tool
compressor tool on inlet
valve such that the
sleeve with screw is
resting on the retainer
valve spring & the
bottom of the tool is
centrally located on the CAUTION:
valve.
 Tighten special tool till Ensure special tool is
springs are compressed correctly located before
fully & the cotters are attempting to compress
free from the valve valve springs.
stem.·
 Remove both cotters &
loosen special tool till NOTE:
springs are fully
expanded & tool can be Ensuresplit collars are
easily removed. removed before releasing
 Remove special tool, springs
retainer, outer spring,
inner spring & spring
seat from the cylinder NOTE:
head.·
The valve guides & valve
 Remove inlet valve by seat inserts should not be
pulling it from bottom of removed from cylinder
cylinder head. head OR reworked as it will
 Remove Valve stem seals affect engine performance.
from the valve guide In the event of any wear
top. out, complete cylinder
 Repeat above procedure head assy. should only be
to dismantle exhaust replaced
valve.
49. Chain guide pads
 Remove chain guide pad
located in the front on
the cylinder head, by
pulling it from the top.

50 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
49. Chain guide pads
 Release the cam chain
from the sprocket on
crankshaft and remove
from the engine.

 RemoveBolt- Stepped, Bolt Stepped: M6 X 14

holding chain tensioner Allen Key: 5
pad to crankcase LH.

 Remove fixed chain CAUTION:

guide pad from the top. Take care to remove the
washer behind the chain
tensioner pad.

50. Cylinder barrel

assembly
 Remove 2 hex flange
nuts on LH side of
cylinder barrel.
 Gently lift cylinder barrel
up to remove from
piston.
Hex flange nut: M6
Double end spanner:
8mm
NOTE:
Ensure the 2 dowels are
removed from crankcase
LH. / cylinder barrel

 Remove cylinder base Special Tool: ST-27529-2

gasket. Piston support special
 Locate special tool on tool.
connecting rod below
piston on inlet side, to
support piston

ROYAL ENFIELD SERVICE MANUAL LS 410 51

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
51. Piston Pin
Special Tool: ST-27529-2
 Remove circlip from one Piston support special
side of piston & push out tool.
gudgeon pin from
opposite side.

 Remove Piston from

Connecting rod

52. Piston rings

 Remove piston rings by
expanding the rings at
their open ends slightly &
lifting towards the top of
the piston.
NOTE:
Do not expand rings too
much since they will break!
The oil control ring is a 3
piece set.

53. Oil Jet Cylinder

barrel seating area
 Remove oil jet from RH
Crankcase / barrel
seating area.

54. Oil Jet - Crankcase

Hex Socket Hd Screw:
LH (outside) M6 X 12
 RemoveHex socket head Allen Key: M5
screw from Crankcase
LH

52 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
54. Oil Jet - Crankcase
NOTE:
LH (outside)
Ensure the small ‘O ’ring is
 Gently pull out & remove removed from seating area
oil jet. in crankcase / behind oil jet.

55. Crankcase
Hex Socket Hd Screw:
Fasteners M6X 12
Remove Allen Key: M5.
 Hex socket head screw
from crankcase LH
front.

 3 hex bolts from crank- Hex bolt: M8 X 70

case LH magneto area. Hex Socket: 12mm

Hex bolt: M6 X 60
Hex Socket: 8mm
 1 Hex flange bolt from LH
NOTE:
crankcase near starter
motor housing. 8 Hex Bolts (1 near Starter
motor housing, 4 in front &
3 at bottom are shorter &
same length.)
6 Hex bolts on rear end are
the longest

ROYAL ENFIELD SERVICE MANUAL LS 410 53

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
55. Crankcase
Hex bolt: M6 X 60
Fasteners Hex Socket: 8mm
Remove
 4 Hex flange bolts from
LH crankcase front.

 6 Hex bolts (Longest)

Hex Flange bolt: M6 X 85
from LH crankcase rear.
Hex Socket: 10mm

 3 Hex bolts from crank- Hex bolt: M6 X 60

case LH bottom Hex Socket: 8mm.

56. Crankcases splitting

 Split crankcases by
locating 2 suitable short
Hex bolts with nuts,
between the front & rear
tabs on the crankcases.
 Unscrew nuts evenly
such that the crank-
cases separate.
 Gently tap on the tabs
using small plastic mallet
to separate crankcases
further.

54 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
57. Crankcase RH
removal
 Remove Crankcase RH
from the shafts by gently
tapping on the shafts
simultaneously, using a
small plastic mallet

NOTE:
Please ensure thrust
washer on counter shaft
does not fall off

58. Balancer shaft

NOTE:
assembly
The gear has a high
 Gently tap balancer
interference fit in balancer
shaft out of the bearing
shaft and hence cannot be
from the Crankcase
separated from the shaft.
LH.(Partial blind hole)

59. Crank shaft

NOTE:
Assembly
The LH shaft main bearing
 Remove crank shaft
is integral with the crank
assembly by slightly
shaft assembly, hence
rotating & tapping from
should NOT be removed or
LH side (magneto side).
serviced separately.

ROYAL ENFIELD SERVICE MANUAL LS 410 55

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
60. Oil Jet -
Hex Socket Head Screw:
crankcaseLH M6X12
(inside) Allen Key: M5
 RemoveHex socket head
screw from Crankcase
LH.

 Gently pull out & remove NOTE:

oil jet.
Ensure the small ‘O ’ring is
removed from seating area
in crankcase / behind oil jet.

61. Gear Operator

Forks
 Remove the 2 spindles
holding the operator
forks to the gear drum
assembly.

 Remove three operator NOTE:

forks from the gears.
Both the long operator
forks are located towards
the rear end of crank case &
the small operator fork at
the center.
The forks are numbered 1,
2 & 3 for easy identification.

56 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
62. Gear shifter drum
 Remove gear shifter
drum from crankcase LH

63. Drive shaft

assembly
 Remove thrust washer

·  Remove 1 st gear with

floating bush.

 Remove thrust washer

ROYAL ENFIELD SERVICE MANUAL LS 410 57

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
63. Drive shaft
assembly
 Remove 5th gear.

 Gently tap drive shaft

from the LH side &
remove from crankcase
LH.
 Remove drive shaft
spacer from crankcase
LH outside.
Caution:
The bush will be tight on
drive shaft, due to the ‘O’
ring inside the bush.
Gently tap the shaft to
remove from crankcase LH.
Take care not to damage
the threads while tapping
on the shaft.

64. Gears in drive shaft

External circlip pliers
 Remove circlip.

58 ROYAL ENFIELD SERVICE MANUAL LS 410

 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
64. Gears in drive shaft
 Remove thrust washer
with 3 lugs.

 Remove 4th gear

 Remove bush with

internal splines.

 Remove splined washer

with outside tabs.

ROYAL ENFIELD SERVICE MANUAL LS 410 59