Service Manual - 2007 Royal Enfield Machismo 500 Chrome
Introduction
This service manual provides detailed maintenance procedures, troubleshooting steps, and repair guidelines for the 2007 Royal Enfield Machismo 500 Chrome. Proper servicing ensures longevity, reliability, and optimal performance.
1. Technical Specifications
Engine
- Type: 499cc, single-cylinder, 4-stroke, air-cooled
- Power: 22 HP @ 5500 RPM
- Torque: 40.85 Nm @ 3000 RPM
- Compression Ratio: 8.5:1
- Ignition: CDI Unit
- Fuel System: Carburetor
- Valve Clearance:
- Intake: 0.08mm (cold)
- Exhaust: 0.20mm (cold)
Transmission
- Type: 5-speed, constant mesh
- Clutch: Wet, multi-plate
- Primary Drive: Chain
Brakes & Suspension
- Front Brake: Disc, 280mm
- Rear Brake: Drum, 152mm
- Front Suspension: Telescopic fork
- Rear Suspension: Twin shock absorbers
Electrical System
- Battery: 12V, 14Ah
- Charging Output: 13.5V - 14.5V @ 3000 RPM
- Spark Plug: NGK BPR5ES (0.7 - 0.8mm gap)
2. Periodic Maintenance Schedule
| Interval | Task |
|---|---|
| Every 500 km | Check engine oil level, chain tension, and tire pressure |
| Every 3,000 km | Change engine oil, inspect brakes, lubricate cables |
| Every 6,000 km | Replace air filter, adjust valve clearance, check battery |
| Every 10,000 km | Replace spark plug, flush brake fluid, check suspension |
3. Maintenance Procedures
A. Engine Oil Change
Tools Required:
- 17mm socket wrench
- Drain pan
- Funnel
- 15W-50 API SL grade oil (~2.25L)
Steps:
- Warm up the engine for 5 minutes.
- Place a drain pan under the engine.
- Remove the drain bolt and let oil drain completely.
- Replace the oil filter.
- Reinstall the drain bolt and tighten to 20Nm torque.
- Pour new oil and check the level.
- Start engine, run for 1 minute, then recheck oil level.
B. Valve Clearance Adjustment
Tools Required:
- Feeler gauge (0.08mm, 0.20mm)
- 10mm wrench
- Flathead screwdriver
Steps:
- Remove cylinder head cover.
- Rotate engine to TDC (Top Dead Center) on compression stroke.
- Use feeler gauge to check clearance:
- Intake: 0.08mm
- Exhaust: 0.20mm
- Adjust using locknut & adjuster screw.
- Reassemble and test engine.
C. Carburetor Tuning
Steps:
- Warm up engine.
- Adjust idle speed screw (1100 ± 100 RPM).
- Adjust air-fuel mixture for optimal performance.
- Sync carburetor if necessary.
D. Chain Adjustment
Steps:
- Place the motorcycle on center stand.
- Loosen rear axle nut and adjust chain tension.
- Maintain 20-25mm slack.
- Tighten axle nut and recheck alignment.
4. Troubleshooting Guide
| Problem | Possible Cause | Solution |
|---|---|---|
| Engine won’t start | Weak battery | Charge/replace battery |
| Rough idling | Dirty carburetor | Clean carburetor |
| Poor mileage | Clogged air filter | Replace air filter |
| Brake fade | Contaminated brake fluid | Flush and replace |
| Overheating | Low engine oil | Top up or change oil |
5. Torque Specifications
| Component | Torque (Nm) |
|---|---|
| Engine drain bolt | 20 Nm |
| Spark plug | 12 Nm |
| Rear axle nut | 80 Nm |
| Handlebar bolts | 25 Nm |
| Front disc brake bolts | 22 Nm |
Conclusion
Proper servicing ensures the best performance and longevity of your Royal Enfield Machismo 500. Regular maintenance and timely inspections will keep your bike running smoothly.
🚀 Ride Safe & Keep It Classic!
Last updated on March 30, 2025