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Royal Enfield's UK Technology Center Tour

We go inside the Indian company's English development facility

Thomas R. “Big Tom” Callahan, Jr., an auto parts salesman from Sandusky, Ohio, once said, “You can get a good look at a T-bone by sticking your head up a bull’s ass, but wouldn’t you rather take a butcher’s word for it?” When it comes to steak, we at MO would be inclined to heed the butcher’s advice, but when it comes to motorcycles , we’d prefer to take that “deeper” look to see for ourselves…

Royal Enfield invited us to take a comprehensive behind-the-scenes look into its UK Technology Center in Leicestershire, England. There, with the collaboration from the Chennai, India factory, they have designed, engineered and tested two all-new from-the-ground-up models that both feature the new 650 parallel-Twin motor. These new models include the Interceptor INT 650 and the Continental GT 650. While there, we were able to speak with several of Royal Enfield’s reps, including all the top dogs, and gain further insight into the company and its new products.

Royal Enfield may not be the household name in America like it is in many other parts of the world. So, to give a little background on the company, Royal Enfield is not only the oldest motorcycle manufacturer in continuous production since 1901, but it’s also the fastest-growing motorcycle brand in the world, as well. Royal Enfield has grown 16-fold in the last eight years. The company has gone from building 50,000 units in 2010 to more than 800,000 by the end of this year and is aiming to produce 950,000 units next year. Royal Enfield’s sales are equivalent to the global sales of Harley-Davidson, KTM, BMW, Triumph, and Ducati, combined . Let that sink in for a second.

What’s most interesting and unique about Royal Enfield is the approach it has taken to become this global heavyweight motorcycle manufacturer. It’s important to make clear what Royal Enfield is , and what it isn’t . Siddhartha Lal, Royal Enfield’s CEO, explicitly states that the company isn’t interested in making high-performance sport bikes or big-displacement cruisers. But rather, it’s chasing after the middleweight market, specifically the 250-750cc segment. For years now, Royal Enfield has been making 350 and 500cc variants of its Classic, Bullet and Thunderbird models, along with the 535cc Continental GT café racer. However, there hasn’t been a larger-displacement bike to upgrade to since 1970, when Royal Enfield stopped making its 736cc Interceptor.

Enter the all-new 650 Twin. It’s a 648cc air/oil cooled parallel-Twin with a single overhead cam and four valves per cylinder. These features combined with a 9.5:1 compression ratio yield a claimed 47 horsepower at 7100 rpm, with about 39 ft.-lbs. of torque waiting at just 4000 rpm. These output numbers won’t make you the king of your local drag strip, but that’s not what Royal Enfield is about.

“Royal Enfield aims to lead and expand the middleweight segment globally,” Lal told us about why RE chose to make the 650 Twin. “While the new 650 Twins will be a compelling upgrade for our large customer base in India, we believe they will attract customers from other developing markets in Southeast Asia and Latin America to graduate to the middleweight segment as well.”

Unlike here in the United States, where many believe there’s no replacement for displacement, developing markets in the rest of the world don’t have a need for such big-bore bikes. In many cases, the roads just simply don’t allow for it. On top of that, certain countries’ governments either restrict engine size or make it very difficult to own large-displacement bikes by implementing steep import tariffs or luxury taxes. For example, learners in Australia are restricted to a motorcycle with a motor no bigger than 660cc for their first two years. In Indonesia, some provinces have import taxes on large-displacement motors starting at 30-40%, and tariffs in Malaysia can be hiked all the way up to 125%.

Royal Enfield reps say they’re out to capture the consumer, not the competition. They’re here to grow the market, not steal other manufacturer’s customers, although that might end up being the case. At the core of Royal Enfield’s goals, more than anything else is to provide motorcycles that are versatile, fun, agile and yet unintimidating and accessible – the key words here being, fun and accessible because that’s what CEO Siddhartha Lal and RE President, Rudratej (Rudy) Singh believe motorcycling is all about.

Now, before all you middle-aged guys holding onto your 15-year-old R1s (who, mind you, aren’t buying new motorcycles anymore) start typing away in the comments section writing off Royal Enfield by complaining that these new bikes are ugly and grossly underpowered, understand this: These bikes aren’t designed for you. Instead, young, urban riders – many of whom are women – are the key demographic to motorcycle growth right now. More and more young people are flocking to cities, where not only is the cost of living higher, but also navigating the urban sprawl is becoming exceedingly difficult and time-consuming. This is where a fun and affordable motorcycle begins to become attractive to a learning rider. This is a big segment of the market that Royal Enfield is after.

Giving budding riders a unique option is not just reserved for young people, although I imagine the new Royal Enfields will pique their interests. The new engine also answers the call of Royal Enfield loyalists who have long yearned for more mid-range torque and top speed from the traditionally styled bikes. In the past, especially in America, the 350, 500 and even top-spec 535cc (29hp) Continental GT models haven’t cranked out enough power to comfortably ride in modern, high-speed traffic conditions ( And vibrated to annoying levels…-Ed. ), so the new counterbalanced 650cc models will help remedy this situation.

There should be a lot of inherent value built into the new Royal Enfield motorcycles for a variety of reasons: They’re approachable in the sense that they’re unintimidating motorcycles. They’re simple in the sense that if you need to work on them, you can easily do so without the hassle of removing multiple body panels to access whichever components need attention. Their basic engineering makes them authentic in the sense that they’re not a replica, recreation or knock-off of some other style bike that was once popular. Royal Enfield has been around for a long time and it has stayed true to its heritage and has stuck to its guns (pun intended, as RE was once a gun manufacturer). And, finally, they’re affordable. The Interceptor INT 650 will cost about $6,000, according to hints from RE reps, and the Continental GT 650 will only be a few hundred more at around $6,500.

If classic roadster or café racer styling isn’t your cup of tea, Royal Enfield is also offering the Himalayan, a more adventure worthy bike with off-road capability. Some of its features include a single-cylinder, fuel-injected, 411cc air-cooled motor, 21- and 17-inch wheels, almost eight inches of suspension travel front and rear, and plenty of room and mounting points for hard and/or soft luggage. The Himalayan is currently Royal Enfield’s most versatile motorcycle and should take you from the beaten paths of the city, off the grid and into the wild. And at $4,499, it will keep your wallet happy too.

2018 Royal Enfield Himalayan Preview

Of course, there are plenty of other, more sophisticated, more powerful bikes out there that will blow the doors off of any Royal Enfield in terms of performance. But, like we mentioned earlier, the company is not out to compete with the high-tech, high-performance machines other manufacturers are making. RE is in the business of selling passion with the mantra less is more.

Above all else, what makes Royal Enfield’s approach to selling motorcycles interesting is that it’s essentially striving to build the Toyota Camry or Honda Civic of motorcycles – relatively simple and cost-effective vehicles that can serve the duties of most buyers. This is in no shape or form an insult of any sort, because there’s one of these cars in just about every other driveway in America…

The new twin-cylinder Royal Enfield models are expected to hit the States and become available to the public sometime in April, about a month after we get to throw a leg over the Interceptor INT and Continental GT 650 during its launch in March. It will be interesting to see how these models stack up against the significantly more expensive Triumph Bonneville lineup of bikes that begin with the $9,100 Street Twin and rise up to $13,000 for a Thruxton. While looks and performance are obviously important, so is price.

We’ll see how this strategy works out for them. If Royal Enfield’s global performance is any indicator, we expect RE’s strategy to make waves Stateside, too.

More by Brent Jaswinski

Join the conversation

Interesting that the article doesn't mention that Royal Enfield "created" their UK technology center by purchasing Harris Performance in 2015.

"Siddhartha Lal, CEO of Royal Enfield confirmed the deal this afternoon, saying 'All of the current staff at Harris Performance will now become employees of Royal Enfield, taking responsibility of performance and development engineering for our new range of motorcycles. They will be part of Royal Enfield’s upcoming UK Tech Centre'."

http://www.motorcyclenews.c ...

• See 1 previous

That's not really the whole story. While purchasing Harris was a smart move to get instant chassis-tech credibility, even more important was RE's hiring of ex-Triumph and -Ducati personnel that are now integral pieces of the Centre.

Maybe not the whole story but Harris is a big part of the story and missing from the article.

OK, where are the dammed cats, or the dismal air injection? Government can't stand this, it's too cool. I can dream though, pre CARB and the EPA. Musn't foul the air with our minuscule contribution. The elites are soooooo sensitive.

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• Royal Enfield factory visit: Watch your motorcycle being built [Video] Royal Enfield factory visit: W...

Royal Enfield factory visit: Watch your motorcycle being built [Video]

Written By: Ajeesh Kuttan Ajeesh specializes both in bikes and cars, delivering timely news reports and excelling in video production.

Published: May 10, 2020, 06:55 IST

Updated: May 10, 2020, 00:50 IST

Ajeesh specializes both in bikes and cars, delivering timely news reports and excelling in video production. (Full bio)

videoRoyal Enfield is very popular motorcycle brand in India as well as abroad. These retro styled modern motorcycle have a cult following and has been ruling this segment for quite a long time. Royal Enfield motorcycle brand is a division of Eicher Motors and is one of the oldest brand in continuous production. Royal Enfield motorcycles are made at their manufacturing facility in Oragadam, near Chennai, Tamil Nadu. It is the one and only manufacturing facility that Royal Enfield has and all the motorcycles that are sold in India as well as abroad are manufactured here. That is one of the reason why these motorcycles have a long waiting period. Here we have a video that takes us on a tour of Royal Enfield’s manufacturing facility and shows how these motorcycles are made.

The video has been uploaded by Autospinn Channel on youtube. The video shows all the stages of manufacturing a Royal Enfield motorcycle. The first it shows the engine assembly plant where the engine casing, gearbox, pistons are all put in place. Most of the work is done by workers on a conveyor belt but there are some works that are specifically done by machines. The work done by by machines include precision cutting and grinding of some parts of the engine.

Also read: FORGOTTEN Royal Enfields of India

The video shows the process of building a RE engine from scratch. The video was concentrating more of the 350 cc engines. After the engine is completed, the other parts of the motorcycle like the fuel tank, chassis, side panels, all are evenly painted at the paint shop. This is done with the help of a robotic arm as seen in the video. The standard bullet which comes with an all black fuel tank still gets a golden pinstripe done by hand. After pinstriping, all the fuel tanks and side panels get a clear coat that gives them a glossy finish.

All the things are then assembled at the assembly line where the chassis meets the wheels, engine, fuel tank, side panel, front and rear suspension, seats headlights and handlebars. Every part has been assigned to a dedicated employee and he moves the motorcycle to the next person once his part is done. After everything is done, a final set of inspection is also done before rolling out the motorcycle from the plant. Finally before dispatching the motorcycle, a test rider test the motorcycle and makes sure that everything is fine in the motorcycle.

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Royal Enfield commences production at Oragadam plant

Royal Enfield has started production at its new plant in Oragadam today, marking a new phase of growth.

RE says that the new high tech production facility situated near Chennai incorporates technologies at par with global two wheeler industry. The factory sprawls over 50 acres and has an initial production capacity of 1,50,000 units per annum.

The facility is equipped with CED paint shop with robotic painting and power coating systems, which has a painting capacity of 600 motorcycles per day. In addition, ergonomic assembly work stations and torque controlled tools with feedback gives the plant an ability to produce a motorcycle every minute. About 800 units can be produced on a single day across two shifts.

The plant also has chassis dynamometers and a 1.4 km long test track to ensure that the vehicles leaving the premises are defect free. The legendary hand painted pin stripes will continue to feature on the Bullets.

Rolling out the first motorcycle from the assembly lines, Mr. Siddhartha Lal, MD & CEO of Eicher Motors stated that, "This new plant has been benchmarked to achieve the highest level of quality and productivity. We have re-tooled many of the parts that make up our motorcycles – so that they are of exacting accuracy and finish."

With the new plant, RE is aiming to increase its international presence and attain global leadership in mid-size motorcycle category.

The demand for Royal Enfield bikes have increased exponentially in the recent years, resulting in waiting periods as long as 6-8 months! The new Oragadam plant is expected to reduce the waiting period and improve the overall quality of the bikes.

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• Royal Enfield Begins Production At New Chennai Facility

1 mins read

Published on August 28, 2017

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• New manufacturing facility is at Vallam Vadagal near Chennai, Tamil Nadu
• Royal Enfield's third manufacturing facility is spread across 50 acres
• Royal Enfield will produce motorcycles for India and global markets

Royal Enfield, a division of Eicher Motors, on Sunday started commercial production from its new manufacturing facility at Vallam Vadagal near Chennai in Tamil Nadu. Spread over 50 acres, the Vallam Vadagal plant will be Royal Enfield 's third manufacturing facility, and will manufacture Royal Enfield motorcycles for India and international markets.

(This story has not been edited by NDTV staff and is auto-generated from a syndicated feed.)

Last Updated on August 28, 2017

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Exclusive: Royal Enfield plots new factory in Tamil Nadu, revs up for global ride and EV foray

Midsize motorcycle major has acquired a 60-acre land parcel in Cheyyar, on the outskirts of Chennai to be ready for future volume expansion for both ICE and electric motorcycles.

Chennai-based midsize motorcycle major Royal Enfield plans to set up a new factory in Tamil Nadu to cater to its growing global ambition and also diversification into electric vehicles.

According to several people in the know, the company has already acquired a 60-acre land parcel in Cheyyar, on the outskirts of Chennai, which is likely to be the key production base for its two-wheeled EVs in the future. Royal Enfield is likely to invest between Rs 1,000 to Rs 1,500 crore in the next 12-24 months towards expanding both its product portfolio and also manufacturing capacity.

While the first electric motorcycle is likely to roll out from a dedicated setup within the existing Vallam Vadagal plant, which is its core IC engine production base, it is learnt that the company has already commenced work at the Cheyyar plot to ensure a smooth transition to EVs as and when the portfolio of zero-emission models are developed and ready for rollout.

While Royal Enfield’s existing plants in Oragadam and Vallam Vadagal have a combined manufacturing capacity of over a million units per annum and capable of meeting growing demand for the next few years, the expected recovery in the domestic two-wheeler market, RE’s aggressive global expansion and diversification into EVs calls for the company to be future-capacity-ready.

The 60-acre plot of land in Cheyyar has been acquired to move some of the activities from the Thiruvottiyur facility – operating since 1995 – which has become a thriving residential area. According to sources, the company may spend about Rs 100 crore to Rs 150 crore in ground-laying work but the brand-new factory may only come up by 2025. 

An email sent to Royal Enfield seeking responses on the new factory did not elicit any response till the time of this report being published.

Shifting gear into EVs

Meanwhile, Royal Enfield has already set up a dedicated EV team led by Umesh Krishnappa, who is the CTO steering the project. Autocar Professional learns that the company is working on two different EV architectures – an in-house-developed (codename L1A) EV which is likely to hit the roads in FY2024-25, and alternatively utilise the EV platform of Stark Motorcycle, a Spanish EV start-up in which Royal Enfield’s parent Eicher Motors acquired an equity stake. 

Autocar Professional had exclusively reported, in early February 2023, that Royal Enfield plans to invest about $100-150 million for EVs . Developmental work on a dedicated L platform has begun with plans to produce three different models with a combined potential of between 120,000 to 180,000 units units per annum

The L platform is being designed factoring a global audience in addition to the emerging electric motorcycle market in India. The prototype is expected to be ready in the next 12 months, with the company wanting to get the EV validated before end-2023 to be ready for a market launch in 2024.

“The EV team is working like a start-up and hence the company brought on board Umesh Krishnappa, the previous CTO from Ola, to define the roadmap. As against the monthly product review meetings, the EV team meets almost on a weekly basis to crystallize the plan. The product portfolio is a slight departure from Royal Enfield’s current DNA. The portfolio is being developed with a big emphasis on creating a model that is compact, light and high on performance,” said one of the five people aware of the company’s plans.

These developments happen at a time when Royal Enfield’s ICE rivals Bajaj Auto, TVS Motor and Honda Motorcycle & Scooter India have already defined an ambitious EV foray. Royal Enfield, however, wants to execute its plans with a “steady surefootedness”. 

Siddhartha Lal, managing director of Eicher Motors, has always maintained that the company does not envisage being the first mover and is fine with entering the EV market later with a differentiated offering.

A Royal Enfield spokesperson had earlier told  Autocar Professional that the company has made huge strides in its “EV journey” over the past few years. The R&D programmes have included a major focus on sustainability mobility technologies and there are several ideas in “advanced stages of testing.”

“Our approach to developing an electric motorcycle has been very different and we have spent considerable time in studying and understanding the market and customers. We are strategically working on our EV portfolio and business model, and have started deeper investment in the segment,” added the spokesperson.

ALSO READ: Royal Enfield sells record 834,895 bikes in FY2023

EV sales in India hit 1.17 million units in FY2023, charge past 100,000 for six months in a row

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Royal enfield plans new factory in tamil nadu.

Royal Enfield, a leading manufacturer of midsize motorcycles with headquarters in Chennai, is to build a new facility in Tamil Nadu to support its expanding worldwide ambitions and its diversification into electric vehicles.

A 60-acre land lot in Cheyyar, on the outskirts of Chennai, which the business has already purchased, is anticipated to serve as the main production facility for its two-wheeled EVs in the future.

For the next 12 to 24 months, Royal Enfield anticipates spending between Rs 1,000 and Rs 1,500 crore to increase both its manufacturing capacity and product line.

While the first electric motorcycle is likely to roll out from a dedicated setup within the existing VallamVadagal plant, which is its core IC engine production base, it is learnt that the company has already commenced work at the Cheyyar plot to ensure a smooth transition to EVs as and when the portfolio of zero-emission models are developed and ready for rollout

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• Royal Enfield begins production at Vallam Vadagal facility

Spread over 50 acres, the Vallam Vadagal plant will be Royal Enfield s third manufacturing facility, and will manufacture Royal Enfield motorcycles for India and international markets, Eicher Motors said in a statement.

• Updated On Aug 27, 2017 at 11:26 AM IST

New Delhi: Royal Enfield , a division of Eicher Motors, today started commercial production from its new manufacturing facility at Vallam Vadagal near Chennai in Tamil Nadu.

According to the statement, the facility starts with an installed production capacity of 300,000 motorcycles per annum in the first phase.

In 2017-18, the combined production capacity from all the three plants is planned to be 825,000 units. In 2016-17, Royal Enfield produced and sold 667,135 motorcycles, nearing its installed capacity.

Royal Enfield acquired a 50-acre plot in Vallam Vadagal in October 2014 as the site for its third manufacturing facility. The construction of the facility started 15 months back and has been completed in record time, it said.

The capacity in this facility will enable the company to meet its next level of growth.

• Published On Aug 27, 2017 at 11:24 AM IST

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Royal Enfield new plant visit

The new plant will produce 1,50,000 units in its first phase, and will expand to 2,50,000 units by 2014.

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Royal Enfield release 'Rentals and Tours' scheme letting riders try their full range around the globe

Anglo Indian small capacity bike firm Royal Enfield have launched a new ‘Rentals and Tours’ program, promising the ability to rent and ride their range of accessible singles and twins across 25 countries around the globe.

The scheme builds on the Royal Enfield Rentals in India initiative and will now work with partners across 52 destinations around the world, covering everything from bike rentals to organised and guided rides. Independent routes are also possible.

“Royal Enfield has long been associated with epic journeys of exploration, with enthusiasts traversing countries, and continents on our motorcycles for decades,” Royal Enfield CEO, B Govindrajan said.

“We believe we deeply understand the desire for adventure and to discover the world on two wheels. The Royal Enfield Rentals and Tours programme not only simplifies the logistics of motorcycle tourism, it also opens a world of new opportunities for those with the spirit of adventure in their hearts.”

The current Royal Enfield range spans everything from long stroke air cooled 350 retros , to a fleet of parallel twin 650s . All are designed with simplicity and ease of use in mind.

Destinations included in the program consist of India, France, South Africa, Peru, Indonesia, Colombia, Turkey, the UK, Namibia, and more. All you need to do is visit either royalenfield.com/rentals and royalenfield.com/tours to find exactly where you want to go.

Once you’ve had a browse and confirmed a booking interest, a call back will be arranged from a tour operator, to finalise the details of your trip.

The Enfield boss continued: “With one of the world’s largest motorcycling communities, we believe this initiative will not just fortify but also expand Royal Enfield’s global motorcycling family, fostering a deeper sense of camaraderie among riders across borders.”

By Dan Sutherland

News Editor, sportsbike nut, and racing fan.

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