Congratulations on becoming the proud owner of a legendary Royal Enfield motorcycle. The new Bullet 500 is a motorcycle with the timeless handcrafted design of the legendary Bullet, now fitted with a solid 500cc Unit Contruction Engine with twin-spark ignition for better combustion, superior power delivery and improved fuel economy.
IMPORTANT NOTICE Keep this manual in a convenient place for easy reference. Beca us e o f co n tino us i m pro vem e nts i n t he pro duct and changes that may occur in the manufacturing process, subsequent to printing of this m anual , i t i s po ssible so me instr uctio ns, illustrations, pictures or designs found within this m anual m ay dif fer fro m tho se fo und on the vehicle. If any information is not understood in the manual contact your Authorised Dealer / Service Point for assistance.
IMPORTANT NOTICE SAFETY DEFINITIONS However i f you have any queries, cl ar ifi cation, Statements in this manual preceded by the following words are of special significance : suggestions/feedback, please write to us or e-mail at “customerservice@royalenfield.com”. WARNING War ni ng i ndicates a potenti all y hazardo us situation, which if not avoided, could result in serious injury.
CONTENTS PERSONAL & VEHICLE INFORMATION ......................... 7 OPERATION OF CONTROLS .............................................. 26 FREE SERVICE RECORD ..................................................... 8 - Ignition Switch ......................................................... 26 SAFE OPERATING RULES .................................................. 9 - Steering lock ............................................................. 26 RULES OF THE ROAD ......................................
CONTENTS GEAR SHIFTING .................................................................. 35 - Rear wheel removal ............................................. 49 PA RKING ............................................................................... 36 - Rear wheel assembly ........................................... 50 - Center Stand ............................................................ 36 - Adjustment - Clutch ................................................ 51 - Side Stand ................
CONTENTS WASHING PROCEDURE .................................................... 62 - Excessive fuel consumption ................................ 72 - Precautions .............................................................. 62 - Ignition knock .......................................................... 73 - After Washing .......................................................... 62 - Brakes poor .............................................................. 73 STORAGE PRECAUT ION .....................
PERSONAL & VEHICLE INFORMATION Name Door No./Street Locality City Contact Nos. State Res: Off: Pin Mobile: Email: Engine No. Battery No. Frame No. Battery make Reg. No. Licence No. Date of Sale Valid till dt. Model Key No. : Tyre make Colour Sold by Dealer Code Vehicle Installation Form (VIF) No.
FREE SERVICE RECORD It is our endeavour to provide excellent service to your Bullet 500 at all times. Towards this we provide 4 free services at specific Intervals. Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, to the service outlet.
SAFE OPERATING RULES Before operating your new motorcycle, it is your Use only genuine Royal Enfield spare parts and responsibility to carefully read and follow the approved accessories. Use of other manufacturer’s operating and maintenance instructions detailed performance parts may affect the performance of in thi s m a nual f or you r o w n s a fety, yo ur your motorcycle and render the motorcycle void of motorcycle and that of others. warranty. See your Royal Enfield dealer for details.
SAFE OPERATING RULES DO NOT fill the tank to its brim. Please fill fuel A new motorcycle must be operated according to the special break-in-procedure. See BREAK-IN-THE FIRST 500KM section. only till the bottom of the filler neck insert, so as to leave air space in the fuel tank to allow for fuel expansion (for Spec. Ref. Page No. 20).
SAFE OPERATING RULES WARNING Ope rat e yo ur m otor cycl e de fens ivel y. Remember, a motorcycle does no t af ford the same protection as an automobile in an accident. One o f the mo st com mon accident situati ons occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist. Avoid overspeeding and never travel over the speed limit. Excessive speed may cause loss of control and could r esult in an accident caus ing serious injury.
SAFE OPERATING RULES WARNING In emergency situations, if a temporary repair is M ai n tai n th e reco m m ended t yre pr ess u r e. made ride slowly with as light a load as possible until Ens ur e the f ro nt and r ear wheel s ar e co rr ectly the tyre is permanently repaired or replaced. aligned and the tyres are seated evenly & properly in the rims. Check for correct tightness of the spokes Failure to heed this warning could result in serious in the r im s.
SAFE OPERATING RULES WARNING WARNING Avoid any contact with the exhaust system. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot, even after the engine is turned off (due to catalic converter). Failure to wear proper or protective clothing could result in serious injury. DO NOT operate motorcycle with a loose, worn or damaged steering system, including the front and rear sus pensio n system.
SAFE OPERATING RULES WARNING on the frame Down tube. (GVWR is the sum of the wei ght of the m otor cycle, acces so ries, and the maximum weight of the rider, passenger and cargo that may be safely carried.) Exceeding GVWR may lead to instability of the motorcycle, which could cause an accident and result in serious injury. Consult your Royal Enfield Dealer regarding any questions or problems that occur in the operation of your motorcycle.
RULES OF THE ROAD Be sure front & rear number plates is installed in the position specified by law and is clearly visible at all times. may cause loss of control of vehicle, which could result in death or serious injury. Ride at a safe speed that is consistent with the type of road surface you are on. Pay strict attention to whether the surface is : Keep to the correct side of the road centre line when meeting oncoming vehicle.
RULES OF THE ROAD When intending to turn, signal at least 100 feet (30.5 meters) before reaching the turning. Be close to the center line (unles s l ocal r ul es requir e otherwise), slow down and then turn carefully. Never jump a traffic light. When a change is imminent from GO to STOP (or vice versa) at intersections, slow down and wait for the light to change to green. Never run through a yellow or red traffic light.
TECHNICAL SPECIFICATIONS ENGINE Engine ............................................................ Single Cylinder, 4 Stroke, Twinspark, Aircooled Capacity ........................................................ 499 cc (Displacement) Bore ................................................................ 84 mm Stroke ............................................................. 90 mm Compression ratio ...................................... 8.5 : 1 Max. Power @ RPM .................................
TECHNICAL SPECIFICATIONS IGNITION SYSTEM Ignition system ........................................... TCI Unit, Multi Curve (Variable Ignition Timing) Spark plug ................................................... WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10 Spark plug Electrode gap ...................... ................................................................. WQR8DC 0.80 to 0.90 mm UR6DC 0.70 to 0.80 mm TRANSMISSION Clutch ............................................................
TECHNICAL SPECIFICATIONS ELECTRICALS Generation ................................................... Alternator System ............................................................ 12V DC Battery ........................................................... 12V - 14 AH Head lamp ................................................... 12V, 60/55 W, Halogen Position lamp .............................................. 12V, 4W Brake / Tail lamp .......................................
TECHNICAL SPECIFICATIONS CHASSIS Frame ............................................................. Tubular Frame Tyre size ......................................................... Front: 90 / 90 - 19” - 52 P Tyre pressure ............................................... Front- Solo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI) ................................................................. Rear: 120 / 80 - 18” - 62 P Rear- Solo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.
TECHNICAL SPECIFICATIONS DIMENSIONS Length ........................................................... 2140 mm Width .............................................................. 810 mm (Without Mirror) Height ............................................................ 1110 mm (Without Mirror) Wheel base .................................................. 1370 mm Saddle height ............................................. 800 mm Ground clearance .....................................
VEHICLE IDENTIFICATION NUMBER - DETAILS FRAME NUMBER ENGINE NUMBER Punched on steering head tube RH side. Punched on top of the engine LH side.
KEY PARTS LOCATION 12 TOP VIEW 12 1. Turn signal switch 6 3 4 2. Horn button 7 3. Clutch lever 4. Day flash switch 5. Head lamp dip switch 8 6. Ignition switch 7. Speedometer 8. Front brake lever 1 10 5 2 11 9 9. Accelerator 10. E-Start Switch 11. Fuel tank cap 12.
KEY PARTS LOCATION RIGHT SIDE VIEW 1. RH Trafficator Front 2 5 2. Starter Motor 1 3. Brake Pedal 6 4. Kick Starter Lever 4 5. Air Filter Box 6.
KEY PARTS LOCATION LEFT SIDE VIEW 1. Trafficator Front LH 2 3 4 5 2. Spark Plug 3. Battery Cover 1 4. Electricals Box LH 6 10 9 8 7 5. Rear Shock Absorber 6. Trafficator Rear LH 7. Side Stand 8. Centre Stand 9. Gear Change Lever 10.
OPERATION OF CONTROLS IGNITION SWITCH STEERING LOCK OFF Turn key clockwise to lock. Lock the steering when leaving bike parked. Turn key anti clockwise to unlock. CAUTION ON Protect your motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head. Turn handle bar to extreme left, before attempting to lock steering. Do NOT lubricate barrel locks with petroleum based lubricants or graphite.
OPERATION OF CONTROLS FUEL TANK CAP SIDE BOX Turn key AIR FILTER BOX RH clockwise Turn Key anti-clockwise to open to open SIDE BOX LH Press cap to lock with key in position Turn Key anti-clockwise to open, it contains Tools Kit & Fuse NOTE NOTE Key can be r em o ved only i n lo ck ed position. Key is common for ignition, petrol tank cap, steering lock, side boxes and battery cover. Key for fuel tank and tool boxes can be removed from the lock only in locked position.
OPERATION OF CONTROLS HEAD LAMP SWITCH DIP SWITCH OFF Low beam Pilot Light ON High Beam Head Light ON HEAD LAMP DAY FLASH Press for Headlight Flash 28
OPERATION OF CONTROLS ENGINE KILL SWITCH TURN SIGNAL SWITCH Run Left Stop OFF (Push to off) HORN Right Press 29
OPERATION OF CONTROLS ENGINE START SWITCH FUEL TAP Press OFF Turn knob to horizontal position Main ON Turn knob downward position BATTERY BOX Turn anti clockwise to open Reserve ON Turn knob upward position 30
PRE OPERATIONAL CHECKS A careful check of the following must be carried out every time before riding and specially after long per io ds o f sto r age to d eter m ine if addi ti on al maintenance is necessary. 5. Engine oil level. MAX MIN 1. Tyres for correct pressure, abrasions or cuts. 2. Rear chain for proper tension. 6. Wh eel Drive Chain s po ke for proper tightness, no breakage. Spokes Clutch 7. Headlamp, tail lamp, brake lamp and indicator 3.
RUNNING IN PERIOD Avoid driving the motorcycle with full throttle o peni ng. Var y the s pe ed o f th e m otor cycl e regularly but avoid using the motorcycle above 3/4 throttle opening position. Proper running-in is very important for obtaining maximum life and performance of a new motorcycle. The following guidelines explain proper running-in procedures. Since the engine is brand new, it should not be loaded excessively for the first 2,000 kms.
STARTING Ens ur e Engi ne s to p swi tch is i n “R UN” position STARTING PROCESS (KS / ES) Turn fuel tap to ‘ON’ Ensur e the side and m ai n st ands ar e in released position Ensure that gears are in neutral and neutral lam p is glo wi ng i n cluster box. Use cho ke i n co ld condition CAUTION N Do not force the gear lever while attempting to shift to neutral. Move the motorcycle back & forth and simultaneously press gear lever to come to neutral.
STARTING Pres s Star ter Butto n and release as soon as engine starts. USING KICK START Sl i ghtl y cr ank the en gine fur the r ti ll com pres s ion eas es over. Release the choke, if applied Start the motorcycle wi th a po werf ul swinging kick. NOTE Release the choke, if applied A clutch switch is provided in the system for the safety of the rider. This is to prevent the vehicle from starting when the vehicle is in gear.
GEAR SHIFTING Pre ss th e gear pedal with heel to eng age 2 nd and higher gear. Warm up engine for 2 minutes - till idling is consistent/ stable GEA R 1 N SH IF T PATT ERN 2 3 4 5 Follow the same procedure for 3rd, 4th and 5th gear. Press clutch lever towards the hand grip. Press gear pedal with toe to engage 1st gear. Gentl y ope n th ro tt le and rele ase clut ch simultaneously. If clutch is released suddenly, the engine may stall and cause a jerky start.
PARKING PARKING VEHICLE ON CENTER STAND PARKING VEHICLE ON SIDE STAND Select a firm, flat surface Select a firm, flat surface Hold handle bar straight Lower Side Stand and gently tilt motorcycle to the left till it rests firmly. Lower center stand, and ensure that both the legs of the stand are resting evenly on firm ground. Apply pressure on the fulcrum lever on the center stand and pull vehicle backwards, gently as shown in pic. WARNING Always park the motor cycle on a firm and flat surface.
TOOLS & FIRST AID KIT 1 2 3 4 5 5 6 7 6 1 4 S.No. Description Qty. 1. Tool bag 1 2. Screw driver O6 X 160 1 3. Tommy bar 1 4. Tubular spanner 1 5. Tool Spark plug 1 6. Double end spanner 10 X 12 2 3 2 S.No. Description 1. 2. 3. 4. 5. 6. 7. Antiseptic cream 5 gms Gauze bandage 5 cm x 2 cm Elastic Gauze bandage 8 cm x 1 mtr. Wash proof plaster 1.9 cm x 7.2 cm Sterilized Gauze Swab 5 cm x 5 cm Sterilized elastic plaster 7 cm x 6 cm First aid kit pouch Qty.
RECOMMENDED LUBRICANTS Engine Oil Grade Royal Enfield 15 W 50 API SL Grade Engine Oil (JASO MA) Grade Front Fork Oil Royal Enfield Front Fork Oil (or 1F Grade Endurance) Capacity 195 ml/leg Brake Fluid Grade DOT 3 or DOT 4 Capacity 60ml ISO 14001 – EMS Operation Control Process Capacity 2.75 Ltrs. (with oil filter) 2.50 Ltrs. (during oil & filter element replacement) WARNING 1. All customers are advised timely replacement of Engine Oil, Fork Oil & Brake Oil at the dealership /ASP.
PERIODICAL MAINTENANCE The maintenance schedule detailed here will help you to maintain your Bullet 500cc meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carried out.
PERIODICAL MAINTENANCE S. No. FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12 DESCRIPTION Months 1.5 3 6 9 R I R I R PAID SERVICE 15 18 21 24 27 30 I R I R I R 1 Engine Oil 2 Engine oil filter element R C R R R R R 3 Engine sump filter (oil strainer) C C C C C C C C C C Check level at every 1000 Kms or earlier as required 5 Magnetic drain plug under gear box and seconC C C dary drain plug under crankshaft in crankcase RH C Spark plugs (2 nos.
PERIODICAL MAINTENANCE S. No. DESCRIPTION FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12 Months 1.
PERIODICAL MAINTENANCE S. No. FREE SERVICE whichever is earlier Kms (x 1000) 0.5 3 6 9 12 DESCRIPTION Months 1.
MINOR MAINTENANCE TIPS The following minor maintenance can be carried out easily with simple tools. However, In case, if it is felt that the adjustments are best done by an expert, we recommend that the motorcycle be taken to a nearest Royal Enfield Authorised Dealer / Service Point. ENGINE OIL LEVEL INSPECTION CONTROL CABLES, HANDLE LEVER, PIVOTS, CENTER / SIDE STAND PIVOTS MAX MIN Main & Side Stand Pivot Place motorcycle on its center stand on a firm surface.
MINOR MAINTENANCE TIPS ENGINE OIL CHANGE Secondary Drain Plug Primary Drain Cap TILT VEHICLE RH & LH Primary Drain Bolt (Refer Periodical Maintenance Chart for frequency) Place motorcycle on its center stand on a firm flat surface. Start engine and warm up for 2 minutes. Keep a clean tray below the engine. Remove the oil filter element on the Crankcase Cover RH. Remove primary drain cap, to drain oil & clean suction filter, magnet. Allow the oil to drain by tilting the motorcycle to both sides.
MINOR MAINTENANCE TIPS Soak a new oil filter element in the oil and refit on the Crankcase Cover RH. SPARK PLUG Assembly 3 bolts and tighten them. Ensure ‘O’ Ring and gaskets are taken seat properly. C l eani ng a nd a djus ti ng gap (Refer Peri odic al Maintenance Chart for frequency) Fill recommendedoil to engine till the oil level is upto “M AX ” level mark in the oil wi ndo w i n C ran kcase Cover RH.
MINOR MAINTENANCE TIPS BRAKE FLUID INSPECTION OF TYRES AND WHEELS Inspect the tyr e peri odically fo r tread wear, cracks and cuts. Check if oil is above ‘min’ level. To top up, remove cover with diaphragm and top up with either DOT 3 or DOT 4 as specified. Minimum tread depth : Front tyre : 1mm Rear tyre : 2 mm Check and remove stone, splinters, nails or other particles embedded in the tyre treads. MAX MIN Bald spots / swelling may be caused by inte rnal dam age. Rep lace the tyr es , i f defective.
MINOR MAINTENANCE TIPS Use o nl y standard tyres & tubes infl ated to correct pressure. FRONT WHEEL REMOVAL Place the vehicle on center stand Place a wooden block th e fr o nt end of engine to support the vehicle. TYRE PRESSURE Solo With Pillion Frontt Rear 1.41 kg/cm2 (20 PSI) 2.11 kg/cm2 (30 PSI) 1.55 kg/cm2 (22 PSI) 2.25 kg/cm2 (32 PSI) Dis co nn ect cable. s peedo Loosen the pinch bolt on the RH fork guide. Hol d fr ont ax le by spanner and loo sen axle nut then remove nut along with washer.
MINOR MAINTENANCE TIPS Tap and remove the front wheel spindle FRONT WHEEL ASSEMBLY Tilt the vehicle to RH Side and take out the wheel along with speedo drive with bush & LH side spacer. Remove the wooden piece / card board sheet placed between the brake pads. Pla ce t he b us h sp eedo dr ive i n positi on and place speedo drive over it. In sert the wheel alo ng wit h speedo drive assembly and LH spacer between the fr ont fo rk ends ens ur ing the brake di sc i s lo cat ed i n between the brake pads.
MINOR MAINTENANCE TIPS REAR WHEEL REMOVAL Place the vehicle on center stand on a firm and flat surface. Note and mark the position of the chain adjuster bu ttin g wi th t he stopper on the right side. Remove split pin and castle nut on the RH side. Tighten the pinch bolt on the RH fork guide. Rotate the wheel and check for smooth rotation. Remove wheel spindle fr om LH s ide al ong with chain adjuster, tak ing care no t to drop the wheel collar and spacer from the LH side of the wheel.
MINOR MAINTENANCE TIPS Ensure that the chain adjuster knotch butts with the stopper as appropriate when both the front & rear wheels are aligned. REAR WHEEL ASSEMBLY Ensure the four cush rubbers are in position inside the rear wheel hub. Tig hten the cas tle nut fir m ly and ensure that the hole o n ax le s ha ft a nd the slot on castle nut are ali gned to en abl e s pl it p in fitment. Tilt vehicle to right and i nsert wheel assembly between the swing arms.
MINOR MAINTENANCE TIPS ADJUSTMENTS - CLUTCH DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM) 2 to 3 mm Remove rear wheel split pin. A B Loo sen castle nut, spindle nut, anchor nut and brake rod nut. Clutch Lever (free play 2 to 3 mm) CLUTCH FREE PLAY ADJUSTMENT Loosen the cable outer lock nut (A). Turn the RH adjuster cam as appr o priately, till 25 to 30 m m sla ckn es s is achieved on the top run of the chain. Turn the Nut (B) Clockwise to reduce the play or Anticlockwise to increase the free play.
MINOR MAINTENANCE TIPS Check brake pedal free play, If necessary adjust. CHECKING REAR BRAKE PEDAL HEIGHT Check that the front and rear wheels are correctly aligned. Turn the LH adjuster cam appropriately, to ali g n bo th t he wheels. C heck and ensure that the knotches on the cam are resting o n the pi n in t he swing arm on both sides. Loosen the lock nut. A p ply bra ke a nd tighten all nuts.
MINOR MAINTENANCE TIPS CHAIN LOCK FITMENT REAR BRAKE PEDAL PLAY ADJUSTMENT 20 - 30 mm Turn in or out the adjuster nut at the brake rod end. The recommended brake pedal travel is 20-30 mm. Check that the brake is not binding and the rear wheel rotates freely. The open end of the chain link master lock to face opposite to normal direction of chain rotation as shown pic. WARNING Please ensure brakes are adjusted to their maximum efficiency. Inefficient brakes can cause an accident.
MINOR MAINTENANCE TIPS Turn the adjuster such that the adjuster moves up to increase the spring tension and vice versa to reduce the spring tension. ADJUSTMENT OF GAS FILLED SHOCKABSORBER RH A djus t both left hand and ri ght hand s hock absorbers so that the same knotch rests on the pin in both sides. WARNING Ri ding the m ot or cy cl e wit h th e kn otch es adjus ted in different pos iti ons can cause lo ss of control and may lead to an accident. LH The rear gas shock absorber is adjustable type i.e.
MINOR MAINTENANCE TIPS BATTERY MAINTENANCE REMOVAL OF BATTERY ON VEHICLE T he veh icle is provided with 12V 14 AH battery. The battery must be periodically checked for Unlock (turn the key anti clockwise) and remove the battery cover. C l eanl i ne ss a nd cor ro si o n f r ee terminals. Electr o l yte lev el m us t be abo ve “MIN” level. Remove the battery holding two rubber straps gently. If electrolyte level is lo w, r em o ve caps and top up with distilled water only.
MINOR MAINTENANCE TIPS WARNING ASSEMBLY OF BATTERY ON VEHICLE Always disconnect the negative (-) battery cable fi rs t and then the Red pos iti ve (+) cable while removing the battery connections. Position the battery in the battery carrier such that the negative terminal of the batter y is towards fuel tap. NOTE Ensure ignition switch is in ‘OFF’ condition. For checking the battery voltage and electrolyte specific gravity, contact authorised Royal Enfield service or battery service centre.
MINOR MAINTENANCE TIPS Remove rubber grommet fr om the r ef lecto r Assembly. CHANGING ELECTRICAL COMPONENTS HEAD LAMP BULB REPLACEMENT Lo o sen the hea d la m p holding top screw. Then pul l out head lam p assembly. Gen tl y pr es s th e bu l b holding ‘U’ clip from both the sides downwards and releas e it from reflecto r slot as shown. Detach bo ttom lug fr om the head lamp ho us ing body. Pull out head lamp bulb and inspect its filament for fuse.
MINOR MAINTENANCE TIPS Connect the wire couplers as mentioned below. ASSEMBLING THE HEADLAMP Refix the new head lamp hal ogen bul b in to reflector unit by locating the wide protrude on top side mounting. TOP SIDE: GREEN COLOUR RIGHT SIDE: BLUE C OLOUR LEFT SIDE: ORANGE COLOUR Position the reflector ring bottom lug into head lamp cas ing slo t and sl ide it, th en t i ght en t he t o p mounting screw.
MINOR MAINTENANCE TIPS TAIL LAMP BULB REPLACEMENT TRAFFICATOR BULB REPLACEMENT Remove the two nuts each from RH & LH side of the rear number plate holder. Remo ve the 2 screws & take out trafficator glass cover. Pul l ou t Ta il Lamp as s em b ly a lo n g wi th bracket and twist the bulb holder in anticlockwise to re m ove bulb holder assembly. Press bulb gently & Turn anticlockwise to take out the bulb.
MINOR MAINTENANCE TIPS Replace the required fuse with the spare fuse available in the fuse carrier. FUSE Open the LH tool box. NOTE Take out tool kit. Please ensure to replace a spare fuse in the holder at the earliest opportunity. Remove fuse holder rub ber & l i ft f us e carrier top cover. BLADE FUSE USAGE LIST Fuse No.
MINOR MAINTENANCE TIPS Tap the filter element to r em o ve d ust as sh o wn and cle an tho ro ug hl y befo r e assembly. AIR FILTER PAPER ELEMENT CLEANING/REPLACEMENT Insert the key, turn an ti cl okw ise to remove RH side air filter box lid. Clean both intake adaptors and duct as shown in pic. Loo sen the fil ter hol di ng nut by 10mm spanner as shown in pic. Assemble the filter element and cover in the reverse order of dismantling process.
WASHING PROCEDURE AFTER WASHING PRECAUTIONS Wash vehicle when the engine is cold. Cover the silencer tail end and control switches with suitable plastic bags and tie it firmly to prevent water entry into them. Remove ignition key and seal key hole using adhesive tape. Use a suitable engine degreaser, available with your local parts store, to remove dirt or grease from the engine external parts if required. Follow the directions in the label carefully before using the degreaser.
STORAGE PRECAUTIONS Rem o ve bat ter y f ro m t he b ike. C le an t he terminals free of corrosion. Incase your Motorcycle is not going to be used for a month or more, we advise the following precautions to the taken. Maintain electrolyte level between max or min mark, by adding distilled water and wipe the battery dry. Carryout required repair / adjustments on the motorcycle. Sto r e t he b atter y i n a co ol , dr y an d wel l ventilated place.
STORAGE PRECAUTIONS Remove spark plug on cylinder head and pour PREPARING THE MOTORCYCLE FOR RE USE in a few drops of engine oil. Crank engine a few Remove anti rust solution from all chrome plated ti mes to lubricate cylinder walls and piston. parts and clean the motorcycle. Clean spark plug and refit. Inflate the tyres to the correct tyre pressure. Switch “ON” ignition switch.
LONG TRIP PRECAUTIONS CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY ITEMS TO BE CARRIED Tool kit. Ser vice the m otor cycle tho ro ughly at Ro yal Enfield Authorised Dealer / Service Point as per periodical maintenance chart. (Ref. Page No. 40, 41 & 42) First aid kit. Bulbs for Headlight, Trafficator light, Rear Tail Lamp and Fuse (10 & 15 Amps). Sufficient quantity of petrol in the fuel tank for the journey planned. Accelerator, Clutch and Speedo Cable.
CARING FOR MILEAGE Both lower and higher road speeds cause low kilometers per litre of petrol. STOP THE DROP THAT LEAKS Petrol leak at a rate of one drop per m inute accumulates to 5,25,600 drops a YEAR! That is, 35 ltrs of Petrol. PERFORM PREVENTIVE MAINTENANCE AS PER RECOMMENDATIONS Petrol leaks cause raw petrol smell. Get the leaks arrested immediately. REGULAR PREVENTIVE MAINTENANCE ENSURES Correctly inflated tyres. USE RECOMMENDED FUELS AND OILS ONLY Fasteners tightened to correct torques.
CARING FOR MILEAGE Sudden acceleration : Ten sudden accelerations wastes 100 ml. of petrol. For better mileage, use front and rear brakes simultaneously when absolutely needed. Control vehicle speed with throttle and gear like smart riders always do. STOP BRAKE RIDING Brake riding pushes the brake shoes to come in contact with revolving drum. To overcome the resulting frictional load, engine burns additional petrol.
COMPLETE WIRING DIAGRAM - BULLET 500 NOTE : Complete Wiring Diagram is attached on this page. VEHICLE STARTING PROCEDURE BASIC GUIDELINES TO BE FOLLOWED “FOR ALL ELECTRIC START VEHICLES” 1. In cold condition of the engine or for initial start, it is advised to use electric start (ES) only. 2. Apply choke in cold start condition. (ambient temperature <25° C) 3. DO NOT ATTEMPT – “HALF START” BY CASUALLY PRESSING ELECTRIC START BUTTON. 4.
D C B LIGHT GREEN NEUTRAL SWITCH PILOT LAMP LIGHT GREEN BROWN LH 10W FRONT TRAFFICATORS RH 2x6.3MM COUPLER IGNITION SWITCH OFF POSITION SPEEDOMETER ASSY 9x2.8 COUPLER PILOT LAMP POSITION LAMP 4W HEAD LIGHT 60/55W HALOGEN BULB CLUTCH SWITCH E START H.LAMP BLACK F E H 9x2.
TROUBLE SHOOTING CAUSES REMEDIES I. ENGINE FAILS TO START 1) Ignition switch in ‘OFF’ Position ............................................... Switch on ignition. 2) Engine Stop switch in ‘OFF’ Position ....................................... Push stop switch to ‘ON’ position. 3) Clogged fuel line / tap .............................................................. Clean the fuel line / tap. 4) Vent hole clogged in fuel tank cap ....................................... Clean vent hole.
TROUBLE SHOOTING CAUSES REMEDIES 13) Poor compression - Auto Decompressor not working .......................................... ......................................................................................................... *Ensure free motion of flyweight in exhaust cam gear assembly - Loose spark plug ...................................................................... *Tighten spark plug. 14) Clutch slipping ............................................................................
TROUBLE SHOOTING CAUSES REMEDIES III. ENGINE STARTS, BUT RUNS IRREGULARLY & STOPS 1) Faulty fuel supply ...................................................................... Clean the fuel line / tap / vent hole 2) Very low idling speed ................................................................ Increase idling speed IV. POOR PICKUP 1) Accelerator cable free play excessive .................................. Adjust cable free play 2) Faulty fuel supply ......................................
TROUBLE SHOOTING CAUSES REMEDIES V. WHITE/BLUE SMOKE 1) Oil level in tank above the middle line in the .................... oil level window *Check and drain excess oil 2) Worn out valve oil seal .............................................................. *Check / Replace 3) Worn out piston ring / cylinder ................................................ *Check / Replace VI. ENGINE OVERHEATING 1) Cylinder fins not clean ..............................................................
TROUBLE SHOOTING CAUSES REMEDIES 2) Worn out carburetor jets ........................................................... *Change the defective jets 3) Incorrect carburetor adjustments .......................................... *Check and adjust correctly 4) Choked air filter .......................................................................... Clean / Replace 5) Poor compression ....................................................................... .........................................
TROUBLE SHOOTING CAUSES REMEDIES 3) Linings worn / Uneven wear .................................................... *Replace linings 4) Drum scored / Uneven wear .................................................... *Rectify or Replace drums X. VEHICLE WOBBLES 1) Wheel rim runout ........................................................................ *Rectify 2) Loose / Broken spokes ................................................................
TROUBLE SHOOTING CAUSES REMEDIES Horn not working 1) Loose connections ...................................................................... *Check and correct 2) Requires tuning ........................................................................... *Tune horn 3) Switch Defective .......................................................................... *Replace 4) Fuse blown ....................................................................................
TROUBLE SHOOTING CAUSES REMEDIES XII. ELECTRIC START VEHICLE NOT STARTING (1) Neutral indicator not glowing ................................................ Bring the vehicle in neutral (2) If vehicle is without neutral indicator ................................... Press the clutch lever & start switch together (3) Loose Connection ....................................................................... *Check & Correct (4) Starter relay not working ...................................................
WARRANTY TERMS & CONDITIONS Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material and workmanship. Royal Enfield (RE) warrants Bullet 500 Motorcycle to be free from manufacturing and material defect under normal use subject to following conditions. 1.
WARRANTY TERMS & CONDITIONS (b) Components like fuel filter, oil filter paper element, control cables, brake shoes / brake pads, clutch plates, drive chain & sprocket kit, which are subjected to normal wear and tear. (c) Damages due to use of lubricant / oil / grease etc. other than specified by RE. (d) Damages due to use of non-genuine parts. (e) Damages due to lack of proper maintenance of the vehicle. (f ) Damages due to incorrect driving or riding habits.
EMISSION WARRANTY In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal Enfield certifies that the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its range of motorcycles, in normal use to which it may be subjected to. This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000 Kms.
EMISSION WARRANTY All parts removed for replacement under warranty will become the property of Royal Enfield. Royal Enfield will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised Dealer / Service Point OR for any loss due to non availability of the motorcycle during the period of examination and repairs by Royal Enfield and / or their Authorised Dealer / Service Point.
EMISSION WARRANTY pursuant upon being directed by an officer as referred to in sub rule (2) of rule 116 of the Central Motor Vehicles Rules (CMVR). Produces the owner’s manual and Log book for verification details. Produces receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date of original purchase of the vehicle. Produces valid certificate of Insurance and R.T.O Registration Certificate (RC Book).
EMISSION WARRANTY The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by Royal Enfield in the Owner’s manual or any other document given to the customer at the time of sale of the motorcycle. The emission related components are tampered with. All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced.
ALL INDIA ROAD SIGNS MANDATORY SIGNS CAUTIONARY SIGNS INFORMATION SIGNS 83
FREE SERVICE COUPONS It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide four free services at specific Intervals. Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory service, kindly return the free service coupon duly filled in and signed, to the service outlet.
1ST FREE SERVICE 1ST FREE SERVICE 500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Customer Name : Dealer Code : Address : 500 Kms or 45+8 days whichever is earlier from the date of sale Frame No: Regn. No: Engine No: Sale Date: Vehicle Installation Form No.
1ST FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .........
2ND FREE SERVICE 2ND FREE SERVICE 3000 KMS OR 90+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Customer Name : Dealer Code : Address : 3000 Kms or 90+15 days whichever is earlier from the date of sale Frame No: Regn. No: Engine No: Sale Date: Vehicle Installation Form No.
2ND FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .........
3RD FREE SERVICE 3RD FREE SERVICE 6000 KMS OR 180+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Customer Name : Dealer Code : Address : 6000 Kms or 180+15 days whichever is earlier from the date of sale Frame No: Regn. No: Engine No: Sale Date: Vehicle Installation Form No.
3RD FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................
4TH FREE SERVICE 4TH FREE SERVICE 9000 KMS OR 270+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE Customer Name : Dealer Code : Address : 9000 Kms or 270+15 days whichever is earlier from the date of sale Frame No: Regn. No: Engine No: Sale Date: Vehicle Installation Form No.
4TH FREE SERVICE ACTIVITIES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Water wash the vehicle and dry it with a clean cloth Electrolyte ...................................................... Check level & top-up Battery terminals ......................................... Clean and apply petroleum jelly Drive chain free play ................................. Check, clean, lubricate & adjust Rear brake pedal pivot ............................ Lubricate Rear brake .....
PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 12,000 + 250 Kms. Service 12,000 + 250 Kms. Service Job Card No :.................Date : ......................... Job Card No :.................Date : ......................... Odo Reading : ................. Dealer Code : ............. Odo Reading : ................. Dealer Code : .............
PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 12,000 + 250 Kms. Service 12,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 15,000 + 250 Kms. Service 15,000 + 250 Kms.
PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 18,000 + 250 Kms. Service 18,000 + 250 Kms. Service Job Card No :.................Date : ......................... Job Card No :.................Date : ......................... Odo Reading : ................. Dealer Code : ............. Odo Reading : ................. Dealer Code : .............
PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 18,000 + 250 Kms. Service 18,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 21,000 + 250 Kms. Service 21,000 + 250 Kms.
PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 24,000 + 250 Kms. Service 24,000 + 250 Kms. Service Job Card No :.................Date : ......................... Job Card No :.................Date : ......................... Odo Reading : ................. Dealer Code : ............. Odo Reading : ................. Dealer Code : .............
PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 24,000 + 250 Kms. Service 24,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 27,000 + 250 Kms. Service 27,000 + 250 Kms.
PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 30,000 + 250 Kms. Service 30,000 + 250 Kms. Service Job Card No :.................Date : ......................... Job Card No :.................Date : ......................... Odo Reading : ................. Dealer Code : ............. Odo Reading : ................. Dealer Code : .............
PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 30,000 + 250 Kms. Service 30,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 33,000 + 250 Kms. Service 33,000 + 250 Kms.
LOG BOOK Sl. No. Date Kms. Idling Co% Details 101 Authorised Dealer / Service Point Stamp & Job Card No.
LOG BOOK Sl. No. Date Kms. Idling Co% Details 102 Authorised Dealer / Service Point Stamp & Job Card No.
LOG BOOK Sl. No. Date Kms. Idling Co% Details 103 Authorised Dealer / Service Point Stamp & Job Card No.
LOG BOOK Sl. No. Date Kms. Idling Co% Details 104 Authorised Dealer / Service Point Stamp & Job Card No.
LOG BOOK Sl. No. Date Kms. Idling Co% Details 105 Authorised Dealer / Service Point Stamp & Job Card No.
NOTES 106
NOTES 107
NOTES 108
Telephone Residence Bike Regn. No. Telephone Office Invoice No. E Delivery Note / Advice No.
PRE DELIVERY INSPECTION LIST MODEL: BULLET 350 / ELECTRA / CLASSIC 350 / CLASSIC 500 / BULLET 500 Model : Engine No: Dealer's Name : Location: Colour : Key Number : Battery Make : Battery Number : Aggregate CHASSIS / ENGINE NUMBER Tyre Number : Defect Code Area 1 CONNECT BATTERY / 2 CHECK VOLTAGE Measure Engine / Vehicle Number Details DF Same Battery Charging D / NC / Weak Battery Voltage 12V-whereas 13.5 V (Max. online voltage) Cell 3 Fill 2.
36 Mudguards - Paint / Plating Related SC / PD / R / DN No Defects (Mudguards / Fuel Tank / Tool Box 37 Fuel Tank - Paint Related SC / PD / R / DN No Defects 38 Tool Box LH, Air Filter Box, Battery Cover Paint / Plating Related SC / PD / R / DN No Defects 39 Head Lamp Casing - Paint Related SC / PD / R / No Defects SC / PD / R No Defects 41 Plated Parts (Scratch / Rusty) SC / R / PO No Defects (Mudguards / Fuel Tank / Wheel Rim / Indicator 42 Buffed components poor Buffing & Scratches SC /
BIKE INSTALLATION CONFIRMATION BY CUSTOMER We congratulate you on becoming a proud owner of Royal Enfield bike. We request you to give this feedback after completion of the delivery process.
YES 13 14 15 16 17 18 19 20 NO Control Switches & Disc Brake System usage explained Fuse Box location shown and explained Recommended Tyre Pressure explained Bike starting & Gear shifting procedure explained Quantity of Fuel in Fuel Tank informed Bike orientation & short distance drive provided Date and Time of Installation Name of Person who did Installation Suggestions If Any: CUSTOMER SIGNATURE Model: Registration No.: Chassis No.
FORM 22 [See Rules 47(g), 115, 124 (2), 126A and 127 (1), 127 (2)] INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETY STANDARDS OF COMPONENTS AND ROAD WORTHINESS Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and the rules made there under, including the following mass emission norms: Bullet 500 Brand name of the vehicle :- Chassis number :- Engine number/motor number (in case of battery operated vehicles) :- Sub-rule No.
