Royal Enfield Bullet 500 2013 Owner's manual

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.

Do read this manual thoroughly before you begin riding to ensure that you operate your motorcycle the right way, are aware of the terms and conditions of warranty, and know how to maintain it properly.

We ur ge you to avail of the fou r free se rvi c es we offer, at the righ t tim e, at any of our Au tho r ise d Dealer / Service Point to keep your motorcycle in peak condition.

Pl e a s e log o n to ww w. r o yalen f i e l d . com to kn o w more ab o u t the h i s t o r y of t h e w o r ld’s o l d e st motorcycle brand, our other products, and for exciting news of riding tours and events organised for Royal Enfield motorcycle owners.

Welcome to motorcycling the Royal Enfield way. Ride safe and enjoy the trip!

IMP ORTAN T NOTICE

n Keep this manual in a convenient place for easy

referenc e.

n If any information is not understood in the manual

contact your Authorised Dealer / Ser vice Point for assistance.

n If t he motorc ycle is being used by any friend,

relatives, or others it is responsibility of the owner to make certain that the owner’s manual is read and fully understood prior to usage and has been instructed on it’s safe and proper use.

n The motorcycle is designed for normal on road

use only. Operation in off-road usage in some areas may be ille gal and could be dangerous.

Obey local law and regulations.

n In the event of motorcycle being resold, it is the

responsibility of the owner of the motorcycle to hand over the manual along with the motorcycle and it’s documents.

n Becaus e of contino u s imp r o v e m e n t s in the

pr oduc t and ch ang es tha t may oc cur in the manufacturing process, subsequent to printing of th i s manual , it is po s sib l e som e inst r uct i ons , illustrations, pictures or designs found within this ma n ual may di f fer fro m th ose foun d on th e vehicle.

n However the technical information found within

this manual wa s correct at the ti m e it w a s approved for publication.

n Roy a l E nfie l d re s e r ves t h e r i gh t t o m a k e

production changes at any time without prio r notice and without i ncurring any obligation to ma k e sam e or si milar chang e s to vehic l e s previously built or sold.

“© Copyright 2013 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt without the express permission in writing of Eicher Motor Limited, Royal Enfield Unit.”

Part N o. 584639/a / Qty.1000 / Mar. ‘13

IMP ORTAN T NOTICE

SAFE TY DEFI NIT ION S

Statements in this manual preceded by the following words are of special significance :

WARN ING

War n i ng in d icat e s a po tent i a lly ha zard o u s situation, which if not avoided, could result in serious injury.

CAUTIO N

Caution indicated a protentially hazardous situation, which if not avoided, may result in property damage, in minor or moderate injury.

NO TE

Indicates important and useful messages for clearer understanding.

All Ima ges show n are for re fe re nc e to expla in and need not to be e xac tly the sa me on t he mod el you own.

Ho weve r if yo u hav e any qu eri e s, cla rif i cat i on,

suggestions/feedback, please write to us or e-mail at

“customerservice @royalenfield.com”.

SERVICE HEAD QUARTERS

Royal Enfield, A Unit of Eicher Motors Limited,

Thiruvottiyur High Road, Thiruvottiyur,

Chennai - 600 019.

Phone : 044 - 4223 0400, Fax : 044 - 4201 1719

E-mail : customerservice@royalenfield.com

Website : www.royalenfield.com

CONTENTS

PERSONAL & VEHICLE INFORMATI ON ........................ 7

FREE SERVICE RECORD .................................................. 8

SAFE OPERATING RULES ................................................ 9

RULES OF THE ROAD ...................................................... 15

TECHNICAL SPECIFICATIONS ....................................... 17

- Engine .................................................................... 17

- Ignition System ..................................................... 18

- Transmission ......................................................... 18

- Elec tricals .............................................................. 19

- Chassis ................................................................... 20

- Dimensions ............................................................ 21

- Weights ................................................................... 21

VEHICLE IDENTIFICATION NUMBER ............................ 22

KEY PARTS LOCATION .................................................... 23

- Top View ................................................................. 23

- Right Side View ..................................................... 24

- Left Side View ........................................................ 25

OPERATION OF CONTROLS ........................................... 26

- Ignition Switch ...................................................... 26

- Steering lock ......................................................... 26

- Fuel tank cap ........................................................ 27

- Side Box .................................................................. 27

- Head lamp switch ............................................... 28

- Dip Switch .............................................................. 28

- Head lamp Day flash ......................................... 28

- Engine Kill Switch ................................................ 29

- Horn ........................................................................ 29

- Turn Signal Switch ............................................... 29

- Engine Start Switch ............................................. 30

- Battery Box ............................................................. 30

- Fuel Tap ................................................................. 30

PRE OPERATIONAL CHECKS .......................................... 31

RUNNING IN .................................................................... 32

STARTING ......................................................................... 33

CONTENTS

GEAR SHIFTING ............................................................... 35

PARKING ........................................................................... 36

- Center Stand ......................................................... 36

- Side Stand ............................................................. 36

TOOLS AND FIRST AID KIT ............................................ 37

RECOMMENDED LUBRICANTS ...................................... 38

PERIODICAL MAINTENANCE ........................................ 39

MINOR MAINTEN ANCE TIPS ......................................... 43

- Control Cables, Handle bar lever,

Pivots, Ce nter / Side Stand Pivots ..................... 43

- Engine Oil Level Inspection .............................. 43

- Engine Oil Change .............................................. 44

- Spark Plug ............................................................. 45

- Brake fluid ............................................................. 46

- Inspection of tyres and wheels ........................ 46

- Tyre pressure ........................................................ 47

- Front Wheel removal ........................................... 47

- Front Wheel assembly ........................................ 48

- Rear wheel removal ........................................... 49

- Rear wheel assembly ......................................... 50

- Adjustment - Clutch ............................................. 51

- Drive Chain tension ...................................... 51

- Checking Rear Brake Pedal height .......... 52

- Rear Brake Pedal height Adjustment ....... 53

- Chain Lock Fitment ....................................... 53

- Adjustment of Gas Filled Shockabsorber ..... 54

- Removal of Battery on Vehicle ......................... 55

- Battery Maintenance .......................................... 55

- Assembly of Batte ry on Vehicle ........................ 56

- Changing Electric al Components ................... 57

- Head Lamp bulb r eplacement .................. 57

- Tail Lamp bulb replacement ..................... 59

- Trafficator bulb replacement .................... 59

- Fuse ................................................................... 60

- Blade Fuse usage List ................................... 60

- Air Filter element cleaning / replacement .... 61

CONTENTS

WASHI NG PROCEDURE .................................................. 62

- Precautions ........................................................... 62

- After Washing ....................................................... 62

STORAGE PRECAUTION ................................................. 63

- Preparing the motorcycle for reuse ................ 64

LONG TRIP PRECAUTIONS ............................................. 65

- Checks prior to the commencement .............. 65

- Checks after e very 1500 kms ............................ 65

- Items to be carried .............................................. 65

CARING FOR MILEAGE .................................................. 66

COMPLETE WIRING DIAGRAM - BULLET 500 ............. 68

TROUBLE SHOOTING ...................................................... 69

- Engine fails to start ............................................. 69

- Engine misfiring ................................................... 70

- Engine starts, but runs irregularly & stops .......... 71

- Poor pickup ........................................................... 71

- Whit e / blu e smoke .............................................. 72

- Engine over heating ........................................... 72

- Excessive fuel consumption .............................. 72

- Igni tion knock ...................................................... 73

- Brakes poor ........................................................... 73

- Vehicle wobbles ................................................... 74

- Elec tricals .............................................................. 74

- Electric Start .......................................................... 76

WARRANTY TERMS & CONDITIONS ............................. 77

EMISSION WARRANTY .................................................... 79

AL L INDIA RO AD SIG N S ... . .... . .... . ... . .... . ... . .... . ... . 83

FREE SERVICE COUPONS ............................................... 84

PAID SERVICE / MAINTENANCE RECORD ................... 93

REGIONAL & AREA OFFI CE S ... .. .. .. .. .. .. ...... .. .. .. .. .. .1 01

LOG BOOK ............................................................... 102

NO TES .... ... . ... ... ... ... ... ... . ... ... ... ... .... ... ... ... . ... ... ... .10 7

ANNE XU RES

- Vehicle Installat ion Form

- Pre-Delivery Inspection Report (PDI)

- Bike Installation Confirmation By Customer

- Form 22

PERSONAL & VEHICLE INFORMATION

Name

Door No./Street

Locality

City State Pin

Contact Nos. Res: Off: 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.

Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, grease etc. used for all free services are chargeable to the customer.

1st Service 4th Service2nd Service 3rd Service Date of Service Kms Covered

Servicing Dealer ’s / ASP Name, Address

Dealer / ASP

Rubber Stamp

NO TE

Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

SAFE OPERATING RULES

n Before operating your new motorcycle, it is your

respons ib il it y to caref ul ly read and follow the

operating and mainte nance instr uctions detailed

in t h i s m an ua l f o r y o ur o w n s afe t y, y our

motorcycle and that of others.

n Know and respect the rules of the road. Be a safe

rider for your own safety and for other road users.

n Before starting the motorcycle, check for proper

operation of brakes, clutch, gear shifter, handle

bar controls, tyre pressu res, fuel and oil levels.

WARN ING

Royal Enfield cautions you against the use of

certain nonstandard parts such as aftermarket and

custom made extended front forks or suspensions,

whic h may ad ver sely af f e c t pe r f o r m a n c e an d

handling. Removing or altering original parts may

adversely affect perfo rmance and could result in an

accident causing serious injury.

n Use only genuine Royal Enfield spare parts and

approved accessories. Use of other manufacturer’s

performance parts may affect the performance of

your motorcycle and render the motorcycle void of

warranty. See your Royal Enfield dealer for details.

n Whene ve r ref uel lin g your moto rcyc le, ple ase

exercise utmost caution and carefully observe the

following rules :

H DO NOT smoke and please ensure that there

are no op e n f l a m e s o r sp a rks nea r t h e

motorcycle, when refuelling OR ser vicing the

fuel system.

H Switch OFF mobile phones and othe r hand

held electronic devices / gadgets.

H Open the fuel filler cap slowly.

H Refuel in a well ventilated area with the engine

turned off.

SAFE OPERATING RULES

H DO NOT fill the tank to its brim. Please fill fuel

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).

WAR NING

Pe t r o l is ex t r e m e l y f l a m mable an d hi ghly

explosive. Use care when handling Petrol. Always stop

the engi ne whe n refu ellin g or ser vicin g the fuel

system. Do not smoke or allow open flames or sparks

near Petrol. Do not store motorcycle with Petrol in

the tank, within the home or garage where open

flames , pilot light s, spark s or elec tric mot or s are

present. Inadequate safety precautions could cause

an explosion or fire which could result in damage to

property, serious injury.

n A new motorcycle must be operated according to

the special break-in-procedure. See BREAK-IN-THE FIRST 500KM section.

n Operate motorcycle only at moderate speeds and

out of traffic until you have become thoroughly fam i l i a r w i t h it s o p era t i o n a nd h andl i n g characteristics under all conditions.

n DO NOT exc eed the legal speed limit or drive too

fast for existing conditions. Always reduce speed when poor driving conditions exist. High speed inc reases the influen ce of any other condition affecting stability and increases the possibility of loss of control.

NO TE

If you are an inexperienced rider we recommend that you obtain formal training on correct motorcycle riding techniques and become thoroughly familiar with the operation of your particular motorcycle. New ri d e r s s h o u ld ga in exp e r i e nce und e r v a r i o u s conditions while driving at moderate speeds.

SAFE OPERATING RULES

WARN ING

Avoid overspeeding and never travel over the speed limit. Excessive speed may cause loss of control and coul d re su lt in an acciden t causing serious injury.

n DO NOT exceed >110 km/h solo riding. n DO NOT exceed >90 Km/h when carrying a pillion

or c argo.

n Pay strict attentio n to road surfaces and wind

co ndi t ion s. An y two wh eel e r veh icle may be subject to the following upsetting forces :

H Wind blasts from passing trucks. H Rough uneven road surfaces. H Slippery road surfaces.

These forces may affec t the handling characteristics of your motorcycle. If this happens, reduce speed and gu i d e th e mo t o rcycl e wi t h a rela x e d gr i p to a controlled condition. Do n ot brake abruptly or force the handlebar.

n Operate your motorcycle defensively. Remember,

a motorcycle does not afford the same protection as an automobile in an accident. One of the most comm on acc ide nt situa tions occ urs when the driver of the other vehicle fails to see or recognize a mo t o r c yc le an d tu r n s into th e o n c o m i n g motorcyclist.

n Wear an approved helmet, clothing, and foot gear

suited for riding a motorcycle. Bright OR light colo rs are bes t fo r greater visibil it y in traffic , especially at night. Avoid loose, flowing garments and scarves.

n Whe n ca r r y i n g a p i l l ion r ide r, i t i s y o u r

responsibili ty to instr uct them on proper riding procedures.

n DO NOT allo w oth e r in d i v idual s , un d e r an y

circumstances, to operate your motorcycle unless you know they are experienced, licensed riders and are thoroughly familiar with the operating conditions of yo ur motorcycle.

SAFE OPERATING RULES

WARN ING

Ma i n t ain t he re comme n d e d ty r e pre ss u r e .

En sure the fr o nt and re ar whee l s are corr e ctly

aligned and the tyres are seate d evenly & properly

in the rims. Check for correct tightness of the spokes

in the ri ms. Insp e ct yo u r tyr es per iod ical ly an d

replace tyres with approved tyres only. Failure to do

so can lead to improper balance, abnormal tread

we ar, poor hand li ng and could res ult in ser ious

injury.

WARN ING

Royal Enfield recommends replacement of any

tube / tyre punctured or damaged. In some cases

small punctures in the tread area may be repaired

from within the demounted tyre by your Royal Enfield

dealer. Speed should not exceed 60 km/h for the first

24 hours after repair and the repaired tyre should

Never be used over 90 km/h (applicable tube less tyre)

In emerg en cy situations, if a tem po rary repair is

made ride slowly with as light a load as possible until

the tyre is permanently repaired or replaced.

Failure to heed this warni ng could result in serious

injury.

n Safe motorcycle operation requires alert mental

judgement combined with a defens ive driv ing

attitude. DO NO T allow fatigue, alc ohol or drugs

to endanger your safety or that of others.

n Maintain your motorcycle in proper oper at ing

condition as per Periodical Maintenance Chart

(Re f Pa g e No.4 0 ) . Pa r t i c ular l y im por t a n t t o

motor c yc l e s t ability is pr o p e r tyre i n f l ation

pressure, tread condition. Pay strict attention to

loose and / or broken spokes, free movement of

steering system.

SAFE OPERATING RULES

WARN ING

DO NOT operate motorcycle with a loose, worn or damaged steering system, including the front and re ar susp ensio n syste m. Cont act you r deale r for repair of steering or suspension system. Damaged steering or suspension components may adversely affect handling which c ould result in serious injur y.

WARN ING

Reg ul arly i ns pect rear shock absorbers and front forks and look for leaks. Replace worn parts. Worn parts c an adversely affect stability and handling.

WARN ING

For your personal welfare, all the liste d ser vice an d maint e n anc e re c o mme n d atio n s shoul d be pe rfo rme d . La ck of regula r maint ena nce at the suggested intervals may affect the safe operation of your motorcycle, which could resu lt in serious injury.

WARN ING

Avoid any contact with the exhaust system. Wear clo th ing that w ill comp letely cover the legs whil e 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.

WARN ING

Exhaust ga s e s contains poison o u s carbon mo nox ide (CO.) and che mic als , known to cause serious health hazards.

WARN ING

Mo to rcycle bat t er ies con tain lead and lea d components, acids and chemicals known to cause seriou s hea lt h hazards. Exe rcise extr em e caution while h andling a battery. Wash hands tho rough ly whenever a battery is handled.

SAFE OPERATING RULES

WARN ING

Consult your Royal Enfield Dealer regarding any questions or problems that occur in the operation of your motorcyc le. Failure to do so may aggravate an initial problem, cause costly repairs, jeopardize your personal safety and could result in serious injury.

WARN ING

Use only genu ine Royal Enfield replac ement fasteners tightened to the proper torque. We caution you against the use of certain non standard parts such as after ma rket and cus to m made faste ne rs which may not have specific strength, finish and type req uirements to per form properly in the assembly and its environment . The use of any nonstandard parts, including faste ne rs , cou ld result in serious injury.

WARN ING

DO NOT exceed the Gross Vehicle Weight Rating of your motorcycle. The Gross Vehicle Weight Rating (GVWR) is shown on the information plate, located

on the frame Down tube. (GVWR is the sum of the we i g ht of the mo t o rcyc l e , ac cess o ries, an d th e maximum weight of the rider, passenger and cargo that may be safely carried.) Exceeding GVWR may lea d to instab ility of the motorcycle, which could cause an accident and result in se rious injury.

WARN ING

DO NOT tow a disabled motorcycle. The steering and hand ling of the dis ab le d motorcycle will be impaired due to the force of the towline. If a disabled mot or cycle must be transported, use a truck or a trailer. Towing a motorcycle may cause loss of control of the motorcycle in the front, leading to an accident resulting in serious injury .

WARN ING

DO NOT pull a tr ail er behi nd a mot o rcycl e. Tow in g a t r a i l e r ma y c a u s e r e d u c ed br ak ing efficiency, tyre overloading and unstable handling. Towing a trailer may cause loss of control of the mo torc ycle in the fr ont , lea ding to an ac cid e nt resulting in serious injur y.

RULES OF THE ROAD

n Be sure front & rear nu mber plates is installed in

the position specified by law and is clearly visible at all times.

n 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 :

H Dry H Oily H Icy H Wet

n Watch for loose debris, such as leaves, slippery

substances or loose gravel that can hamper the stability of your vehicle.

n DO NOT exceed the legal spe ed limit or drive too

WARN ING

Avoid exce ssive speed and never travel at a

speed faste r than the speed limit. Excessive speed

may c au se los s of contr ol of vehicle, w hich could result in death or serious injur y.

n Keep to the correct side of the road centre line

when meeting oncoming vehicle.

n Always sound your horn, actuate your turn signals,

and e x e r c i s e C A U T I O N w h e n pa s s i n g other vehicles going in the same direction. Ne ver try to pass another vehicle going in the same direction at street inter sections, on curves, or when going up/or dow n a hill.

n At street intersec tion giv e the right- of-way to the

vehicle on your left or right. DO NOT presume you have the right- of-way.

n Alw ays signal when preparin g to stop , turn or

pass.

n Wh i l e tu r n i n g ei ther ri ght or le ft, watch fo r

pedestrians, animals as well as vehicles.

n All traff ic signs , inc luding man ua l cont ro ls at

intersections, should be obeyed promptly. SLOW DOWN at traffic signs near schools and CAUTION signs at railroad c rossings.

RULES OF THE ROAD

n When intending to turn, signal at least 100 feet

(30.5 meters) before reaching the turning. Be close to th e cent er lin e (un l ess lo cal ru les re quir e otherwise), slow down and then turn carefully.

n Never jump a traffic light. When a

change is imminent from GO to STOP (or vice versa) at intersections, slow

Red

Yellow

down and wait for the light to change to green. Never run through a yellow

Green

or r ed traffic light.

n DO NOT leave the curb or parking area without

si gna ling. Be sur e you r way is cl ear to ent er moving traffic. A moving line of traff ic always has the right-of-way.

n Park your motorcycle on a firm and flat surface to

prevent it from falling over.

n Pr o t e c t y our mo t o r c y c l e ag a i n s t the f t . Aft e r

parking your mot or cycle, rem ov e Ignition key from switch and lock the stee ring head.

SIDE VIEW MIRRORS

Your motorcycle is equipped with convex mirrors and have a curved surface. This type of mirror is designed

to give a much wider view t o the rear than a flat mirror; however, c ars and other objects seen in this type of mirror will look smaller and fart her away than when se en in a flat mirror.

Use care when judging the size or distance of objects

seen in these mirrors.

NO TE

To help you establish the relative distance of vehicles behind your motorcyc le, adjust each mirror in such a way, that a small portion of your shoulder is visible and a large portion behind your motorcycle is seen clearly.

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 ................................... 26.1 BHP @ 5100 rpm

Max. Torque @ RPM ................................. 40.9 Nm @ 3800 rpm

Air Filter Element ...................................... Corrugated Paper Element

Fuel Supply ................................................ Carburetor with Throttle Position Sensor (TPS)

Engine Start ............................................... Electric / Kick

Engine Oil Capacity ................................. 2.75 Litres.

Lubrication ................................................ Wet Sump, Forced Lubrication

Engine Oil Grade ...................................... Royal Enfield 15W50 API SL Grade Engine Oil (JASO MA)

Cooling system .......................................... Natural Air Flow

Carburetor ................................................ UCD 33

TECHNICAL SPECIFICATIONS

IGNITION SYSTEM

Ignition syste m ......................................... TCI Unit, Multi Curve (Variable Ignition Timing)

Spark plug ................................................ WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10

Spark plug Ele ctrode gap ..................... WQR8DC 0.80 to 0.90 mm

.............................................................. UR6DC 0.70 to 0.80 mm

TRANSMISSION

Clutch ......................................................... Wet Multiplat e (7 Plates Clutch)

Primary drive ............................................ Duplex Chain

Primary Drive Ratio ................................. 2.15 : 1

Gear box .................................................... 5 Speed Constant Mesh

Gear shift pat tern .................................... 1 - N - 2 - 3 - 4 - 5

Gear Ratios ............................................... 1st-3.06:1 2nd-2.01:1 3rd- 1.52:1 4th-1.21:1 5th-1:1

Secondary Drive (F.D. Sprocket) ........... 18 Teeth

Final Ratio ................................................. 2. 11 : 1

Drive C hain links ..................................... 102 links

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 ..................................... 12V, 21/5 W

Turn signal ................................................ 12V, 10W - 4 nos.

Pilot lamp .................................................. 12V, 2 W - 2 nos.

Speedometer lamp ................................. 12V, 3.4 W - 1 no.

Turn signal / High beam indicator ...... 12V, 1.7 W - 2 nos.

Neutral Indicator ..................................... 12V, 1.7 W - 1 no.

Horn (Dual) ............................................... 12V, 2.5 Amp (Max.) X2

Starter Motor ............................................. 12V, 0.9 KW

WAR NI N G

Using bul bs / other electrica l gadgets other than specif ied r ating may lead to over load in g / errati c be h avi o ur / pre matu r e fai l ure of electri cal sys tem.

Mod ific ations on the b ike which ar e not approved b y Royal Enfield ma y not only disqualify for warranty, but also affects perf ormance of the bike .

TECHNICAL SPECIFICATIONS

CHASSIS

Frame ......................................................... Tubular Frame

Tyre size ..................................................... Front: 90 / 90 - 19” - 52 P Rear: 120 / 80 - 18” - 62 P

Tyre pressure ............................................ Front- Solo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI)

.............................................................. Rear- Solo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.25 Kg/cm2 (32 PSI)

Fuel tank capacity .................................. 13.5 Litres ***

Reserve capacity ..................................... 2 Litres (approx.)

Dead stock of petrol (unusable fuel) .. 0.75 Litres (approx.)

Suspension ................................................ Front: Telescopic, 130mm Travel

.............................................................. Rear: Twin gas charged shock absorbers, 80mm travel

Front fork oil capacity ............................ 195 ml per leg

Front fork oil .............................................. 1F Endurance (or Royal Enfield) fork oil

Brakes ......................................................... Front : Hydraulic 280 mm Ventilated Disc

.............................................................. Rear : Foot Operated 153mm Single Lead Internal expanding

Brake oil capacity ................................... 60 ml

Brake oil grade ........................................ DOT 3 or DOT 4

***Fu e l ta n k i s no t a me a s u r i n g inst rument. The capacity of tank may var y sl ightly from specifie d value.

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 clearanc e ................................... 135 mm

WEIGHTS

Kerb Weight (with 90% Fuel) .................. 193 Kg

Max pay load ........................................... 172 Kg

NO TE

1. Values / Dimensions given above are for your guidelines only.

2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.

VEHI CLE IDENTIFICATION NUMBER - DETAILS

FRAME NUMBER

Punched on steering head tube RH side.

ENGINE NUMBER

Punched on top of the engine LH side.

KEY PARTS LOCATION

TOP VIEW

1. Turn signal switch

2. Horn button

3. Clutch lever

4. Day flash switch

5. Head lamp dip switch

6. Ignition switch

7. Speedometer

8. Front brake lever

9. Accelerator

10. E-Start Switch

11. Fuel tank cap

12. Rear View Mirror

KEY PARTS LOCATION

RIGHT SIDE VIEW

1. RH Trafficator Front

2. Starter Motor

3. Brake Pedal

4. Kick Starter Lever

5. Airfilter Box

6. RH Trafficator Rear

KEY PARTS LOCATION

3 4 5

LEFT SIDE VIEW

1. Trafficator Front LH

2. Spark Plug

3. Battery Cover

4. Electricals Box LH

5. Rear Shock Absorber

6. Trafficator Rear LH

7. Side Stand

8. Centre Stand

9. Gear Change Lever

10. Horn

OPERATION OF CONTROLS

IGNITION SWITCH

OFF

STEERING LOCK

Turn key clockwise to lock.

Lock the steering when leaving

bike parked.

Turn key ant i clockwise to u nlock.

CAUTIO N

Prot ect yo ur motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head.

Turn handle b ar to extreme left, before attem pting to lock steering.

Do NOT lubricate barrel locks with petro leum based lubricants or graphite. Inoperative locks may re sult in damage to your vehicle.

OPERATION OF CONTROLS

FUEL TANK CAP

n Turn key

clockwise

to open

n Press cap to lock with key in position

NO TE

Ke y c a n be remov e d onl y in l o c k e d position.

SIDE BOX

AIR FILTER BOX RH

Turn Key anti-clockwise to open

SIDE BOX LH

Turn Key anti-clockwise to open, it c ontains Tools Kit & Fuse

NO TE

n Key is common for ignitio n, petrol tank cap, steering lock,

side boxes and battery cover.

n Key for fuel tank and tool boxes can be removed from the

lock only in locked position.

OPERATION OF CONTROLS

HEAD LAMP SWITCH

OFF

Pilot Light ON

Head Light ON

DIP SWITCH

Low beam

High Beam

HEAD LAMP DAY FLASH

Press for

Headlight Flash

OPERATION OF CONTROLS

ENGINE KILL SWITCH

Run

Stop

HORN

Press

TURN SIGNAL SWITCH

Left

OFF (Push to off)

Right

OPERATION OF CONTROLS

ENGINE START SWITCH

Press

BATTERY BOX

Turn ant i clockw is e to open

FUEL TAP

OFF

Turn knob to horizontal position

Main ON

Turn knob downward position

Reserve ON

Turn knob upward position

PRE OPERATIONAL CHECKS

A careful c heck of the following must be carried out eve ry time before rid ing and speciall y after long per i o d s o f sto r a g e to de t e r m i n e if ad d i t i o n a l maintenance is necessary.

1. Tyres for cor rect pressure, abrasions or cuts.

2. Rear chain for proper tension.

Drive Chain

Clutch

3. B r a k e s , s t e e r in g

a n d t h r ot tl e f o r

responsiveness.

4. Cable for fraying or

cr im p i ng and fr e e

operation.

5. Engine oil level.

MAX

MIN

6. Wh e e l sp o k e f o r

proper tightness, no

breakage .

Spokes

7. Headlamp, tail lamp, brake lamp and indicator

lamps for proper operation.

WARN ING

For you r personal welfare and safety, all the poin t s mentione d above sh o u l d be performed per i o d i c a l l y. Fa i lure to do so, ma y af f e c t saf e operation and damage you r motorcycle and could result in an accident causing serious injury.

RUNNING IN

Proper running-in i s ver y 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. During the first few hundred kms, the various parts in the engine wear and polish themselves to the correct operating clearances. Driving with prolonged full throttle operation, or any high speed conditions might result in excessive heating of the engine and cause abnormal wear of the moving parts and hence must be avoided.

1. 0 - 500 Kms :

The reco mme nde d speeds for the first 500 Kms is be l o w 5 0 K m p h . D u r ing this per i o d a v o i d oper at i n g the mo t o r c ycle wi t h full t h r o t t l e opening. Stop the motorcycle for about 5 to 10 minu tes to let it cool down, after every hour of ru n n i n g. Var y th e sp e e d of the motorcycl e regularly d uring running but avoid using the motorcycle above ½ throttle opening position.

2. 501 - 2000 Kms.

The reco mm e nd ed spee d is below 80 Kmph .

Avoid d ri ving the motorcycle with full throttle op e n i ng. Vary the speed of the mo t orcyc le regularly but avoid using the motorcycle abo ve 3/4 throttle opening position.

3. 2,001 kms and above

Avoi d prolo ng ed fu ll- th rot t le ope r ati on. Vary speed occasionally.

CAUTIO N

After cove ring the first 500 kms. please replace the engine oil and oil filter element.

Royal Enf i e l d en g i nes are air- c o o l e d and consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature. Extended periods of idling may over heat the engine, resulting in serious engine damage.

DO NOT run the engine at e xtremely high RPM with clutch disengage d or transmission in neutral as it can cause serious engine damage.

An engine running long distances at high speed must be given close attention to avoid over heating and possible engine damage.

STARTING

STARTING PROCESS (KS / ES)

n Turn fuel tap to

‘ON’

n Use ch o k e in co l d

condition

n Switch on ignition.

n En s u r e Engi n e st o p

sw i t c h is i n “RUN ” position

n Ensu re the sid e and

main stands ar e in released position

n Ensure that gears are

in neutral and neutral lamp i s gl o w i ng i n cluster box.

CAUTIO N

Do not force the gear lever while attempting to shift to neutral . Move t he mot orcycle back & forth and simultaneously press gear lever to c ome to neutral. Ensure neutral indica to r light com es “ON”’ in the Speedometer.

WARN ING

Before starting engine, always shift gears into neutral.

STARTING

USING KICK START

n Sligh t l y c r a n k t h e

en gi n e f u r the r t i ll compression ea s e s over.

n Start the motorcyc le

wi t h a p ow e r f u l swinging kick.

n Rele ase the choke, if

applied

USING ELECTRIC START

n Press Clutch Lever.

n Pr e ss St arter Bu t ton

and r elease as soon as engine starts.

n Release the choke, if

applied

NO TE

n 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. To start the engine when it is in gear, pull clutch lever, press starter button and release as soon as the engine starts.

n Pre ss starter button and rel ease starter switch

once the engine starts.

n If the engine does not start on the first attempt in

cold climate, release the star ter button, wait for 30 se co nds before pressi ng the star ter butto n again.

GEAR SHIFTING

n Warm up engine

for 2 minutes - till

idling is consistent /

stable

GE A R SHI F T PATTER N 1 N 2 3 4 5

n Press clutch lever towards the hand grip. n Press gear pedal with to e to engage 1st gear. n Ge nt l y ope n th rot t l e and r ele a s e cl u t c h

simultaneously. If clutch is released suddenly, the engine may stall and cause a jerky start.

CAUTIO N

The clu t c h m u st be fu l l y d i s e n g a g e d be f o r e attempting a gear shift. Failure to fully disengage the clutch may cause a jerky s tart and / OR stalling the engi ne besi de s causing dam ag e to transmis sio n parts.

l Press t h e g e a r

pedal with heel to enga g e 2nd a nd higher gear.

l Follow the same

procedure for 3rd, 4th and 5th gear.

NO TE

Always move the motorcycle in first gear position only.

When engine spe ed decreases, whil e cli mbing a gradient or running at a reduced speed, shift to the appropriate lower gear to prevent the engine from stalling or straining to pull.

PARKING

PARKING VEHICLE ON CENTER STAND

n Select a firm, flat surface n Hold handle bar straight n Lower center stand, and ensure that both the legs

of the stand are resting evenly on firm ground.

n Apply pressure on the fulcrum lever on the center

st and and pull vehi cle bac kwards , gently as shown in pic.

PARKING VEHICLE ON SIDE STAND

l Select a firm, flat surface l Lower Side Stand and gently tilt motor cycle to the

left till it rests firmly.

WARN ING

Always park the motor cycle on a firm and flat

surface. Parking in a soft ground may cause stand to sink and the motorcycle to fall, causing injury to you or t o others and damage to the motorcycle parts.

TOOLS & FIRST AID KIT

S.No. Description Qty.

1. Tool bag 1

2. Screw driver 1

3. Tommy bar 1

4. Tubular spanner 1

5. Tool Spark plug 1

6. Double end spanner 10 X 12 2

3 4 5 6

5 6

S.No. De scription Qty.

1. Antiseptic cream 5 gms 1

2. Gauze bandage 5 cm x 2 cm 1

3. Elastic Gauze bandage 8 cm x 1 mtr. 1

4. Wash proof plaster 1.9 cm x 7.2 cm 2

5. Sterilized Gauze Swab 5 cm x 5 cm 2

6. Sterilized elastic plaster 7 cm x 6 cm 1

7. First aid kit pouch 1

NO TE

This Tool Kit is kept in Tool box. Refer Page No. 27.

RECOMMENDED LUBRICANTS

Engine Oil

Grade Royal Enfield 15 W 50 API SL Grade

Engine Oil (JASO MA)

Front Fork Oil

Grade 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

1. All customers are advised timely replacement of Engine Oil, Fork Oil & Brake Oil at the dealership /ASP. In case done privately, it is advise to reach old/used Oil to our authorised vendor through RE

Capacity 2.75 Ltrs. (with oil filter)

2.50 Ltrs. (during oil replacement)

Dealer/ASP

2. Similarly we advise for disposal of old/ use d Battery, Tube & Tyres as mentioned in above point No.1.

WARN ING

DO NOT sw itch oil br ands indis crim ina tel y bec a use some oil inter act ch emi cally wh en mix ed.

Use of inferior oils or non-detergent o ils can damage the engine.

DO NOT Mix DOT 3 & DOT 4 brake fluid together.

PERIODICAL MAINTENANCE

The maintenance schedule detailed here will help you to maintain your Royal Enfield motorcycle meticulo usly

and to get a long trouble free service. The sche dule provided herein is based upon average riding conditions

and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be

carried out.

The frequency of the maintenance must be shortened d epending upon the severity of the driving condition

OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads,

stagnant water etc., Contact a nearest Royal Enfield Authorised Dealer / Service Point for expert advice and to

carry out the periodical maintenance.

WARN ING

For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of regular maintenance at the suggested intervals may affe ct the saf e oper ation of your motorcycle causing the motorcycle to malfunction and stall abruptly resulting in an accident and cause se rious injury.

PERIODICAL MAINTENANCE

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

1 Engine Oil R I R I R I R I R I R

2 Engine oil filter paper element R R R R R R

3 Engine suction filter & secondary drain magnetic plug C C C C C C

4 Spark plugs (2 nos.) C,A C,A C,A C,A C,A R C,A C,A C,A C,A R

5 HT leads for crack I I I I I I I I I I I

6 Carburetor

7 Fuel Tap / Filter C C C C C C

8 Fuel tank C C C C C

9 Fuel hose / pipe I I I R I I I R I I I

10 Accelerator & Carburetor cable play adjustment A A A A A A A A A A A

11 Rubbe r hose, Air filter to Carburetor I I I I R I I I R I I

A : Adj ust C : Cle an D : D e-c arb on ise I : Inspe ct L : Lubri cat e R : Re place

DESCRIPTION

FREE SERVICE

whichever is earlier

Check level every 1000 Kms or earlier as required

Clean, Inspect and Tune at every 6000 Kms. of run

PAID SERVICE

Replace with minor kit

PERIODICAL MAINTENANCE

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

12 Rubber hose, Adaptor I I I I R I I I R I I

13 Exhaust system D

14 Air filter eleme nt C C C C R C C C R C C

15 Inlet / Exhaust valve seating I I

16 Clutc h lever free play Check & Adjust every 1000 Kms or earlier as required

17 Cylinder head (Combustion chamber) D

18 Hand levers & kick starter lever pivot Lubricate every 1000 Kms or earlier as requ ired

19 PAV pipes & hose clip I I C I C I C I C I C

20 Rear brake pedal pivot L L L L L L L L L L L

21 Battery terminals (apply petroleum jelly) C C C C C C C C C C C

22 Battery Electrolyte level I I I I I I I I I I I

23 Earth wire eyelet (behind batter y carrier) I I

24 Front Fork oil / leak I R I R I

A : Adj ust C : Cle an D : D e-c arb on ise I : Inspe ct L : Lubri cat e R : Re place

DESCRIPTION

FREE SERVICE

whichever is earlier

PAID SERVICE

PERIODICAL MAINTENANCE

No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

25 Rear Wheel Drive Chain

26 Rear brake pedal free play Adjust every 1000 Kms or earlier as required

27 Rear brake c am L L L L L

28 Steering ball races / play adjustment A L A L A

29 Spokes tightness & Wheel rim run out I I I I I I

30 Swing Arm pivot bush & spacer L L L R L

31 Tyre wear (Front & Rear) I I I I I I I I R I

32 Brake Fluid (Disc brake) I I I I R I I I R I I

33 Pivot-Side Stand, Center Stand, Pillion foot rest

A : Adj ust C : Cle an D : D e-c arb on ise I : Inspe ct L : Lubri cat e R : Re place

DESCRIPTION

Adjust for every 1000 Kms / Cle an, Lubricate &

FREE SERVICE

whichever is earlier

Adjustever y 3000 kms or earlier as required

L L L L L L L L L L L

PAID SERVICE

NO TE

For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultat ion with a Royal Enfield Authorised Dealer / Service Point.

MIN OR MAINTENANCE TIPS

The following minor maintenance can be carried out easily with simple tools. However, In case, if it is felt that the adjustme nts are best done by an expert, we recommend that the motorcycle be taken to a nearest Royal Enfield Authorised Dealer / Service Point.

CONTROL CABLES, HANDLE LEVER, PIVOTS, CENTER / SIDE STAND PIVOTS

Main & Side Stand Pivot

Lever Pivot

n Lubricate after using the motorcycle in rain, after

water wash or if used in dusty c onditions.

n Wipe the area free of dirt / grease.

n Apply a few drops of oil on the pivo ts.

ENGINE OIL LEVEL INSPECTION

MAX

MIN

n Place motorcycle on its cent er stand on a firm

surf ace.

n Warm up engine for a few minutes & switch off.

n The level is correct if the oil level is in the middle

of the oil level window.

n Top up with recommended oil if required.

MIN OR MAINTENANCE TIPS

ENGINE OIL CHANGE

Seco nda ry Drai n Plu g

Primary Drai n C ap

Primary Drai n Bol t

(Refer Periodical Maintenance Chart for frequenc y)

n Place motorcycle on its center stand on a firm flat

surf ace.

n Start e ngine and warm up for 2 minutes. n Keep a clean tray below the engine. n Remove primary drain cap, to drain oil & clean

suction filter, magnet.

n Then remove secondary drain plug to drain oil &

clean the magnet.

n Finally remove primay drain bolt to drain the

complete oil.

TILT VEHICLE

RH & LH

n Remove the oil filter element on the Crankcase

Cover RH.

n Assembly 3 bolts and tighten them. Ensure ‘O’ Ring

and gaskets are taken seat properly.

n Allow the oil to drain by tilting the motorcycle to

both sides.

MIN OR MAINTENANCE TIPS

n Wash the primary and sec ondary drain plugs

along with suction filter thoroughly and refit on the crankc ase after all the oil is drained out.

n Soak a new oil filter element in the oil and refit

on the Crankcase Cover RH.

n Fill recommendedoil

to engine till the oil le vel is upto “M AX” level mark in the oil win d o w i n C rankcase Cover RH.

Max

Min

NO TE

Re pla ce oil filt er el eme nt when eve r oil is bein g replaced.

CAUTIO N

Filling up oil over MAX mark may cause smoke and / or loss of power. Do NOT allow oil level to fall below MIN m ark. Doing so may result in engine internal damage or malf uncton.

SPARK PLUG

Clea n i n g and adjusting gap (R efer Periodic al Maintenance Chart for frequency)

n Remove HT Lead and

th e spar k plu g from

M10

the c y l i n der h e a d us i n g the pl ug sp ann er an d tom my bar as shown in pic.

n Clean the insulator tip

and elect rodes of the

M14

plug carefully using a po i n t e d s c r a pe r o r spark plug cleaner.

n Set the gap between

0.70 to 0.80 mm for UR6DC & 0.80 to 0.90 mm for WQR8DC

n Refit the spark plug on

the cylinder head and connect H.T. Lead.

MIN OR MAINTENANCE TIPS

MIN

MAX

BRAKE FLUID

Check if oil is above ‘min’ leve l. To top up, remove cover with diaphragm and top up with either DOT 3 or D OT 4 as specified.

CAUTIO N

Please take care that it does not spill over any other parts of the motorcycle. Please wipe the spille d brake fluid immediately, if there is any spill over, using a soft cloth (preferably a wet cloth) to avoid damage to paint work or other parts.

Don’t mix DOT 3 & DOT 4 Brake fluid together.

INSPECTION OF TYRES AND WHEELS

n Insp ect the tyre pe rio dic all y for tre a d wea r,

cracks and cuts.

Minimum tread depth :

Front tyre : 1mm Rear tyre : 2 mm

n Check and remove stone, splinters, nails or other

particles embedded in the tyre treads.

n Bald spots / swelling may be caused by internal

damage. Replace the tyres, if defective.

n Replace tyres when the tread depth has reached

the minimum as specif ied.

n Periodically inspect wheels for spokes breakage

and wheel rim run out.

n Check prope r seating of the tyre beading on the

rim whenever the t yre is reassembled.

n Whenever a new tyre is installed, ensure rim and

spokes do not get damaged on acco unt of using wrong levers.

MIN OR MAINTENANCE TIPS

n Use only standard tyres & tubes inflated to correct

pressure.

TYRE PRESSURE

Frontt

Solo 1.41 kg/cm2 2.11 kg/cm2

(20 PSI) (30 PSI)

With Pillion 1.55 kg/cm2 2.25 kg/cm2

(22 PSI) (32 PSI)

Rear

WARN ING

Tyres, rims and air valves must be corr ec tly matched to wheel rims. See your Royal Enfield Dealer. Mismatching tyre, tubes, rims and air valves may result in damage to the tyre bead during mounting, allow tyre slippage on the rim and cause tyre failure.

FRONT WHEEL REMOVAL

n Place the vehicle on center stand

n Place a wooden block

the f r o n t e n d o f engine to support the vehicle.

n Dis c o n n e ct s p e e d o

cable.

n Loosen the pinch bolt

on the RH fork guide.

n Ho l d f ron t a x l e b y

sp ann e r and loose n axle nut then remove nut along with washer.

MIN OR MAINTENANCE TIPS

n Tap and remove the fr ont wheel spindle n Tilt the vehicle to RH Side and take out the wheel

along with speedo drive with bush & LH side spacer.

n Take out Speedo drive

and bush on the RH side as shown in pic.

CAUTIO N

Do not press the front brake lever when wheel is removed as this will re sult in the brake pads coming too far out of the brake caliper.

n Place a 4 mm thick wooden piece or cardboard

sheet bet we en the bra ke pads to avoid pads activation in the event the front brake lever is accidently pressed.

FRONT WHEEL ASSEMBLY

n Remove t he woo den piece / card board sheet

placed betwe en the brake pads.

n Pl a c e the bu sh

sp e e d o d r i v e i n po s iti o n and pl ace speedo drive over it.

n Ins e r t t he w h e e l

al o n g wi t h sp e e d o drive assembl y and LH space r bet wee n th e fr o n t fork end s en sur ing the brak e disc is lo c a t e d in be t ween the bra ke pads.

n Insert an d ta p t h e

fro n t wh e e l a x l e gently inside.

n Refit the washer and

tighten the nut firmly.

MIN OR MAINTENANCE TIPS

n Tighten the pinch bolt on the RH fork guide .

n Rotate the wheel and che ck for smooth rotation.

n Connect the speedo cable t o speedo drive unit

and rotate the wheel to check for proper working of speedo meter.

n Press brake lever 2 or 3 times to check front brake

efficiency.

NO TE

Ensure that the speedo drive is correctly located such that the cable can be connected without dif ficulty.

REAR WHEEL REMOVAL

n Place the vehicle on center stand on a firm and

flat surface.

n Note and mark the position of the chain adjuster

but t i n g w i t h th e stop per on the right side.

n Remove split pin and

cas tle nut on the RH side.

n Remove wheel spindle

fro m LH side al o n g wi th chai n adjust er, ta ki n g ca r e n o t t o drop the wheel collar and spacer from the LH side of the wheel.

n Tilt vehicle to RH side

and s l ide o u t r e a r wheel.

MIN OR MAINTENANCE TIPS

REAR WHEEL ASSEMBLY

n Ensure the four cush rubbers are in position inside

the rear wheel hub.

n Tilt vehicle to right

an d ins e r t wheel assembly betwee n the swing arms.

n Po s i t ion th e re ar

wh e e l wi t h cu s h rubber on the rear chain sprocket.

n Hold whe el coll ar

and s p a c e r i n position.

n Ass e m b l e th e

whe e l sp i n d l e al ong with ch a in ad jus ter fro m the LH side of veh icle an d gent ly ta p it through the wheel.

n Ensure that the chain adjuster knotch butts with

the stopper as appropriate when both the front & rear w heels are aligned.

n Ti g hten the ca st le

nu t fi r m l y a nd ensure that the hole on ax l e sh a f t an d the slot on castle nut ar e al i g n e d to enab l e s p lit p i n fitment.

n Fix the split pin.

CAUTIO N

Do not force the spindle into the wheel as the threads may get damaged. Tap it through the wheel gently.

WARN ING

Ensure the vehicle does not come off centre stand wh i l e a s s e mbli n g / dis a s s e m b ling t he w h e e l assembly. Failure to adhere could result in damage or serious injur y.

MIN OR MAINTENANCE TIPS

ADJUSTMENTS - CLUTCH

2 to 3 mm

Clutch Lever (free play 2 to 3 mm)

CLUTCH FREE PLAY ADJUSTMENT

n Loosen the cable outer lock nut (A).

n Turn the Nut (B) Clockwise to reduce the play or

Anticlockwise to inc rease the free play.

n Check free play 2 t o 3 mm at Clutc h lever pivot

on handle bar end.

n Tighten lock nut ( A) after adjustment is do ne.

DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM)

n Remove rear wheel

split pin.

n Lo o sen cas t le nut,

spindle nut, anchor nut and brake rod nut.

n Turn the RH adjuster

cam a s a ppr o priately, t ill 25 to 30 mm s l a c k n e ss i s achieved on the top run of the chain.

MIN OR MAINTENANCE TIPS

n Check brake pedal free play, If necessary adjust.

n Check that the front

and rear wheels are correc tly aligned.

n Turn the LH adjuster

cam appro pr iately, to a l i g n b o t h t h e wheels.

n Ch e ck an d ens u re

that the knotches on the cam are resting on t h e p i n i n the swi ng arm on both sides.

n Ap p l y b r ake a n d

tighten all nuts.

n Fi n all y Torq u e th e

anchor Nut.

CHECKING REAR BRAKE PEDAL HEIGHT

n Loosen the lock nut.

n Turn in or out the pedal stop pin bolt till the brake

pedal and front f ootrest are in the same he ight / level as shown in above pic.

n Tighten the lock nut

n Check for free rotation of rear wheel.

MIN OR MAINTENANCE TIPS

REAR BRAKE PEDAL PLAY ADJUSTMENT

20 - 30 mm

l Turn in or out the adjuster nut at the brake rod end.

The recommended brake pedal travel is 20-30 mm.

l Check that the brake is not binding and the rear

wheel rotates freely.

WARN ING

Please ensure brakes are adjusted to their maximum

efficiency. Inefficient brakes can cause an accident.

Please ensure adequate caution while applying brakes. Sudden application OR pressing the levers fully can caused the wheels to lock. This may cause the motorcycle to skid with possible los s of control and result in an accident causing. Brake shoes must be inspected for wear every 4000 Kms. If you ride under adverse conditi ons, (steep hills, heavy traffic, etc.) a more frequent inspection at 1600 Kms or less, is required.

CHAIN LOCK FITMENT

The open end of the chain link master lock to face opposite to normal direction of chain rotation as shown pic.

WARN ING

The fitment in wrong dir ection lock can lead to falling off of chain link thus disengaging the drive. Th is will lead to pot e nti all y ha zar dou s sit u ati on which, if not avoided, could result in serious injury.

MIN OR MAINTENANCE TIPS

ADJUSTMENT OF GAS FILLED SHOCKABSORBER

n The rear gas shock absorber is adjustable type i.e.,

the spring tension can be increased or reduced.

n Increase the spring tension for high load operation.

n Reduce the spring tension for low load operation.

n The adjuster provided on the bottom of the spring

has five knotches.

n Insert special ‘C ’ spanner on the bottom adjuster

and rotate to change knotch position.

n Turn the adjuster such that the adjuste r moves

up to increase the spring tension and vice versa to reduce the spring tension.

n Ad just both le ft ha nd an d righ t han d sho c k

absorbers so that the same knotch rests on the pin in both sides.

WARN ING

Ri d i n g t h e m o t o r cy c l e wit h t h e kn o t c h e s ad ju sted in dif fer ent pos iti ons can cau se los s of control and may lead to an accident.

Regularly inspect shock absorbers and front forks for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.

NO TE

Ensure no fouling of any accessories with rear shock ab s o r b er. Ch e c k for su ffici e n t ga p av ailab i l i ty bet ween the shock absorber and the attachments when the rear end of the motorcycle is fully loaded and the shock absorbers are fully compressed.

MIN OR MAINTENANCE TIPS

REMOVAL OF BATTERY ON VEHICLE

n Th e ve h i c l e i s

provided with 12V 14 AH batt ery.

n Unlock (turn the key

anti clockwise) and remove the battery cover.

n Remove t he batter y

holding two rubber straps gently.

n Pull out t he batte ry

and t urn , th e n disconnect both the te r m i n a l wire s (neg a t i v e a n d positive respectively)

n Take out the battery.

BATTERY MAINTENANCE

n The battery must be

periodically checked for

H Cle anline ss and

co r r o s io n fr e e terminals.

H Elec t r o l y t e level

mus t b e a b o ve “MIN” level.

H If electrolyte level

is l o w, remo v e caps and top up with distilled water only.

n Apply petroleum jelly

ove r t h e b a t ter y terminals to avo i d sulphation.

MIN OR MAINTENANCE TIPS

WARN ING

Always disconnect the negative (-) battery cable fi r st and th e n the Re d po siti ve (+) ca ble whi l e removing the battery connections.

NO TE

For chec king the batter y voltage and elec trolyte specific gravity, contact author ised Royal Enfi el d service or battery service centre.

CAUTIO N

n Do not use battery with low electrolyte level as

the bat tery internals cells w ill get damaged.

n Do not overfill the batter y elec trolyte level as it

will spill out through the overflow pipe and cause corrosion to vehicle parts.

n Use only distilled water meant for use in batteries

to avoid damage to battery.

n Elec trolyte should not be filled when the level is

betwee n minimum & maximum levels indicated in battery as “MIN” & “MAX”.

ASSEMBLY OF BATTERY ON VEHICLE

n Position the battery in the battery carrier such that

the negative terminal of the batter y is towards fuel tap.

n Ensure ignition switch is in ‘OFF ’ condition. n Connect the positive terminal (Red wire) first. n Connect the negative terminal (Black wire) next. n Smear the terminals with petroleum jelly. (Do not

use grease).

n Refit the rubbe r strap bracket to hold the battery. n Refit LH side panel.

NO TE

Clean the wire terminals free of corrosion and keep the terminals coated with petroleum jelly.

CAUTIO N

Connec t the +ve and -ve cables to the respective batt e ry ter min als. Failu re to do so may result in damage t o the motorcycle electric al system.

MIN OR MAINTENANCE TIPS

CHANGING ELECTRICAL COMPONENTS

HEAD LAMP BULB REPLACEMENT

n Loos e n th e he a d lam p

holdin g top scr ew. Then pu l l o u t he a d l a m p assembly.

n De tac h botto m lu g from

th e head lamp ho u sin g body.

n Dis c o n n e c t he a d l a m p

wi r e co n n e c tors Green, Ora n g e and Blue co l o r terminals.

n Remove rubber grommet

from t h e r e f l e c t o r Asse mb ly.

n Gent l y p r e s s t h e b u l b

holding ‘U’ clip from both the sides downwards and re lease it from refl ecto r slot as shown.

n Pull out head lamp bulb

and inspect its filament for fuse.

CAUTIO N

Ne ver to uch th e bul b with your fingers, Finger prints will etch the glass and decrease bu l b li fe. Alway s ho ld th e bulb with paper or clean dry cloth during handling.

MIN OR MAINTENANCE TIPS

ASSEMBLING THE HEADLAMP

n Refix the new head lamp

halo g e n bulb in t o reflector unit by locating the wide protrude on top side mounting.

n Fix bulb holding U clip into

re f l e c tor b o dy k n otc h , then press the both ends of clip and lock in its slot.

n Fit the rubber grommet.

n Connect the wire couplers

as mentioned below.

TOP SIDE: GREEN COLOUR RI G H T S I D E : B LU E C O LO UR

LEF T SIDE: ORANGE COLOUR

n Position the reflector ring

bottom lug into head lamp ca sing slo t and sl ide it , the n t i g hte n t h e top mounting screw.

NO TE

After connecting above said procedure, turn ignit ion switch to “ON” condit ion and then check, ensure that flash light w orking in HIGH BEAM mode.

If you use the bulb other than specified rating (12V 55/60W) may result in over loading electrical system lead to premature fa i l u r e or fr e q u e n t batte r y discharge.

MIN OR MAINTENANCE TIPS

TAIL LAMP BULB REPLACEMENT

n Remove the two nuts each

from RH & LH side of the rear number plate holder.

n Pu l l o u t Ta i l L a m p

as se m b l y a l o n g wi t h bracket and twist the bulb holder in anticlockwise to rem o v e bul b h old er assembly.

n Turn old bulb to remove

and replace with a new bulb.

n Refit the bulb holder and

turn clockwise to lock the bulb holder.

n Re f i t t h e t ai l la mp

wi t h b r a c k e t on t he reverse order of removal process.

TRAFFICATOR BULB REPLACEMENT

n Re m ove th e 2 scr e ws &

take out trafficator glass cover.

n Press bulb gently & Turn

anticlockwise to take out the bulb.

n Po s i t ion t h e new b u l b

insi d e th e ho l der, ensuring t hat the pins in the bulb, match with the slots in the holder.

n Pre ss the bulb and tu rn

clockwise to lock the bulb in the holder.

n Refit the trafficator cover

cut s l o t m a r k f acin g downwards and tight en the 2 screws.

Cut Mark

MIN OR MAINTENANCE TIPS

FUSE

n Open the LH tool box.

n Take out tool kit.

n Remove fuse holder

ru b b e r & l i f t fus e carrier top cover.

l Rep la ce the required fuse with the spar e fus e

available in the fuse carrier.

NO TE

Please e nsure to replace a spare fuse in the holder at the earliest opportunity.

BLADE FUSE USAGE LIST

Fuse No.

1 Blue Main Fuse (15A)

2 Red Ignition Fuse (10A)

3 Red Spare Fuse (10A)

4 Blue Spare Fuse (15A)

Color

Remarks

MIN OR MAINTENANCE TIPS

AIR FILTER ELEMENT CLEANING / REPLACEMENT

n Insert the key, turn

anti c l o k w i se to remove RH side air filter box lid.

n Lo o sen th e fi l ter

ho l d i n g n u t by 10mm spanner as shown in pic.

n Re m o v e t h e nut,

washer and cover air filter to take out air filter element.

n Tap the filter element

to re m o v e d u s t a s sh o w n a n d c lea n tho r o u g h ly b e f o r e assembly.

Clean both intake adaptors and duct as shown in pic.

n As sem ble the fil ter

element and cover in the reverse order of dismantling process.

n Please ensure proper

sealing of cover plate agai nst air fil ter element.

WASHING PROCEDURE

PRECAUTIONS

n Wash vehicle when the engine is cold. n Cover the silencer tail end and control switches with

suitable plastic bags and tie it firmly to prevent water entry into them.

n Remove igni ti on key and seal key hole us ing

adhesive tape.

n 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.

n Use low pressure jet of water to clean the entire vehicle. n Never spray water with great force on head lamp,

speedometer, trafficator lights, front and rear wheel hubs, electrical connections and wires, control cables, sparkplug, battery, etc.

n Use luke warm water and mild detergent on the

painted components to remove dirt, etc.

n Rinse vehicle thoroughly with plain water to remove

the detergent and wipe vehicle dry.

n If possible, use compressed air and blow off water

particles from the obscure areas of the vehicle, electrical connections etc.

AFTER WASHING

n Ensure, the vehicle is thoroughly dry by wiping with

a clean soft absorbent cloth or chamois leather.

n Remove all plastic bags and adhesive tapes. n Lubricate control cables, pivot and rear chain with

lube oil

n Polish the painted and plate d surfaces using

polishing wax.

n Start the bike allow engine to idle and warm up. n Drive the motorcycle slowly, applying both brakes

intermittently to dry up the brake shoes.

n Test brakes for full efficiency.

WARN ING

Observe warnings and cautions given on labels

of cleaning compounds.

When washing your motorcycle, be careful not to get the brakes, engine, mufflers or air cleaner etc., too wet.

STORAGE PRECAUTIONS

Incase you r Motorcycle is not going to be used for a

month or mor e, we advise the following precautions

to the taken.

n Carryout required repair / adjus tments on the

motorcycle.

n Wash the motorcycle thoroughly and lubricate as

per the maintenance chart.

n Start the engine, warm up for a few minutes and

switch off.

n Drain out the fuel comple tely from the fuel tank

and fuel lines.

n Remove spark plug. Pour in about 25ml of clean

engine oil through spark plug hole. Close the hole and cra n k en g i n e s e v e r a l ti me s and re f i t sparkplug.

n Clean rear chain thoroughly and apply a thin

film of lu be oil.

n Re m o v e b a t ter y f r o m t h e bi k e . C l e an the

terminals fre e of corrosion.

n Maintain electrolyte level between max or min

mark, by adding distilled water and wipe the batter y dry.

n Sto r e t h e ba tte r y i n a c o ol, dr y a n d w e ll

ventilated place.

n Do not place the battery in direct sun light, near

open flame or where temperature is above 40oC or below 0oC

n Cover the silencer with plastic bags to prevent

moisture entr y. Set the motorcyc le on its center stand.

n Apply anti rust solutio n on al l chrome plated

part s. Take care not to apply this solution on

rubber or painte d parts.

n Store motorcycle in a clean covered area free -

of moisture and keep it covered to prevent dust settling on it.

STORAGE PRECAUTIONS

PREPARING THE MOTORCYCLE FOR RE USE

n Remove anti rust solution from al l chrome plated

parts and clean the motorcycle.

n Inflate the tyres to the correc t tyre pressure.

n En s u re bat t e r y is fully cha rged an d pr oper

electrolyte level is maintained.

n Connect the battery.

n Lubricate all c ontrol cables and pivots.

n Check proper level of oil in engine.

n Fill fuel tank with fresh petrol.

n Check fuel line / hose for any cracks or cuts.

n Clean the air filter.

n Remove plastic covering from the silencer.

n Remove spar k plug on cylinder head and pour

in a few drops of engine oil. Cr ank engine a few

ti mes to lubr ica te cyli nde r walls and pis ton .

Clean spark plug and refit.

n Switch “ON” ignition switch.

n St ar t vehic le and war m up eng ine for a fe w

minu tes before riding the vehicle.

NO TE

Do not raise the engine rpm the moment it is started, but allow the engine to ru n at idling speed.

CAUTIO N

Proper long-term storage is important for the safe , tro u b l e -f r e e o p er at i o n o f y ou r R o y a l E n fie l d motorcycle.

LONG TRIP PRECAUTIONS

CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY

n Se r v ice the mot o r c ycle thor o u ghly at Ro y al

Enfield Authorised Dealer / Service Point as per periodical maintenance chart. (Ref. Page No. 40, 41 & 42)

n Sufficient quantity of petrol in the fuel tank for

the journey planned.

n Check and correct tyre pressure if necessar y.

CHECKS AFTER EVERY 1500 KMS OF RUN

n Tightness of all fasteners.

n Tyre tread condition and wear of tyres.

n Battery condition and elect rolyte level.

n Correct oil level in engine.

n Working of all lights and horn.

n Proper drive chain tension.

ITEMS TO BE CARRIED

n Tool kit.

n First aid kit.

n Bulbs for Headlight, Trafficator light , Rear Tail

Lamp and Fuse (10 & 15 Amps).

n Accele rator, Clutch and Speedo Cable.

n Rear chain master link lock assembly.

n Spare tube, puncture repair kit - cold vulc anising

type.

n Foot operat ed Air Pump.

n Insulation tape.

n Spark plugs (M14 & M10), Fuel hose.

CARING FOR MILEAGE

STOP THE DROP THAT LEAKS

n Petrol leak at a rate of one dro p per min ute

accumulates to 5,25,600 drops a YEAR! That is, 35 ltrs of Petrol.

n Petrol leaks cause raw petrol smell. Get the leaks

arrested immediately.

USE RECOMMENDED FUELS AND OILS ONLY

n Wrong grade or adulterated petr ol does not burn

fully and resu lts in heav y smoke , high r ate of ca r b on deposi t i on in cyl i n der an d ex h a ust system and low mileage.

n Wrong grade and inferior quality oils do not

lub r i c a t e we l l . T h e movi n g p a r t s wear prematurely.

n Always use r ecommended fuel (unleaded > 87

octane petrol) and oils only.

RIDE AT COST EFFECTIVE SPEED

n Cost effective speed (in top ge ar) is 45 to 50 Km

per hour.

n Both lower and higher road speeds cause low

kilometers per litre of pe trol.

PERFORM PREVENTIVE MAINTENANCE AS PER RECOMMENDATIONS

REGULAR PREVENTIVE MAINTENANCE ENSURES

n Correc tly inflated tyres. n Fasteners tightened to correct torques. n Freely moving engine & transmission components. n Properly tuned and adjusted engine .

CUT OFF NEEDLESS LOW IDLING

Ten minutes of low idling wastes 70 ml. of petrol. So cut off the engine when you know you have to wait for one minute or more.

STOP

n Revving : Ten revvings wastes 20 ml. of petrol

n Rac in g s tart s : Ten racing starts wastes 150 ml.

of petrol.

CARING FOR MILEAGE

n Sudden accel er ation : Ten sudden accelerations

wastes 100 ml. of petrol.

STOP BRAKE RIDING

n Brake riding pushes the brake shoes to come in

contac t with revolving drum. To overcome the resulting frictional load, engine burns additional petrol.

Result : Low mileage, loss of power, faster wear of brake shoes and drum.

NEVER CLUTCH RIDE

n Clutch riding slips the clutch & engine drive does

not get tota lly transferre d to the rear wheel. Besides low mileage, clutch riding ends up with burnt friction plates of clutch, loss of power and engine overheating.

AVOID FREQUENT BRAKING

n Br a king ar r ests th e ro a d spee d . Mo torc y c le

momentum is reduced. Additional fuel is burnt for subsequent acc eleration.

n For better mileage, use front and rear brakes

simultaneously when absolutely needed. Control vehicle speed with throttle and gear like smart riders alw ays do .

AVOID OVER LOADING

n Over loading tyres the e ngine, wears the part s

faster and reduces mileage.

PARK YOUR VEHICLE IN SHADE WHEN NOT IN USE

n Pet rol is hi ghly vola tile . It evap ora tes unde r

no r m a l atm o s p h e r ic tem p e r a t ure . T he evaportion increases with temperature. Pre vent this loss by alw ays parking your vehicle under shade.

n Too few Kms running per day allows more time

for evaporation affecting the mileage.

COMPLETE WIRING DIAGRAM - BULLET 500

NOTE : Co mplete Wiring D iagram is att ached on this pa ge.

VEHICLE STARTING PROCEDURE

BA SI C GUIDELINES TO BE FOL LO WED “ FOR ALL EL EC TRIC START V EHICLES”

1. In cold condition of the engine or for initial start, it is advised to use electric start (ES) only.

2. Apply choke in c old start condition. (ambient temperature <25° C)

3. DO NOT ATTEMPT – “HALF START” BY CASUALLY PRESSI NG ELECTRIC START BUTTON.

4. PLEASE P RESS AND HOLD ELECTRI C START BUTTON FOR ATLEA ST 3 SECO ND S CONTINUO USLY FOR

THE CRANKI NG OR UNTIL THE ENGINE FIRE S AND SUSTAINS, WHICHEVER IS EARLIER.

5. If engine doesn’t start in the first attempt, rele ase the ES button and repeat the above Procedure.

6. It is advised no t to apply ex cessive throttle during starting.

COMPLETE WIRING DIAGRAM - BULLET 500

COMPLETE WIRING DIAGRAM

BLA DE FUS E L IST

Fuse 1

T C I F U S E

IG N I T IO N L O A D S

Fuse 2

Fuse 3

Fuse 4

TROUBLE SHOOTING

CAUSES REMEDIES

I. E NGINE FAI LS TO STA RT

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.

5) Fuse blown ............................................................................... Check and Replace (Ref. Page No. 60)

6) Carburetor passage & jets blocked ..................................... *Dismantle carburetor & clean jets

.................................................................................................... / passages

7) Carburetor float stuck in closed position ........................... Ensure correct movement of float

8) Spark plug cap / lead not connected ................................. Fix cap / lead firmly

9) Loose HT connections ............................................................. Fix connections firmly

10) HT Lead Damaged ................................................................. *Replace HT Lead

11) Spark plug electrode dirty / fouled ..................................... Clean spark plug & Reset gap.

12) Spark plug insulation cracked ............................................. Replace spark plug

* Contact Authorised Dealer / Service Point

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 ........................................................................ *Adjust clutch cable free play

II. EN GINE MI SFIRING

1) Water in petrol tank/carburetor ........................................... *Clean carburetor / petrol tank. Fill tank

.................................................................................................... with fresh petrol.

2) Leak through intake hose ..................................................... Tighten rubber hose suitably.

.................................................................................................... Replace if necessary

3) Loose spark plug cap ............................................................ Fix cap / lead firmly

4) Spark plug fouled/insulation broken .................................. Clean / reset gap or, replace.

5) Poor Compression ................................................................... *Auto decompressor sticky or not working

6) Loose electrical connections / coupler ............................... *Battery cable / fuse carrier / coils / TCI unit / Switch

* Contact Authorised Dealer / Service Point

TROUBLE SHOOTING

CAUSES REMEDIES

III. ENGINE STARTS, BUT R UNS I RREGULARLY & STOPS

1) Faulty fuel supply ................................................................... Clean the fuel line / tap / vent hole

2) Very low idling speed ............................................................. Increase idling speed

IV. PO OR PICKUP

1) Accelerator cable free play excessive ................................ Adjust cable free play

2) Faulty fuel supply .................................................................... Clean the fuel line / tap / vent hole

3) Choked air filter ...................................................................... Clean / Replace air filter

4) Loose carburetor mounting .................................................. Tighten clamps firmly

5) Brakes adjusted too tight ....................................................... *Re-adjust properly

6) Rear chain adjusted too tight ............................................... *Re-adjust properly

7) Clutch Slipping ........................................................................ *Adjust clutch cable free play

8) Under inflated tyres ................................................................ *Inflate to correct pressure

* Contact Authorised Dealer / Service Point

TROUBLE SHOOTING

CAUSES REMEDIES

V. WHI TE/BLUE SMO KE

1) Oil level in tank above the middle line in the ................... *Check and drain excess oil

oil level window

2) Worn out valve oil seal ........................................................... *Check / Replace

3) Worn out piston ring / cylinder ............................................. *Check / Replace

VI. EN GINE OV ERH EATI NG

1) Cylinder fins not clean ........................................................... Clean the cylinder fins at regular intervals

2) Clutch slipping ........................................................................ *Check and correct

3) Suction leakage ...................................................................... *Check and correct

4) Incorrect carburetor adjustments ........................................ *Check and correct

VII. E XCESS IVE F UEL CON SUM PTION

1) Fuel leakage ............................................................................ *Check and rectify

* Contact Authorised Dealer / Service Point

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 .................................................................... *Auto decompressor sticky or

.................................................................................................... not working properly

6) Under inflated tyres ................................................................ Inflate to correct pressure

VIII. IGNIT ION KNOC K

1) Carburetor adjusted too lean ............................................... *Check and readjust

2) Suction / intake system leakage ........................................... *Check and correct

IX. BR AKES POOR

1) Not adjusted properly ............................................................ *Adjust properly

2) Oil / grease on lining or drum or disc ................................. *Clean and refit

* Contact Authorised Dealer / Service Point

TROUBLE SHOOTING

CAUSES REMEDIES

3) Linings worn / Uneven wear ................................................. *Replace linings

4) Drum scored / Uneven wear ................................................. *Rectify or Replace drums

X. VEHICLE WO BBL ES

1) Wheel rim runout .................................................................... *Rectify

2) Loose / Broken spokes ............................................................ *Tighten / Replace spokes

3) Tyres not fitted correctly ........................................................ *Refit tyres correctly

4) Wheels misaligned ................................................................. *Ensure proper alignment

5) Under inflated tyres ................................................................ Inflate to correct pressure

XI. ELECTRICAL S

Bulbs do not glow

1) Loose / improper connection ................................................ *Check and correct

2) Bulb fused ................................................................................. *Replace bulb

3) Fuse blown ............................................................................... Replace fuse

4) Switch defective ...................................................................... *Replace switch

* Contact Authorised Dealer / Service Point

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 ............................................................................... Replace fuse

Trafficators not working

1) Loose / improper connections .............................................. Check and correct

2) Bulb fused / Fuse blown ......................................................... Replace

3) Switch defective ...................................................................... *Replace

4) I.C. Flasher defective .............................................................. *Replace

Brake light remains “ON”

(1) Switch not adjusted properly ................................................ *Adjust switch properly

(2) Switch sticky ............................................................................. *Replace switch

* Contact Authorised Dealer / Service Point

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 ....................................................... *Check & Replace

(5) Malfunctioning of clutch switch ........................................... *Check & Replace

(6) Malfunctioning of Starter switch .......................................... *Check & Replace

(7) Battery discharge .................................................................... *Check & Recharge

(8) Motor not working .................................................................. *Check & Replace

(9) Battery not fully charged ....................................................... *Check & charge

(10) Failure of sprag clutch ........................................................... *Check & replace

* Contact Authorised Dealer / Service Point

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. RE will replace or repair defective part / parts at their Authorised Dealer / Service point, free of charge within

a period of 12 months from the date of sale (date of Installation) or 10,000 kms whichever occurs earlier.

2. The warranty is applicable only to first registered owner.

3. The warranty shall be applicable only if all the free services are availed at the respective period / kilometer

range as per the schedule given in the owner’s manual from Authorised Dealer / Service Point.

4. During the warranty period, RE’s obligations shall be limited to repairing / replacing free of charge such part

or parts of the vehicle, which on examination to have manufacturing defect. Such defective part / parts which have been replaced becomes property of RE.

5. Cost of oil, oil filter, fuel and other consumables are chargeable to the customer.

6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken up with respective

manufacturer or their authorised agents in the area directly by customer. RE shall not be liable in any manner to replace them though their Dealers will provide assistance in preferring such claims on their manufacturer.

7. Warranty shall not apply to:

(a) Normal ageing, detoriation or rusting of plated parts paints coat, rubber parts, soft items, glass items,

plastic parts etc.

WARRANTY TERMS & CONDITIONS

(b) Components like fuel line, oil filter element, control cables, brake pads, brake shoes, clutch plates, which

are subjected to normal wear and tear.

(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.

(g) Parts damaged due to accidents, collision, abuse etc.

(h) Irregularities not recognized as affecting the quality or function of the vehicle such as slight vibration, oil

leakage, discoloration of exhaust bent pipe / silencer / soft, hard shock absorber etc.

(i) Defects arising from fitment of unauthorised / additional Electrical loads.

(j) Vehicle serviced / repaired at unauthorised service points.

(k) Vehicle used for competition / racing.

(l) Electrical component like bulbs, fuses etc.

(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine tune up and

other such adjustments

8. RE reserves the right to finally decide on all warranty claims

9. RE reserves the right to make changes in Design of the vehicle without any obligation to install these changes

on previously supplied vehicles.

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. or 36 months, whichever occurs earlier, from the date of sale to the first customer and is in addition to and parallel to the warranty policy, conditions and obligations laid down in the Owner ’s Manual.

Royal Enfield further warranty that if on examination by its Authorised Dealer / Service Point, the motorcycle fail to meet the specified emission standards, then the Authorised Dealer / Service Point shall take necessary corrective measures and shall at its sole discretion, repair or replace free of charge such components of the emission control system to meet the required emission standards.

The method/s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfield and / or our Authorised Dealer / Service Point and results of such examination will be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royal enfield will have the right to charge all, or part of the cost of such examination to the customer in addition to the cost of the components.

In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge, the component/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeable to the customer as per actual.

In case any of the components covered under emission warranty or the associated parts, are not independently replaceable. Royal Enfield will have the sole discretion to replace either the entire assembly or parts of the assembly, through suitable repairs.

Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace any part, in addition to the repair or replacement of the components covered under emission warranty, to establish compliance to in-use emission standards. Such repairs / replacements will be chargeable to the customer.

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.

Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on account of failure to comply with the in-use emission standards.

That cost/s incurred to check emission of the motorcycle will have to be borne by the customer.

Emission warranty will be applicable irrespective of the change of ownership of the vehicle provided all the conditions as laid down in this document are met from the date of original sale of the motorcycle.

THE WARRANTY SHALL APPLY IF THE CUSTOMER

n Observes all the important instructions and any other precautions listed in the owner’s manual. n Under all circumstances uses lubricants and fuel as recommended by Royal Enfield. n Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the

details in the Log book.

n Immediately approaches the nearest Authorised Dealer / Service Point upon discovery of failure to comply

with the IN-USE emission standard inspite of having maintained and used the vehicle in accordance with the instructions in the owner’s manual and having carried out such repairs and adjustments as may be required with a view to establish such compliance.

n Produces the ‘Pollution Under Control’ certificate valid for the period immediately preceding the test during

which the failure is discovered, the test having been carried out either for obtaining a new certificate or

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).

n Produces the owner’s manual and Log book for verification details. n Produces receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date

of original purchase of the vehicle.

n Produces valid certificate of Insurance and R.T.O Registration Certificate (RC Book).

THE EMISSION WARRANTY SHALL NOT APPLY IF

n A valid “Pollution under control” certificate is not produced. n The motorcycle is not serviced by Authorised Dealer / Service Point as per the service schedule described in

the maintenance chart.

n The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met

with an accident.

n Replacement parts not specified and approved by Royal Enfield have been used. n The motorcycle, or parts thereof, has been altered, tampered with or modified or replaced in an unauthorised

manner.

n The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, so

that the actual distance covered cannot be readily determined.

n The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records. n On examination by Royal Enfield or its Authorised Dealer / Service Point, if the motorcycle shows that any of

the conditions stipulated in the Owner ’s manual with regard to use and maintenance have been violated.

EMISSION WARRANTY

n 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.

n The emission related components are tampered with. n All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not

produced.

n All maintenance activities carried out on the vehicle during the tenure of the emission warranty is not entered

in the log book.

TIPS TO BE ON TH E R IGHT SIDE OF LAW

n Always get your vehicle checked to meet the emission regulations through and authorised emission checking

center.

n Always carry a valid ‘Pollution Under Control’ certificate with you at all times during the validity of the emission

warranty (30,000 Kms / 3 years from the date of first sale)

TIPS T O RED UCE POLLUTI ON

1. Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal

Enfield Authorised Dealer / Service Point.

2. Use only Unleaded petrol (> 87 Octane) from reputed fuel pumps.

3. Ensure the fuel used is not adulterated.

4. Use correct spark plug as recommended in the owner’s manual.

5. Use lubricants as per recommendations given on grade / brand in the owner’s manual.

ALL INDIA ROAD SIGNS

MANDATORY SIGNS

INFORMATION SIGNS

CAUTIONARY SIGNS

FREE SERVICE COUPONS

It is our endeavour to provide exce lle nt service to your Royal Enfield Motor Cycle at all times. Towards this we

provide four free services at specific Intervals.

Please avail these se rvices at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point

nearest to you and as a token of satisfactor y service, kindly retu rn the free service coupon duly filled in and

signed, to the service outlet.

Availing the free ser vic es in the specified time is a prerequisite to warranty consideration.

1ST FREE SERVICE

1 FREE SERVICE

500 Kms or 45+8 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installa tion Form No.

ODO Reading :

Sold by (Dealer’s Name & Ad dress)

Received the above vehicle after the service having been done to my entire satisfaction.

Customer ’s Signature : ................................. Date :

Contact Phone / Mobile No.:

Regn. No:

Sale Date:

Serviced Date:

Serviced by (Dealer’s/ASP Name & Address)

1ST FREE SERVICE ACTIVITIES

1. Water wash the vehicle and dry it with a clean cloth

2. Electrolyte .................................................... Check level & top-up

3. Battery terminals ........................................ Clean and apply petroleum jelly

4. Drive chain free play ................................. Check, clean, lubricate & adjust

5. Rear brake pedal pivot ............................. Lubricate

6. Rear brake .................................................. Adjust

7. Wheel rims front & rear ............................. Check spokes tightness

8. Front & Rear brake ..................................... Check & Adjust

9. Front fork oil leak ....................................... Check for leakage

10. Air filter ........................................................ Clean

11. Spark plugs (2 Nos) .................................... Check, clean & adjust gap

12. H.T. Leads .................................................... Inspect for cracks

13. Carburetor ................................................... Drain & Tune

14. Fuel filter ...................................................... Clean

15. Fuel hose ...................................................... Inspect for cracks

16. Rubber hose, Air filter to carburetor ....... Inspect for cracks

17. Accelerator cable ....................................... Check & adjust play

18. Clutch cable ................................................ Adjust play

19. Engine oil sump strainer ........................... Clean

20. Engine oil ..................................................... Replace

21. Engine oil filter element ............................ Replace

22. Hand levers & kick starter pivot ............... Lubricate

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp &

Signature

2ND FREE SERVICE

2 FREE SERVICE

3000 Kms or 90+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

3000 KMS OR 90+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installa tion Form No.

ODO Reading :

Sold by (Dealer’s Name & Ad dress)

Received the above vehicle after the service having been done to my entire satisfaction.

Customer ’s Signature : ................................. Date :

Contact Phone / Mobile No.:

Regn. No:

Sale Date:

Serviced Date:

Serviced by (Dealer’s/ASP Name & Address)

2ND FREE SERVICE ACTIVITIES

1. Water wash the vehicle and dry it with a clean cloth

2. Electrolyte .................................................... Check level & top-up

3. Battery terminals ........................................ Clean and apply petroleum jelly

4. Drive chain free play ................................. Check, clean, lubricate & adjust

5. Rear brake pedal pivot ............................. Lubricate

6. Rear brake .................................................. Adjust

7. Wheel rims front & rear ............................. Check spokes tightness

8. Front & Rear brake ..................................... Check & Adjust

9. Front fork oil / leak ..................................... Check for leakage

10. Air filter ........................................................ Clean

11. Spark plugs (2 Nos) .................................... Check, clean & adjust gap

12. H.T. Leads .................................................... Inspect for cracks

13. Carburetor ................................................... Drain & Tune

14. Fuel filter ...................................................... Clean

15. Fuel hose ...................................................... Inspect for cracks

16. Rubber hose, Air filter to carburetor ....... Inspect for cracks

17. Accelerator cable ...................................... Check & adjust play

18. Clutch cable................................................ Adjust play

19. Steering free play ....................................... Check & Adjust

20. Engine oil ..................................................... Check level & top-up

21. Hand levers & kick starter pivot ............... Lubricate

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp &

Signature

3RD FREE SERVICE

3 FREE SERVICE

6000 Kms or 180+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

6000 KMS OR 180+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installa tion Form No.

ODO Reading :

Sold by (Dealer’s Name & Ad dress)

Received the above vehicle after the service having been done to my entire satisfaction.

Customer ’s Signature : ................................. Date :

Contact Phone / Mobile No.:

Regn. No:

Sale Date:

Serviced Date:

Serviced by (Dealer’s/ASP Name & Address)

3RD FREE SERVICE ACTIVITIES

1. Water wash the vehicle and dry it with a clean cloth

2. Electrolyte .................................................... Check level & top-up

3. Battery terminals ........................................ Clean and apply petroleum jelly

4. Drive chain free play ................................. Check, clean, lubricate & adjust

5. Rear brake pedal pivot ............................. Lubricate

6. Rear brake .................................................. Cam clean, lubricate & Adjust play

7. Swing Arm Bush & Spacer ......................... Lubricate

8. Wheel rims front & rear ............................. Check spokes tightness

9. Front & Rear brake ..................................... Check & Adjust

10. Tyres front & rear ........................................ Check wear and tread depth

11. Air filter ........................................................ Clean

12. Spark plugs (2 Nos) .................................... Check, clean & adjust gap

13. H.T. Leads .................................................... Inspect for cracks

14. Carburetor ................................................... Clean, O/H & Tune

15. Fuel filter ...................................................... Clean

16. Fuel hose ...................................................... Inspect for cracks

17. Rubber hose, Air filter to carburetor ....... Inspect for cracks

18. Accelerator cable ....................................... Check & adjust play

19. Clutch cable ................................................ Adjust play

20. Engine oil sump strainer ........................... Clean

21. Engine oil ..................................................... Replace

22. Engine oil filter element ............................ Replace

23. Hand levers & kick starter pivot ............... Lubricate

24. PAV System ................................................... Check & Clean

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp &

Signature

4TH FREE SERVICE

4 FREE SERVICE

9000 Kms or 270+15 days whichever is earlier from the date of sale

Enter the Details in Free Service Record

(Cost of oil, oil filter element and other consumables used are chargeable to the customer)

9000 KMS OR 270+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE

Customer Name : Dealer Code :

Address :

Frame No:

Engine No:

Vehicle Installa tion Form No.

ODO Reading :

Sold by (Dealer’s Name & Ad dress)

Received the above vehicle after the service having been done to my entire satisfaction.

Customer ’s Signature : ................................. Date :

Contact Phone / Mobile No.:

Regn. No:

Sale Date:

Serviced Date:

Serviced by (Dealer’s/ASP Name & Address)

4TH FREE SERVICE ACTIVITIES

1. Water wash the vehicle and dry it with a clean cloth

2. Electrolyte .................................................... Check level & top-up

3. Battery terminals ........................................ Clean and apply petroleum jelly

4. Drive chain free play ................................. Check, clean, lubricate & adjust

5. Rear brake pedal pivot ............................. Lubricate

6. Rear brake .................................................. Adjust

7. Wheel rims front & rear ............................. Check spokes tightness

8. Front & Rear brake ..................................... Check & Adjust

9. Front fork oil / leak ..................................... Check level & replace oil

10. Air filter ........................................................ Clean

11. Spark plugs (2 Nos.) ................................... Check, clean & adjust gap

12. H.T. Leads .................................................... Inspect for cracks

13. Carburetor ................................................... Drain & Tune

14. Fuel filter ...................................................... Clean

15. Fuel hose ...................................................... Inspect for cracks

16. Rubber hose, Air filter to carburetor ....... Inspect for cracks

17. Accelerator cable ...................................... Check & adjust play

18. Clutch cable................................................ Adjust play

19. Engine oil strainer ...................................... Clean

20. Engine oil ..................................................... Check level & top-up

21. Hand levers & kick starter pivot ............... Lubricate

22. Steering free play / system ........................

23. Tyres ............................................................. Check wear and tread depth

Check and Lubricate Steering Balls & Adjust

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

..........................

ASP / Dealer’s

Stamp &

Signature

PAID SERVICE / MAINTENANCE RECORD

CU ST OME R COP Y

12,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

CU ST OME R COP Y

15,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

12,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

15,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

PAID SERVICE / MAINTENANCE RECORD

DEAL ER / ASP C OPY CUSTO MER C OPY

12,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY CU ST OME R COP Y

15,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

15,000 + 250 Kms. Ser vic e

PAID SERVICE / MAINTENANCE RECORD

CU ST OME R COP Y

18,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

CU ST OME R COP Y

21,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

18,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

21,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

PAID SERVICE / MAINTENANCE RECORD

DEAL ER / ASP C OPY CUSTO MER C OPY

18,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY CU ST OME R COP Y

21,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

21,000 + 250 Kms. Ser vic e

PAID SERVICE / MAINTENANCE RECORD

CU ST OME R COP Y

24,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

CU ST OME R COP Y

27,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

24,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY

27,000 + 250 Kms. Ser vic e

Job Card No :.................Date : .........................

Odo Reading : ................. Dealer Code : .............

Brief Work Done :

Dealer ’s Stamp & Signature

PAID SERVICE / MAINTENANCE RECORD

DEAL ER / ASP C OPY CUSTO MER C OPY

24,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

DEAL ER / ASP C OPY CU ST OME R COP Y

27,000 + 250 Kms. Ser vic e

Brief Work Done :

Dealer ’s Stamp & Signature

Brief Work Done :

Dealer ’s Stamp & Signature

27,000 + 250 Kms. Ser vic e

Royal Enfield Bullet 500 2013 Owner's manual

Specifications and Main Features

Frequently Asked Questions

User Manual