Royal Enfield Classic 500 2011 Owner's manual

Foreword

We congratulate you on your choice of the legendary Bullet motorcycle and welcome you to the exciting world of motorcycling on a Royal Enfield.This manual will help you to operate your Classic 500cc motorcycle, the right way and guide you to maintain your motorcycle meticulously. We have also provided tips on safe riding and on minor adjustments for the care of your motorcycle. Please avail the four free services at the nearest Authorised Service Point, at the appropriate time to maintain your Bullet motorcycle in top riding condition.Log on to the exciting world of Royal Enfield website: www.royalenfield.com to get to know more about the company, its products and exciting news from time to time. We request you to carefully read the terms and conditions of warranty and other useful information given in this manual before starting to use your Bullet Motorcycle.

Service Headquarters

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

Part No. 591822 / b / Qty. 500 / Dec ‘11

Notice

All information in this manual is based on the latest product information available at the time of publication. Due to continues improvements or other changes, there may be discrepancies between information in this manual and your vehicle. Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold.

All images shown are for reference to explain and need not to be exactly the same on the model you own. Technical specification are subject to change without prior notice.

Contents

PERSONAL & VEHICLE INFORMATION... 6

FREE SERVICE RECORD........................ 7

TECHNICAL SPECIFICATIONS................ 8

z Engine................................................ 8

z Ignition System................................... 9

z Transmission...................................... 9

z Electricals........................................... 10

z Chassis.............................................. 11

z Dimensions......................................... 12

z Weights.............................................. 12

SAFETY DEFINITIONS ............................ 13

SAFE DRIVING TIPS/GUIDELINES........... 14

SAFE & HAPPY RIDING........................... 18

RULES OF THE ROAD............................. 19

VEHICLE IDENTIFICATION...................... 21

z Chassis Number.................................. 21

z Engine Number................................... 21

KEY PARTS LOCATION........................... 22

z Top View............................................ 22

z Right Side View.................................. 23

z Left Side View .................................... 24

OPERATION OF CONTROLS ................... 25

z Ignition Switch .................................... 25

z Steering Lock...................................... 25

z Fuel tank cap ..................................... 26

z Side Box ............................................ 26

z Battery Carrier ................................... 27

z Utility Box .......................................... 27

z Head lamp switch ............................... 28

z Head lamp Day flash .......................... 28

z Dip Switch ......................................... 28

z Engine Start Switch ............................ 29

z Engine Stop Switch ............................ 29

z Turn Signal Switch ............................. 29

z Horn .................................................. 30

z Manual Bi Starter (choke) ................... 30

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

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

Contents

ELECTRONIC FUEL INJECTION & MIL..... 33

z EFI .................................................... 33

z The Advantages of EFI ....................... 33

z Malfunction Indicator Lamp (MIL)......... 33

ROLL OVER SENSOR ............................. 34

STARTING ............................................. 35

GEAR SHIFTING ..................................... 38

PARKING ............................................... 39

z Center Stand ...................................... 39

z Side Stand ......................................... 39

TOOLS & FIRST AID KIT.......................... 40

RECOMMENDED LUBRICANTS ............... 41

PERIODICAL MAINTENANCE .................. 42

MINOR MAINTENANCE TIPS .................. 46

z Control Cables, Hand lever, Pivots,

Center / Side Stand Pivots .................. 46

z Oil Level Inspection ............................ 46

z Engine oil change ............................... 47

z Spark Plug ......................................... 48

z Brake fluid ......................................... 49

z Inspection of tyres and wheels............. 49

z Tyre pressure ..................................... 50

z Front Wheel removal .......................... 50

z Front Wheel reassembly ..................... 51

z Rear wheel removal ........................... 52

z Rear wheel reassembly....................... 53

z Adjustments-Clutch............................. 54

z Drive Chain free play .......................... 54

z Rear Brake Pedal Height .................... 55

z Rear Brake free play adjustment.......... 56

z Chain lock fitment .............................. 56

z Adjustment of gas shockabsorber........ 57

z Removal of Battery from the Vehicle.... 58

z Battery Maintenance........................... 58

z Reassembly of Battery on Vehicle ....... 59

CHANGING ELECTRICAL COMPONENTS.... 60

z Head Lamp Bulb Replacement .......... 60

z Reassembling the Head Lamp............. 61

Contents

z Tail Lamp bulb Replacement................ 62

z Trafficator bulb Replacement .............. 62

z Fuse .................................................. 63

z Blade fuse usage list ........................... 63

PILLION(REAR)SEAT REMOVAL & REFITTING 64

z Pillion (Rear) seat removal .................. 64

z Pillion (Rear) seat refitting ................... 65

WASHING PROCEDURE ......................... 66

z Precautions ....................................... 66

z After washing ..................................... 66

STORAGE PRECAUTION ........................ 67

z Preparing the motorcycle for re-use...... 68

LONG TRIP PRECAUTIONS .................... 69

COMPLETE WIRING DIAGRAM ............... 70

TROUBLE SHOOTING ............................ 71

z Engine fails to start ............................ 71

z Engine misfiring ................................. 72

z Poor pickup ....................................... 72

z White / Blue smoke ............................ 73

z Engine overheating ............................ 73

z Excessive fuel consumption ................ 73

z Brakes Poor........................................ 74

z Vehicle wobbles ................................. 74

z Electricals .......................................... 75

z Electronic Fuel Injection (EFI) ............ 75

WARRANTY ............................................ 76

EMISSION WARRANTY ........................... 78

FREE SERVICE COUPONS ..................... 82

PAID SERVICE / MAINTENANCE RECORD.. 91

LOG BOOK ............................................. 99

REGIONAL & AREA OFFICES ................. 100

ALL INDIA ROAD SIGNS ......................... 101

NOTES ................................................... 102

ANNEXURES

z Vehicle Installation Form z Pre-Delivery Inspection Report z Bike Installation Confirmation By Customer z 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 Classic 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 Dealerships / Authorised Service Points 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.

Service 4th Service2nd Service

Date of Service Kms Covered Servicing ASP / Dealer’s Name Address

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

Service

Technical Specification

ENGINE

Engine ........................................................ 4 Stroke, air cooled, single cylinder, OHV, SI & FI Engine

Capacity ..................................................... 499 cc (Displacement)

Bore ........................................................... 84 mm

Stroke ........................................................ 90 mm

Compression ratio ..................................... 8.5 : 1

Max. Power @ RPM .................................. 27.2 BHP @ 5250 rpm

Max. Torque @ RPM................................. 41.3 Nm @ 4000 rpm

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

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

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

Engine Oil Grade ....................................... MOTUL 3000 4T Plus 15W50 API SL JASO MA

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

Fuel Supply ............................................... Electronic Fuel Injection Programmed (PGM-EFI)

Technical Specification

IGNITION SYSTEM

Ignition system .......................................... Electronic Ignition (ECU / Variable)

Spark plug Electrode gap ........................ 0.7 to 0.8 mm

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

TRANSMISSION

Clutch ........................................................ Wet Multiplate (7 Plates)

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

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

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

Gear shift pattern...................................... 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. Sproket) .............. 18 Teeth

Final ratio ................................................. 2. 11 : 1

Drive Chain links ...................................... 102 links

Technical Specification

ELECTRICALS

Generation ................................................ Alternator

System ....................................................... 12V DC

Battery ....................................................... 12V - 14 AH MF

Head lamp ................................................. 12V, 60/55 W, Halogen

Brake / Tail lamp ...................................... 12V, 21/5 W

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

Pilot lamp .................................................. 12V, 2 W - 2 nos. & 12V, 4 W - 1 no.

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

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

Neutral Indicator ....................................... 12V, 2 W - 1 no.

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

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

Technical Specification

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 (MIN)

Low fuel warning....................................... 2.5 Litres

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

Suspension ............................................... Front: Telescopic (Dia 35mm), Hydraulic Damping Stroke 130mm

............................................................ Rear: Swing arm with gas filled shock absorbers Stroke 80 mm

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

Fron 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

Technical Specification

DIMENSIONS

Length........................................................ 2170 mm

Width ......................................................... 800 mm

Height ........................................................ 1070 mm

Wheel base ............................................... 1370 mm

Saddle height ............................................ 800 mm

Ground clearance ..................................... 135 mm

WEIGHTS

Kerb Weight (with 90% Fuel) .................. 190 Kg

Max pay load ............................................ 178 Kg

NOTE :

1. Values 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.

Safety Definitions

The information given under the titles : Warning, Caution and Note are for your safety and for the care and safety to your motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others and damages to the motorcycle.

Warning

Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider or other persons.

CAUTION :

This message if disregarded may result in damage to the vehicle.

NOTE :

Indicates important and useful messages for clear understanding.

Safe Riding Tips / Guidelines

z Before operating your new motorcycle, it is your

responsibility to carefully read and follow the operating and maintenance instructions detailed in this manual for your own safety, your motorcycle and that of others.

z Know and respect the rules of the road. Be a

safe rider for your own safety and for other road users.

z Before starting the motorcycle, check for proper

operation of brakes, clutch, gear shifter, handle bar controls, tyre pressures, fuel and oil levels.

z 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.

z Whenever refuelling your motorcycle, please

exercise utmost caution and carefully observe the following rules :

Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom made extended front forks or suspensions, which may adversely affect performance and handling. Removing or altering original parts may adversely affect performance and could result in an accident.

9 DO NOT smoke and please ensure that

there are no open flames or sparks near the motorcycle, when refuelling OR servicing the fuel system.

9 Switch OFF mobile phones and other hand

held electronic devices.

9 Open the fuel filler cap slowly.

9 Refuel in a well ventilated area with the

engine turned off.

9 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.

Warning

Safe Riding Tips / Guidelines

z A new motorcycle must be operated according

to the special running-in-procedure. See running-in-procedure mentioned in Page No. 32.

z Operate motorcycle only at moderate speeds

and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions.

z DO NOT exceed the legal speed limit or drive

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

NOTE :

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 riders should gain experience under various conditions while driving at moderate speeds.

Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be subject to the following upsetting forces :

9 Wind blasts from passing trucks.

9 Rough uneven road surfaces.

9 Slippery road surfaces.

These forces may affect the handling characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.

z Operate your motorcycle defensively.

Remember, a motorcycle does not afford the same protection as an automobile in an accident. One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist.

Safe Riding Tips / Guidelines

z Wear an approved helmet, clothing, and foot

gear suited for riding a motorcycle. Bright OR light colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves.

z When carrying a pillion rider, it is your

responsibility to instruct them on proper riding procedures.

z DO NOT allow other individuals, under any

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

Warning

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

Warning

For your personal welfare, all the listed service and maintenance recommendations should be performed. Lack of regular maintenance at the suggested intervals may affect the safe operation of your motorcycle.

Warning

Avoid any contact with the exhaust system. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot, even after the engine is turned off. Failure to wear proper or protective clothing could result in serious injury.

Warning

Exhaust gases contains poisonous carbon monoxide and chemicals, known to cause Cancer, Birth Defects or other reproductive defects.

Safe Riding Tips / Guidelines

Warning

Motorcycle batteries contain lead and lead components, acids and chemicals known to cause cancer, birth defects or other reproductive harm. Exercise extreme caution while handling a battery. Wash hands thoroughly whenever a battery is handled.

Warning

Consult your Royal Enfield Dealer regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so may aggravate an initial problem, cause costly repairs & jeopardize your personal safety.

Warning

DO NOT tow a disabled motorcycle. The steering and handling of the disabled motorcycle will be impaired due to the force of the towline. If a disabled motorcycle 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.

Warning

DO NOT pull a trailer behind a motorcycle. Towing a trailer may cause reduced braking efficiency, tyre overloading and unstable handling. Towing a trailer may cause loss of control of the motorcycle in the front, leading to an accident.

Safe & Happy Riding

RIDING DRESS

z Please wear a proper riding apparel. z A pair of riding boots or shoes. z Soft leather gloves. z Goggles or spectacles to safe guard eyes. z A certified helmet. Affix light reflecting strips of

stickers at the front and rear.

NOTE :

A light coloured shirt enables greater visibility to other road users especially during nights.

CAUTION :

Loose clothing may get caught on moving parts of your motorcycle.

SITTING POSTURE

Correct sitting posture is a pre-requisite for stable and safe riding

z Sit Straight with your shoulders completely relaxed. z Keep your elbows close to your body.

z Keep your toes in straight ahead direction. z Slightly grip the petrol tank with both knees. z Hold the handle bar grips, close to its inner end. z Look extensively ahead, including rear view

mirrors, without turning the head.

BRAKING

z Apply front and rear brakes gently and

simultaneously for maximum braking efficiency.

WARNING

Applying any one of the brakes suddenly may cause the vehicle to skid. The hydraulic disc brake fitted on your motorcycle requires very less effort. High effort or sudden application may lock the wheel. Please use utmost caution while applying the brakes.

z While riding on wet or bad road conditions use

brakes cautiously.

z Avoid excessive banking, otherwise footrest

may touch the ground and cause instability.

Rules of the Road

z Be sure your number plate is installed in the

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

z 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 :

9 Dry

9 Oily

9 Icy

9 Wet

z Watch for loose debris, such as leaves, slippery

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

z DO NOT exceed the legal speed limit or drive

z Keep to the correct side of the road center line

when meeting oncoming vehicle.

z Always sound your horn, actuate your turn

signals, and exercise caution when passing other vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up/or down a hill.

z At street intersection give the right-of-way to

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

z Always signal when preparing to stop, turn or

pass.

z While turning either right or left, watch for

pedestrians, animals, as well as vehicles.

z All traffic signs, including manual controls at

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

Rules of the Road

z When intending to turn, signal at least 100 feet

(30.5 meters) before reaching the turning. Be close to the center line (unless local rules require otherwise), slow down and then turn carefully.

z Never jump a traffic light. When a

change is imminent from GO to STOP (or vice versa) at intersections, slow down and wait for the light to change to green. Never run through a yellow or red traffic light.

z DO NOT leave the curb or parking area without

signaling. Be sure your way is clear to enter moving traffic. A moving line of traffic always has the right-of-way.

z Park your motorcycle on a firm and flat surface

to prevent it from falling over.

z Protect your motorcycle against theft. After

parking your motorcycle, remove Ignition key from switch and lock the steering head.

Red

Yellow

Green

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 to the rear than a flat mirror; however, cars and other objects seen in this type of mirror will look smaller and farther away than when seen in a flat mirror.

Use care when judging the size or distance of objects seen in these mirrors.

NOTE :

To help you establish the relative distance of vehicles behind your motorcycle, 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.

Vehicle Identification

CHASSIS NUMBER

Punched on the streering head tube

ENGINE NUMBER

Punched on top of the engine LH side.

Key Parts Location

TOP VIEW

4 5 6

7 8 9 10

1. Turn signal switch

2. Horn button

3. Clutch lever

4. Day flash switch

5. Head lamp dip switch

6. Manual Bistarter / Choke

7. Ignition switch

8. Speedometer

9. Malfunction / Low fuel Indicator

10. Engine Kill switch

11. Pilot head light switch

12. E-Start Switch

13. Fuel tank cap

Key Parts Location

RIGHT SIDE VIEW

1. RH Trafficator front

2. Brake Pedal

3. Starter Motor

4. Utility Box

5. Air Filter Box

6. RH Trafficator Rear

Key Parts Location

LEFT SIDE VIEW

1. Trafficator front LH

2. Horn

3. Spark plug

4. Gear Change Pedal

5. Battery Cover

6. Side Stand

7. Centre stand

8. Trafficator rear LH

Operation of Controls

IGNITION SWITCH

OFF

STEERING LOCK

Turn key clockwise to lock.

z Lock the steering when

leaving bike parked.

CAUTION :

Protect your motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head.

DO NOT lubricate barrel locks with petroleum based lubricants or graphite. Inoperative locks may result in damage to your vehicle.

Operation of Controls

FUEL TANK CAP

Turn key clockwise to open. Press cap to lock with key in position.

NOTE :

z Key can be removed only in

locked position.

z Use high quality unleaded

high octane petrol (91 octane and above) for enhanced performance.

SIDE BOX

SIDE BOX LH AIR FILTER BOX RH

Turn Key anti-clockwise to open Turn Key anti-clockwise to open

NOTE :

z Key is common for ignition, petrol tank cap, steering lock, side

boxes and battery cover.

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

only in locked

Operation of Controls

BATTERY CARRIER

Battery Box Cover

Turn Key clockwise & lift the battery box cover gently

UTILITY BOX

To remove cover turn key anti clock-wise and pull the oval cover by applying finger pressure

Operation of Controls

HEAD LAMP SWITCH

z OFF

PRESS FOR HEAD LIGHT FLASH

PILOT LIGHT ON

DIP SWITCHHEAD LAMP DAY FLASH

LOW BEAM

HIGH BEAM

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