Foreword |
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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 |
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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.
“© Copyright 2011 Royal Enfield. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt without the express permission in writing of Royal Enfield.
Contents |
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PERSONAL & VEHICLE INFORMATION... |
6 |
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FREE SERVICE RECORD........................ |
7 |
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TECHNICAL SPECIFICATIONS................ |
8 |
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Engine................................................ |
8 |
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Ignition System................................... |
9 |
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Transmission...................................... |
9 |
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Electricals........................................... |
10 |
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Chassis .............................................. |
11 |
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Dimensions......................................... |
12 |
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Weights.............................................. |
12 |
SAFETY DEFINITIONS ............................ |
13 |
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SAFE DRIVING TIPS/GUIDELINES........... |
14 |
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SAFE & HAPPY RIDING........................... |
18 |
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RULES OF THE ROAD............................. |
19 |
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VEHICLE IDENTIFICATION...................... |
21 |
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Chassis Number.................................. |
21 |
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Engine Number................................... |
21 |
KEY PARTS LOCATION........................... |
22 |
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Top View............................................ |
22 |
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Right Side View .................................. |
23 |
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Left Side View .................................... |
24 |
OPERATION OF CONTROLS ................... |
25 |
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Ignition Switch .................................... |
25 |
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Steering Lock...................................... |
25 |
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Fuel tank cap ..................................... |
26 |
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Side Box ............................................ |
26 |
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Battery Carrier ................................... |
27 |
z |
Utility Box .......................................... |
27 |
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Head lamp switch ............................... |
28 |
z Head lamp Day flash .......................... |
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Dip Switch ......................................... |
28 |
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Engine Start Switch ............................ |
29 |
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Engine Stop Switch ............................ |
29 |
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Turn Signal Switch ............................. |
29 |
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Horn .................................................. |
30 |
z Manual Bi Starter (choke) ................... |
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PRE OPERATIONAL CHECKS ................. |
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RUNNING IN ........................................... |
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Contents |
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ELECTRONIC FUEL INJECTION & MIL..... |
33 |
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EFI .................................................... |
33 |
z The Advantages of EFI ....................... |
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z Malfunction Indicator Lamp (MIL)......... |
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ROLL OVER SENSOR ............................. |
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STARTING ............................................. |
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GEAR SHIFTING ..................................... |
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PARKING ............................................... |
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Center Stand ...................................... |
39 |
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Side Stand ......................................... |
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TOOLS & FIRST AID KIT .......................... |
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RECOMMENDED LUBRICANTS ............... |
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PERIODICAL MAINTENANCE .................. |
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MINOR MAINTENANCE TIPS .................. |
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zControl Cables, Hand lever, Pivots,
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Center / Side Stand Pivots .................. |
46 |
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Oil Level Inspection ............................ |
46 |
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Engine oil change ............................... |
47 |
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Spark Plug ......................................... |
48 |
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Brake fluid ......................................... |
49 |
z Inspection of tyres and wheels............. |
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Tyre pressure ..................................... |
50 |
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Front Wheel removal .......................... |
50 |
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Front Wheel reassembly ..................... |
51 |
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Rear wheel removal ........................... |
52 |
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Rear wheel reassembly....................... |
53 |
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Adjustments-Clutch............................. |
54 |
z Drive Chain free play .......................... |
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z Rear Brake Pedal Height .................... |
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z Rear Brake free play adjustment.......... |
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Chain lock fitment .............................. |
56 |
z Adjustment of gas shockabsorber ........ |
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z Removal of Battery from the Vehicle.... |
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Battery Maintenance........................... |
58 |
z Reassembly of Battery on Vehicle ....... |
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CHANGING ELECTRICAL COMPONENTS.... |
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Head Lamp Bulb Replacement .......... |
60 |
z Reassembling the Head Lamp............. |
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Contents |
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z Tail Lamp bulb Replacement................ |
62 |
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Trafficator bulb Replacement .............. |
62 |
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Fuse .................................................. |
63 |
z Blade fuse usage list ........................... |
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PILLION(REAR)SEAT REMOVAL & REFITTING |
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z Pillion (Rear) seat removal .................. |
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z Pillion (Rear) seat refitting ................... |
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WASHING PROCEDURE ......................... |
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Precautions ....................................... |
66 |
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After washing ..................................... |
66 |
STORAGE PRECAUTION ........................ |
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z Preparing the motorcycle for re-use...... |
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LONG TRIP PRECAUTIONS .................... |
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COMPLETE WIRING DIAGRAM ............... |
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TROUBLE SHOOTING ............................ |
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z Engine fails to start ............................ |
71 |
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Engine misfiring ................................. |
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Poor pickup ....................................... |
72 |
z White / Blue smoke ............................ |
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Engine overheating ............................ |
73 |
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Excessive fuel consumption ................ |
73 |
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Brakes Poor ........................................ |
74 |
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Vehicle wobbles ................................. |
74 |
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Electricals .......................................... |
75 |
z Electronic Fuel Injection (EFI) ............ |
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WARRANTY ............................................ |
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EMISSION WARRANTY ........................... |
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FREE SERVICE COUPONS ..................... |
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PAID SERVICE / MAINTENANCE RECORD.. |
91 |
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LOG BOOK ............................................. |
99 |
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REGIONAL & AREA OFFICES ................. |
100 |
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ALL INDIA ROAD SIGNS ......................... |
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NOTES ................................................... |
102 |
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ANNEXURES
zVehicle Installation Form
zPre-Delivery Inspection Report
zBike Installation Confirmation By Customer
zForm 22
Personal & Vehicle Information |
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Name |
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Door No./Street |
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Locality |
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City |
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State |
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Contact Nos. |
Res: |
Off: |
Mobile: |
Email: |
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Engine No. |
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Battery No. |
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Frame No. |
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Battery make |
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Reg. No. |
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Licence No. |
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Date of Sale |
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Valid till dt. |
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Model |
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Key No. |
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Tyre make |
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Colour |
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Sold by |
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Dealer Code |
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Vehicle Installation Form (VIF) No.
Free Service Record |
7 |
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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.
1st Service |
2nd Service |
3rd Service |
4th 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.
Technical Specification |
8 |
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ENGINE |
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Engine ........................................................ |
4 Stroke, air cooled, single cylinder, OHV, SI & FI Engine |
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Capacity ..................................................... |
499 cc (Displacement) |
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Bore ........................................................... |
84 mm |
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Stroke ........................................................ |
90 mm |
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Compression ratio ..................................... |
8.5 : 1 |
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Max. Power @ RPM .................................. |
27.2 BHP @ 5250 rpm |
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Max. Torque @ RPM ................................. |
41.3 Nm @ 4000 rpm |
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Air Filter Element ....................................... |
Corrugated Paper Element |
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Engine Oil Capacity ................................... |
2.75 Litres. |
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Lubrication ................................................. |
Forced Lubrication, Wet Sump |
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Engine Oil Grade ....................................... |
MOTUL 3000 4T Plus 15W50 API SL JASO MA |
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Cooling system .......................................... |
Natural Air Flow |
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Fuel Supply ............................................... |
Electronic Fuel Injection Programmed (PGM-EFI) |
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Technical Specification |
9 |
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IGNITION SYSTEM |
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Ignition system .......................................... |
Electronic Ignition (ECU / Variable) |
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Spark plug Electrode gap ........................ |
0.7 to 0.8 mm |
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Spark plug ................................................. |
WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10 |
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TRANSMISSION |
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Clutch ........................................................ |
Wet Multiplate (7 Plates) |
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Primary drive ............................................. |
Duplex Chain |
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Primary Drive Ratio .................................. |
2.15 : 1 |
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Gear box .................................................... |
Constant Mesh 5 Speed |
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Gear shift pattern ...................................... |
1 - N - 2 - 3 - 4 - 5 |
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Gear Ratios ............................................... |
1st-3.06:1 2nd-2.01:1 3rd-1.52:1 4th-1.21:1 5th-1:1 |
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Secondary Drive (F.D. Sproket) .............. |
18 Teeth |
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Final ratio ................................................. |
2. 11 : 1 |
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Drive Chain links ...................................... |
102 links |
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Technical Specification |
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10 |
ELECTRICALS |
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Generation ................................................ |
Alternator |
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System ....................................................... |
12V DC |
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Battery ....................................................... |
12V - 14 AH MF |
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Head lamp ................................................. |
12V, 60/55 W, Halogen |
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Brake / Tail lamp ...................................... |
12V, 21/5 W |
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Turn signal ................................................ |
12V, 10W - 4 nos. |
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Pilot lamp .................................................. |
12V, 2 W - 2 nos. & 12V, 4 W - 1 no. |
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Speedometer lamp ................................... |
12V, 3.4 W - 1 no. |
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Turn signal / High beam indicator ........... |
12V, 2 W - 2 nos. |
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Neutral Indicator ....................................... |
12V, 2 W - 1 no. |
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Horn (Dual) ............................................... |
12V, 2.5 Amp (Max.) X2 |
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Starter Motor ............................................. |
12V, 0.9 KW |
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Technical Specification |
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11 |
CHASSIS |
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Frame ........................................................ |
Tubular Frame |
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Tyre size .................................................... |
Front: 90 / 90 - 19” - 52 P |
Rear: 120 / 80 - 18” - 62 P |
Tyre pressure ............................................ |
FrontSolo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI) |
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RearSolo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.25 Kg/cm2 (32 PSI) |
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Fuel tank capacity .................................... |
13.5 Litres (MIN) |
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Low fuel warning ....................................... |
2.5 Litres |
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Dead stock of petrol (unusable fuel) ....... |
0.75 Litres |
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Suspension ............................................... |
Front: Telescopic (Dia 35mm), Hydraulic Damping Stroke 130mm |
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Rear: Swing arm with gas filled shock absorbers Stroke 80 mm |
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Front fork oil capacity ............................... |
195 ml per leg |
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Fron fork oil ............................................... |
1F Endurance (or Royal Enfield) fork oil |
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Brakes ....................................................... |
Front : Hydraulic 280 mm Ventilated Disc |
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Rear : Foot Operated 153mm Single Lead Internal expanding |
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Brake oil capacity ..................................... |
60 ml |
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Brake oil grade ......................................... |
DOT 3 or DOT 4 |
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Technical Specification |
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12 |
DIMENSIONS |
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Length ........................................................ |
2170 mm |
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Width ......................................................... |
800 mm |
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Height ........................................................ |
1070 mm |
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Wheel base ............................................... |
1370 mm |
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Saddle height ............................................ |
800 mm |
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Ground clearance ..................................... |
135 mm |
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WEIGHTS |
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Kerb Weight (with 90% Fuel) .................. |
190 Kg |
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Max pay load ............................................ |
178 Kg |
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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 |
13 |
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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 |
14 |
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zBefore 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.
zKnow and respect the rules of the road. Be a safe rider for your own safety and for other road users.
zBefore starting the motorcycle, check for proper operation of brakes, clutch, gear shifter, handle bar controls, tyre pressures, fuel and oil levels.
zUse 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.
zWhenever refuelling your motorcycle, please exercise utmost caution and carefully observe the following rules :
9DO NOT smoke and please ensure that there are no open flames or sparks near the motorcycle, when refuelling OR servicing the fuel system.
9Switch OFF mobile phones and other hand held electronic devices.
9Open the fuel filler cap slowly.
9Refuel in a well ventilated area with the engine turned off.
9DO 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
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.
Safe Riding Tips / Guidelines |
15 |
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zA new motorcycle must be operated according to the special running-in-procedure. See running-in-procedure mentioned in Page No. 32.
zOperate motorcycle only at moderate speeds and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions.
zDO 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 :
9Wind blasts from passing trucks.
9Rough uneven road surfaces.
9Slippery 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.
zOperate 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 |
16 |
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zWear 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.
zWhen carrying a pillion rider, it is your responsibility to instruct them on proper riding procedures.
zDO 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
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
Regularly inspect shock absorbers and front forks and look for leaks. Replace worn parts. Worn parts can adversely affect stability and handling.
Exhaust gases contains poisonous carbon monoxide and chemicals, known to cause Cancer, Birth Defects or other reproductive defects.
Safe Riding Tips / Guidelines |
17 |
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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
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
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 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 |
18 |
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RIDING DRESS
zPlease wear a proper riding apparel.
zA pair of riding boots or shoes.
zSoft leather gloves.
zGoggles or spectacles to safe guard eyes.
zA 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
zSit Straight with your shoulders completely relaxed.
zKeep your elbows close to your body.
zKeep your toes in straight ahead direction.
zSlightly grip the petrol tank with both knees.
zHold the handle bar grips, close to its inner end.
zLook extensively ahead, including rear view mirrors, without turning the head.
BRAKING
zApply 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.
zWhile riding on wet or bad road conditions use brakes cautiously.
zAvoid excessive banking, otherwise footrest may touch the ground and cause instability.
Rules of the Road |
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zBe sure your number plate is installed in the position specified by law and is clearly visible at all times.
zRide at a safe speed that is consistent with the type of road surface you are on. Pay strict attention to whether the surface is :
9Dry
9Oily
9Icy
9Wet
zWatch for loose debris, such as leaves, slippery substances or loose gravel that can hamper the stability of your vehicle.
zDO 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.
zKeep to the correct side of the road center line when meeting oncoming vehicle.
zAlways 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.
zAt street intersection give the right-of-way to the vehicle on your left or right. DO NOT presume you have the right-of-way.
zAlways signal when preparing to stop, turn or pass.
zWhile turning either right or left, watch for pedestrians, animals, as well as vehicles.
zAll 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 |
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zWhen 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.
zNever jump a traffic light. When a
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zDO 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.
zPark your motorcycle on a firm and flat surface to prevent it from falling over.
zProtect your motorcycle against theft. After parking your motorcycle, remove Ignition key from switch and lock the steering 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 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 |
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CHASSIS NUMBER |
ENGINE NUMBER |
Punched on the streering head tube |
Punched on top of the engine LH side. |
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Key Parts Location |
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TOP VIEW |
3 4 5 6 |
7 8 9 |
10 |
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11 |
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12 |
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13 |
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1. |
Turn signal switch |
6. |
Manual Bistarter / Choke |
11. |
Pilot head light switch |
2. |
Horn button |
7. |
Ignition switch |
12. |
E-Start Switch |
3. |
Clutch lever |
8. |
Speedometer |
13. |
Fuel tank cap |
4. |
Day flash switch |
9. |
Malfunction / Low fuel Indicator |
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5. |
Head lamp dip switch |
10. |
Engine Kill switch |
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Key Parts Location |
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RIGHT SIDE VIEW |
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RH Trafficator front |
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Brake Pedal |
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3. |
Starter Motor |
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4. |
Utility Box |
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5. |
Air Filter Box |
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6. |
RH Trafficator Rear |
6 |
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5 |
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Key Parts Location |
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1. Trafficator front LH
LEFT SIDE VIEW
2. Horn
3. Spark plug
4. Gear Change Pedal
5. Battery Cover
6. Side Stand
7. Centre stand
1 |
8. Trafficator rear LH |
8
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Operation of Controls |
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IGNITION SWITCH
OFF
ON
STEERING LOCK
Turn key clockwise to lock.
zLock 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 |
26 |
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FUEL TANK CAP
Turn key clockwise to open. Press cap to lock with key in position.
NOTE :
zKey can be removed only in locked position.
zUse high quality unleaded high octane petrol (91 octane and above) for enhanced performance.
SIDE BOX
SIDE BOX LH
Turn Key anti-clockwise to open
NOTE :
AIR FILTER BOX RH
Turn Key anti-clockwise to open
zKey is common for ignition, petrol tank cap, steering lock, side boxes and battery cover.
zKey for fuel tank and tool boxes can be removed from the lock only in locked
Operation of Controls |
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BATTERY CARRIER |
UTILITY BOX |
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Battery Box Cover
Turn Key clockwise & lift the battery box cover gently
To remove cover turn key anti clock-wise and pull the oval cover by applying finger pressure
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Operation of Controls |
28 |
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HEAD LAMP SWITCH |
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z OFF |
PILOT LIGHT ON |
ON |
HEAD LAMP DAY FLASH |
DIP SWITCH |
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PRESS FOR HEAD LIGHT FLASH |
LOW BEAM |
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HIGH BEAM |
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