Royal Enfield Bullet 500 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 urge you to avail of the four free ser vices we offer, at the right time, at any of our Authorised

Dealer / Service Point to keep your motorcycle in peak condition.

Please log on to www.r o yal enf i el d .co m to know more about the history of the world’s oldest 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!

IMPORTANT NOTICE

Keep this manual in a convenient place for easy reference.

If any information is not understood in the manual contact your Authorised Dealer / Service Point for assistance.

If the motorcycle 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.

The motorcycle is designed for normal on road use only. Operation in off-road usage in some areas may be illegal and could be dangerous.

Obey local law and regulations.

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.

Becaus e of contino us i mpro vements in the product and changes that may occur in the manufacturing process, subsequent to printing of this manual, it is possible some instructions, illustrations, pictures or designs found within this manual may differ from those found on the vehicle.

However the technical information found within thi s manual was cor rect at the time it was approved for publication.

Ro yal Enfi eld reser ves the rig ht t o make production changes at any time without prior notice and without incurring any obligation to make same or s imilar changes to vehicles previously built or sold.

“© Copyright 2014 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 No. 584639/A / Qty.1000 / Apr. ‘14

2

IMPORTANT NOTICE

SAFETY DEFINITIONS

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

WARNING

Warning indicates a potentially hazardous situation, which if not avoided, could result in serious injury.

However if you have any queries, clarification, suggestions/feedback, please write to us or e-mail at

“[email protected]”.

CAUTION

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

NOTE

Indicates important and useful messages for clearer understanding.

All Images shown are for reference to explain and need not to be exactly the same on the model you own.

3

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 : [email protected]

Website : www.royalenfield.com

CONTENTS

PERSONAL & VEHICLE INFORMATION ......................... 7

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

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

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

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

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

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

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

- Electricals ................................................................. 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

4

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 PERIOD ........................................................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 MAINTENANCE TIPS .........................................43

- Control Cables, Handle bar lever,

Pivots, Center / 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

5

- 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 Battery on Vehicle .........................56

- Changing Electrical Components ....................57

Head Lamp bulb replacement ..................57

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

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

Fuse .......................................................................60

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

- Air Filter element cleaning / replacement ...61

CONTENTS

WASHING 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 every 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

- White / blue smoke ................................................ 72

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

6

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

- Ignition knock ..........................................................73

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

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

- Electricals ..................................................................74

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

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

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

ALL INDIA ROAD SIGNS ....................................83

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

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

LOG BOOK ............................................................... 101

NOTES ...............................................................106

ANN EXURES

- Vehicle Installation Form

- Pre-Delivery Inspection Report (PDI)

- Bike Installation Confirmation By Customer

- Form 22

PERSONAL & VEHICLE INFORMATION

Name

Door No./Street

Locality

City

Contact Nos. Res:

Engine No.

Frame No.

Reg. No.

Date of Sale

Model

Tyre make

Sold by

Off:

State

Mobile:

Vehicle Installation Form (VIF) No.

7

Email:

Battery No.

Battery make

Licence No.

Valid till dt.

Key No. :

Colour

Dealer Code

Pin

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.

1 st Service 2 nd Service 3 rd Service 4 th Service

Date of Service

Kms Covered

Servicing

Dealer’s / ASP

Name, Address

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

Dealer / ASP

Rubber Stamp

NOTE

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

8

SAFE OPERATING RULES

Before operating your new motorcycle, it is your responsibility to carefully read and follow the operating and maintenance instructions detailed in thi s manual for you r own safety, yo ur motorcycle and that of others.

Know and respect the rules of the road. Be a safe rider for your own safety and for other road users.

Before starting the motorcycle, check for proper operation of brakes, clutch, gear shifter, handle bar controls, tyre pressures, fuel and oil levels.

WARNING

Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom made extended front forks or suspensions, whi ch m ay adver sely aff ect perf ormance and handling. Removing or altering original parts may adversely affect performance and could result in an accident causing serious injury.

9

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.

Whenever refuelling your motorcycle, please exercise utmost caution and carefully observe the following rules :

DO NOT smoke and please ensure that there are no open flames or s parks near t he motorcycle, when refuelling OR servicing the fuel system.

Switch OFF mobile phones and other hand held electronic devices / gadgets.

Open the fuel filler cap slowly.

Refuel in a well ventilated area with the engine turned off.


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).

WARNING

Petrol is extremely fl amm able and highly explosive. Use care when handling Petrol. Always stop the engine when refuelling or servicing 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 lights, sparks or electric motors are present. Inadequate safety precautions could cause an explosion or fire which could result in damage to property, serious injury.

A new motorcycle must be operated according to the special break-in-procedure. See BREAK-IN-THE

FIRST 500KM section.

Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly famili ar with its oper atio n and handli ng characteristics under all conditions.

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.

10

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 ri ders sho uld gain exp eri ence und er v ario us conditions while driving at moderate speeds.


WARNING

Avoid overspeeding and never travel over the speed limit. Excessive speed may cause loss of control and could result in an accident causing serious injury.

DO NOT exceed >110 km/h solo riding.

DO NOT exceed >90 Km/h when carrying a pillion or cargo.

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

Wind blasts from passing trucks.

Rough uneven road surfaces.

Slippery road surfaces.

These forces may affect the handling characteristics of your motorcycle. If this happens, reduce speed and guide the moto rcycle wi th a rel axed grip to a controlled condition. Do not brake abruptly or force the handlebar.

11

Operate yo ur m otor cycl e defens ivel y.

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.

Wear an approved helmet, clothing, and foot gear suited for riding a motorcycle. Bright OR light colors are best for greater visibility in traffic, specially at night. Avoid loose, flowing garments and scarves.

When carr yi ng a pil lion rid er, it i s yo ur responsibility to instruct them on proper riding procedures.

DO NOT allow other individual s, 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

Maintain the recomm ended tyre pr essure.

Ensure the front and rear wheels are correctly aligned and the tyres are seated evenly & properly in the rims. Check for correct tightness of the spokes in the rims. Inspect your tyres periodically and replace tyres with approved tyres only. Failure to do so can lead to improper balance, abnormal tread wear, poor handling and could result in serious injury.

In emergency situations, if a temporary repair is made ride slowly with as light a load as possible until the tyre is permanently repaired or replaced.

Failure to heed this warning could result in serious injury.

WARNING

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)

12

Safe motorcycle operation requires alert mental judgement combined with a defensive driving attitude. DO NOT allow fatigue, alcohol or drugs to endanger your safety or that of others.

Maintain your motorcycle in proper operating condition as per Periodical Maintenance Chart

(Ref Page No.4 0). Particularl y im portant to mot orcy cle stab ility is pro per tyre inf lati on pressure, tread condition. Pay strict attention to loose and / or broken spokes, free movement of steering system.


WARNING

DO NOT operate motorcycle with a loose, worn or damaged steering system, including the front and rear suspension system. Contact your dealer for repair of steering or suspension system. Damaged steering or suspension components may adversely affect handling which could result in serious injury.

WARNING

Avoid any contact with the exhaust system. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot, even after the engine is turned off (due to catalic converter).

Failure to wear proper or protective clothing could result in serious injury.

WARNING

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

WARNING

Ex haus t gases contains po isonous carb on monoxide (CO.) and chemicals, known to cause serious health hazards.

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, which could result in serious injury.

13

WARNING

Motorcycle batteries contain lead and lead components, acids and chemicals known to cause serious health hazards. 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 and could result in serious injury.

on the frame Down tube. (GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of the rider, passenger and cargo that may be safely carried.) Exceeding GVWR may lead to instability of the motorcycle, which could cause an accident and result in serious injury.

WARNING

Use only genuine Royal Enfield replacement fasteners tightened to the proper torque. We caution you against the use of certain non standard parts such as aftermarket and custom made fasteners which may not have specific strength, finish and type requirements to perform properly in the assembly and its environment. The use of any nonstandard parts, including fasteners, could result in serious injury.

WARNING

DO NOT exceed the Gross Vehicle Weight Rating of your motorcycle. The Gross Vehicle Weight Rating

(GVWR) is shown on the information plate, located

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 resulting in serious injury .

14

WARNING

DO NOT pull a trailer behind a motorcycle.

Towing a tr ailer may cause redu ced 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 resulting in serious injury.

RULES OF THE ROAD

Be sure front & rear number plates is installed in the position specified by law and is clearly visible at all times.

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 :

Dry

Icy

Oily

Wet

Watch for loose debris, such as leaves, slippery substances or loose gravel that can hamper the stability of your vehicle.

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.

WARNING

Avoid excessive speed and never travel at a speed faster than the speed limit. Excessive speed

15 may cause loss of control of vehicle, which could result in death or serious injury.

Keep to the correct side of the road centre line when meeting oncoming vehicle.

Always sound your horn, actuate your turn signals, and exercis e CAUTION when pass ing 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.

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.

Always signal when preparing to stop, turn or pass.

Whi le tur ning either right or l eft, watch for pedestrians, animals as well as vehicles.

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

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.

SIDE VIEW MIRRORS

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.

Red

Yellow

Green

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.

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.

Park your motorcycle on a firm and flat surface to prevent it from falling over.

Pr otect yo ur m otor cycl e agains t theft. After parking your motorcycle, remove Ignition key from switch and lock the steering head.

16

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.

TECHNICAL SPECIFICATIONS

ENGINE

Engine ............................................................

Capacity ........................................................

Bore ................................................................

Stroke .............................................................

Compression ratio ......................................

Max. Power @ RPM .....................................

Max. Torque @ RPM ...................................

Air Filter Element .........................................

Fuel Supply ...................................................

Engine Start ..................................................

Engine Oil Capacity ...................................

Lubrication ...................................................

Engine Oil Grade ........................................

Cooling system ............................................

Carburetor ...................................................

Single Cylinder, 4 Stroke, Twinspark, Aircooled

499 cc (Displacement)

84 mm

90 mm

8.5 : 1

26.1 BHP @ 5100 rpm

40.9 Nm @ 3800 rpm

Corrugated Paper Element

Carburetor with Throttle Position Sensor (TPS)

Electric / Kick

2.75 Litres.

Wet Sump, Forced Lubrication

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

Natural Air Flow

UCD 33

17


IGNITION SYSTEM

Ignition system ...........................................

Spark plug ...................................................

Spark plug Electrode gap ......................

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

TRANSMISSION

Clutch ............................................................

Primary drive ..............................................

Primary Drive Ratio ...................................

Gear box .......................................................

Gear shift pattern ......................................

Gear Ratios ..................................................

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

Final Ratio ....................................................

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

TCI Unit, Multi Curve (Variable Ignition Timing)

WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10

WQR8DC 0.80 to 0.90 mm

UR6DC 0.70 to 0.80 mm

Wet Multiplate (7 Plates Clutch)

Duplex Chain

2.15 : 1

5 Speed Constant Mesh

1 - N - 2 - 3 - 4 - 5

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

18 Teeth

2. 11 : 1

102 links

18


ELECTRICALS

Generation ...................................................

System ............................................................

Battery ...........................................................

Head lamp ...................................................

Position lamp ..............................................

Brake / Tail lamp .......................................

Turn signal ...................................................

Pilot lamp .....................................................

Speedometer lamp ...................................

Turn signal / High beam indicator ......

Neutral Indicator .......................................

Horn (Dual) ..................................................

Starter Motor ...............................................

Alternator

12V DC

12V - 14 AH

12V, 60/55 W, Halogen

12V, 4W

12V, 21/5 W

12V, 10W - 4 nos.

12V, 2 W - 2 nos.

12V, 3.4 W - 1 no.

12V, 1.7 W - 2 nos.

12V, 1.7 W - 1 no.

12V, 2.5 Amp (Max.) X2

12V, 0.9 KW

19

WARNING

Using bulbs / other electrical gadgets other than specified rating may lead to over loading / erratic behaviour / premature failure of electrical system.

Modifications on the bike which are not approved by Royal Enfield may not only disqualify for warranty, but also affects performance of the bike.


CHASSIS

Frame .............................................................

Tyre size.........................................................

Tyre pressure ...............................................

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

Fuel tank capacity ....................................

Reserve capacity .......................................

Dead stock of petrol (unusable fuel) ..

Suspension ...................................................

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

Front fork oil capacity ..............................

Front fork oil ................................................

Brakes ............................................................

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

Brake oil capacity .....................................

Brake oil grade ..........................................

Tubular Frame

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

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)

13.5 Litres ***

2 Litres (approx.)

***Fuel tank is not a measuring instrument. The capacity of tank may vary slightly from specified value.

0.75 Litres (approx.)

Front: Telescopic, 130mm Travel

Rear: Twin gas charged shock absorbers, 80mm travel

195 ml per leg

1F Endurance (or Royal Enfield) fork oil

Front : Hydraulic 280 mm Ventilated Disc

Rear : Foot Operated 153mm Single Lead Internal expanding

60 ml

DOT 3 or DOT 4

20


DIMENSIONS

Length ...........................................................

Width ..............................................................

Height ............................................................

Wheel base ..................................................

Saddle height .............................................

Ground clearance .....................................

WEIGHTS

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

Max pay load .............................................

2140 mm

810 mm (Without Mirror)

1110 mm (Without Mirror)

1370 mm

800 mm

135 mm

N O TE : B S I I I

This vehicle meets Emission Norms -

Bharat (Trem) Stage - III

193 Kg

172 Kg

NOTE

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.

21

VEHICLE IDENTIFICATION NUMBER - DETAILS

FRAME NUMBER ENGINE NUMBER

Punched on steering head tube RH side.

Punched on top of the engine LH side.

22

KEY PARTS LOCATION

12

3 4 6 7

5 2

1

23

10

11

12

9

8

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

5 2

6

4

3

24

RIGHT SIDE VIEW

1. RH Trafficator Front

2. Starter Motor

1

3. Brake Pedal

4. Kick Starter Lever

5. Air Filter Box

6. RH Trafficator Rear

KEY PARTS LOCATION

2 3 4 5

1

10 9 8 7

25

LEFT SIDE VIEW

6

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.

ON

Turn key anti clockwise to unlock.

CAUTION

Protect your motorcycle against theft.

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

Turn handle bar to extreme left, before attempting to lock steering.

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

26


FUEL TANK CAP

Turn key clockwise to open

SIDE BOX

AIR FILTER BOX RH

Turn Key anti-clockwise to open

Press cap to lock with key in position

SIDE BOX LH

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

NOTE

Key can be remo ved only in locked position.

NOTE

Key is common for ignition, petrol tank cap, steering lock, side boxes and battery cover.

Key for fuel tank and tool boxes can be removed from the lock only in locked position.

27


HEAD LAMP SWITCH

OFF

Pilot Light ON

DIP SWITCH

Low beam

High Beam

Head Light ON

28

HEAD LAMP DAY FLASH

Press for

Headlight Flash


ENGINE KILL SWITCH

Run

Stop

TURN SIGNAL SWITCH

Left

OFF (Push to off)

Right

HORN

Press

29


ENGINE START SWITCH

Press

BATTERY BOX

Turn anti clockwise to open

30

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 check of the following must be carried out every time before riding and specially after long per iods of stor age to d eter mine if addi tional maintenance is necessary.

1. Tyres for correct 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 i n g a nd t h r o tt l e f o r responsiveness.

4. Cable for fraying or cri mping and f ree operation.

5. Engine oil level.

MAX

MIN

6. Wheel spo ke f or proper tightness, no breakage.

Spokes

7. Headlamp, tail lamp, brake lamp and indicator lamps for proper operation.

31

WARNING

For your personal welfare and safety, all the poi nts ment ioned above shou ld b e perfor med per iodi call y. Failu re to do so, may affect s afe operation and damage your motorcycle and could result in an accident causing serious injury.

RUNNING IN PERIOD

Proper running-in is very important for obtaining maximum life and performance of a new motorcycle.

The following guidelines explain proper running-in procedures.

Since the engine is brand new, it should not be loaded excessively for the first 2,000 kms. 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.

3.

Avoid driving the motorcycle with full throttle openi ng. Var y the speed of the motorcycle regularly but avoid using the motorcycle above

3/4 throttle opening position.

2,001 kms and above

Avoid prolonged full-throttle operation. Vary speed occasionally.

CAUTION

1.

0 - 500 Kms :

The recommended speeds for the first 500 Kms is below 50 Kmph. Dur ing thi s period avo id operating the moto rcycle with ful l throttle opening. Stop the motorcycle for about 5 to 10 minutes to let it cool down, after every hour of running. Var y the speed of the mo torcy cle regularly during running but avoid using the motorcycle above ½ throttle opening position.

2.

501 - 2000 Kms.

The recommended speed is below 80 Kmph.

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

Roy al Enfi eld engi nes are air- cool ed 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.

32

DO NOT run the engine at extremely high RPM with clutch disengaged 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)

Turn fuel tap to

‘ON’

Use cho ke i n co ld condition

Switch on ignition.

Ensure Engine stop swi tch is i n “RUN” position

Ensure the side and mai n st ands are in released position

Ensure that gears are in neutral and neutral lam p is glo wing in cluster box.

CAUTION

N

Do not force the gear lever while attempting to shift to neutral. Move the motorcycle back & forth and simultaneously press gear lever to come to neutral.

Ensure neutral indicator light comes “ON”’ in the

Speedometer.

33

WARNING

Before starting engine, always shift gears into neutral.

STARTING

USING KICK START

Sli ghtl y cr ank the engine fur ther ti ll com pres sion eas es over.

Start the motorcycle wi th a po werf ul swinging kick.

Release the choke, if applied

USING ELECTRIC START

Press Clutch Lever.

Press Starter Button and release as soon as engine starts.

Release the choke, if applied

34

NOTE

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.

Press starter button and release starter switch once the engine starts.

If the engine does not start on the first attempt in cold climate, release the starter button, wait for

30 seconds before pressing the starter button again.

GEAR SHIFTING

Warm up engine for 2 minutes - till idling is consistent/ stable

Press the gear pedal with heel to eng age 2nd and higher gear.

GEA R SHIFT PATT ERN

1 N 2 3 4 5

Press clutch lever towards the hand grip.

Press gear pedal with toe to engage 1st gear.

Gently open thrott le and release clutch simultaneously. If clutch is released suddenly, the engine may stall and cause a jerky start.

Follow the same procedure for 3rd, 4th and 5th gear.

CAUTION

The clutch mus t be ful ly disengaged befo re attempting a gear shift. Failure to fully disengage the clutch may cause a jerky start and / OR stalling the engine besides causing damage to transmission parts.

35

NOTE

Always move the motorcycle in first gear position only.

When engine speed decreases, while climbing 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

Select a firm, flat surface

Hold handle bar straight

Lower center stand, and ensure that both the legs of the stand are resting evenly on firm ground.

Apply pressure on the fulcrum lever on the center stand and pull vehicle backwards, gently as shown in pic.

PARKING VEHICLE ON SIDE STAND

Select a firm, flat surface

Lower Side Stand and gently tilt motorcycle to the left till it rests firmly.

36

WARNING

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 to others and damage to the motorcycle parts.

TOOLS & FIRST AID KIT

1 2 3 4 5 6

5 6 7

1

S.No.

1.

2.

3.

4.

5.

6.

Description Qty.

Tool bag 1

Screw driver O6 X 160

Tommy bar

1

1

Tubular spanner

Tool Spark plug

Double end spanner 10 X 12

1

1

2

37

4 3 2

S.No. Description Qty.

1.

2.

3.

4.

5.

6.

7.

Antiseptic cream 5 gms

Gauze bandage 5 cm x 2 cm

Elastic Gauze bandage 8 cm x 1 mtr.

Wash proof plaster 1.9 cm x 7.2 cm

Sterilized Gauze Swab 5 cm x 5 cm

Sterilized elastic plaster 7 cm x 6 cm

First aid kit pouch

1

2

2

1

1

1

1

NOTE

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

RECOMMENDED LUBRICANTS

Grade

Engine Oil

Royal Enfield 15 W 50 API SL Grade

Engine Oil

(JASO MA)

Grade

Front Fork Oil

Royal Enfield

Front Fork Oil

(or 1F Grade

Endurance)

Capacity 195 ml/leg

Grade

Brake Fluid

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

Dealer/ASP

Capacity 2.75 Ltrs. (with oil filter)

2.50 Ltrs. (during oil & filter element replacement)

2. Similarly we advise for disposal of old/used

Battery, Tube & Tyres as mentioned in above point

No.1.

WARNING

DO NOT switch oil brands indiscriminately because some oil interact chemically when mixed.

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

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

38

PERIODICAL MAINTENANCE

The maintenance schedule detailed here will help you to maintain your Bullet 500cc meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carried out.

The frequency of the maintenance must be shortened depending 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.

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 causing the motorcycle to malfunction and stall abruptly resulting in an accident and cause serious injury.

39


S.

No.

DESCRIPTION

FREE SERVICE whichever is earlier

Kms (x 1000) 0.5

3 6

PAID SERVICE

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

Check level at every 1000 Kms or earlier as required

2 Engine oil filter element R C R R R R R

C C C C C C C 3 Engine sump filter (oil strainer)

4

Magnetic drain plug under gear box and secondary drain plug under crankshaft in crankcase RH

5 Spark plugs (2 nos.)

6 HT leads for crack

7 Carburetor (C.V. Type)

8 Fuel Tap / Filter

9 Fuel tank

10 Fuel hose / pipe

11 Accelerator & Carburetor cable play adjustment

C C C C C C C

C,A C,A C,A C,A C,A R C,A C,A C,A C,A R

I I I I I I I I I I I

C

I

A

I

A

C

C

I

A

*Clean, Inspect and Tune

C C C

R

A

C

I

A

I

A

C

I

A

R

A

C

I

A

I

A

C

C

I

A

12 Rubber hose, Air filter to Carburetor I I I I R I I I R I I

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace

40


S.

No.

DESCRIPTION


Kms (x 1000) 0.5

3 6

PAID SERVICE

9 12 15 18 21 24 27 30

Months 1.5

13 Rubber hose, Adaptor I

3

I

6

I

9

I R I I I R I I

14 Exhaust system

15 Air filter paper element

16 Inlet / Exhaust valve seating

C C C C R C

I

C C R C

D

C

I

17 Clutch lever free play Check & Adjust every 1000 Kms or earlier as required

18 Cylinder head (Combustion chamber)

19 Hand levers & kick starter lever pivot Lubricate every 1000 Kms or earlier as required

D

20 PAV pipes & hose clip

21 Rear brake pedal pivot

22 Battery terminals (apply petroleum jelly)

23 Battery Electrolyte level

24 Earth wire eyelet (behind battery carrier)

I

L

C

I

I

L

C

I

C

L

C

I

I

L

C

I

C

L

C

I

I

I

L

C

I

C

L

C

I

I

L

C

I

C

L

C

I I

I

L

C C

I

C

L

I

25 Front Fork oil / leak I R I R I


41


S.

No.

DESCRIPTION


Kms (x 1000) 0.5

3 6

PAID SERVICE

9 12 15 18 21 24 27 30

Months 1.5

26 Rear wheel drive chain

3 6 9

Adjust for every 1000 Kms / Clean, Lubricate &

Adjustevery 3000 kms or earlier as required

27 Rear brake pedal free play

28 Rear brake cam

29 Steering ball races / play adjustment

30 Spokes tightness & Wheel rim run out

31 Rear wheel cush rubbers

32 Swing Arm pivot bush & spacer

33 Tyre wear (Front & Rear)

34 Brake fluid (Disc brake)

35 Pivot-Side Stand, Center Stand, Pillion foot rest L

I

I

Adjust every 1000 Kms or earlier as required

A

I

L

L

L

I

L

I

I

L

A

I

I

L

L

R

I

I & R

L

I

R

L

A

L

I

I

L

L

I

L

L

I

I

A

L

I

I

L

R

I

I & R

R

I

R

L

A

R

I

L

L

L

I


NOTE

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

* Refer Service Manual.

42

I

L

L

I

MINOR MAINTENANCE TIPS

The following minor maintenance can be carried out easily with simple tools. However, In case, if it is felt that the adjustments are best done by an expert, we recommend that the motorcycle be taken to a nearest

Royal Enfield Authorised Dealer / Service Point.

CONTROL CABLES, HANDLE LEVER, PIVOTS,

CENTER / SIDE STAND PIVOTS

Main & Side

Stand Pivot

ENGINE OIL LEVEL INSPECTION

MAX

MIN

Lever Pivot

Lubricate after using the motorcycle in rain, after water wash or if used in dusty conditions.

Wipe the area free of dirt / grease.

Apply a few drops of oil on the pivots.

43

Place motorcycle on its center stand on a firm surface.

Warm up engine for a few minutes & switch off.

The level is correct if the oil level is in the middle of the oil level window.

Top up with recommended oil if required.


ENGINE OIL CHANGE

Secondary

Drain Plug Primary

Drain Cap

Primary

Drain Bolt

(Refer Periodical Maintenance Chart for frequency)

Place motorcycle on its center stand on a firm flat surface.

Start engine and warm up for 2 minutes.

Keep a clean tray below the engine.

Remove primary drain cap, to drain oil & clean suction filter, magnet.

Then remove secondary drain plug to drain oil & clean the magnet.

Finally remove primay drain bolt to drain the complete oil.

44

TILT VEHICLE

RH & LH

Remove the oil filter element on the Crankcase

Cover RH.

Allow the oil to drain by tilting the motorcycle to both sides.

Wash the primary and secondary drain plugs along with suction filter thoroughly and refit on the crankcase after all the oil is drained out.


Soak a new oil filter element in the oil and refit on the Crankcase Cover RH.

Assembly 3 bolts and tighten them. Ensure ‘O’ Ring and gaskets are taken seat properly.

Fill recommendedoil to engine till the oil level is upto “MAX ” level mark in the oil wi ndow in Crankcase Cover RH.

Max

Min

NOTE

Replace oil filter element whenever oil is being replaced.

CAUTION

Filling up oil over MAX mark may cause smoke and / or loss of power. Do NOT allow oil level to fall below

MIN mark. Doing so may result in engine internal damage or malfuncton.

45

SPARK PLUG

Cl eani ng and adjus ting gap (Refer Peri odical

Maintenance Chart for frequency)

Remove HT Lead and the spark plug from the cyl inder head usi ng t he p lug spanner and tommy bar as shown in pic.

Clean the insulator tip and electrodes of the plug carefully using a poi nted scr aper or spark plug cleaner.

Set the gap between

0.70 to 0.80 mm for

UR6DC & 0.80 to 0.90

mm for WQR8DC

Refit the spark plug on the cylinder head and connect H.T. Lead.

M10

M14


BRAKE FLUID INSPECTION OF TYRES AND WHEELS

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

MAX

MIN

CAUTION

Please take care that it does not spill over any other parts of the motorcycle. Please wipe the spilled 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.

46

Inspect the tyre periodically for tread wear, cracks and cuts.

Minimum tread depth :

Front tyre : 1mm Rear tyre : 2 mm

Check and remove stone, splinters, nails or other particles embedded in the tyre treads.

Bald spots / swelling may be caused by internal dam age. Rep lace the tyr es, if defective.

Rep lace tyr es when the tread depth has reached the minimum as specified.

Periodically inspect wheels for spokes breakage and wheel rim run out.

Check proper seating of the tyre beading on the rim whenever the tyre is reassembled.

Whenever a new tyre is installed, ensure rim and spokes do not get damaged on account of using wrong levers.


Use only standard tyres & tubes inflated to correct pressure.

TYRE PRESSURE

Solo

With Pillion

Front t

1.41 kg/cm2

(20 PSI)

1.55 kg/cm2

(22 PSI)

Rear

2.11 kg/cm2

(30 PSI)

2.25 kg/cm2

(32 PSI)

FRONT WHEEL REMOVAL

Place the vehicle on center stand

Place a wooden block the fr ont end of engine to support the vehicle.

Dis connect speedo cable.

Loosen the pinch bolt on the RH fork guide.

Hol d fr ont axle by spanner and loosen axle nut then remove nut along with washer.

WARNING

Tyres, rims and air valves must be correctly 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.

47


Tap and remove the front wheel spindle

Tilt the vehicle to RH Side and take out the wheel along with speedo drive with bush & LH side spacer.

Take out Speedo drive and bush on the RH side as shown in pic.

CAUTION

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

Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid pads activation in the event the front brake lever is accidently pressed.

48

FRONT WHEEL ASSEMBLY

Remove the wooden piece / card board sheet placed between the brake pads.

Place the bush sp eedo dr ive in position and place speedo drive over it.

Insert the wheel alo ng wit h speedo drive assembly and

LH spacer between the front fork ends ensuring the brake di sc i s lo cated in between the brake pads.

Ins ert and tap the fr ont wheel ax le gently inside.

Refit the washer and tighten the nut firmly.


Tighten the pinch bolt on the RH fork guide.

Rotate the wheel and check for smooth rotation.

Connect the speedo cable to speedo drive unit and rotate the wheel to check for proper working of speedo meter.

Press brake lever 2 or 3 times to check front brake efficiency.

NOTE

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

49

REAR WHEEL REMOVAL

Place the vehicle on center stand on a firm and flat surface.

Note and mark the position of the chain adjuster butting wi th the stopper on the right side.

Remove split pin and castle nut on the RH side.

Remove wheel spindle from LH side along with chain adjuster, taking care not to drop the wheel collar and spacer from the

LH side of the wheel.

Tilt vehicle to RH side and sli de o ut r ear wheel.


REAR WHEEL ASSEMBLY

Ensure the four cush rubbers are in position inside the rear wheel hub.

Tilt vehicle to right and insert wheel assembly between the swing arms.

Pos itio n the rear wheel with cush rubber on the rear chain sprocket.

Hold wheel collar and spacer in position.

As semb le the wheel s pindle along with chain adjuster from the

LH side of vehicle and gently tap it through the wheel.

Ensure that the chain adjuster knotch butts with the stopper as appropriate when both the front

& rear wheels are aligned.

Tig hten the cas tle nut fir mly and ensure that the hole on axle shaft and the slot on castle nut are ali gned to enable spl it p in fitment.

Fix the split pin.

50

CAUTION

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

WARNING

Ensure the vehicle does not come off centre stand whi le assem bling / disassem bling the wheel assembly. Failure to adhere could result in damage or serious injury.


ADJUSTMENTS - CLUTCH

2 to 3 mm

B

A

DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM)

Remove rear wheel split pin.

Clutch Lever (free play 2 to 3 mm)

CLUTCH FREE PLAY ADJUSTMENT

Loosen the cable outer lock nut (A).

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

Anticlockwise to increase the free play.

Check free play 2 to 3 mm at Clutch lever pivot on handle bar end.

Tighten lock nut (A) after adjustment is done.

51

Loosen castle nut, spindle nut, anchor nut and brake rod nut.

Turn the RH adjuster cam as appr o priately, till 25 to 30 mm slackness is achieved on the top run of the chain.


Check brake pedal free play, If necessary adjust.

Check that the front and rear wheels are correctly aligned.

Turn the LH adjuster cam appropriately, to align bo th t he wheels.

Check and ensure that the knotches on the cam are resting on the pin in t he swing arm on both sides.

Apply brake and tighten all nuts.

Finally Torque the anchor Nut.

CHECKING REAR BRAKE PEDAL HEIGHT

Loosen the lock nut.

Turn in or out the pedal stop pin bolt till the brake pedal and front footrest are in the same height / level as shown in above pic.

Tighten the lock nut

Check for free rotation of rear wheel.

52


REAR BRAKE PEDAL PLAY ADJUSTMENT CHAIN LOCK FITMENT

20 - 30 mm

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

The recommended brake pedal travel is 20-30 mm.

Check that the brake is not binding and the rear wheel rotates freely.

WARNING

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 loss of control and result in an accident causing. Brake shoes must be inspected for wear every 4000

Kms. If you ride under adverse conditions, (steep hills, heavy traffic, etc.) a more frequent inspection at 1600 Kms or less, is required.

53

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

WARNING

The fitment in wrong direction lock can lead to falling off of chain link thus disengaging the drive.

This will lead to potentially hazardous situation which, if not avoided, could result in serious injury.


ADJUSTMENT OF GAS FILLED SHOCKABSORBER

RH

Turn the adjuster such that the adjuster moves up to increase the spring tension and vice versa to reduce the spring tension.

Adjust both left hand and right hand shock absorbers so that the same knotch rests on the pin in both sides.

LH

WARNING

Ri ding the mot orcy cle with the knotches adjusted in different positions can cause loss of control and may lead to an accident.

The rear gas shock absorber is adjustable type i.e., the spring tension can be increased or reduced.

Increase the spring tension for high load operation.

Reduce the spring tension for low load operation.

The adjuster provided on the bottom of the spring has five knotches.

Insert special ‘C’ spanner on the bottom adjuster and rotate to change knotch position.

54

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

NOTE

Ensure no fouling of any accessories with rear shock absorber. Check for sufficient gap availability between the shock absorber and the attachments when the rear end of the motorcycle is fully loaded and the shock absorbers are fully compressed.


REMOVAL OF BATTERY ON VEHICLE

The vehicle is provided with 12V -

14 AH battery.

Unlock (turn the key anti clockwise) and remove the battery cover.

Remove the battery holding two rubber straps gently.

Pull out the battery and turn, then disconnect both the ter minal wi res

(negati ve and positive respectively)

Take out the battery.

55

BATTERY MAINTENANCE

The battery must be periodically checked for

Cl eanl iness and cor rosi on f ree terminals.

Electro lyte level mus t be abo ve

“MIN” level.

If electrolyte level is low, rem ove caps and top up with distilled water only.

Apply petroleum jelly over the batter y ter minals to av oid sulphation.


WARNING

Always disconnect the negative (-) battery cable first and then the Red positive (+) cable while removing the battery connections.

NOTE

For checking the battery voltage and electrolyte specific gravity, contact authorised Royal Enfield service or battery service centre.

CAUTION

Do not use battery with low electrolyte level as the battery internals cells will get damaged.

Do not overfill the battery electrolyte level as it will spill out through the overflow pipe and cause corrosion to vehicle parts.

Use only distilled water meant for use in batteries to avoid damage to battery.

Electrolyte should not be filled when the level is between minimum & maximum levels indicated in battery as “MIN” & “MAX”.

ASSEMBLY OF BATTERY ON VEHICLE

Position the battery in the battery carrier such that the negative terminal of the battery is towards fuel tap.

Ensure ignition switch is in ‘OFF’ condition.

Connect the positive terminal (Red wire) first.

Connect the negative terminal (Black wire) next.

Smear the terminals with petroleum jelly. (Do not use grease).

Refit the rubber strap bracket to hold the battery.

Refit LH side panel.

NOTE

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

56

CAUTION

Connect the +ve and -ve cables to the respective battery terminals. Failure to do so may result in damage to the motorcycle electrical system.


CHANGING ELECTRICAL COMPONENTS

HEAD LAMP BULB REPLACEMENT

Lo osen the head lamp holding top screw. Then pull out head lamp assembly.

Detach bottom lug from the head lamp housing body.

Di sconnect head lamp wir e co nnectors Green,

Orange and Blue col or terminals.

Remove rubber grommet from the reflector

Assembly.

Gently pres s the bulb holding ‘U’ clip from both the sides downwards and release it from reflector slot as shown.

Pull out head lamp bulb and inspect its filament for fuse.

57

CAUTION

Never touch the bulb with your fingers, Finger prints will etch the glass and decrease bulb life. Always hold the bulb with paper or clean dry cloth during handling.


ASSEMBLING THE HEADLAMP

Refix the new head lamp hal ogen bul b into reflector unit by locating the wide protrude on top side mounting.

Fix bulb holding U clip into ref lector body knotch, then press the both ends of clip and lock in its slot.

Fit the rubber grommet.

Connect the wire couplers as mentioned below.

TOP SIDE: GREEN COLOUR

RIGHT SIDE: BLUE COLOUR

LEFT SIDE: ORANGE COLOUR

Position the reflector ring bottom lug into head lamp casing slot and slide it, then tighten t he top mounting screw.

NOTE

After connecting above said procedure, turn ignition switch to “ON” condition and then check, ensure that flash light working in HIGH BEAM mode.

58

If you use the bulb other than specified rating (12V

55/60W) may result in over loading electrical system lead to prematu re f ailu re o r fr equent b atter y discharge.


TAIL LAMP BULB REPLACEMENT

Remove the two nuts each from RH & LH side of the rear number plate holder.

Pul l ou t Tail Lamp as semb ly along wi th bracket and twist the bulb holder in anticlockwise to remove bulb holder assembly.

Turn old bulb to remove and replace with a new bulb.

Refit the bulb holder and turn clockwise to lock the bulb holder.

Refit the tai l lamp wi th b racket on the reverse order of removal process.

59

TRAFFICATOR BULB REPLACEMENT

Remove the 2 screws & take out trafficator glass cover.

Press bulb gently & Turn anticlockwise to take out the bulb.

Pos itio n the new bulb ins ide the hold er, ensuring that the pins in the bulb, match with the slots in the holder.

Press the bulb and turn clockwise to lock the bulb in the holder.

Refit the trafficator cover cut sl ot m ark faci ng downwards and tighten the 2 screws.

Cut Mark


FUSE

Open the LH tool box.

Take out tool kit.

Remove fuse holder rub ber & li ft f use carrier top cover.

4

3

2

1

Replace the required fuse with the spare fuse available in the fuse carrier.

NOTE

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

60

BLADE FUSE USAGE LIST

Fuse No.

1

2

3

4

Color

Blue

Red

Red

Blue

Remarks

Main Fuse (15A)

Ignition Fuse (10A)

Spare Fuse (10A)

Spare Fuse (15A)


AIR FILTER PAPER ELEMENT CLEANING/REPLACEMENT

Insert the key, turn anti clokwise to remove RH side air filter box lid.

Tap the filter element to remo ve d ust as shown and clean tho roug hly befo re assembly.

Clean both intake adaptors and duct as shown in pic.

Loosen the filter hol ding nut by

10mm spanner as shown in pic.

Remove the nut, washer and cover air filter to take out air filter element.

Assemble the filter element and cover in the reverse order of dismantling process.

Please ensure proper sealing of cover plate against air filter element.

61

WASHING PROCEDURE

PRECAUTIONS AFTER WASHING

Wash vehicle when the engine is cold.

Cover the silencer tail end and control switches with suitable plastic bags and tie it firmly to prevent water entry into them.

Remove ignition key and seal key hole using adhesive tape.

Use a suitable engine degreaser, available with your local parts store, to remove dirt or grease from the engine external parts if required. Follow the directions in the label carefully before using the degreaser.

Use low pressure jet of water to clean the entire vehicle.

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.

Use luke warm water and mild detergent on the painted components to remove dirt, etc.

Rinse vehicle thoroughly with plain water to remove the detergent and wipe vehicle dry.

If possible, use compressed air and blow off water particles from the obscure areas of the vehicle, electrical connections etc.

62

Ensure, the vehicle is thoroughly dry by wiping with a clean soft absorbent cloth or chamois leather.

Remove all plastic bags and adhesive tapes.

Lubricate control cables, pivot and rear chain with lube oil

Polish the painted and plated surfaces using polishing wax.

Start the bike allow engine to idle and warm up.

Drive the motorcycle slowly, applying both brakes intermittently to dry up the brake shoes.

Test brakes for full efficiency.

WARNING

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 your Motorcycle is not going to be used for a month or more, we advise the following precautions to the taken.

Carryout required repair / adjustments on the motorcycle.

Wash the motorcycle thoroughly and lubricate as per the maintenance chart.

Start the engine, warm up for a few minutes and switch off.

Drain out the fuel completely from the fuel tank and fuel lines.

Remove spark plug. Pour in about 25ml of clean engine oil through spark plug hole. Close the hole and cr ank engi ne s ever al times and ref it sparkplug.

Clean rear chain thoroughly and apply a thin film of lube oil.

63

Remove batter y fro m the b ike. Clean t he terminals free of corrosion.

Maintain electrolyte level between max or min mark, by adding distilled water and wipe the battery dry.

Sto re the b atter y i n a cool , dr y and well ventilated place.

Do not place the battery in direct sun light, near open flame or where temperature is above 40 o C or below 0 o C

Cover the silencer with plastic bags to prevent moisture entry. Set the motorcycle on its center stand.

Apply anti rust solution on all chrome plated parts. Take care not to apply this solution on rubber or painted parts.

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

Remove anti rust solution from all chrome plated parts and clean the motorcycle.

Inflate the tyres to the correct tyre pressure.

Ensure batter y is fully charged and proper electrolyte level is maintained.

Connect the battery.

Lubricate all control cables and pivots.

Check proper level of oil in engine.

Fill fuel tank with fresh petrol.

Check fuel line / hose for any cracks or cuts.

Clean the air filter.

Remove plastic covering from the silencer.

Remove spark plug on cylinder head and pour in a few drops of engine oil. Crank engine a few times to lubricate cylinder walls and piston.

Clean spark plug and refit.

Switch “ON” ignition switch.

Start vehicle and warm up engine for a few minutes before riding the vehicle.

NOTE

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

64

CAUTION

Proper long-term storage is important for the safe, tr oubl e-fr ee o peration of your Roy al Enfield motorcycle.

LONG TRIP PRECAUTIONS

CHECKS PRIOR TO THE COMMENCEMENT OF

LONG JOURNEY

Ser vice the motorcycle thoroughly at Royal

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

41 & 42)

Sufficient quantity of petrol in the fuel tank for the journey planned.

Check and correct tyre pressure if necessary.

CHECKS AFTER EVERY 1500 KMS OF RUN

Tightness of all fasteners.

Tyre tread condition and wear of tyres.

Battery condition and electrolyte level.

Correct oil level in engine.

Working of all lights and horn.

Proper drive chain tension.

65

ITEMS TO BE CARRIED

Tool kit.

First aid kit.

Bulbs for Headlight, Trafficator light, Rear Tail

Lamp and Fuse (10 & 15 Amps).

Accelerator, Clutch and Speedo Cable.

Rear chain master link lock assembly.

Spare tube, puncture repair kit - cold vulcanising type.

Foot operated Air Pump.

Insulation tape.

Spark plugs (M14 & M10), Fuel hose.

CARING FOR MILEAGE

STOP THE DROP THAT LEAKS

Petrol leak at a rate of one drop per minute accumulates to 5,25,600 drops a YEAR! That is, 35 ltrs of Petrol.

Petrol leaks cause raw petrol smell. Get the leaks arrested immediately.

Both lower and higher road speeds cause low kilometers per litre of petrol.

PERFORM PREVENTIVE MAINTENANCE AS PER

RECOMMENDATIONS

REGULAR PREVENTIVE MAINTENANCE ENSURES

USE RECOMMENDED FUELS AND OILS ONLY

Wrong grade or adulterated petrol does not burn fully and results in heavy smoke, high rate of carbon deposition in cylinder and exhaust system and low mileage.

Wrong grade and inferior quality oils do not lub ricate well. The mov ing parts wear prematurely.

Always use recommended fuel (unleaded > 87 octane petrol) and oils only.

Correctly inflated tyres.

Fasteners tightened to correct torques.

Freely moving engine & transmission components.

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.

RIDE AT COST EFFECTIVE SPEED

Cost effective speed (in top gear) is 45 to 50 Km per hour.

66

STOP

Revving : Ten revvings wastes 20 ml. of petrol

Racing starts : Ten racing starts wastes 150 ml.

of petrol.

CARING FOR MILEAGE

Sudden acceleration : Ten sudden accelerations wastes 100 ml. of petrol.

STOP BRAKE RIDING

For better mileage, use front and rear brakes simultaneously when absolutely needed. Control vehicle speed with throttle and gear like smart riders always do.

Brake riding pushes the brake shoes to come in contact 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

Clutch riding slips the clutch & engine drive does not get totally transferred 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

Braking arrests the road speed. Motorcycle momentum is reduced. Additional fuel is burnt for subsequent acceleration.

67

AVOID OVER LOADING

Over loading tyres the engine, wears the parts faster and reduces mileage.

PARK YOUR VEHICLE IN SHADE WHEN NOT IN USE

Petrol is highly volatile. It evaporates under no rmal atm ospheric temper atur e. T he evaportion increases with temperature. Prevent this loss by always parking your vehicle under shade.

Too few Kms running per day allows more time for evaporation affecting the mileage.

COMPLETE WIRING DIAGRAM - BULLET 500

NOTE : Complete Wiring Diagram is attached on this page.

VEHICLE STARTING PROCEDURE

BASIC GUIDELINES TO BE FOLLOWED “FOR ALL ELECTRIC START VEHICLES”

1.

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

5.

6.

2.

3.

4.

Apply choke in cold start condition. (ambient temperature <25° C)

DO NOT ATTEMPT – “HALF START” BY CASUALLY PRESSING ELECTRIC START BUTTON.

PLEASE PRESS AND HOLD ELECTRIC START BUTTON FOR ATLEAST 3 SECONDS CONTINUOUSLY FOR

THE CRANKING OR UNTIL THE ENGINE FIRES AND SUSTAINS, WHICHEVER IS EARLIER.

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

It is advised not to apply excessive throttle during starting.

68

BLACK

BLACK/GREEN

BLACK

GREY

LIGHT GREEN

WHITE

RED

BROWN

BROWN

WHITE/RED

BLACK

BLACK

BLACK

RED

YELLOW/WHTE

BLACK

GREY

LIGHT GREEN

GREY

GREY

BLUE

GREY

GREY

BLACK

BLACK/WHITE

BLACK/GREEN

RED/WHITE

RED/WHITE

GREEN

GREEN

B/G

B/W

B/G

B/W

BLADE FUSE LIST

TCI FUSE

IGNITION LOADS

Fuse 1

Fuse 2

Fuse 3

Fuse 4

TROUBLE SHOOTING

CAUSES REMEDIES

I. ENGINE FAILS TO START

1) Ignition switch in ‘OFF’ Position ...............................................

2) Engine Stop switch in ‘OFF’ Position .......................................

3) Clogged fuel line / tap ..............................................................

4) Vent hole clogged in fuel tank cap .......................................

5) Fuse blown ....................................................................................

6) Carburetor passage & jets blocked .......................................

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

7) Carburetor float stuck in closed position .............................

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

9) Loose HT connections ................................................................

10) HT Lead Damaged .....................................................................

11) Spark plug electrode dirty / fouled ........................................

12) Spark plug insulation cracked ...............................................

Switch on ignition.

Push stop switch to ‘ON’ position.

Clean the fuel line / tap.

Clean vent hole.

Check and Replace (Ref. Page No. 60)

*Dismantle carburetor & clean jets

/ passages

Ensure correct movement of float

Fix cap / lead firmly

Fix connections firmly

*Replace HT Lead

Clean spark plug & Reset gap.

Replace spark plug

* Contact Authorised Dealer / Service Point

69

TROUBLE SHOOTING

CAUSES

13) Poor compression

- Auto Decompressor not working ..........................................

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

- Loose spark plug ......................................................................

14) Clutch slipping ............................................................................

REMEDIES

*Ensure free motion of flyweight in exhaust cam gear assembly

*Tighten spark plug.

*Adjust clutch cable free play

II. ENGINE MISFIRING

1) Water in petrol tank/carburetor ..............................................

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

2) Leak through intake hose ........................................................

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

3) Loose spark plug cap ................................................................

4) Spark plug fouled/insulation broken ....................................

5) Poor Compression .......................................................................

6) Loose electrical connections / coupler .................................

*Clean carburetor / petrol tank. Fill tank with fresh petrol.

Tighten rubber hose suitably.

Replace if necessary

Fix cap / lead firmly

Clean / reset gap or, replace.

*Auto decompressor sticky or not working

*Battery cable / fuse carrier / coils / TCI unit / Switch


70

TROUBLE SHOOTING

CAUSES REMEDIES

III. ENGINE STARTS, BUT RUNS IRREGULARLY & STOPS

1) Faulty fuel supply ......................................................................

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

Clean the fuel line / tap / vent hole

Increase idling speed

IV. POOR PICKUP

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

2) Faulty fuel supply .......................................................................

3) Choked air filter ..........................................................................

4) Loose carburetor mounting .....................................................

5) Brakes adjusted too tight ..........................................................

6) Rear chain adjusted too tight .................................................

7) Clutch Slipping ............................................................................

8) Under inflated tyres ...................................................................

Adjust cable free play

Clean the fuel line / tap / vent hole

Clean / Replace air filter

Tighten clamps firmly

*Re-adjust properly

*Re-adjust properly

*Adjust clutch cable free play

*Inflate to correct pressure


71

TROUBLE SHOOTING

CAUSES REMEDIES

V. WHITE/BLUE SMOKE

1) Oil level in tank above the middle line in the ....................

oil level window

2) Worn out valve oil seal ..............................................................

3) Worn out piston ring / cylinder ................................................

VI. ENGINE OVERHEATING

1) Cylinder fins not clean ..............................................................

2) Clutch slipping ............................................................................

3) Suction leakage ..........................................................................

4) Incorrect carburetor adjustments ..........................................

VII. EXCESSIVE FUEL CONSUMPTION

1) Fuel leakage ................................................................................

*Check and drain excess oil

*Check / Replace

*Check / Replace

Clean the cylinder fins at regular intervals

*Check and correct

*Check and correct

*Check and correct

*Check and rectify


72

TROUBLE SHOOTING

CAUSES

2) Worn out carburetor jets ...........................................................

3) Incorrect carburetor adjustments ..........................................

4) Choked air filter ..........................................................................

5) Poor compression .......................................................................

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


VIII. IGNITION KNOCK

1) Carburetor adjusted too lean .................................................

2) Suction / intake system leakage .............................................

IX. BRAKES POOR

1)

2)

Not adjusted properly ...............................................................

Oil / grease on lining or drum or disc ...................................

REMEDIES

*Change the defective jets

*Check and adjust correctly

Clean / Replace

*Auto decompressor sticky or not working properly

Inflate to correct pressure

*Check and readjust

*Check and correct

*Adjust properly

*Clean and refit


73

TROUBLE SHOOTING

CAUSES

3) Linings worn / Uneven wear ....................................................

4) Drum scored / Uneven wear ....................................................

X. VEHICLE WOBBLES

1) Wheel rim runout ........................................................................

2) Loose / Broken spokes ................................................................

3) Tyres not fitted correctly ............................................................

4) Wheels misaligned .....................................................................


XI. ELECTRICALS

Bulbs do not glow

1) Loose / improper connection ..................................................

2) Bulb fused .....................................................................................

3) Fuse blown ....................................................................................

4) Switch defective ..........................................................................

REMEDIES

*Replace linings

*Rectify or Replace drums

*Rectify

*Tighten / Replace spokes

*Refit tyres correctly

*Ensure proper alignment

Inflate to correct pressure

*Check and correct

*Replace bulb

Replace fuse

*Replace switch


74

TROUBLE SHOOTING

CAUSES

Horn not working

1) Loose connections ......................................................................

2) Requires tuning ...........................................................................

3) Switch Defective ..........................................................................

4) Fuse blown ....................................................................................

Trafficators not working

1) Loose / improper connections .................................................

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

3) Switch defective ..........................................................................

4) I.C. Flasher defective .................................................................

Brake light remains “ON”

(1) Switch not adjusted properly ..................................................

(2) Switch sticky .................................................................................

REMEDIES

*Check and correct

*Tune horn

*Replace

Replace fuse

Check and correct

Replace

*Replace

*Replace

*Adjust switch properly

*Replace switch


75

TROUBLE SHOOTING

CAUSES

XII. ELECTRIC START

VEHICLE NOT STARTING

(1) Neutral indicator not glowing ................................................

(2) If vehicle is without neutral indicator ...................................

(3) Loose Connection .......................................................................

(4) Starter relay not working ..........................................................

(5) Malfunctioning of clutch switch .............................................

(6) Malfunctioning of Starter switch ............................................

(7) Battery discharge .......................................................................

(8) Motor not working ......................................................................

(9) Battery not fully charged ..........................................................

(10) Failure of sprag clutch ..............................................................

REMEDIES

Bring the vehicle in neutral

Press the clutch lever & start switch together

*Check & Correct

*Check & Replace

*Check & Replace

*Check & Replace

*Check & Recharge

*Check & Replace

*Check & charge

*Check & replace


76

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.

77

WARRANTY TERMS & CONDITIONS

(b) Components like fuel filter, oil filter paper element, control cables, brake shoes / brake pads, clutch plates, drive chain & sprocket kit, which are subjected to normal wear and tear.

(c) Damages due to use of lubricant / oil / grease etc. other than specified by RE.

(d) Damages due to use of non-genuine parts.

(e) Damages due to lack of proper maintenance of the vehicle.

(f) Damages due to incorrect driving or riding habits.

(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.

78

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.

79

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

Observes all the important instructions and any other precautions listed in the owner’s manual.

Under all circumstances uses lubricants and fuel as recommended by Royal Enfield.

Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the details in the Log book.

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.

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

80

EMISSION WARRANTY pursuant upon being directed by an officer as referred to in sub rule (2) of rule 116 of the Central Motor

Vehicles Rules (CMVR).

Produces the owner’s manual and Log book for verification details.

Produces receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date of original purchase of the vehicle.

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

THE EMISSION WARRANTY SHALL NOT APPLY IF

A valid “Pollution under control” certificate is not produced.

The motorcycle is not serviced by Authorised Dealer / Service Point as per the service schedule described in the maintenance chart.

The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met with an accident.

Replacement parts not specified and approved by Royal Enfield have been used.

The motorcycle, or parts thereof, has been altered, tampered with or modified or replaced in an unauthorised manner.

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.

The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records.

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.

81

EMISSION WARRANTY

The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by Royal

Enfield in the Owner’s manual or any other document given to the customer at the time of sale of the motorcycle.

The emission related components are tampered with.

All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced.

All 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 THE RIGHT SIDE OF LAW

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

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 TO REDUCE POLLUTION

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.

82

ALL INDIA ROAD SIGNS

MANDATORY SIGNS CAUTIONARY SIGNS

INFORMATION SIGNS

83

FREE SERVICE COUPONS

It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide four free services at specific Intervals.

Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory service, kindly return the free service coupon duly filled in and signed, to the service outlet.

Availing the free services in the specified time is a prerequisite to warranty consideration.

84

1

ST

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)

1ST FREE SERVICE

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

Customer Name :

Address :

Dealer Code :

Frame No:

Engine No:

Vehicle Installation Form No.

ODO Reading :

Sold by (Dealer’s Name & Address)

Regn. No:

Sale Date:

Serviced Date:

Serviced by

(Dealer’s/ASP Name & Address)

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

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

Contact Phone / Mobile No.:

85

1ST FREE SERVICE ACTIVITIES

1.

Water wash the vehicle and dry it with a clean cloth

2.

Electrolyte ......................................................

3.

Battery terminals .........................................

Check level & top-up

Clean and apply petroleum jelly

4.

Drive chain free play .................................

5.

Rear brake pedal pivot ............................

6.

Rear brake ....................................................

7.

Wheel rims front & rear .............................

8.

Front & Rear brake .....................................

9.

Front fork oil leak .........................................

10. Air filter element ..........................................

11. Spark plugs (2 Nos) ....................................

12. H.T. Leads ......................................................

13. Carburetor ....................................................

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

15. Fuel hose ........................................................

16. Rubber hose, Air filter to carburetor .....

17. Accelerator cable .......................................

18. Clutch cable ..................................................

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

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

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

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

Check, clean, lubricate & adjust

Lubricate

Adjust

Check spokes tightness

Check & Adjust

Check for leakage

Clean

Check, clean & adjust gap

Inspect for cracks

Drain & Tune

Clean

Inspect for cracks

Inspect for cracks

Check & adjust play

Adjust play

Clean

Replace

Replace

Lubricate

86

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

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

ASP / Dealer’s

Stamp &

Signature

2

ND

FREE

SERVICE

3000 Kms or



Record


2ND FREE SERVICE


Customer Name :

Address :

Dealer Code :

Frame No:

Engine No:


ODO Reading :


Regn. No:

Sale Date:

Serviced Date:

Serviced by





87

2ND FREE SERVICE ACTIVITIES

1.


2.

Electrolyte ......................................................

3.


4.


5.





Lubricate

6.

Rear brake ....................................................

7.


8.

Front & Rear brake .....................................

9.

Front fork oil / leak .......................................


11. Spark plugs (2 Nos) ....................................

12. H.T. Leads ......................................................

Adjust


Check & Adjust

Check for leakage

Clean


Inspect for cracks

13. Carburetor ....................................................

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

15. Fuel hose ........................................................



18. Clutch cable ..................................................

19. Steering free play .......................................

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


22.

Oil filter element, oil strainer & magnetic drain plugs.

Drain & Tune

Clean

Inspect for cracks

Inspect for cracks

Check & adjust play

Adjust play

Check & Adjust


Lubricate

Clean

88

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

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

ASP / Dealer’s

Stamp &

Signature

3

RD

FREE

SERVICE

6000 Kms or



Record


3RD FREE SERVICE


Customer Name :

Address :

Dealer Code :

Frame No:

Engine No:


ODO Reading :


Regn. No:

Sale Date:

Serviced Date:

Serviced by





89

3RD FREE SERVICE ACTIVITIES

1.


2.

Electrolyte ......................................................

3.


4.


5.





Lubricate

6.

Rear brake ....................................................

7.

Swing Arm Bush & Spacer ........................

8.


9.

Front & Rear brake .....................................

10. Tyres front & rear ........................................


12. Spark plugs (2 Nos) ....................................

13. H.T. Leads ......................................................

Cam clean, lubricate & Adjust play

Lubricate


Check & Adjust

Check wear and tread depth

Clean


Inspect for cracks

14. Carburetor ....................................................

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

16. Fuel hose ........................................................



19. Clutch cable ..................................................

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

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

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


24. PAV System .....................................................

25. Steering System ............................................

Clean, O/H & Tune

Clean

Inspect for cracks

Inspect for cracks

Check & adjust play

Adjust play

Clean

Replace

Replace

Lubricate

Check & Clean

Check, Lub. steering balls & adj. play

90

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

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

ASP / Dealer’s

Stamp &

Signature

4

TH

FREE

SERVICE

9000 Kms or



Record


4TH FREE SERVICE


Customer Name :

Address :

Dealer Code :

Frame No:

Engine No:


ODO Reading :


Regn. No:

Sale Date:

Serviced Date:

Serviced by





91

4TH FREE SERVICE ACTIVITIES

1.


2.

Electrolyte ......................................................


3.



4.


5.


6.

Rear brake ....................................................

7.


8.

Front & Rear brake .....................................

9.

Front fork oil / leak .......................................


Lubricate

Adjust


Check & Adjust

Check level & replace oil


11. Spark plugs (2 Nos.) ...................................

12. H.T. Leads ......................................................

13. Carburetor ....................................................

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

Clean


Inspect for cracks

Drain & Tune

Clean

15. Fuel hose ........................................................



18. Clutch cable ..................................................

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

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


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

23. Tyres ................................................................

Inspect for cracks

Inspect for cracks

Check & adjust play

Adjust play

Clean


Lubricate

Check and Lubricate Steering Balls & Adjust

Check wear and tread depth

92

CUSTOMER

COPY

Job Card No:

Date :

Odo Reading :

Name of Dealer/

ASP with Code:

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

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

ASP / Dealer’s

Stamp &

Signature

PAID SERVICE / MAINTENANCE RECORD

CUSTOMER COPY

12,000 + 250 Kms. Service

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

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

Brief Work Done :

Dealer’s Stamp & Signature

DEALER / ASP COPY


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


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93


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100


LOG BOOK

Sl.

No.

Date Kms.

Details

Idling

Co%

Authorised Dealer / Service Point

Job Card No.

Stamp &

Signature

101

LOG BOOK

Sl.

No.

Date Kms.

Details

Idling

Co%


Job Card No.

Stamp &

Signature

102

LOG BOOK

Sl.

No.

Date Kms.

Details

Idling

Co%


Job Card No.

Stamp &

Signature

103

LOG BOOK

Sl.

No.

Date Kms.

Details

Idling

Co%


Job Card No.

Stamp &

Signature

104

LOG BOOK

Sl.

No.

Date Kms.

Details

Idling

Co%


Job Card No.

Stamp &

Signature

105

NOTES

106

NOTES

107

NOTES

108

Telephone Office

E

Sales Representative or

Telephone Residence

Bike Regn. No.

Invoice No.

Delivery Note / Advice No.

Have you visited Royal Enfield website? Yes No

PRE DELIVERY INSPECTION LIST

MODEL: BULLET 350 / ELECTRA / CLASSIC 350 / CLASSIC 500 / BULLET 500

Model :

Dealer's Name :

Engine No:

Location:

Colour : Key Number :

Battery Number : Battery Make : Tyre Number : Front :

Aggregate Area

Defect

Code

Measure

CHASSIS / ENGINE

NUMBER

1

CONNECT BATTERY /

CHECK VOLTAGE

2

ENGINE OIL

LOCK OPERATION

PETROL

5

6

Engine / Vehicle Number Details DF Same

3

4

Battery Charging

D / NC / Weak Battery Voltage 12V-whereas

Cell 13.5 V (Max. online voltage)

Replace oil & oil filter / Check Oil level (3 Drain

EO - (Drained

Bolts system Hex 19mm, 8mm X 2nos and

Hex 12mm head bolts)

Oil Level)

Fill 2.5 Litres (Capacity is

2.75 Litres) - Remove 3

Drain Bolts to Drain the complete Oil

Clean Clean Primary Oil Strainer screen

Ignition / Side Air Filter Box / Tool Box Lock /

Fuel Tank Lock

Fill Petrol

H / LF / NW

-

Same

5 Litres

Defect

#1

Defect

#2

Defect

#3

Rear :

7 Brake Lever Free Play EP / T 2-3 mm / (STD)

Remarks

FRONT WHEEL

CLUTCH

8

9

Caliper Mounting Bolts

Front Wheel Rotation

LF

W / T / LF / N

2.7 to 3.0 Kgm

Free ( Check Spokes

Looseness & Runout

10

Front Mudguard Alignment / Cover Tube

Rubbing

11 Front Wheel Nut

M / RB

LF

12 Front Tyre Condition (Check Tyre Line Seating) WF

Straight

7.0 to 7.7 Kgm

Good

13

14

15

16

Front Tyre Pressure

Clutch Operation

Clutch Lever Free Play

Accelerator Operation

LESS

H / N

EP / V / T

T / SY

22 PSI

Smooth

2 - 3 mm

Smooth

17 Lever Brackets Tightness

18

HANDLE BAR

CONTROLS &

19

ELECTRICAL SWITCH

20

OPERATIONS

21

Switch Modules Tightness

Steering Movement

Handle Bar Positioning

Lock Nut T- Stem

22 Electrical Switch Operation

FUEL SYSTEM

REAR WHEEL

23

24

25

26

27

28

29

30

Neutral Lamp

Fuel Tap Operation

Fuel Leak

Fuel Tank Alignment

Rear Brake Pedal Free Play

Pedal Position w.r.t foot rest

Chain Tension

Rear Wheel Rotation

31 Anchor Pin Nut

32 Rear Mudguard Alignment

LF

LF

T

WF

LF

NW / F

NW / F

H / NW

L

M

T / EP

DF

Tight

Tight

Free

W.r.to Dot Punch

T / EP

W / T / LF / N

LF

20 - 25 mm

Free (Check Spokes

Looseness & Runout)

4.5 Kgm

M

33 Rear Tyre Pressure

35 RR Shock Absorber Operation / Adjustment

LESS

34 Rear Tyre Condition (Check Tyre Line Seating) WF

H / N / AD

4.5 to 5.5 Kgm

No Defects

No Defects

Smooth / Main / Reserve

No Leak ( Tank, Tap,

Carburetor)

Straight

20 - 30 mm

Same Level

Straight

32 PSI

Good

Smooth

AESTHETICS

OTHERS

TEST RIDE

36 Mudguards - Paint / Plating Related

37 Fuel Tank - Paint Related

39 Head Lamp Casing - Paint Related

40

Powder Coated Parts (Scratch / Rust /

Chipped OFF)

41 Plated Parts (Scratch / Rusty)

42 Buffed components poor Buffing & Scratches SC / DU

43 Seat Alignment

44 Indicators Alignment (MFR / Amber)

45 Stickers / Knee Pads

46 Nuts, Bolts, Fasteners (Torque)

47 Owner's Manual & Tool Kit Content

48 Spare Fuse in Fuse Carrier

49 Starting (Kick Start / Self Start)

50 Front / Rear Brakes Effectiveness / Feel

51 Pulling

52 Vibration

53 Wobbling

54 Front Fork / Drive Chain Noise

SC / PD / R /

DN

No Defects (Mudguards /

Fuel Tank / Tool Box

SC / PD / R /

DN

SC / PD / R /

DN

No Defects

No Defects

SC / PD / R / No Defects

SC / PD / R

SC / R / PO

M

M

M / LF / SC

LF

-

NA

ST / N

AD / SG

P

V

W

N

No Defects

No Defects (Mudguards /

Fuel Tank / Wheel Rim /

Indicator

No Defects

No Defects

No Defect / Colour

No Defects

Tight (RH, LH Cover /

Engine Foundation /

Accessories / Wheel Nut)

Availability

Tubular / Blade Fuse

Easy Start

Sharp

Straight

Smooth

No Defects

No Defects

56 Any Rattling / Squeaking Noise

57 Easy Start (Hot Condition)

STATIC CHECK

(AFTER TEST RIDE)

58 Leak

59 Smoke / Oil Droplets in Silencer

60 Cam Noise / Top End Noise

N / ST / J / H Smooth

N

ST / NW

L

SK / EO

N

Nil (Silencer / Accessories

/ Body Parts /

Suspension)

Smooth

No Leak (Oil / Fuel /

Hydraulic / Acid Leakage)

No Smoke

Smooth

Lens Colour Check

ANY OTHER

Note ** Any Abnormal Noise or Engine Open cases during PDI Inform to Plant / Factory

1. Check the vehicle thoroughly for any transit damages or shortage of parts.

INSTRUCTIONS

4. Please ensure delivery of the vehicle in brand new condition.

5. Claim transit loss and damage through ‘TRANSIT’ insurance only.

2. Carry out all jobs listed under Pre-delivery Inspection Schedule.

3. Thoroughly road - test the vehicle for performance.

6. Claim Parts replaced for Manufacturing defects only under warranty.

Misalignment

M

Noise

N

Vibration

V

Leak

L

Starting

Trouble/Missing

ST

Less

LESS

Wobbling

W

Loose

Fitment

LF

Discharing Tight Fused Scratch Pulling

D T F SC P

Dent

DN

Wrong

Fitment

WF

Hard

H

Jerking

J

Excess Play

EP

Different

DF

Spongy Sticky

SG SY

Format No : F/14A/CS/02, Mar. 2013

Not

Available

NA

Smoke Adjustment

SK AD

Not

Working

NW

Paint Defect

PD

Rust

R

Peel Off

PO

Dull

DU

Excessive Oil Rubbing Not Charging

EO RB NC

DLR / CS COPY

BIKE INSTALLATION CONFIRMATION BY CUSTOMER

We congratulate you on becoming a proud owner of Royal Enfield bike. We request you to give this feedback after completion of the delivery process.

YES NO

1 Bike Documents explained

(Invoice, Insurance, RC / Road Tax Receipt)

2 Owner’s Manual received

3 Recommended Lubricants explained

4 Maintenance Schedule sheet in Owner’s Manual shown and explained

5 Next Free Service due explained

6 All Free / Paid Services explained

7 Warranty Guidelines explained

8 “Running in period” details shown in the manual explained

9 Service Station Address given and Location explained

10 Service Incharge Name & Mobile No given

11 Bike delivered in neat and clean condition

12 Tool Kit & First Aid Kit received and explained

YES NO

13 Control Switches & Disc Brake System usage explained

14 Fuse Box location shown and explained

15 Recommended Tyre Pressure explained

16 Bike starting & Gear shifting procedure explained

17 Quantity of Fuel in Fuel Tank informed

18 Bike orientation & short distance drive provided

19 Date and Time of Installation

20 Name of Person who did Installation

Suggestions If Any:

CUSTOMER

SIGNATURE

Model: Registration No.:

Chassis No.:

We thank you and request you to return this filled up form to the person who did the bike installation for you

KEEP RIDING

P

FORM 22

[See Rules 47(g), 115, 124 (2), 126A and 127 (1), 127 (2)]

INITIAL CERTIFICATE OF COMPLIANCE WITH POLLUTION STANDARDS, SAFETY

STANDARDS OF COMPONENTS AND ROAD WORTHINESS

Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and the rules made there under, including the following mass emission norms:

Brand name of the vehicle :Bullet 500

Chassis number :-

Engine number/motor number

(in case of battery operated vehicles)

Sub-rule No. of rule

Emission norms

[Bharat Stage-I/II/III/Bharat (Trem) Stage-III etc.]

:-

:-

:-

Date :

115(2)(i), 115(14)(F)

Bharat Stage III

For ROYAL ENFIELD

Quality Assurance

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