Royal Enfield Bullet 500 2018 User manual

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FOREWORDFOREWORD
Welcome to the Royal Enfield family.
Royal Enfield motorcycles are being manufactured by us since 1955 with state of the art technology, while taking
care to maintain the traditional Classic looks.
The motorcycle that you have just bought, confirms to United States Environment Protection Agency laws, Federal
Motor Vehicle Safety Standards and California Air Resources Board regulations.
This Owner’s manual will help you to acquaint with the important aspects of operation, care and minor maintenance
of your new Royal Enfield motorcycle. We recommend that you read this manual carefully, before using the
motorcycle which will help you to maintain your motorcycle in top riding condition. Major repairs are detailed in the
Royal Enfield service manual. Such major repairs require the attention of a skilled technician and use of special
tools and techniques. Your Royal Enfield Authorised Dealer has the facilities, experience and genuine Royal
Enfield spare parts necessary to render those valuable services in a correct procedure.
We have also provided several vital safety information for the rider and for the care and safety of the motorcycle.
Please read and follow these carefully for safe riding and for maximum riding pleasure. Please ride cautiously,
safely and within the law. Always wear a helmet, good riding goggles and proper riding clothes while riding the
motorcycle. Please insist and ensure that your pillion rider also follows these guidelines while riding with you.
Log on to the exciting world of Royal Enfield web site: www.royalenfield.com to get to know more about us and
exciting news from time to time.
We wish you many years of riding pleasure with your Royal Enfield motorcycle.
Royal Enfield team
Chennai,India.

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NOTICE
Part No. RAM00103/A / Qty. 250 / Nov. ‘18
Because of continous improvements 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 this manual was correct at the time it was approved for publication.
Royal Enfield,
Chennai
India.
© Copyright 2018 Royal Enfield (A unit of Eicher Motors Ltd.). All Rights Reserved. No part of this
manual shall be copied, distributed or otherwise dealt without the express permission in writing
of Royal Enfield.
Toll free no : 1-866-600-1122
E mail ID : [e-mail]

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IMPORTANT
United States Environment Protection laws, Federal Motor Vehicle Safety Standards and California
Air Resources Board strictly prohibits tampering with the Exhaust Emission Control, Noise Control
and Evaporative Emission Control systems:
We would like to emphasize that any repairs to the induction, emission, exhaust and evaporative systems
must be performed only by a Royal Enfield Authorised Dealer so that the motorcycle confirms to the United
States Environment Protection laws, Federal Motor Vehicle Safety Standards and California Air Resources
Board regulation.
It is the responsibility of the Owner / User of the motorcycle to read this manual carefully and to comply with
the safety guidelines, operating instructions, and periodical maintenance instructions given here. Keep this
manual in a convenient place for easy reference. DO NOT use the motorcycle until you have become familiar
with this motorcycle and after reading and understanding this manual completely. In case you need any
further clarifications, please contact a Royal Enfield Authorised Dealer, nearest to you, for assistance.
If your motorcycle is being used by a friend, relative, or any other person, it is your responsibility to make
certain that they have completely understood the operating procedures of the motorcycle, and the contents
in this manual with particular reference to the safety aspects, before riding your motorcycle.
This motorcycle is designed for NORMAL ON ROAD USE ONLY. Operation in off-road usage in some areas
may be illegal and could be dangerous. Please obey local laws and regulations.
In the event of your motorcycle being sold to another person, it is your responsibility to hand over this
manual along with the motorcycle to the new owner.

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If you believe your motorcycle has a defect which could cause a crash and result in serious injury or loss
of life, you should immediately contact the National Highway Traffic Safety Administration (NHTSA) in
addition to notifying Royal Enfield North America Limited, 226 N Water St., Milwaukee WI 53202 US.
If NHTSA receives similar complaints, it may open an investigation and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in any individual problems between you, and your dealer or Royal Enfield North America Limited.
To contact NHTSA you may call the Auto Safety Hotline toll-free within the United States on 1-800-
424-9393 or write to: NHTSA, 400 Seventh Street SW, Washington, DC 20590. You can also obtain
other information about motor vehicle safety from the hotline.
REPORTING SAFETY DEFECTS

5
SAFETY DEFINITIONS
Statements in this manual preceded by the following words are of special significance:
WARNING
Indicates a potentially hazardous situation, which if not avoided, could result in an accident causing
serious injury or loss of life.
CAUTION
Caution with the safetyalert symbol, indicates a potentially hazardous situation, which if not avoided, may
result in minor or moderate injury leading to disability.
Caution :
Caution without the safetyalert symbol indicates a potentiallyhazardous situation, which if not avoided,
may result in damage to the motorcycle and its rider, property etc.
All images in this manual are only for reference and to explain the relevance. They may not be exactly
the same in themotorcycle you own. Technical specifications aresubject tochange without prior notice.
IMPORTANT NOTICE !

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CONTENTS
PERSONAL&VEHICLEINFORMATION ........................ 7
SAFEOPERATINGRULES.............................................. 8
RULESOFTHEROAD .................................................. 15
ACCESSORIESANDCARGO ....................................... 17
TECHNICALSPECIFICATIONS.................................... 19
RECOMMENDEDLUBRICANTS ................................... 22
MOTORCYCLE IDENTIFICATIONNUMBERDETAILS..23
ENGINENUMBERDETAILS .......................................... 25
KEY PARTSLOCATION ............................................... 26
OPERATIONOFCONTROLS ..................................... - 29
PREOPERATIVECHECKS ........................................... 33
SIDEVIEWMIRRORS................................................... 34
SAFE&HAPPY RIDING ............................................... 35
RUNNINGIN.................................................................. 36
EVAPORATIVEEMISSION IMPORTANT NOTE ........... 38
WARNING INDICATIONS &SAFETY SYSTEMS .......... 39
STARTING .................................................................... 43
GEARSHIFTING ........................................................... 46
PARKING ...................................................................... 47
PERIODICALMAINTENANCE ...................................... 48
TOOLS KIT .................................................................. 52
WHEELREMOVAL/ASSEMBLY ................................. 53
MINOR MAINTENANCE TIPS....................................... 57
LONGTRIPPRECAUTIONS ......................................... 76
WASHINGPROCEDURE................................................ 77
STORAGEPRECAUTIONS ........................................... 78
WIRINGDIAGRAM ....................................................... 80
TROUBLESHOOTING .................................................. 81
WARRANTY.................................................................. 86
EMISSIONCONTROLSYSTEMWARRANTY ..............88
NOISECONTROLSYSTEMWARRANTY ..................... 90
EVAPORATIVEEMISSIONCONTROL
SYSTEMWARRANTY .................................................. 92
SERVICEMAINTENANCERECORD ............................. 94
NOTES .......................................................................... 96

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PERSONAL & MOTORCYCLE INFORMATION
Name
Door No. / Street
Locality
City Country
Contact Res : Off :
Mobile : Email :
Licence No. Valid till :
Model Color :
Engine No.
VIN. No.
Tire make Front : Rear :
Tire Nos. Front : Rear :
Battery make Battery No.
Sold by
Date of Sale

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SAFE OPERATING RULES
Royal Enfield motorcycles are designed to serve as
a means of personal transport, and for on-road use
only. It is not meant to be used as an off-road
motorcycle.
WARNING
Using the motorcycle for Off-road purposes
could lead to loss of control which could result
in an accident causing serious injury or loss of
life.
Before operating your new motorcycle, it is your
responsibility to carefully read and follow the
operating and maintenance instructions detailed in
this manual for your own safety, your motorcycle and
that of others
Before starting the motorcycle, check for proper
operation of brakes, clutch, gear shift, electrical
components,handle bar controls, tirepressures, fuel
and oil levels.
Know and respect the rules of the road. Be a safe
rider for your own safety and for other road users.
FUEL / REFUELING
Royal Enfield motorcycles are designed to
perform best with unleaded gasoline only. Use a
good quality unleaded gasoline of 87 RON or
higher. If ‘knocking’ or ‘pinging’ occurs at a
steady engine speed under normal load, use a
different brand of gasoline or gasoline which has
a higher octane rating.
WARNING
Do not use leaded gasoline in this
motorcycle. It will cause serious damage to the
internals of the engine, exhaust emission system
and the motorcycle will not meet the emission
norms. Using leaded gasoline will also render the
warranty void.
It is illegal to use leaded gasoline as it is known
to cause serious health problems
Fuels containing methanol should not be used
as it can cause damage to the fuel system
components.

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SAFE OPERATING RULES
WARNING
Gasoline is extremely flammable and highly
explosive under certain conditions. Any fuel leak,
spillage, or negligence of adhere to safety norms
may lead to a fire hazard or explosion, which
could cause damage to property, injuryto persons
or loss of life. When refueling your motorcycle,
please exercise utmost caution and carefully
observe the following rules:
Turn the ignition switch to the ‘OFF’ position
Open the fuel filler cap slowly. This will help to
release any pressure that may have built up in
the fuel tank.
DO NOT smoke and please ensure that there
are no open flames or sparks near the
motorcycle, when refueling OR servicing the fuel
system.
Refuel in a well ventilated area.
DO NOT use a mobile telephone. Switch OFF
mobile telephones and any other electrical and
electronic devices including any appliances with
a pilot light.
DO NOT fill the fuel tank to its brim. Please fill
fuel only till the bottom of the filler neck insert so
as to leave air space for fuel expansion, inside
the fuel tank. Overfilling the tank can lead to fuel
spillage.
Avoid filling the tank in rainy or dusty conditions
whereairbornematerialcancontaminate thefuel.
Contaminated fuel may cause damage to fuel
system components.
After refueling, please ensure the fuel filler cap
is closed firmly and correctly.
WARNING
Fuel spilled on the floor or on motorcycle
tires will reduce the tire’s ability to grip the road.
This can result in dangerous riding condition,
potentially causing loss of control and could
result in an accident If fuel is spilled, thoroughly
clean up the spillage immediately. Take care not
to spill any fuel on the engine, exhaust pipes,
rubber parts or any other part of the motorcycle.

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SAFE OPERATING RULES
Do not store motorcycle with gasoline in the tank,
within your home or garage where open flames,
pilot lights, spark or any appliance with a pilot
light, electric motors are present. Inadequate
safety precautions could cause an explosion or
fire and could result in damage to property,
serious injury or loss of life.
Tires & Suspension
Please inspect and ensure tires are seated evenly &
properly in the rims. Maintain the recommended tire
pressures as it is very important for riding stability.
Pay strict attention to loose and / or broken spokes
Ensure the front and rear wheels are correctly
aligned. Check spokes for correct tightness in the
rims and free movement of steering system.
Inspect the tires thread condition periodically and
replace worn out tires with approved make only.
Failure to do so can lead to improper balance, poor
stability, poor handling, and abnormal tread wear.
Please replace tires which are punctured or
damaged. Small punctures in the tread area may be
repaired from within the tire. The motorcycle should
not be driven over 40 MPH (60 Kmph) for the first 24
hours and over 55 MPH (90 Kmph) thereafter with a
repaired tire.
WARNING
In emergency situations, please ride slowly
with least possible load until the tire is
permanently repaired or replaced. Failure to heed
to this warning could result in serious injuryor loss
of life.
Regularly inspect front forks, rear shockabsorbers
and rear suspensions for any wear, looseness / side
play, oil leaks etc. Replace worn parts. Worn parts
can adversely affect stability and handling.
WARNING
DO NOT operate motorcycle with a loose,
worn or damaged steering system, including the
front and rear suspension system. Contact your
Royal Enfield Authorised Dealer for repair of
steering or suspension system. Damaged
steering or suspension components may
adversely affect handling which could result in
serious injury or loss of life.

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SAFE OPERATING RULES
Running in
A new motorcycle must be operated according to the
special break-in-procedure. (See BREAK-IN-THE
FIRST 300 Miles (500 Kms) section.) Operate
motorcycleonly at moderate speeds and outof traffic
until you have become thoroughly familiar with its
operation and handling characteristics under all
condition
DO NOT exceed the legal speed limit or drive too
fast for existing conditions. Always reduce speed
when poor driving conditions exist. High speed
increases the influence of any other condition
affecting stability and increases the possibility of loss
of control.
NOTE :
If you are an inexperienced rider we recommend
that you obtain formal training on correct
motorcycle riding techniques and become
thoroughly familiar with the operation of your
particular motorcycle. New riders should gain
experience under various conditions while
driving at moderate speeds.
WARNING
Avoid over speeding and never travel over
the speed limit. Excessive speed may cause loss
of control and could result in an accident causing
serious injury or loss of life.
DO NOT exceed 70 MPH (110 Kmph) riding solo.
DO NOT exceed 55 MPH (90 Kmph) when carrying
a passenger and/or cargo.
Pay strict attention to road surfaces and wind
conditions. Any two wheeled motorcycle 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 motorcycle with a
relaxed grip to a controlled condition. Do not brake
abruptly or force the handlebar.

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SAFE OPERATING RULES
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 or loss of life.
Operate your motorcycle defensively. Remember, a
motorcycle does not afford the same protection as
an automobile in an accident. One of the most
common accident situations occurs when the driver
of the other vehicle fails to see or recognize a
motorcycle and turns into the oncoming motorcyclist.
Safe motorcycle operation requires alert mental
judgment combined with a defensive driving attitude.
DO Not allow fatigue, alcohol or drugs to endanger
your safety OR that of others.
Wear an approved helmet, clothing, and foot gear
suited for riding a motorcycle. Bright OR light colors
are best for greater visibility in traffic, especially at
night. Avoid loose, flowing garments and scarves.
Whencarryingapillionrider, itis your responsibility
to instruct them on proper riding procedures.
DO NOT allow other individuals, under any
circumstances, to operate your motorcycle unless
you know they are experienced, licensed riders and
are thoroughly familiar with the operating conditions
of your motorcycle
Additional electrical accessories and equipments
may overload the motorcycle’s electrical system and
will result in system and/or component failure.
Maintain your motorcycle in proper operating
condition in accordance with the Maintenance
intervals chart in this Owner’s Manual.
Use only genuine Royal Enfield spare parts and
approved accessories. Use of other manufacturer’s
performancepartsmayaffecttheperformanceofyour
motorcycle and render the motorcycle void of
warranty. Contact your Royal Enfield Authorised
Dealer for further details

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SAFE OPERATING RULES
WARNING
Consult your Royal Enfield Authorised
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 or loss of life.
WARNING
Avoid any contact with the exhaust system.
Wear clothing that will completely cover the legs
while riding. The exhaust system gets very hot
when the engine is running and remains too hot,
even after the engine is turned off. Failure to wear
proper or protective clothing could result in
serious injury.
WARNING
Exhaust gases contains poisonous carbon
monoxide and chemicals, known to cause Cancer,
Birth Defects or other reproductive defects. DO
NOT INHALE exhaust gases. Do not stay inside a
closed garage after parking the motorcycle as the
residual fumes from the exhaust can contain
WARNING
Motorcycle batteries contain lead and lead
components, acids and chemicals known to
cause cancer, birth defects or other reproductive
harm. Exercise extreme caution while handling a
battery. Wash hands thoroughly whenever a
battery is handled.
This motorcycle is not designed to tow a trailer or be
used with a sidecar. It is designed to be used as a
two wheeler, for carrying a rider and a pillion.
WARNING
Towing a trailer may cause loss of control
of the motorcycle in the front, reduced braking
efficiency, tire overloading and unstable handling,
leading to an accident resulting in serious injury
or loss of life.
Using the motorcycle with a side car could cause
loss of control, resulting in an accident which may
cause serious injury or loss of life.
harmful gases. Failure to heed to these warnings
can result in loss of life.

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WARNING
DO NOT tow a diabled 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 or loss of life.
DO NOT exceed the Gross Vehicle Weight Rating
(GVWR) of your motorcycle which is provided in the
information plate, located on the frame down tube.
(GVWR is the total sum of the weight of the
motorcycle, accessories, rider, pillion and cargo that
may be safely carried).
WARNING
Exceeding GVWR may lead to instability of
the motorcycle, leading to an accident and result
in serious injury or loss of life.
WARNING
Royal Enfield cautions you against the use
of certain nonstandard parts such as aftermarket
and custom made extended front forks or
suspensions, which may adversely affect
performance and handling. Removing or altering
original parts may adversely affect performance
and could result in an accident causing serious
injury or loss of life.
WARNING
Use only genuine Royal Enfield
replacement fasteners tightened to the proper
torque. We caution you against the use of certain
nonstandard 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
or loss of life.
SAFE OPERATING RULES

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RULES OF THE ROAD
Be sureall equipment required byFederal, State,
provinceandlocallawisinstalledandareingood
condition.
Be sure your license plate is installed in the
position specified by law and is clearly visible at
all times.
Keep to the correct side of the road center line
when meeting oncoming vehicle.
Watchforloosedebris,suchasdryorwetleaves,
slippery substances or loose gravel that can
hamper the stability of your motorcycle.
DO NOT leave the curb or parking area without
signaling. Be sure your way is clear to enter
moving traffic.Amoving line of traffic always has
the right of way.
Always actuate your turn signals, and exercise
utmost caution when passing other vehicles
going in the same direction. Never try to pass
another vehicle going in the same direction at
street intersections, on curves, or when going
up/or down a hill.
While turning either right or left, watch out for
pedestrians, animals, as well as vehicles.
At street intersectionsalways allow vehicles from
yourright andleftto passbeforeturning.DONOT
assume you have the right of way.
Always signal when preparing to stop, turn or
pass. 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.
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.

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RULES OF THE ROAD
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.
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.
Oily
Wet.
Icy.
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 may cause loss of control of motorcycle,
which could result in loss of life or serious injury.
Park your motorcycle on a firm and flat surface
to prevent it from falling over.
Protect your motorcycle against theft. After
parkingyourmotorcycle,removeIgnitionkeyfrom
switch and lock the steering head.

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ACCESSORIES AND CARGO
Royal Enfield cannot test and make specific
recommendations concerning specific or a
combinationof accessories sold.Therefore, therider
must be responsible for safe operation of the
motorcycle when installing accessories or carrying
additional weight.
Please adhere to the following guidelines when
carrying a pillion, cargo or when fitting any
accessories.
DONOT exceed 70 MPH (110 km/h) whenriding
solo.
DO NOT exceed 55 MPH (90 Km/h) when
carrying a pillion and/or cargo.
Keep cargo weight concentrated close to the
motorcycle and as low as possible; this
minimizessuddenshiftin themotorcycle’scenter
of gravity.
Distribute weight evenly on both sides of the
motorcycle.
DO NOT load bulky items too far behind the rider
or add weight to the handlebars or front forks.
DO NOT exceed 5 pounds (2.3 kgs) maximum
hanging load on either side of the motorcycle at
the rear end.
Recheck the cargo periodically to be sure it is
secured and will not shift while riding.
Accessoriessecuredlooselymayaffecttheriding
of the motorcycle and affect the stability of the
motorcycle.
Large surfaces such as fairings, windshields,
backrestsandluggagerackscanadverselyaffect
handling of the motorcycle. Only genuine Royal
Enfield accessories, designed specifically for the
motorcycle model should be used with proper
installation.
WARNING
DO NOT load weight or install accessories
improperly on the motorcycle. Doing so may affect
the motorcycle’s stability, handling characteris-
tics, and safe operation and could result in an
accident causing serious injury or loss of life.

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ACCESSORIES AND CARGO
WARNING
Royal Enfield motorcycles have been
carefully designed and engineered for riding in
their original configuration. DO NOT alter the
handling characteristics of these motorcycles.
Doing so may affect its stability and could cause
an accident resulting in serious injury or loss of
life.
WARNING
Royal Enfield cautions you against use of
nonstandard parts such as aftermarket and
custom made extended front forks which may
adversely affect the performance and handling
of the motorcycle. Removing or altering original
parts may adversely affect the performance of the
motorcycle, causing an accident, which could
result in serious injury or loss of life.
WARNING
DO NOT ignore model / design
specifications. Doing so constitutes to
motorcycle misuse which may adversely affect
the handling and performance of the motorcycle
causing an accident, which could result in
serious injury or loss of life.

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Engine
Engine ............................... 4 Stroke, air cooled,
........................................... single cylinder
Capacity............................. 499 cc (Displacement)
Bore ................................... 84 mm
Stroke ................................ 90 mm
Compression ratio............. 8.5 : 1
Max. Power @ RPM ......... 20.3 Kw @ 5250 rpm
Max. Torque @ RPM ........ 41.3 Nm @ 4000 rpm
Air Filter Element .............. Paper Element
Engine Oil Tank Capacity . 2.75 Litre Dry Fill
Lubrication......................... Forced Lubrication,
........................................... Wet Sump
Engine Oil Grade .............. 15 W, 50 API, SLGrade,
........................................... JASO MA, ESTER -
........................................... Semi Synthetic oil
Fuel Supply ....................... Electronic Fuel Injection
TECHNICAL SPECIFICATIONS
Ignition system
Ignition system................. Digital Electronic Ignition
Spark plug gap.................. 0.7 mm
Spark plug ......................... WQR8DC
Transmission
Clutch ................................ Wet Multiplate
Drive Chain links .............. 102 pitch
Primary drive..................... Duplex Chain drive
........................................... 3/8” pitch
Gear box............................ 5 Speed Constant Mesh
Gear Ratios ....................... I - 3.063 : 1
........................................... II - 2.013 : 1
........................................... III - 1.522 : 1
........................................... IV - 1.212 : 1
........................................... V - 1.000 : 1
Primary Drive Ratio .......... 2.15 : 1
Secondary Drive ............... Chain Drive
Secondary ratio................. 2. 11 : 1