Royal Enfield Bullet 500 User manual

BS IV

FOREWORD
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 & three paid services we offer, at the right time, at any of our Royal Enfield
Authorised Dealer / Service Center to keep your motorcycle in peak condition.
Please log o n t o w w w. r o y a l e nf i e l d . co m to kno w m ore about the histo r y o f t he wo rl d’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!

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All information in this manual is based on the latest product information available at the time of publication.
Due to continuous improvements, there may be discrepancies between the information in this manual and your
motorcycle. Royal Enfield reserves the right to make production changes at any time without prior notice and
without incurring any obligation to make the same or similar changes to motorcycles previously built or sold.
All images shown are for reference to explain and need not to be exactly the same on the model you own.
Technical specifications are subject to change without prior notice.
“© Copyright 2017 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”.
NOTICE
Part No. 1041008/A / Qty. 5,000 / Feb. ‘17
NOT E: BS IV
T h i s m o to r c y cl e m e et s E m i s s i o n N o r m s - B h ar a t ( Tr e m ) S t a ge - I V
C o n t a ct U s :
Royal Enfield Support : 1800-2100-007
Email : [e-mail]
Twitter : @RoyalEnfieldSupport
Web : www.royalenfield.com

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CONTENTS
Personal and Motorcycle Information 4
Technical Specifications 5
Recommended Lubricants 8
Safety Definitions 9
Motorcycle Identification Numbers 10
Location of Key Parts 11
Operation of Controls 14
Pre-Operational Checks 17
Safe & Happy Riding 18
Running in Period 19
Starting 20
Gear Shifting, Riding & Stopping 21
Parking 22
Periodical Maintenance Chart 23
Tools & First Aid kit 26
Minor Maintenance Tips 27
Long Trip Precautions 37
Washing Procedure 38
Storage Precautions 39
Trouble Shooting 40
Warranty Terms & Conditions 41
Emission Warranty 43
EVAP 46
Service Coupons 48
Paid Service & Maintenance Record 63
Regional & Area Offices 65
Authorised Dealer Address 66
Notes 92
A n n e x u r e s
Motorcycle Installation Form
Pre-Delivery Inspection Report
Motorcycle Installation Confirmation By Customer

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PERSONAL & MOTORCYCLE INFORMATION
Name
Door No./Street
Locality
City State Pin
Contact Nos. Res: Off: Mobile : Email :
Engine No. Battery No.
Frame No. Battery make
Reg. No. Licence No.
Date of Sale Valid till dt.
Model Key No. :
Tyre make Colour
Sold by Dealer Code
Motorcycle Installation Form (MIF) No.

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IGNITION SYSTEM
Ignition system ........ Digital Electronic Ignition
Spark plug Electrode gap
0.80 to 0.90 mm
Spark plug ............... WQR8DC (Bosch)
TRANSM ISSION
Clutch ......................... Wet multiplate
Primary drive .......... Duplex chain 3/8” pitch
Primary ratio ........... 2.15 : 1
Gear box .................. Constant Mesh, 5 Speed
Gear Ratio ................ 1st 3.06:1
............................. 2nd 2.01:1
............................. 3rd 1.52:1
............................. 4th 1.21:1
............................. 5th 1:1
Final drive ................ 18 Teeth (Sprocket)
Primary drive ratio 2.15:1
Secondary drive ratio 2.11:1 2.375:1
Drive Chain links .... 102 links
ENGINE
Engine Type .............
Sin gle Cy lin der 4 Stro ke, Spark
................................. Ignition, Air cooled, Fuel injection
Bore ............................ 84mm
Stroke ......................... 90mm
Swept volume .......... 499cc
Compression ratio . 8.5:1
Max Power .....................
27.2 bhp @ 5250 rpm
Max Torque ....................
41.3 Nm @ 4000 rpm
Idle RPM .................... 1100+200
Starting ...................... Kick Start / E-Start
Airfilter element ..... Paper element
Lubrication ............... Wet sump, Forced lubrication
Engine oil capacity 2.75 litres (First Fill only)
............................. 2.30 to 2.50 litres (subsequent refills)
Engine oil grade .... Royal Enfield 15W50 API SL
............................. Grade & above, (JASOMA2)
Fuel Supply ............... Electronic Fuel Injection
Cooling ...................... Natural air flow

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CHASSIS
Frame ......................... Single Down Tube, using
............................. engine as stressed member
Suspension
Front .................... Telescopic, 35mm forks,
............................. 130mm travel
Rear .................... Twin gas charged shock-
............................. absorbers with 5-step adjustable
............................. preload, 80mm travel.
Brakes
Front Disc ........... 280mm Disc, 2 Piston Caliper
Rear .................... 153 mm Drum, Single
............................. lead internal expanding
Tyre size
Front .................... 90 / 90 - 19” - 52 P
Rear .................... 120 / 80 - 18” - 62 P
Tyre Pressure
Solo
Front .................... 20 psi
Rear .................... 30 psi
With Pillion
Front .................... 22 psi
Rear .................... 32 psi
Steering lock ............ In built
Fuel tank capacity .. 13.5 litres approx. *
Reserve ..................... 3.8+0.3 litres approx. *
ELECTRICALS
Generation ............... Alternator
System ....................... 12V - DC (III Phase)
Battery ....................... 12V - 14 AH MF (III Phase)
Head lamp .............. 12V, H4-60/55W (Halogen)
Brake/Tail lamp ..... 12V, P21/5W
* The above values are approximate and the actual fuel
filling capacity will vary from the values mentioned.

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Values / Dimensions given above are for your guidance only.
In view of continuous improvements being done on our products, the specifications are likely to change
without prior notice.
W A R N IN G
Using bulbs / other electrical gadgets other than specified
rating may lead to over loading / erratic behaviour / premature
failure of electrical system.
Modifications on the motorcycle which are not approved by
Royal Enfield may not only disqualify for warranty, but also
affects performance of the motorcycle.
DIMEN SIONS
Length ........................ 2140 mm
Width .......................... 810 mm
Height ........................ 1110 mm
Wheel base .............. 1360 mm
Ground clearance. 135 mm
Saddle Height ......... 805 mm
WEIGHTS
Kerb weight (90% fuel & oil) ....................... 194 Kgs.
Max. pay load ................................................ 171 Kgs
Max. technical permissible mass ............. 365 Kg
Turn signal ............... 12V, R10W X 4 Nos.
Pilot lamp .................. 12V, 2 W X 2 Nos.
............................. 12V, 4 W X 1 No.
Speedometer lamp 12V, 3.4 W X 1 No.
Turn signal / ............. 12V, 1.7 W each
High beam indicator
Neutral Indicator ... 12V, 1.7 W X 1 No.
Horn ............................ 12V, 2.5 Amp (Max.) X 2 Nos.

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RECOMMENDED LUBRICANTS
Capacity 2.75 Ltrs. (First Fill only )
2.30 to 2.50 Ltrs. (during oil & filter
element replacement in periodical
maintenance)
I SO 1 4 0 0 1 O pe r at io n C o nt r o l P r oc es s
As per the guidelines in the ISO 14001 Environmental Management
System, customers are advised to carry out timely replacement of
Engine, Front Fork and Brake oils, ONLY through a Royal Enfield
Authorised Dealer / Service Center for the safe disposal of the
used oils to prevent Environmental pollution.
In case the oils are replaced privately, it is advised to ensure the
old/ removed oils are collected carefully and reached to a certified
disposal agency, nearest to you to safely disposing the oils.
Similarly, hazardous wastes such as old/discarded Batteries, Tyres,
Tubes, Cables, Gaskets, Oil filters etc. should also be disposed off
carefully and properly only through a certified disposal agency.
C A U T I O N
Use of Wrong grade oil will reduce the life of the moving
parts and seriously affect performance
NOTE
Recommendation subject to change without notice.
DO NOT Mix DOT 3 & DOT 4 brake fluid together.
E ng i n e O i l
Grade Royal Enfield 15 W 50 API SL
Engine Oil
(JASOMA 2)
B r a k e F l u i d
Capacity 60ml
Grade DOT 3 or
DOT 4
Fr ont Fork O il
Grade Royal Enfield Front
Fork Oil (or 1F
Grade Endurance)
Capacity 195 ml/leg

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The information given under the titles : Warning, Caution and Note are for your safety and for the
care and safety to your motorcycle and other s. Please read these carefully and if disregarded may
result in injury to yourself o r others and damages to the mo torcycle.
W A R N I N G
Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider
or ot her persons.
C A U T I O N
This message if disr ega rded m ay result in damage to t he motorcycl e.
NOTE
Indicates i mp ortant and u seful messages for clearer understanding.
All Images shown in subsequent pages are for reference to explain and need not to be exactly the
same on the model you own.
SAFETY DEFINITIONS