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.

5
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

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MOTORCYCLE IDENTIFICATION NUMBERS
FRAME NUMBER
Punched on steering head tube right side.
ENGINE NUMBER
Punched on crankcase left top side.

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1
2
5
4
11
10
3
7
8
6
9
12 12
LOCATION OF KEY PARTS
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

12
LOCATION OF KEY PARTS
1. Right Trafficator Rear
2. Air Filter Box
3. Starter Motor
4. Right Trafficator Front
5. Brake Pedal
6. Kick Starter Lever
1
3
56
2
4

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LOCATION OF KEY PARTS
1. Left Trafficator Front
2. Spark Plug
3. Battery Cover
4. Left Electricals & Tool Box
5. Rear Shockabsorber
6. Left Trafficator Rear
7. Canister
8. Side Stand
9. Center Stand
10. Gear Change Lever
11. Horn
1
34 5 2
6
8
9
1011 7

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OPERATION OF CONTROLS
STEERING LOCK
Turn Clockwise to lock
Turn Anticlockwise to Unlock
IGNITION SWITCH
FUEL TANK CAP
O P E N
Turn Key Clockwise & lift the lid
C L O S E
Gently press lid till it “click” into
lock position.
FILTER / ELECTRICAL / BOXES
Turn anti clockwise to open
BATTERY BOX
Turn anti clockwise to open
OFF ON
C A U T I O N
Please ensure fuel is filled till
fuel tank mouth (A), Failure to
do so wil l lead to ca nis ter
damage. A

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ENGINE STOP SWITCH
Engine OFF
DIMMER SWITCH
Engine ON High beam Low beam
HORN
Press
E-START SWITCH
Depress & hold till engine
starts
C A U T I O N
Turn off ignition switch when engine is not in
running condition. Failure to do so will discharge
the battery due to continuous headlamp ON.
NOTE
Key i s c om mo n f or ignition, petr ol tank cap,
steering lock, battery cover and tool boxes.
Key can be removed only in locked position from
fuel tank, Filter box, Electrical boxes locks in “OFF”
position from Ignition switch.
Turn handle bar to extreme left, before attempting
to lock steering.

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TURN SIGNAL SWITCH
OFF (Push to off)
Right turn signal ON
Left turn signal ON
OPERATION OF CONTROLS
DAY FLASH
Press for Head Light Flash

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PRE OPERATIONAL CHECKS
CHECK FOR
NOTE
Start engine, r un for 2 m in utes bef o r e checki ng
Engine Oil Level
1. Petrol level in the tank and leakage if any.
2. Smooth operation and free play in Front and Rear
Brake levers.
Front Brake Rear Brake
3. Free pl a y and s mo othness of a ll o p erating
controls.
4. Free movement of steering
5. Any cuts, cracks in the tyre and correct tyre
pressure.
8. Engine Oil Level is
between “ M AX & M IN”
Level.
6. Operation of all electrical equipments.
7. Brake Fluid level is above the “MIN” mark in the
master cylinder
(Disc Brake models)
Brake Pedal M I N
MAX
MIN
Clutch

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RIDING DRESS
A proper riding apparel
Proper Riding Boots
Soft Leather Gloves
Goggles or spectacles
An ISI Certified helmet. (Affix light reflecting strips
of stickers on the front and rear of the helmet for
good visibility at night).
NOTE
A light coloured shirt enables greater visibility to other
road users especially during nights.
C A U T I O N
Loose clothing may get caught on moving parts of the
motorcycle.
SITTING POSTURE
Correct sitting posture is a must for stable and safe
riding
Sit Straight with your shoulders completely relaxed.
Keep your elbows close to your body.
Hold the handle grip close to its inner end.
Slightly grip the fuel tank with the knees.
Keep your toes in “straight ahead” direction.
Before turning, look extensively in the rear view
mirror, without turning your head.
BRAKING
Use both front and rear brakes simultaneously for
maximum braking efficiency.
While riding on wet or bad road conditions use
brakes cautiously.
W A R N I N G
Applying any one of the brakes suddenly may cause
the motorcycle to skid.
SAFE & HAPPY RIDING

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RUNNING IN PERIOD
The Roy al Enf ield M o to r cy cl e as you wo uld be
experiencing, is capable of consistent high speeds.
However as with any new motorcycle, a “RUNNING-
IN” procedure is essential to help in proper “Bedding-
In” of the various moving parts in your motorcycle and
to achieve optimum performance subsequently.
1. During the first 2000 Kms of run, do not exceed the
speed limits as shown in the table below.
2. Do not exceed maximum specified pay load.
3. Warm up the engine for a few minutes at idling
speed to allow engine oil to lubricate all the
moving parts in the engine before riding the
motorcycle.
4. Avoid full throttle operation and do not ride at
constant throttle continuously. Vary the speed by
10% while riding.
5. Avoid sudden accelerations and racing starts.
First 500 kms 501 - 2000 kms
1 15 KMPH 20 KMPH
2 25 KMPH 30 KMPH
3 30 KMPH 40 KMPH
4 45 KMPH 55 KMPH
5 60 KMPH 70 KMPH
Motorcycle
Speed
Gear