Royal Enfield Bullet 500 User 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 yo u t o avail o f the four free ser vices we o ff er, at the r i gh t tim e, at any of our Au thori se d
Dealer / Service Point to keep your motorcycle in peak condition.
Please log o n to w w w. r o y a l e nf i e l d . c o m to know mor e abo ut the history of the worl d’s o ld es t
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!

2
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.
“© 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.”
B ec au s e o f co n tin o us i mp ro v em en ts i n t he
produ ct and changes that may occur in the
manufacturing process, subsequent to printing of
thi s manu al , it is po s sib le s o me in str uctio ns ,
illustrations, pictures or designs found within this
manual m ay di f f er from t ho se found on the
vehicle.
However the technical information found within
th i s m a nual was co r rect at the time it was
approved for publication.
R o ya l E nf i el d r es e r v es t he r ig h t t o ma k e
production changes at any time without prior
notice and without incurring any obligation to
m ak e s am e o r s i mi l ar ch an g es t o v e hi cl es
previously built or sold.
Part No. 584639/A / Qty.1000 / Apr. ‘14

3
IMPORTANT NOTICE
SAFETY DEFINITIONS
Statements in this manual preceded by the following
words are of special significance :
WARNING
Warning i ndicates a po t en tiall y ha zardo us
situation, which if not avoided, could result in serious
injury.
CAUTION
Caution indicated a protentially hazardous situation,
which if not avoided, may result in property damage,
in minor or moderate injury.
NOT E
Indicates important and useful messages for clearer
understanding.
All I mages shown are for reference to explain and
need not to be exactly the same on the model
you own.
However i f you ha ve any qu eries, clarification,
suggestions/feedback, please write to us or e-mail at
“[e-mail]”.
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 : [e-mail]
Website : www.royalenfield.com

4
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
OPERATION OF CONTROLS ..............................................26
- Ignition Switch ......................................................... 26
- Steering lock .............................................................26
- Fuel tank cap ............................................................27
- Side Box ...................................................................... 27
- Head lam p switch .................................................. 28
- Dip Switch ..................................................................28
- Head lamp Day flash ...........................................28
- Engine Kill Switch .................................................... 29
- Ho rn .............................................................................29
- Turn Signal S witch .................................................. 29
- Engine Start Switch ................................................. 30
- Battery Box ................................................................30
- Fuel Tap ......................................................................30
PRE OPERATIONAL CHECKS ............................................31
RUNNING IN PERIOD ........................................................32
STA RT ING ............................................................................. 33
CONTENTS

5
CONTENTS
GEAR SH IF TI NG .................................................................. 35
PARKING ...............................................................................36
- Center Stand ............................................................36
- Side Stand .................................................................36
TOOLS AND FIRST AID KIT .............................................37
RECOM ME ND ED LUBRI CANTS ....................................... 38
PERIODIC AL MAI NT EN ANC E ......................................... 39
MI NO R M AI NT EN ANC E TIPS ......................................... 43
- Control Cables, Handle bar lever,
Pivo ts, 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
- 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 Batter y on Vehicle ........................... 55
- Battery Maintenance ............................................55
- Assembly of Battery on Vehicle .........................56
- Changing Electrical Comp onents .................... 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

6
CONTENTS
WASHING PROCEDURE .................................................... 62
- Precautions .............................................................. 62
- After Washing .......................................................... 62
STORAGE P RECAUT ION .................................................. 63
- Preparing the motorcycle for reuse .............. 64
LONG TR IP 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 DI AGRAM - 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
- Excessive fuel consumption ................................72
- Ignition knock ..........................................................73
- Brakes poor ..............................................................73
- Vehicl e wo bbles ...................................................... 74
- Electricals ..................................................................74
- Electric Start ..............................................................76
WARRANTY TERMS & CONDITIONS ............................77
EMI SSION WARRA NTY ......................................................79
ALL IND IA R OA D S I GNS . .............. ............... ...... 83
FREE SERVICE COUPONS ..................................................84
PAID SERVICE / MAINTENANC E RECORD ...................93
LOG BOOK ............................................................... 101
NOT ES ..................................... .... ................ .... ..106
A NN E XU RE S
- Vehicle Installation Form
- Pre-Delivery Inspection Report (PDI)
- Bike Installation Confirmation By Customer
- Form 22

7
PERSONAL & VEHICLE INFORMATION
Vehicle Installation Form (VIF) No.
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

8
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.
NOT E
Please ensure that the free service details are recorded in this sheet immediately after the service is carried out.
Date of Service
Kms Covered
Servicing
Dealer’s / ASP
Name, Address
1st Service 4th Service2nd Service 3rd Service
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp
Dealer / ASP
Rubber Stamp

9
Before operating your new motorcycle, it is your
responsibility to carefully read and follow the
operating and maintenance instructions detailed
in thi s m a nu al f o r y o u r ow n sa fet y, 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 fr ont forks or suspensions,
wh i ch m a y a dv er s el y a ff e ct p er f o rm a nc e an d
handling. Removing or altering original parts may
adversely affect performance and could result in an
accident causing serious injury.
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 refu ell ing your mo torcy cle, pl ease
exercise utmost caution and carefully observe the
following rules :
DO NOT smoke and please ensure that there
a re n o o p en f la m e s o r s p a r k s n e ar t h e
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.
SAFE OPERATING RULES

10
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
Pe t r ol i s e x tr e m el y f l am m a bl e a n d h i gh l y
explosive. Use care when handling Petrol. Always stop
the engine when refuelling or servicing the fu el
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
f a mi l i ar w i th i ts o p er a ti o n an d ha n dl i 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.
NOT E
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
r i de rs sh o u ld ga in ex p e ri e nc e u nd er v a r io u s
conditions while driving at moderate speeds.
SAFE OPERATING RULES

11
WARNING
Avoid overspeeding and never travel over the
speed limit. Excessive speed may cause loss of control
and cou ld r esul t in an a ccident caus ing serious
injury.
DO NOT exceed >110 km/h solo riding.
DO NOT exceed >90 Km/h when carrying a pillion
or cargo.
Pay strict attentio n to road surfaces and wind
con ditions . Any two wheeler vehicle may b e
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
gui de the m o t o rcy cle wi th a rel ax ed grip to a
controlled condition. Do not brake abruptly or force
the handlebar.
Op er at e yo u r m o to r cy cl e de f ens i vel y.
Reme mb er, a moto rcycle do es no t affo rd t he
same protection as an automobile in an accident.
One o f the mo st commo n accide nt situati ons
occurs when the driver of the other vehicle fails
to see or recognize a motorcycle and turns into
the oncoming motorcyclist.
Wear an appro ved 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.
W he n c a r r yi n g a pi l l io n r id e r, i t i s y o u r
responsibility to instruct them on proper riding
procedures.
DO NOT all o w o ther indiv i d ual s , under an y
circumstances, to operate your motorcycle unless
you know they are experienced, licensed riders
and are thoroughly familiar with the operating
conditions of your motorcycle.
SAFE OPERATING RULES

12
WARNING
M ai n ta in th e r eco m m en de d t y re p r e ss u r e.
Ensure the fr o nt and r ear wheel s ar e co rr ect ly
aligned and the tyres are seated evenly & properly
in the rims. Check for correct tightness of the spokes
in th e r im s. I n sp ect your tyres periodica ll y and
replace tyres with approved tyres only. Failure to do
so can lead to improper balance, abnormal tread
wea r, p oor h andli ng and co uld r esul t in serio us
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)
SAFE OPERATING RULES
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.
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
(R e f Pa ge N o .4 0 ) . Par t i cu l ar l y i m p or t an t t o
m ot o r cy cl e s tab i l it y i s p ro p er ty r e i nf l a ti o n
pressure, tread condition. Pay strict attention to
loose and / or broken spokes, free movement of
steering system.

13
WARNING
DO NOT operate motorcycle with a loose, worn
or damaged steering system, including the front and
rear suspension system. Contact your dealer f or
repair of steering or suspension system. Damaged
steering or suspension components may adversely
affect handling which 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
For your personal welfare, all the listed service
and main tenance re comm en dat i o ns sho ul d be
per form ed. Lack of r egular maintenan ce at the
suggested intervals may affect the safe operation of
your motorcycle, 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
Ex hau s t ga ses cont a i n s p o ison o us car b o n
mo no xi de (CO.) and chemi cals, known to cause
serious health hazards.
WARNING
Mo tor cy cle ba tteries conta in 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.
SAFE OPERATING RULES

14
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 .
WARNING
DO NOT pull a tr ailer behind a motorcycle.
To w i ng a t r ai l e r m a y c a us e r e du c ed b r a ki ng
efficiency, tyre overloading and unstable handling.
Towing a trailer may cause loss of control of the
motorcycl e in th e f ront, l eading to an accident
resulting in serious injury.
SAFE OPERATING RULES
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.
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 after market and cus tom made f asteners
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 r esult 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
on the frame Down tube. (GVWR is the sum of the
weigh t o f the m o t o r cycle, acc es s o r i es, and the
maximum weight of the rider, passenger and cargo
that may be safely carried.) Exceeding GVWR may
lead to instability o f the motorcycle, which could
cause an accident and result in serious injury.

15
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 Oily
Icy 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.
Keep to the correct side of the road centre line
when meeting oncoming vehicle.
Always sound your horn, actuate your turn signals,
an d ex e rci s e CA UT I ON w he n pa ss i ng o th er
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.
Wh i le t ur n ing e ith er r ig h t o r l eft , wa tch f o r
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.
WARNING
Avoid excessive speed and never travel at a
speed faster than the speed limit. Excessive speed
may cause loss of control of vehicle, which could
result in death or serious injury.

16
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 lin e (u nles s local r ul es req ui r e
otherwise), slow down and then turn carefully.
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.
DO NOT leave the curb or parking area without
signali ng . Be s ur e your wa y is clear to enter
moving traffic. A moving line of traffic always has
the right-of-way.
Park your motorcycle on a firm and flat surface to
prevent it from falling over.
Pr o tec t y o ur m o to r cy cl e ag a in s t t he ft . A ft er
parking your motorcycle, remove Ignition key
from switch and lock the steering head.
NOT E
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.
SIDE VIEW MIRRORS
Red
Yellow
Gree n
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.

17
TECHNICAL SPECIFICATIONS
ENGINE
Engine ............................................................ Single Cylinder, 4 Stroke, Twinspark, Aircooled
Capacity ........................................................ 499 cc (Displacement)
Bore ................................................................ 84 mm
Stroke ............................................................. 90 mm
Compression ratio ...................................... 8.5 : 1
Max. Power @ RPM ..................................... 26.1 BHP @ 5100 rpm
Max. Torque @ RPM ................................... 40.9 Nm @ 3800 rpm
Air Filter Element ......................................... Corrugated Paper Element
Fuel Supply ................................................... Carburetor with Throttle Position Sensor (TPS)
Engine Start .................................................. Electric / Kick
Engine Oil Capacity ................................... 2.75 Litres.
Lubrication ................................................... Wet Sump, Forced Lubrication
Engine Oil Grade ........................................ Royal Enfield 15W50 API SL Grade Engine Oil (JASO MA)
Cooling system ............................................ Natural Air Flow
Carburetor ................................................... UCD 33

18
IGNITION SYSTEM
Ignition system ........................................... TCI Unit, Multi Curve (Variable Ignition Timing)
Spark plug ................................................... WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10
Spark plug Electrode gap ...................... WQR8DC 0.80 to 0.90 mm
................................................................. UR6DC 0.70 to 0.80 mm
TRANSMISSION
Clutch ............................................................ Wet Multiplate (7 Plates Clutch)
Primary drive .............................................. Duplex Chain
Primary Drive Ratio ................................... 2.15 : 1
Gear box ....................................................... 5 Speed Constant Mesh
Gear shift pattern ...................................... 1 - N - 2 - 3 - 4 - 5
Gear Ratios .................................................. 1st-3.06:1 2nd-2.01:1 3rd-1.52:1 4th-1.21:1 5th-1:1
Secondary Drive (F.D. Sprocket) ............ 18 Teeth
Final Ratio .................................................... 2. 11 : 1
Drive Chain links ....................................... 102 links
TECHNICAL SPECIFICATIONS

19
ELECTRICALS
Generation ................................................... Alternator
System ............................................................ 12V DC
Batter y ........................................................... 12V - 14 AH
Head lamp ................................................... 12V, 60/55 W, Halogen
Position lamp .............................................. 12V, 4W
Brake / Tail lamp ....................................... 12V, 21/5 W
Turn signal ................................................... 12V, 10W - 4 nos.
Pilot lamp ..................................................... 12V, 2 W - 2 nos.
Speedometer lamp ................................... 12V, 3.4 W - 1 no.
Turn signal / High beam indicator ...... 12V, 1.7 W - 2 nos.
Neutral Indicator ....................................... 12V, 1.7 W - 1 no.
Horn (Dual) .................................................. 12V, 2.5 Amp (Max.) X2
Starter Motor ............................................... 12V, 0.9 KW
TECHNICAL SPECIFICATIONS
WARNING
Using bulbs / other electrical
gadgets other than specified rating
may lead to over loadin g / erratic
behavio ur / pre ma tur e 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.