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

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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

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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