Royal Enfield Bullet 500CC 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 you to avail of the four free services we offer, at the right time, at any of our Authorised
Dealer / Service Point to keep your motorcycle in peak condition.
Please log on to w ww. r oyalenfield.c om to know mo re about the histor y of the world’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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IMPORTANT NOTICE
nKeep this manual in a convenient place for easy
reference.
nIf any information is not understood in the manual
contact your Authorised Dealer / Service Point for
assistance.
nIf 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.
nThe 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.
nIn 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 2013 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.”
nBecause of c o n ti nous imp rovements 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.
nHowever the technical information found within
this manual was corre c t at the time it was
approved for publication.
nRoyal Enf ie l d r e ser ves t h e right to m ake
production changes at any time without prior
notice and without incurring any obligation to
make same o r similar change s to vehic les
previously built or sold.
Part No. 584639/a / Qty.1000 / Mar. ‘13

3
IMPORTANT NOTICE
SAFETY DEFINITIONS
Statements in this manual preceded by the following
words are of special significance :
WARNING
Warning indicates a potentially hazardous
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.
NOTE
Indicates important and useful messages for clearer
understanding.
All Images shown are for reference to explain and
need not to be exactly the same on the model
you own.
However if you have any queries, 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 lamp switch ............................................... 28
- Dip Switch .............................................................. 28
- Head lamp Day flash ......................................... 28
- Engine Kill Switch ................................................ 29
- Horn ........................................................................ 29
- Turn Signal Switch ............................................... 29
- Engine Start Switch ............................................. 30
- Battery Box ............................................................. 30
- Fuel Tap ................................................................. 30
PRE OPERATIONAL CHECKS .......................................... 31
RUNNING IN .................................................................... 32
STARTING ......................................................................... 33
CONTENTS

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CONTENTS
GEAR SHIFTING ............................................................... 35
PARKING ........................................................................... 36
- Center Stand ......................................................... 36
- Side Stand ............................................................. 36
TOOLS AND FIRST AID KIT ............................................ 37
RECOMMENDED LUBRICANTS ...................................... 38
PERIODICAL MAINTENANCE ........................................ 39
MINOR MAINTENANCE TIPS ......................................... 43
- Control Cables, Handle bar lever,
Pivots, 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 Battery on Vehicle ......................... 55
- Battery Maintenance .......................................... 55
- Assembly of Battery on Vehicle ........................ 56
- Changing Electrical Components ................... 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

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CONTENTS
WASHING PROCEDURE .................................................. 62
- Precautions ........................................................... 62
- After Washing ....................................................... 62
STORAGE PRECAUTION ................................................. 63
- Preparing the motorcycle for reuse ................ 64
LONG TRIP 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 DIAGRAM - 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
- Vehicle wobbles ................................................... 74
- Electricals .............................................................. 74
- Electric Start .......................................................... 76
WARRANTY TERMS & CONDITIONS ............................. 77
EMISSION WARRANTY .................................................... 79
ALL INDIA ROAD SIGNS ....................................83
FREE SERVICE COUPONS ............................................... 84
PAID SERVICE / MAINTENANCE RECORD ................... 93
REGIONAL & AREA OFFICES ................................101
LOG BOOK ............................................................... 102
NOTES ...............................................................107
ANNEXURES
- Vehicle Installation Form
- Pre-Delivery Inspection Report (PDI)
- Bike Installation Confirmation By Customer
- Form 22

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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

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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.
NOTE
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
nBefore operating your new motorcycle, it is your
responsibility to carefully read and follow the
operating and maintenance instructions detailed
in t his man ual for yo ur own safety, your
motorcycle and that of others.
nKnow and respect the rules of the road. Be a safe
rider for your own safety and for other road users.
nBefore 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 front forks or suspensions,
whic h may adversely af fect performance and
handling. Removing or altering original parts may
adversely affect performance and could result in an
accident causing serious injury.
nUse 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.
nWhenever refuelling your motorcycle, please
exercise utmost caution and carefully observe the
following rules :
HDO NOT smoke and please ensure that there
are no o p en flames o r s p arks near t h e
motorcycle, when refuelling OR servicing the
fuel system.
HSwitch OFF mobile phones and other hand
held electronic devices / gadgets.
HOpen the fuel filler cap slowly.
HRefuel in a well ventilated area with the engine
turned off.
SAFE OPERATING RULES