Royal Enfield BULLET TRIALS 500 User manual

BULLET TRIALS 500 - EURO IV

FOREWORD
Congratulations! Now you are a part of the most enduring tale in motorcycling!
Bullet, introduced in 1932, the world’s oldest motorcycle model in continuous production, is at the heart of the
Royal Enfield’s storied heritage. The Bullet Trials Works, arriving at 1948 Colmore Cup Trials with their rear
swinging arm suspension, dominated the Trials competitions across Europe for the next decade and changed
the way motorcycles were designed since. Hugely successful in the competitions that tested endurance & resilience,
Bullet Trials Works Replicas were subsequently made available for the public and caught the interest of the
army of a newly independent nation, tasked to patrol a long border of arduous terrains. To know more about
this and the exciting world of Royal Enfield, please log on to www.royalenfield.com
This manual will help you to operate your Bullet Trials Replica, came to be known as Trials Bullet, the right way
and guide you to maintain your motorcycle meticulously. We have also provided tips on safe riding and on
minor adjustments for the care of your motorcycle. Please do avail of all the services at your nearest Authorised
Service Centre to make sure that your motorcycle gets the right treatment which it so deserves. Please also read
through the terms and conditions of warranty and other useful information in this manual before riding into the
world of pure motorcycling.
Keep riding.

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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 2019 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. RAM00069/A / Qty. 200 / Mar. ‘19
Disclaimer
Applicable for all Matt finish motorcycles
1. Do not polish matt finished paint surfaces in your motorcycle as it will increase the
gloss level.
2. Wash the painted parts only with plain water and do not use any strong solvents,
cleaning agents or detergents.
3. Scratches, if happens on the matt finish parts cannot be touched up and corrected
/ removed
4. Warranty is not applicable for any matt finished painted parts of the motorcycle.
5. The Heat Resistance Coated components such as silencer pipe, exhaust etc... shall
not be wiped clean with oiled cloth as it can generate smoke when the vehicle is
driven and also leave patch marks.

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CONTENTS
Personal and Motorcycle Information 4
Safe Operating Rules 5
Rules of the Road 11
Technical Specifications 13
Recommended Lubricants 16
Safety Definitions 17
Motorcycle Identification Numbers 18
Location of Key Parts 19
Operation of Controls 22
Pre-Operational Checks 26
Safe & Happy Riding 27
Running in Period 28
Warning Indication & Safety Systems 29
Starting 34
Gear Shifting, Riding & Stopping 35
Parking 36
Periodical Maintenance Chart 37
Tools kit 40
Wheel Removal & Assembly 41
Minor Maintenance Tips 45
Long Trip Precautions 56
Washing Procedure 57
Storage Precautions 58
Trouble Shooting 59
Warranty Terms & Conditions 61
EVAP 63
Environment Care 65
Service Maintenance Record 67
Notes 71

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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

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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 this manual for your own safety, your 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.
SAFE OPERATING RULES
W A R N I N G
Use only genuine Royal Enfield spare parts
and approved accesso ries. 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 Authorized Dealer for details.
Whenever refuelling your motorcycle, please
exercise utmost caution and carefully observe the
following rules :
HDO NOT smoke and please ensure that there
are no open flames or sparks near the
motorcycle, when refuelling OR servicing the
fuel system.
HSwitch OFF mobile phones and other hand
held electronic devices.
HOpen the fuel filler cap slowly.
HRefuel in a well ventilated area with the engine
turned off.
Royal Enfield cautions you against the use of certain
nonstandard parts such as aftermarket and custom
made extended front forks or suspensions, which may
adversely affect performance and handling.
Removing or altering original parts may adversely
affect performance and could result in an accident
causing serious injury.

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SAFE OPERATING RULES
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
riders should gain experience under various
conditions while driving at moderate speeds.
Gasoline is extremely flammable and highly
explosive. Use care when handling gasoline. Always
stop the engine when refuelling or servicing the fuel
system. Do not smoke or allow open flames or sparks
near gasoline. Do not store motorcycle with gasoline
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.
W A R N I N G
HDO 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.
A new motorcycle must be operated according to
the special break-in-procedure. See BREAK-IN-
THE FIRST 300 MILES (500KM) section.
Operate motorcycle only at moderate speeds and
out of traffic until you have become thoroughly
familiar with its operation and handling
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.
NOTE

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SAFE OPERATING RULES
W A R N I N G
Avoid overspeeding and never travel over the speed
limit. Excessive speed may cause loss of control and
could result in an accident causing serious injury.
DO NOT exceed 70 MPH (110 km/h) riding solo.
DO NOT exceed 55 MPH (90Km/h) when carrying
a passenger or cargo.
Pay strict attention to road surfaces and wind
conditions. Any two wheeled motorcycle may be
subject to the following upsetting forces :
HWind blasts from passing trucks.
HRough uneven road surfaces.
HSlippery road surfaces.
These forces may affect the handling characteristics
of your motorcycle. If this happens, reduce speed and
guide the motorcycle with a relaxed grip to a controlled
condition. Do not brake abruptly or force the handlebar.
Operate your motorcycle defensively. Remember,
a motorcycle does not afford the same protection
as an automobile in an accident. One of the most
common accident situations occurs when the
driver of the other motorcycle fails to see or
recognize a motorcycle and turns into the
oncoming motorcyclist.
Wear an approved helmet, clothing, and foot gear
suited for riding a motorcycle. Bright OR light colors
are best for greater visibility in traffic, especially
at night. Avoid loose, flowing garments and
scarves.
It is not recommended to drive this motorcycle with
pillion seat fitment / pillion rider, Failure to adhere
this may cause damage to motorcycle / rider.
DO NOT allow other individuals, under any
circumstances, to operate your motorcycle unless
you know they are experienced, licensed riders
and are thoroughly familiar with the operating
conditions of your motorcycle.

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SAFE OPERATING RULES
W A R N I N G
Maintain the recommended tyre pressure. Ensure the
front and rear wheels are correctly aligned and the
tyres are seated evenly & properly in the rims. Check
for correct tightness of the spokes in the rims. Inspect
your tyres periodically and replace tyres with approved
tyres only. Failure to do so can lead to improper
balance, abnormal tread wear, poor handling and
could result in serious injury.
W A R N I N G
Royal Enfield recommends replacement of any 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 Authorized
Dealer. Speed should not exceed 60 Km/h (40 MPH) for
the first 24 hours after repair and the repaired tyre
should Never be used over 90 Km/h (55 MPH).
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. D O N OT allow fatigue, alcohol or
drugs to endanger your safety or that of others.
Maintain your motorcycle in proper operating
condition in accordance with the Maintenance
in te r val s ch a r t in t h i s Ow n er’s M anua l .
Particularly important to motorcycle stability is
proper tyre inflation pressure, tread condition.
Pay strict attention to loose and / or broken
spokes, free movement of steering system.

9
SAFE OPERATING RULES
W A R N I N G
W A R N I N G
DO NOT operate motorcycle with a loose, worn or
damaged steering system, including the front and
rear suspension system. Contact your Royal Enfield
Authorized Dealer for repair of steering or suspension
system. Damaged steering or suspension components
may adversely affect handling which could result in
serious injury.
Regularly inspect rear shockabsorbers and front forks
for any defective suspension can adversely affect
stability and handling which could result in serious injury.
For your personal welfare, all the listed service and
maintenance recommendations should be performed.
Lack of regular maintenance at the suggested intervals
may affect the safe operation of your motorcycle, which
could result in serious injury.
W A R N I N G
W A R N I N G
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. Failure to wear proper or protective clothing
could result in serious injury.
W A R N I N G
Exhaust gases contains poisonous carbon monoxide
and chemicals, known to cause Cancer, Birth Defects
or other reproductive defects.
DO NOT INHALE exhaust gases. Never stand close to
the exhaust system of the motorcycle when the engine
is running.
W A R N I N G
Motorcycle batteries contain lead and lead
components, acids and chemicals known to cause
cancer, birth defects or other reproductive harm.
Exercise extreme caution while handling a battery.
Wash hands thoroughly whenever a battery is handled.

10
SAFE OPERATING RULES
W A R N I N G
Consult your Royal Enfield Authorized 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.
W A R N I N G
Use only genuine Royal Enfield replacement fasteners
tightened to the proper torque (See your Royal Enfield Work
Shop Manual). We caution you against the use of certain
nonstandard parts such as aftermarket and custom made
fasteners 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 result in serious injury.
W A R N I N G
DO NOT exceed the Gross Motorcycle Weight Rating of your
motorcycle. The Gross Motorcycle Weight Rating (GVWR) is
shown on the information plate, located on the frame Down
tube. (GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider,
passenger and cargo that may be safely carried.)
Exceeding GVWR may lead to instability of the motorcycle,
which could cause an accident and result in serious injury.
W A R N I N G
DO NOT tow a disabled motorcycle. The steering and
handling for 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.
W A R N I N G
DO NOT pull a trailer behind a motorcycle. Towing a
trailer may cause reduced braking efficiency, tyre
overloading and unstable handling. Towing a trailer
may cause loss of control of the motorcycle in the front,
leading to an accident resulting in serious injury.

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RULES OF THE ROAD
Be sure all equipment required by Federal, State,
and local law is installed and are in good
condition.
Be sure your license plate 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 :
HDry
HOily
HIcy
HWet
Watch for loose debris, such as leaves, slippery
substances or loose gravel that can hamper the
stability of your motorcycle.
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 center line
when meeting oncoming motorcycle.
Always sound your horn, actuate your turn signals,
and exercise cau t i on w hen passing other
motorcycles going in the same direction. Never
try to pass another motorcycle 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
motorcycle on your left or right. DO NOT presume
you have the right-of-way.
Avoid excessive speed and never travel at a speed
faster than the speed limit. Excessive speed may cause
loss of control of motorcycle, which could result in death
or serious injury.
W A R N I N G

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RULES OF THE ROAD
Always signal when preparing to stop, turn or
pass.
While turning either right or left, watch for
pedestrians, animals, as well as motorcycles.
All traffic signs, including manual controls at
intersections, should be obeyed promptly. SLOW
DOW N at traffic signs near schools and
CAUTION signs at railroad crossings.
When intending to turn, signal at least 100 feet
(30.5 meters) before reaching the turning. Be close
to the center line (unless local rules require
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
signaling. Be sure your way 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.
Protect your motorcycle against theft. After
parking your motorcycle, remove Ignition key from
switch and lock the steering head.

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TECHNICAL SPECIFICATIONS
ENGINE
Engine Type ............ S ingle Cylinder 4 Stroke, Spark
............................... Ignition, Air cooled, Fuel injection
Bore ........................... 84mm
Stroke ........................ 90mm
Swept volume ......... 499cc
Compression ratio . 8.5:1
Max Power ................... 20.3kw @ 5250 rpm
Max Torque .................. 41.3 Nm @ 4000 rpm
Idle RPM ................... 1150+150 RPM
Starting ..................... Kick Start / E-Start
Air filter 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 .... 15W50 API SL Grade & above,
............................ (JASOMA2)
Fuel Supply .............. Electronic Fuel Injection
Cooling ..................... Natural air flow
IGNITION SYSTEM
Ignition system ....... Digital Electronic Ignition
Spark plug Electrode gap 0.80 to 0.90 mm
Spark plug .............. WQR8DC (Bosch)
TRANSMISSION
Clutch ........................ Wet multiplate (7 plates)
Primary drive .......... Duplex chain
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 ............... 17 Teeth (Sprocket)
Final Ratio ................ 2.235:1
Drive Chain links .... 102 links

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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 ...................... Hydraulic Disc Brakes Front
............................ & Rear with ABS System
Front: ................. 280 mm dia disc with twin
............................ piston caliper
Rear: .................. 240 mm dia disc with single
............................ piston & floating caliper
Tyre size
Front ................... 90 / 90 - 19” - 52 P
Rear ................... 110 / 80 - 18” - 58 P
Tyre Pressure
Front ................... 20 psi/1.41 kg/cm2
Rear ................... 30 psi/2.11 kg/cm2
Steering lock ........... In built
Fuel tank capacity . 13.5 litres approx.*
Low fuel warning ... 3.5 litres (approx)
Dead stock of Petrol 0.75 litres (approx)
(unusable fuel)
* The above values are approximate and the actual fuel filling
capacity will vary from the values mentioned.
ELECTRICALS
Generation .............. Alternator (III Phase)
System : E-Start ...... 12V - DC (III Phase)
Battery : E-Start ...... 12V, 12AH MF
Head lamp .............. 12V, H4-60/55W (Halogen)
Position Lamp .......... 12V, 4W
Brake/Tail lamp ..... 12V, P21/5W
TECHNICAL SPECIFICATIONS

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Parking lamp ...................... 12V, 2W X 2 Nos.
Speedometer lamp ........... 12V, 3.4W
Hi beam indicator ............. 12V,1.7W
Neutral lamp tell tale ......... 12V,1.7W
Turn signal tell tale ............ 12V,1.7W
Turn signal .......................... 12V, R10W X 4 Nos.
Warning Indicator lamps . 12V, 2W X 3 Nos.
Horn ...................................... 12V, 2.5 amp (Max)
Starter Motor ....................... 12V, 0.90 KW
TECHNICAL SPECIFICATIONS
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 I N 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.
DIMENSIONS
Length ................................ 2100 mm
Width ................................... 800 mm
Height ................................. 1160 mm
Wheel base ....................... 1360 mm
Saddle Height ................... 805 mm
WEIGHTS
Kerb weight (90% fuel&oil) 198 Kgs.
Max. Pay load ................... 92 Kgs.
Luggage load carrier .... should not be more
...................................... than 15 Kgs.

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Capacity 2.75 Ltrs. (First Fill only )
2.30 to 2.50 Ltrs. (during oil & filter
element replacement in periodical
maintenance)
ISO 14 00 1 Op e r at i o n C o ntro l Pr oc ess
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 4 & other brake fluid together.
Br a ke Flui d
Capacity 60ml
Grade DOT 4
Fr ont Fo rk Oi l
Grade 2W35
Capacity 195 ml/leg
RECOMMENDED LUBRICANTS
En gi ne Oil
Grade 15 W 50 API SL Engine Oil
(JASOMA2)

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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 others. Please read these carefully and if disregarded may
result in injury to yourself or others and damages to the motorcycle.
SAFETY DEFINITIONS
Indicates important and useful 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.
NOTE
This message if disregarded may result in damage to the motorcycle.
C AU T I O N
Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider
or other persons.
W A R N I N G

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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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LOCATION OF KEY PARTS
1. Horn Button
2. Turn Signal Switch
3. Cluth Lever
4. Day Flash
5. Head Lamp Dip Switch
6. Ignition Switch
7. Speedo Meter
8. Warning Indicator
9. Engine Kill Switch
10. Brake Lever
11. E-Start Switch Button
12. Petrol Tank Cap
13. Rear View Mirrors
2
6
3
5
1
78910
11
12
4
13
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