Royal Enfield Classic 500 User manual

EURO IV

1
FOREWORD
Welcome to the Royal Enfield family.
The Royal Enfield motorcycles are being manufactured by us since 1955 with state of the art technology,
while taking care to maintain the traditional Classic looks.
The Bullet Classic EFI that you have just bought, confirms to all applicable European homologation
regulations pertaining to EURO IV.
This manual will help to acquaint yourself with the important aspects of operation, care and minor
maintenance of your new Royal Enfield Motorcycle. We recommend that you read this manual carefully,
before using the motorcycle, to get maximum performance and to maintain your Motorcycle in top riding
condition.
We have also detailed, vital safety information for the rider and for the care and safety of the motorcycle.
Please read and follow these carefully to get maximum riding pleasure and for safe riding.
We request you to exercise utmost caution while riding. Please ride cautiously, safely and within the law.
Always wear a helmet, good riding goggles and proper riding clothes while riding the motorcycle. Please
also insist and ensure that your pillion also follows these while riding with you.
Log on to the exciting world of Royal Enfield website : www.royalenfield.com to get to know more about the
company, its products and exciting news from time to time.
We wish you many years of riding pleasure with your Royal Enfield motorcycle.
Royal Enfield team
Chennai, India.

2
NOTICE
Due to continous improvements being carried out 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 motorcycle.
However the technical information found within this manual was correct at the time it was approved for
publication.
Royal Enfield,
Chennai
India.
© Copyright 2016 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.
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
Part No. 1010221/A / Qty. 250 / Sep. ‘16

3
It is the responsibility of the Owner to read this manual and comply with safety guide lines,
operating instructions, service & maintenance instructions set forth therein. Keep this manual in
a convenient place for easy reference. DO NOT use the motorcycle until this manual has been
read and understood thoroughly.
If any information is not understood in the manual contact an authorised Royal Enfield dealer.
If the motorcycle is being used by any friend, relative or others, it is responsibility of the owner to
make certain that this 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 you sell your motorcycle to another person, it is your responsibility to hand over this
manual along with the motorcycle.
IMPORTANT

4
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 indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate
injury.
Caution :
Caution used without safety alert symbol indicates a potentially hazardous situation, which if not avoided,
may result in property damage.
All images shown are for reference to explain and may not to be exactly the same on the model you own.
Technical specification are subject to change without prior notice.
IMPORTANT NOTICE !

5
CONTENTS
PERSONAL & MOTORCYCLE INFORMATION .. 6
SAFE OPERATING RULES ................................. 7
RULES OF THE ROAD ...................................... 13
ACCESSORIES AND CARGO ........................... 15
TECHNICAL SPECIFICATIONS ........................ 17
RECOMMENDED OILS ..................................... 20
MOTORCYCLE IDENTIFICATION
NUMBER - DETAILS .......................................... 21
ENGINE NUMBER - DETAILS ........................... 23
KEY PARTS LOCATION .................................... 24
OPERATION OF CONTROLS ............................ 27
PRE OPERATIVE CHECKS ............................... 30
SAFE & HAPPY RIDING .................................... 31
RUNNING IN ....................................................... 32
WARNING INDICATIONS & SAFETY SYSTEMS .. 34
STARTING .......................................................... 38
GEAR SHIFTING ................................................ 40
PARKING ............................................................ 41
PERIODICAL MAINTENANCE .......................... 42
TOOLS KIT ......................................................... 46
MINOR MAINTENANCE TIPS ........................... 47
LONG TRIP PRECAUTIONS ............................. 67
WASHING PROCEDURE ................................... 68
STORAGE PRECAUTIONS ............................... 69
WIRING DIAGRAM............................................. 71
ABS WIRING DIAGRAM .................................... 72
TROUBLE SHOOTING ...................................... 73
WARRANTY ....................................................... 78
EVAPORATIVE EMISSION CONTROL ............. 80
SYSTEM WARRANTY
SERVICE MAINTENANCE RECORD ................ 82
NOTES ................................................................ 84

6
PERSONAL & MOTORCYCLE INFORMATION
Name
Door No./ Street
Locality
City Country
Contact Res : Off :
Mobile : Email :
Licence No. Valid till :
Model Color :
Engine No.
VIN. No.
Tyre make Front : Rear :
Tyre Nos. Front : Rear :
Battery make Battery No.
Sold by
Date of Sale

7
Before operating your new motorcycle, it is your
responsibility to carefully read and follow the
oper ating and m a inte nanc e instruct io ns
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.
WARNING
Royal Enfield cautions you against the use
of certain nonstandard parts such as aftermarket
a n d c u s to m m a de e x t e nd e d f r o nt f or k s o r
s u spe n sio n s , wh ic h m ay a d v er se l y a ff ec t
performance and 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 Authorized Dealer for details.
Whenever refuelling your motorcycle, please
exercise utmost caution and carefully observe
the following rules :
DO NOT smoke and please ensure that
there are no open flames or sparks near the
motorcycle, when refuelling OR servicing the
fuel system.
Switch OFF mobile phones and other hand
held electronic devices.
Open the fuel filler cap slowly.
Refuel in a well ventilated area with the
engine turned off.
SAFE OPERATING RULES

8
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.
WARNING
Gasoline is extremely flammable and highly
explosive. Use care wh en han dling gasoline.
Alwa ys s to p th e e ngin e w hen re fue lli n g o r
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.
A new motorcycle must be operated according
to the special break-in-procedure. See BREAK-
IN-THE FIRST 300 MILES (500KM) section.
SAFE OPERATING RULES
Operate motorcycle only at moderate speeds
and out of traffic until you have become
thoroughly f amiliar 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 :
If you are an inexperienced rider we recommend
that you obtain formal training on correct motor-
cycle riding techniques and become thoroughly
familiar with the operation o f your particular
motorcycle. New riders should gain experience
u n d er v a ri o us c o n di ti o n s w h il e d r iv i ng a t
moderate speeds.

9
WARNING
Avoid overspeeding and never travel over
the speed limit. Excessive speed may cause loss
of control and could result in an accident caus-
ing 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 :
Wind blasts from passing trucks.
Rough uneven road surfaces.
Slippery road surfaces.
These f orces m ay af fe ct the ha nd ling
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.
Op erat e your mo torcycle def ensively.
Remember, a motorcycle does not afford the
sam e prot ectio n as an autom ob ile in a n
accident. One of the most common accident
situations occurs when the driver of the other
motorcycle f ails to se e or recog nize a
mot or cycle and turns int o the o ncom ing
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.
W hen carrying a pillion rider, i t is your
responsibility to instruct them on proper riding
procedures.
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.
SAFE OPERATING RULES

10
WARNING
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. Fail-
ure to do so can lead to improper balance, ab-
normal tread wear, poor handling and could result
in serious injury.
WARNING
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 Dea ler. 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).
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 warn ing cou ld 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 in accordance with the Maintenance
intervals chart in t his Owner’s Manual.
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.

11
SAFE OPERATING RULES
WARNING
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
s te e ri n g o r s u s pe n s io n s ys te m . D a ma g e d
s te e rin g o r s u sp e ns i on c o m po n e nt s m a y
adversely affect handling which could result in
serious injury.
WARNING
Regularly inspect rear shockabsorbers and
fro nt fork sfor any defective su spensio n can
adversely affect stability and handling which
could result in serious injury.
WARNING
For your personal welfare, all the listed
s erv ic e a n d ma in te na n ce re co mm en dati on s
s h o ul d be p e rf or me d . L a c k of re g u la r
main tenance at the suggested in tervals may
affect the safe ope ration 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. Failure to wear
proper or protective clothing could result in
serious injury.
WARNING
Exhaust gases contains poisonous carbon
monoxide and chemicals, known to cause Can-
cer, Birth Defects or other reproductive defects.
DO NOT INHALE exhaus t gases. Never stand
close to the exhaust system of the motorcycle
when the engine is running.
WARNING
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 th orou g hly wh ene ver a
battery is handled.

12
SAFE OPERATING RULES
WARNING
Con sult your Ro yal Enfield Authorized
Dealer regarding any questions or problems that
occur in the operation of your motorcycle. Fail-
ure 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 (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 assem-
b ly a nd i ts e nv ir o n m en t . T h e u s e o f an y
nonstandard parts, including fasteners, could
result in serious injury.
WARNING
DO NOT ex ceed the Gros s 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 we ight of the
motorcycle, a c cess ories, and the ma ximum
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.
WARNING
DO NOT to w a diabled motorcycle. The
steering and handling fo 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 trailer behind a motorcycle.
Tow in g a trailer may cause reduced braking
efficiency, tyre overloading and unstable han-
dling. Towing a trailer may cause loss of control
of the motorcycle in the front, leading to an acci-
dent resulting in serious injury.

13
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 :
Dry
Oily
Icy
Wet
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.
WARNING
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.
Keep to the correct side of the road center line
when meeting oncoming motorcycle.
Always sound your horn, actuate your turn
signals, and exercise caution when 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.

14
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 DOWN 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. W hen 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.

15
ACCESSORIES AND CARGO
Royal Enfield cannot te st and make spec ific
re c o mm en d a ti o ns c o nc er n in g s p ec i fic o r a
combination of accessories sold. Therefore, the
rider must be responsible for safe operation of
the motorcycle when installing accessories or
carrying additional weight.
The following guidelines should be used when
equipping a motorcycle, carrying cargo and /or
passengers.
WARNING
DO NOT load weight or install accessories
improperly on the motorcycle. Doing so may affect
the motorcycle’s stability handling characteristics,
and safe operating speed which could result in
serious accident causing serious injury.
DO NOT exceed 70 MPH (110 Km/h) riding solo.
DO NOT exceed 55 MPH (90 Km/h) when
carrying a passenger or cargo.
Keep cargo weight concentrated close to the
mot orcycle and a s low as possible; this
minimizes the change in the motorcycle’s center
of gravity
Distribute weight evenly on both sides
of the motorcycle.
DO NOT load bulky items too far behind
the rider or add weight to the handlebars
or front forks.
DO NOT exceed 5 pounds (2.3 kgs)
maximum load in each saddlebag.
Recheck the cargo periodically
Be sure cargo is secured and will not shift while
riding. Accessories secured loosely may affect
the riding of the motorcycle and affect the
stability of the motorcycle.
Ad ditional electr ical accesso ries and
equipments may overload the motorcycle’s
electrical system and will result in system and/
or component failure.

16
ACCESSORIES AND CARGO
Large surfaces such as fairings, windshields,
backrests and luggage racks can adversely
affect handling of the motorcycle. Only genuine
Royal Enfield accessories, designed specifically
for the motorcycle model should be used with
proper installation.
WARNING
Royal Enfield motorcycles have been care-
fully designed and engineered for riding in their
original configuration. DO NOT alter the handling
characteristics of these motorcycles. Doing so
may affect its stability and could cause an acci-
dent resulting in serious injury.
WARNING
Royal Enfield cautions you against use of
nonstandard parts such a s aftermarket and
custom made extended front forks which may
adversely affect the performance and handling of
the motorcycle. Removing or altering original
parts may adversely affect the performance of the
motorcycle, causing an accident, which could
result in serious injury.
WARNING
DO NOT ignore model / design specifica-
tions. Doing so constitutes to motorcycle misuse
which may adversely affect the handling and per-
formance of the motorcycle causing an accident,
which could result in serious injury.

17
Engine
Engine ............................... 4 Stroke, air cooled,
........................................... single cylinder
Capacity............................. 499 cc (Displacement)
Bore ................................... 84 mm
Stroke ................................ 90 mm
Compression ratio ............. 8.5 : 1
Max. Power @ RPM ......... 20.3 Kw @ 5250 RPM
Max. Torque @ RPM ........ 41.3 Nm @ 4000 RPM
Air filter Element ............... Paper Element
Lubrication ......................... Forced Lubrication,
........................................... Wet Sump
Fuel Supply ....................... Electronic Fuel Injection
TECHNICAL SPECIFICATIONS
Ignition system
Ignition system .................. Digital Electronic Ignition
Spark plug gap .................. 0.8 mm
Spark plug ......................... WQR8DC (Bosch)
Transmission
Clutch ................................ Wet Multiplate
Drive Chain links ............... 102 pitch
Primary drive ..................... Duplex Chain drive
........................................... 3/8” pitch
Gear box ............................ 5 Speed Constant Mesh
Gear Ratios ....................... I - 3.063 : 1
........................................... II - 2.013 : 1
........................................... III - 1.522 : 1
........................................... IV - 1.212 : 1
........................................... V - 1.000 : 1
Primary Drive Ratio .......... 2.15 : 1
Secondary Drive ............... Chain Drive
Secondary ratio ................. 2.235:1

18
Electricals
Generation......................... Alternator
System ............................... 12V DC
Battery ............................... 12V - 14 AH
Head lamp ......................... 12V, 60/55 W
Tail / Brake lamp ............... 12V, 5/21 W
Turn signal ......................... 12V, 10W X 2 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.)
TECHNICAL SPECIFICATIONS
Chassis
Frame ................................ Tubular Frame
Tyre size ........ Front ......... 90 / 90-19” - 52 V
....................... Rear .......... 110 / 80-18” - 58 V
Tyre pressure Front-Solo 18 PSI
....................... - Pillion 20 PSI
....................... Rear-Solo . 28 PSI
....................... - Pillion 30 PSI
Fuel tank capacity ............. 14.5 + 1 Litres
Suspension ... Front: ........ Telescopic, Hydraulic
........................................... Damping stroke 110 mm
....................... Rear: ......... Swing arm with g as
........................................... filled shockabsorbers
........................................... with adjustable 5 step
........................................... spring tension load.
Brakes ...................... Hydraulic Disc Brakes Front
........................... & Rear with ABS System
Front: ................. 300 mm dia disc with twin
........................... piston caliper
Rear: ................. 240 mm dia disc with single
........................... piston & floating caliper
Brake oil grade ......... DOT 4 or above