Royal Enfield Classic 500 User manual

EURO IV

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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.

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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

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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

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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 !

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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

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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

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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

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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.

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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