Royal Enfield Classic 500 User manual

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We congratulate you on your choice of the legendary Bullet motorcycle and welcome you to the exciting world
of motorcycling on a Royal Enfield.This manual will help you to operate your Classic 500cc motorcycle, 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 avail the four free services at the nearest Authorised Service
centre, at the appropriate time to maintain your Bullet motorcycle in top riding condition.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 request you to carefully read the terms and conditions of warranty and other useful
information given in this manual before starting to use your Bullet Motorcycle.
Foreword
Service Headquarters
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 : [email protected]
Website : www.royalenfield.com Part No. 591822 / b / Qty. 500 / April ‘11

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Notice
All information in this manual is based on the latest product information available at the time of publication.
Due to continues improvements or other changes, there may be discrepancies between information in this
manual and your vehicle. Royal Enfield reserves the right to make production changes at any time without prior
notice and without incurring any obligation to make same or similar changes to vehicles 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 specification are subject to change without prior notice.
“© Copyright 2011 Royal Enfield. All Rights Reserved. No part of this manual shall be copied, distributed or
otherwise dealt without the express permission in writing of Royal Enfield.

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PERSONAL & VEHICLE INFORMATION... 6
FREE SERVICE RECORD........................ 7
TECHNICAL SPECIFICATIONS................ 8
zEngine................................................ 8
zIgnition System................................... 9
zTransmission...................................... 9
zElectricals........................................... 10
zChassis.............................................. 11
zDimensions......................................... 12
zWeights.............................................. 12
SAFETY DEFINITIONS ............................ 13
SAFE DRIVING TIPS/GUIDELINES........... 14
SAFE & HAPPY RIDING........................... 18
RULES OF THE ROAD............................. 19
VEHICLE IDENTIFICATION...................... 21
zChassis Number.................................. 21
zEngine Number................................... 21
KEY PARTS LOCATION........................... 22
zTop View............................................ 22
zRight Side View.................................. 23
zLeft Side View .................................... 24
OPERATION OF CONTROLS ................... 25
zIgnition Switch .................................... 25
zSteering Lock...................................... 25
zFuel tank cap ..................................... 26
zSide Box ............................................ 26
zBattery Carrier ................................... 27
zUtility Box .......................................... 27
zHead lamp switch ............................... 28
zHead lamp Day flash .......................... 28
zDip Switch ......................................... 28
zEngine Start Switch ............................ 29
zEngine Stop Switch ............................ 29
zTurn Signal Switch ............................. 29
zHorn .................................................. 30
zManual Bi Starter (choke) ................... 30
PRE OPERATIONAL CHECKS ................. 31
RUNNING IN ........................................... 32
Contents

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Contents
ELECTRONIC FUEL INJECTION & MIL..... 33
zEFI .................................................... 33
zThe Advantages of EFI ....................... 33
zMalfunction Indicator Lamp (MIL)......... 33
ROLL OVER SENSOR ............................. 34
STARTING ............................................. 35
GEAR SHIFTING ..................................... 38
PARKING ............................................... 39
zCenter Stand ...................................... 39
zSide Stand ......................................... 39
TOOLS & FIRST AID KIT.......................... 40
RECOMMENDED LUBRICANTS ............... 41
PERIODICAL MAINTENANCE .................. 42
MINOR MAINTENANCE TIPS .................. 46
zControl Cables, Hand lever, Pivots,
Center / Side Stand Pivots .................. 46
zOil Level Inspection ............................ 46
zEngine oil change ............................... 47
zSpark Plug ......................................... 48
zBrake fluid ......................................... 49
zInspection of tyres and wheels............. 49
zTyre pressure ..................................... 50
zFront Wheel removal .......................... 50
zFront Wheel reassembly ..................... 51
zRear wheel removal ........................... 52
zRear wheel reassembly....................... 53
zAdjustments-Clutch............................. 54
zDrive Chain free play .......................... 54
zRear Brake Pedal Height .................... 55
zRear Brake free play adjustment.......... 56
zChain lock fitment .............................. 56
zAdjustment of gas shockabsorber........ 57
zRemoval of Battery from the Vehicle.... 58
zBattery Maintenance........................... 58
zReassembly of Battery on Vehicle ....... 59
CHANGING ELECTRICAL COMPONENTS.... 60
zHead Lamp Bulb Replacement .......... 60
zReassembling the Head Lamp............. 61

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Contents
zTail Lamp bulb Replacement................ 62
zTrafficator bulb Replacement .............. 62
zFuse .................................................. 63
zBlade fuse usage list........................... 63
PILLION(REAR)SEAT REMOVAL & REFITTING 64
zPillion (Rear) seat removal.................. 64
zPillion (Rear) seat refitting................... 65
WASHING PROCEDURE ......................... 66
zPrecautions ....................................... 66
zAfter washing ..................................... 66
STORAGE PRECAUTION ........................ 67
zPreparing the motorcycle for re-use...... 68
LONG TRIP PRECAUTIONS .................... 69
COMPLETE WIRING DIAGRAM ............... 70
TROUBLE SHOOTING ............................ 71
zEngine fails to start ............................ 71
zEngine misfiring ................................. 72
zPoor pickup ....................................... 72
zWhite / Blue smoke ............................ 73
zEngine overheating ............................ 73
zExcessive fuel consumption ................ 73
zBrakes Poor........................................ 74
zVehicle wobbles ................................. 74
zElectricals .......................................... 75
zElectronic Fuel Injection (EFI) ............ 75
WARRANTY ............................................ 76
EMISSION WARRANTY ........................... 78
REGIONAL & AREA OFFICES ................. 82
ALL INDIA ROAD SIGNS ......................... 83

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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 Classic 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 Dealerships / Authorised service centres
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 ASP /
Dealer’s Name
Address
1st Service 4th Service2nd Service 3rd Service

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Technical Specification
ENGINE
Engine ........................................................ 4 Stroke, air cooled, single cylinder, OHV, SI & FI Engine
Capacity ..................................................... 499 cc (Displacement)
Bore ........................................................... 84 mm
Stroke ........................................................ 90 mm
Compression ratio ..................................... 8.5 : 1
Max. Power @ RPM .................................. 27.2 BHP @ 5250 rpm
Max. Torque @ RPM................................. 41.3 Nm @ 4000 rpm
Air Filter Element ....................................... Corrugated Paper Element
Engine Oil Capacity ................................... 2.75 Litres.
Lubrication ................................................. Forced Lubrication, Wet Sump
Engine Oil Grade ....................................... MOTUL 3000 4T Plus 15W50 API SL JASO MA
Cooling system .......................................... Natural Air Flow
Fuel Supply ............................................... Electronic Fuel Injection Programmed (PGM-EFI)