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)

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IGNITION SYSTEM
Ignition system .......................................... Electronic Ignition (ECU / Variable)
Spark plug Electrode gap ........................ 0.7 to 0.8 mm
Spark plug ................................................. WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10
TRANSMISSION
Clutch ........................................................ Wet Multiplate (7 Plates)
Primary drive ............................................. Duplex Chain
Primary Drive Ratio .................................. 2.15 : 1
Gear box .................................................... Constant Mesh 5 Speed
Gear shift pattern...................................... 1 - N - 2 - 3 - 4 - 5
Gear Ratios ............................................... 1st-3.06:1 2nd-2.01:1 3rd-1.52:1 4th-1.21:1 5th-1:1
Secondary Drive (F.D. Sproket) .............. 18 Teeth
Final ratio ................................................. 2. 11 : 1
Drive Chain links ...................................... 102 links
Technical Specification

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ELECTRICALS
Generation ................................................ Alternator
System ....................................................... 12V DC
Battery ....................................................... 12V - 14 AH MF
Head lamp ................................................. 12V, 60/55 W, Halogen
Brake / Tail lamp ...................................... 12V, 21/5 W
Turn signal ................................................ 12V, 10W - 4 nos.
Pilot lamp .................................................. 12V, 2 W - 2 nos. & 12V, 4 W - 1 no.
Speedometer lamp ................................... 12V, 3.4 W - 1 no.
Turn signal / High beam indicator ........... 12V, 2 W - 2 nos.
Neutral Indicator ....................................... 12V, 2 W - 1 no.
Horn (Dual) ............................................... 12V, 2.5 Amp (Max.) X2
Starter Motor ............................................. 12V, 0.9 KW
Technical Specification

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CHASSIS
Frame ........................................................ Tubular Frame
Tyre size .................................................... Front: 90 / 90 - 19” - 52 P Rear: 120 / 80 - 18” - 62 P
Tyre pressure ............................................ Front- Solo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI)
............................................................ Rear- Solo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.25 Kg/cm2 (32 PSI)
Fuel tank capacity .................................... 13.5 Litres (MIN)
Low fuel warning....................................... 2.5 Litres
Dead stock of petrol (unusable fuel) ....... 0.75 Litres
Suspension ............................................... Front: Telescopic (Dia 35mm), Hydraulic Damping Stroke 130mm
............................................................ Rear: Swing arm with gas filled shock absorbers Stroke 80 mm
Front fork oil capacity ............................... 195 ml per leg
Fron fork oil ............................................... 1F Endurance (or Royal Enfield) fork oil
Brakes ....................................................... Front : Hydraulic 280 mm Ventilated Disc
............................................................ Rear : Foot Operated 153mm Single Lead Internal expanding
Brake oil capacity ..................................... 60 ml
Brake oil grade ......................................... DOT 3 or DOT 4
Technical Specification

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DIMENSIONS
Length........................................................ 2170 mm
Width ......................................................... 800 mm
Height ........................................................ 1070 mm
Wheel base ............................................... 1370 mm
Saddle height ............................................ 800 mm
Ground clearance ..................................... 135 mm
WEIGHTS
Kerb Weight (with 90% Fuel) .................. 190 Kg
Max pay load ............................................ 178 Kg
NOTE :
1. Values given above are for your guidelines only.
2. In view of continuous improvements being done on our products, the specifications are subject to change without notice.
Technical Specification

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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.
Warning
Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider or other persons.
CAUTION :
This message if disregarded may result in damage to the vehicle.
NOTE :
Indicates important and useful messages for clear understanding.
Safety Definitions

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Safe Riding Tips / Guidelines
zBefore 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.
zKnow and respect the rules of the road. Be a
safe rider for your own safety and for other road
users.
zBefore starting the motorcycle, check for proper
operation of brakes, clutch, gear shifter, handle
bar controls, tyre pressures, fuel and oil levels.
zUse only genuine Royal Enfield spare parts and
approved accessories. Use of other manu-
facturer’s performance parts may affect the
performance of your motorcycle and render the
motorcycle void of warranty. See your Royal
Enfield dealer for details.
zWhenever refuelling your motorcycle, please
exercise utmost caution and carefully observe
the following rules :
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9DO NOT smoke and please ensure that
there are no open flames or sparks near the
motorcycle, when refuelling OR servicing
the fuel system.
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9Switch OFF mobile phones and other hand
held electronic devices.
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9Open the fuel filler cap slowly.
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9Refuel in a well ventilated area with the
engine turned off.
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9DO 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
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.

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Safe Riding Tips / Guidelines
zA new motorcycle must be operated according
to the special running-in-procedure. See
running-in-procedure mentioned in Page No. 32.
zOperate motorcycle only at moderate speeds
and out of traffic until you have become
thoroughly familiar with its operation and
handling characteristics under all conditions.
zDO 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 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.
Pay strict attention to road surfaces and wind
conditions. Any two wheeled vehicle may be subject
to the following upsetting forces :
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9Wind blasts from passing trucks.
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9Rough uneven road surfaces.
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9Slippery 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.
zOperate 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
vehicle fails to see or recognize a motorcycle
and turns into the oncoming motorcyclist.

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Safe Riding Tips / Guidelines
zWear 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.
zWhen carrying a pillion rider, it is your
responsibility to instruct them on proper riding
procedures.
zDO 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.
Warning
Regularly inspect shock absorbers and front forks
and look for leaks. Replace worn parts. Worn parts
can adversely affect stability and handling.
Warning
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.
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 Cancer,
Birth Defects or other reproductive defects.

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Safe Riding Tips / Guidelines
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 thoroughly whenever a battery is
handled.
Warning
Consult your Royal Enfield 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.
Warning
DO NOT tow a disabled motorcycle. The steering
and handling of 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.
Warning
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.

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Safe & Happy Riding
RIDING DRESS
zPlease wear a proper riding apparel.
zA pair of riding boots or shoes.
zSoft leather gloves.
zGoggles or spectacles to safe guard eyes.
zA certified helmet. Affix light reflecting strips of
stickers at the front and rear.
NOTE :
A light coloured shirt enables greater visibility to other
road users especially during nights.
CAUTION :
Loose clothing may get caught on moving parts of your
motorcycle.
SITTING POSTURE
Correct sitting posture is a pre-requisite for stable
and safe riding
zSit Straight with your shoulders completely relaxed.
zKeep your elbows close to your body.
zKeep your toes in straight ahead direction.
zSlightly grip the petrol tank with both knees.
zHold the handle bar grips, close to its inner end.
zLook extensively ahead, including rear view
mirrors, without turning the head.
BRAKING
zApply front and rear brakes gently and
simultaneously for maximum braking efficiency.
WARNING
Applying any one of the brakes suddenly may cause
the vehicle to skid. The hydraulic disc brake fitted on
your motorcycle requires very less effort. High effort
or sudden application may lock the wheel. Please use
utmost caution while applying the brakes.
zWhile riding on wet or bad road conditions use
brakes cautiously.
zAvoid excessive banking, otherwise footrest
may touch the ground and cause instability.