Royal Enfield Thunderbird 500 User manual

FOREWORD
We congratulate you on your choice of the legendar y Royal Enfield motorcycle and welcome you to the
exciting world of motorcycling. The Thunderbird 500, the ultimate highway cruiser now comes with a solid
500cc engine, a bigger 20 litre tank, ergonomic seating and a powerful projector headlamp. This manual
will help you to operate your motorcycle the right way and guide you to maintain it meticulously. We have
also provided tips on safe riding and on minor adjustments for the care of your motorcycle. Please avail the
four free & three paid services at the nearest Authorised Service Center, at the appropriate time to maintain
your motorcycle in top riding condition. Log on to the exciting world of Royal Enfield on 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 Thunderbird 500.

2
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 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”.
NOTICE
Part No. 594069/B / Qty. 500 / Nov. ‘16
NOT E : BS II I
T h i s m o t o r cy c l e m e et s E m i s s io n N o r m s -
B h ar a t ( Tr e m ) S ta g e - I I I
D i s c l a i m e r
Following precautions are to be taken, to ensure longer
paint life of your motorcycle.
1. Do not polish your motorcycle as it increases gloss.
2. Wash only with plain water.
3. Scratches or marks cannot be removed or touched up.
Applicable for Stone Black Colour / Matt Paint Finish
NOTE: Warranty is not applicable for Stone Black Colour /
Matt paint finish due to uniqueness of the paint.
C o n ta c t U s :
Royal Enfield Support : 1800-2100-007
Email : [e-mail]
Twitter : @RoyalEnfieldSupport
Web : www.royalenfield.com

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CONTENTS
Personal and Motorcycle Information 4
Technical Specifications 5
Recommended Lubricants 8
Safety Definitions 9
Motorcycle Identification Numbers 10
Location of Key Parts 11
Operation of Controls 14
Pre-Operational Checks 21
Safe & Happy Riding 22
Running in Period 23
Starting 24
Gear Shifting, Riding & Stopping 25
Parking 26
Periodical Maintenance Chart 27
Tools & First Aid kit 30
Minor Maintenance Tips 31
Long Trip Precautions 43
Washing Procedure 44
Storage Precautions 45
Trouble Shooting 46
Warranty Terms & Conditions 47
Emission Warranty 49
Service Coupons 52
Paid Service & Maintenance Record 67
Regional & Area Offices 69
Authorised Dealer Address 70
Notes 88
A n n e x u r e s
Motorcycle Installation Form
Pre-Delivery Inspection Report
Motorcycle Installation Confirmation By Customer
Form 22

4
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
Motorcycle Installation Form (MIF) No.

5
ENGINE
Engine Type .............
Single Cylinder 4 Stroke, Air cooled
Bore ............................ 84mm
Stroke ......................... 90mm
Swept volume .......... 499cc
Compression ratio . 8.5:1
Max Power BHP @ RPM
27.2@5250
Max Torque in NM@ RPM
41.3@4000
Idle RPM .................... 1050+200
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 .... Royal Enfield 15W50 API SL (JASOMA)
Cooling ...................... Natural air flow
IGNITION SYSTEM
Ignition system ........ Electronic Ignition ECU / Variable
Spark plug Electrode gap
0.70 to 0.80 mm
Spark plug ............... WR8DP M14 (Bosch) &
............................. UR6DC M10 (Bosch)
TRANSM ISSION
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 ................ 18 Teeth (F.D. Sprocket)
Final Ratio ................. 2.11:1
Drive Chain links .... 102 links

6
CHASSIS
Frame......................... Single Down Tube, Using
............................. engine as stressed member.
Suspension
Front ....................
Inline Telescopic Fork (dia 41mm)
................................. hydraulic damping stroke 130mm
Rear ....................
Rigid oval section swing arm with
................................. gas filled shockabsorbers stroke
................................. 80mm (5 steps adjustable)
Brakes
Front Disc ........... 280mm ventilated disc,
............................. Double piston caliper
Rear Disc ........... 240mm ventilated disc,
............................. Single piston caliper
Tyre size
Front .................... 90 / 90 - 19” - 52 P
Rear .................... 120 / 80 - 18” - 62 P
Tyre Pressure
Solo
Front .................... 20 psi/1.41 kg/cm2
Rear .................... 30 psi/2.11 kg/cm2
With Pillion
Front .................... 22 psi/1.55 kg/cm2
Rear .................... 32 psi/2.25 kg/cm2
Steering lock ............ In built
Fuel tank capacity .. 19 litres approx. *
Low fuel warning ... Last bar blink system
............................. 5.5+0.50 litres approx.
Dead stock of Petrol 0.5 litre approx.
(unusable fuel)
* The above values are approximate and the actual fuel filling
capacity will vary from the values mentioned.
ELECTRICALS
Generation ............... Alternator
System : E-Start ....... 12V - DC
Battery : E-Start ...... 12V - 14 AH MF

7
DIMENSIONS
Length .................................. 2060 mm
Width ..................................... 790 mm
Height ................................... 1205 mm
Wheel base ......................... 1350 mm
Ground clearance............ 135 mm
Saddle Height .................... 775 mm
WEIGHTS
Kerb weight (90% fuel&oil) 195 Kgs.
Max. Pay load ..................... 170 Kgs.
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.
Head lamp .............. Projection type, H7 bulb 55/55W
............................. with LED light guide ring
Position indicator .... LED, 12V X 1 No.
Brake/Tail lamp .....
LED lamp with position light guides
Hi beam indicator . LED, 12V X 1 No.
Neutral indicator ..... 12V-1.4W X 1 No.
Turn signal indicator LED, 12V X 2 Nos.
Turn signal / ............. 12V, 10W X 4 Nos.
hazard warning
Horn ............................ 12V, 2.5 Amp (Max.) X 2 Nos.
Starter Motor ........... 12V, 900 Watts
Instrument Cluster .. Digital cluster with LCD panel
Hazard indicator ... LED, 12V X 1 No.
Side stand indicator 12V-1.4W X 1 No.
Malfunction ............... LED, 12V X 1 No.
Indicator Lamp (MIL)
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.

8
Capacity 2.75 Ltrs. (First Fill only )
2.30 to 2.50 Ltrs. (during oil & filter
element replacement in periodical
maintenance)
I SO 1 4 00 1 O pe r at io n C o nt ro l P r oc es s
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.
RECOMMENDED LUBRICANTS
E ng i n e O i l
Grade Royal Enfield 15 W 50 API SL
Engine Oil
(JASO MA)
DO NOT Mix DOT 3 & DOT 4 brake fluid together.
Front Fo r k Oil
Grade Royal Enfield Front
Fork Oil (or
Gabriel Fork Oil
2w 35)
Capacity 430+3 ml/leg
B r a ke F l u i d
Capacity Fr. 60 ml
Rr. 100 ml
Grade
DOT 3 or
DOT 4

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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.
W A R N I N G
Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider
or other perso ns.
C AU T I O N
This message if disr egarded m ay result in damage to the motorcycle.
NOTE
Indicates i mportant and useful mes sages f or cl earer understand ing.
All Images shown in subsequent pages are for reference to explain and need not to be exactly the
same on the model you own.
SAFETY DEFINITIONS

10
MOTORCYCLE IDENTIFICATION NUMBERS
FRAME NUMBER
Punched on steering head tube right side.
ENGINE NUMBER
Punched on crankcase left top side.

11
1
2
3 4 5 6 7 8 9 10
11
1213
LOCATION OF KEY PARTS - TOP VIEW
1. Turn Signal Switch
2. Horn Button
3. Clutch Lever
4. Day Flash Switch
5. Head Lamp Dip Switch
6. Manual Bistarter / Choke
7. Speedometer
8. Ignition Switch
9. Malfunction / Low Fuel Indicator
10. Engine Kill Switch
11. Pilot Head Light Switch
12. E-Start Switch
13. Fuel Tank Cap

12
LOCATION OF KEY PARTS - RIGHT SIDE VIEW
1. Right Trafficator Rear
2. Right Trafficator Front
3. Brake Pedal
4. Starter Motor
5. Air Filter Box (Side Panel)
6. Utility Box (Tool Kit)
2
1
6534

13
LOCATION OF KEY PARTS - LEFT SIDE VIEW
1. Left Trafficator Front
2. Utility Box (Fuse Carrier)
3. Left Trafficator Rear
4. Center Stand
5. Side Stand
6. Battery Cover
7. Spark Plug
8. Gear Change Pedal
9. Horn
1 3
2
98 7 654

14
OPERATION OF CONTROLS
IGNITION SWITCH
OFF ON
STEERING LOCK
Turn the handle bar to extreme left or
right position.
Push the key inside in “OFF” position, press
and further t urn to a nticlock wise
direction to lock the steering system.
Push the key in steering lock Position,
and turn clockwise direction to unlock
the steering.
FUEL TANK CAP
Turn key clockwise to open.
Press cap to lock with key in position.
SIDE PANEL LEFT / BATTERY COVER
Turn anti clockwise to open
Pull the side panel outside for opening
the same.
SIDE PANEL RIGHT
Unscrew the indicated screw and then pull
the side panel for opening the same.
NOTE
Key is com mo n for i gni tion, petr ol tank cap,
steering lock, battery cover and tool boxes.
Key can be removed only in locked position from
fuel tank, Filter box, Electrical boxes locks in “OFF”
position from Ignition switch.
Turn handle bar to extreme left, before attempting
to lock steering.
ENGINE STOP SWITCH
Engine OFF
E-START SWITCH
Depress & hold till engine starts
Engine ON

15
TURN SIGNAL SWITCH
OFF (Push to off)
Right turn signal ON
Left turn signal ON
Apply choke in cold start condition
while starting the Motorcycle
MANUAL BI STARTER (CHOKE)
C AU T I O N
Choke should be used only to start engine in cold
climates (less than 200C) or first time in the morning.
Riding with the Choke “ON” will result in Engine
Misfiring, Erratic behaviour, High fuel consumption,
and increased Emission values.
HEAD LIGHT SWITCH
OFF
Pilot ON
Head Lamp ON
DIMMER SWITCH
High beam Low beam
DAY FLASH
Press for Head Light Flash
HORN
Press

16
OPERATION OF CONTROLS
SIDE DECOR
Removing Left or Right side
decor
4 mm allen key is used.
DIGITAL INSTRUMENT CLUSTER
1. Speedometer
2. RPM (Tacho) Meter
3. Alpha-Numeric Display Unit
4. Select Button
5. Set Button
6. Hazard Button
3
1 2
5
4
6
Turn Signal Indicator Left
Turn Signal Indicator Right
High Beam Indicator
Neutral Indicator
Hazard Warning Indicator
Malfunction Indicator Lamp
Parking Lamp Indicator
Side stand Indicator
RIDER & PILLION SEAT CABLE LOCK
There are 2 cable hooks, Black
& Yellow on right side of the
battery (below the hook, Index
mark “R” - Rider & “P”-Pillion)
The allen key is located in the
battery carrier rubber strap (as
shown in fig.).
RP

N
SIDE
STAND

17
OPERATION OF CONTROLS
INSTRUMENT CLUSTER DISPLAY PATTERN




ODOMETER KM & TIME (AM/PM)
PRESS SET SWITCH > 3 SEC.
CHANGE TIME
1. PRESS SET SWITCH FOR TOGGLE BETWEEN HOUR & MINUTE
2. PRESS SELECT SWITCH FOR INCREMENT
3. PRESS SET SWITCH TO FIX THE TIME
RESET VALUES OF TRIP ‘A’ TO ZERO AND AVG SPEED TO ZERO
RESET VALUES OF TRIP ‘A’ AND AVG SPEED TO ZERO
RESET VALUES OF TRIP ‘B’ TO ZERO AND AVG SPEED TO ZERO
RESET VALUES OF TRIP ‘B’ AND AVG SPEED TO ZERO




PRESS SET
SWITCH > 1 SEC.
TRIP ‘A’ KM & TIME (AM/PM)
TRIP ‘A’ KM & AVG SPEED (TRIP ‘A’) KMPH
TRIP ‘B’ KM & TIME (AM/PM)
TRIP ‘B’ KM & AVG SPEED (TRIP ‘B’) KMPH
PRESS SET SWITCH > 3 SEC.
PRESS SET SWITCH > 3 SEC.
PRESS SET SWITCH > 3 SEC.
PRESS SET
SWITCH > 3 SEC.
PRESS SET
SWITCH > 1 SEC.
PRESS SET
SWITCH > 1 SEC.
PRESS SET
SWITCH > 1 SEC.

18
ALPHA-NUMERIC DISPLAY UNIT
This unit in the speedometer
consists of
1. Odometer
2. Trip A /AVG speed of Trip A
3. Trip B /AVG speed of Trip B
4. Clock
5. Fuel level indicator
6. Battery low voltage indicator
7. Service Reminder
OPERATION OF CONTROLS
ODOMETER MODE
Odo meter mod e is a initial
mo de. It di splays odo meter
and time.
NOTE
Once you turn “ON” the ignition key, whatever the last
selection mode will be displayed. If the current display
mode is “TRIP A”, you just turn off the ignition key.
Once you turn the ignition key the display mode
remaining same.
TRIP METER MODE
A brief push (less than one
second) on the “SELECT” button
switches the disp lay from
odometer to Trip meter (TRIP A)
TRIP METER AVG SPEED MODE
Again press the “SELECT” button
switches the display from “TRIP
A” to “TRIP A AVG”.
Again press the “SELECT” button
switches the display from “TRIP
A AVG” to “TRIP B”.
Again press the “SELECT” button
switches the display from “TRIP
B” to “TRIP B AVG”.
1
4
2 3 7 6 5




2& 3

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NOTE
After running of One kilometer only AVG TRIP A/B
Speed will be displayed.
RESET TRIP METER
1. Change TRIP A/B as a current mode.
2. Press the “SET” button (more than 3 Seconds).
3. Automatically the display will be zero
CLOCK
The clock indicates the Hours/
Minutes and AM/PM.
RESET CLOCK
1. Change Odometer/as a current mode.
2. Press the “SET” button (more than 3 Seconds).
3. The Hours will be blinking, and press the “SELECT”
button to change the Hours.
4. Again press the “SET” button (more than 3 seconds)
5. The Minutes will be bli nking, then press the
“SELECT” button to change the Minutes
NOTE
Once you press the “SELECT” button the Hours/Minutes
will increase in ascending order only, it not decrease.
The Hour/Minutes blinks less than 1 minute, within the
time limit you have to reset the clock otherwise it will
come out from the reset mode.
FUEL LEVEL INDICATOR
The fuel level indicator indicates
the level of fuel in the fuel tank.
The display bars of the fuel


meter disappears towards the Empty (E) if the fuel
level decreases.
When last bar will start blinks, (Fuel capacity is less
than 5.5 Ltrs.) refuel as soon as possible.