Royal Enfield Classic 500 Owner's Manual
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Royal Enfield Classic 500 Owner's Manual

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  • Page 1 EURO IV...
  • Page 2 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.
  • Page 3 Warranty is not applicable for any matt finished painted parts of the motorcycle © 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.
  • Page 4 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 ...
  • Page 5 IMPORTANT NOTICE ! 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.

  • Page 6: Table Of Contents

    CONTENTS PERSONAL & MOTORCYCLE INFORMATION .. 6 GEAR SHIFTING ..........40 PARKING ............41 SAFE OPERATING RULES ......... 7 RULES OF THE ROAD ........13 PERIODICAL MAINTENANCE ......42 TOOLS KIT ............46 ACCESSORIES AND CARGO ......15 MINOR MAINTENANCE TIPS ......47 TECHNICAL SPECIFICATIONS ......

  • Page 7: Personal & Motorcycle Information

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

  • Page 8: Safe Operating Rules

    SAFE OPERATING RULES Use only genuine Royal Enfield spare parts Before operating your new motorcycle, it is your   and approved accessories. Use of other responsibility to carefully read and follow the operat ing and m aintenanc e instruct ions manufacturer’s performance parts may affect the...
  • Page 9 SAFE OPERATING RULES Operate motorcycle only at moderate speeds  DO NOT fill the tank to its brim. Please fill  fuel only till the bottom of the filler neck and out of traffic until you have bec ome insert, so as to leave air space in the fuel thoroughly familiar with its operation and tank to allow for fuel expansion.
  • Page 10 SAFE OPERATING RULES WARNING Operat e your m otorc yc le def ensively.  Remember, a motorcycle does not afford the Avoid overspeeding and never travel over sam e protec tion as an autom obile in an the speed limit. Excessive speed may cause loss of control and could result in an accident caus- accident.
  • Page 11 Owner ’s Manual. WARNING Particularly important to motorcycle stability is Royal Enfield recommends replacement of proper tyre inflation pressure, tread condition. any tyre punctured or damaged. In some cases Pay strict attention to loose and / or broken...
  • Page 12 Contact your while riding. The exhaust system gets very hot Royal Enfield Authorized Dealer for repair of when the engine is running and remains too hot, stee ri ng o r su sp en sion s ys te m.
  • Page 13 (See your will be impaired due to the force of the towline. Royal Enfield Work Shop Manual). We caution you If a disabled motorcycle must be transported, use against the use of certain nonstandard parts such a truck or a trailer.

  • Page 14: Rules Of The Road

    RULES OF THE ROAD Be sure all equipment required by Federal, speed when poor driving conditions exist. High  State, and local law is installed and are in good speed increases the influence of any other condition. condition affecting stability and increases the possibility of loss of control.
  • Page 15 RULES OF THE ROAD Always signal when preparing to stop, turn or  DO NOT leave the curb or parking area without  pass. signaling. Be sure your way is clear to enter moving traffic. A moving line of traffic always W hile turning either right or left, watch for ...

  • Page 16: Accessories And Cargo

    ACCESSORIES AND CARGO m ot orc ycle and as low as possible; this Royal Enfield cannot test and make specific rec ommen datio ns co ncerning specific o r a minimizes the change in the motorcycle’s center combination of accessories sold. Therefore, the...
  • Page 17 WARNING Royal Enfield cautions you against use of nonstandard parts such as aftermarket and custom made extended front forks which may adversely affect the performance and handling of the motorcycle.

  • Page 18: Technical Specifications

    TECHNICAL SPECIFICATIONS Ignition system Engine Ignition system ....Digital Electronic Ignition Engine ....... 4 Stroke, air cooled, Spark plug gap ....0.8 mm ........... single cylinder Spark plug ......WQR8DC (Bosch) Capacity ......499 cc (Displacement) Transmission Bore ........84 mm Clutch ........
  • Page 19 TECHNICAL SPECIFICATIONS Electricals Chassis Frame ........ Tubular Frame Generation......Alternator Tyre size ..Front ..90 / 90-19” - 52 V System ....... 12V DC ....... Rear ..110 / 80-18” - 58 V Tyre pressure Front-Solo 18 PSI Battery ....... 12V - 14 AH .......
  • Page 20 TECHNICAL SPECIFICATIONS Dimensions Weights Length ............. 2140 mm Mass of motorcycle in running order ..270 Kg Width ............800 mm Max pay load .......... 95 Kg Height ............. 1080 mm Max technical permissible mass ... 365 Kg Wheel base ..........1360 mm Saddle height .........

  • Page 21: Recommended Oils

    RECOMMENDED OILS GRADE CAPACITY 1. Engine Oil 15W50 API SL 1. Dry Initial Fill : 2.75 Litres JASO MA ESTER 2. Periodical Maintenance fill : 2.30 to 2.50 Litres Semi synthetic oil (Including filter replacement) 2. Front Fork Fork oil 2W 35 195 ml / leg 3.

  • Page 22: Motorcycle Identification Number - Details

    MOTORCYCLE IDENTIFICATION NUMBER - DETAILS The VIN is a 17 digit number punched on the right side steering head tube and in the information plate rivetted to the frame down tube. Sample VIN : X X X X X X Manufacturer’s code Type of Frame Type of Engine...
  • Page 23 MOTORCYCLE IDENTIFICATION NUMBER - DETAILS CHASSIS NUMBER VIN INFORMATION PLATE Punched on the steering head tube Riveted on the frame down tube right side Caution : It is illegal of tamper with the VIN / information plate as it is the only means of identification of the motorcycle.

  • Page 24: Engine Number - Details

    ENGINE NUMBER - DETAILS The engine number is punched on the left hand side Crankcase. It is the means of identification of the Engine and its production details. Please do not tamper with the engine number as it is prohibited by law.

  • Page 25: Key Parts Location

    KEY PARTS LOCATION Right Side View Right Trafficator Rear Right Trafficator Front Air Filter Box Starter Motor ABS Cover Brake Pedal...
  • Page 26 KEY PARTS LOCATION Left Side View 1. Left Trafficator Front 4. Center stand 7. Gear Change Lever 2. Electrical & Tool Box 5. Side Stand 8. Spark plug 3. Left Trafficator Rear 6. Battery Cover 9. Horn...
  • Page 27 KEY PARTS LOCATION Top View 11. Engine Kill switch 1. Turn signal switch 6. Manual Bistarter 12. Front Brake Lever 2. Horn button 7. Rear View Mirrors 3. Clutch lever 8. Ignition switch 13. Starter Switch 4. Day flash switch 9.

  • Page 28: Operation Of Controls

    OPERATION OF CONTROLS Steering lock Ignition Switch Turn key clockwise to  lock. Caution : P ro tect you r m ot orcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head. Fuel tank cap To Open: Turn cap anticlockwise...
  • Page 29 OPERATION OF CONTROLS Head lamp day flash DIP switch Low Beam High Beam Depress to flash Horn Kill switch Depress Stop...
  • Page 30 OPERATION OF CONTROLS Turn Signal Switch Right Left OFF (Push to off) Engine Start Switch Manual Bi Starter Depress...

  • Page 31: Pre Operative Checks

    PRE OPERATIVE CHECKS A careful check of the following must be carried out everytime before riding and especially after long periods of storage to determine if additional maintenance is necessary. 1. Adequate fuel in the tank. 2. Free play and smoothness of all operating cables. 3.

  • Page 32: Safe & Happy Riding

    SAFE & HAPPY RIDING Riding dress Keep your toes in straight ahead direction.  Slightly grip the petrol tank with both knees. Please wear a proper riding apparel.   Hold the handle bar grips, close to its inner end. A pair of riding boots or shoes.

  • Page 33: Running In

    RUNNING IN Proper running-in is very important for obtaining maximum life and performance of a new motorcycle. The following guidelines explain proper running-in procedures. This will help the various parts of the engine and vehicle to "bed in" smoothly with prolonged full throttle operation, or in high speed conditions might result in excessive heating of the engine and cause abnormal wear of the moving parts and result in premature failure.
  • Page 34 Avoid prolonged full-throttle operation. Vary speed occasionally. CAUTION Royal Enfield engines are air-cooled and consequently require forced air cooling over the cylinders and heads to maintain proper operating temperature. Extended periods of idling may over heat the engine, resulting in serious engine damage.

  • Page 35: Warning Indications & Safety Systems

    MIL will glow continuously. It is recommended to motorcycle running out of fuel. BUT will also cause take the motorcycle to a nearest Royal Enfield serious damage to the fuel pump. Please refuel as Authorized service station for a detailed inspection soon as the low fuel indication comes ON.
  • Page 36 Royal Enfield Distributor. Failure to do so can result in a serious injuries and loss of will signal the ABS moderator to momentarily and continously reduce the hydraulic pressure and life.
  • Page 37 WARNING INDICATIONS & SAFETY SYSTEMS CAUTION : (ABS) Failure to adhere to the above can cause an accident resulting in serious injuries and loss of life. ABS is a safety feature to help prevent locking of wheels during sudden application of brakes. It is by no means a substitute for good riding practices and anticipatory braking.
  • Page 38 In the event of the ABS indicator remaining  continuously ON please take the motorcycle to a nearest authorized Royal Enfield service station to inspect the brakes system.control of the vehicle. 4. Roll over Sensor Ensure the motorcycle is made upright and is on ...

  • Page 39: Starting

    STARTING WARNING Turn ignition switch  ‘ON’ Before starting engine, always shift gears to neutral. Ensure the side stand  Caution : is in released position Do not force the gear lever while attempting to shift to neutral. Move the motorcycle back & forth and Ensure gears are in ...
  • Page 40 STARTING Caution : Warm up engine for 2  Never accelerate the engine immediately after a minutes - till idling is cold start. The engine should be allowed to run consistent. slowly for 15-30 seconds. This will allow the engine to warm up and let oil reach all surfaces needing lubrication.

  • Page 41: Gear Shifting

    GEAR SHIFTING CAUTION Lift the gear lever  The clutch must be fully disengaged before with toe to engage attempting a gear shift. Failure to fully disengage 2nd gear. the clutch may cause a jerky start and / OR stalling the engine besides causing damage to transmission parts.

  • Page 42: Parking

    PARKING Parking Motorcycle on Side Stand Parking Motorcycle on Center Stand Select a firm, flat surface.  Select a firm, flat surface.  Hold handle bar straight.  Lower side stand and gently tilt motorcycle to  Lower center stand, and ensure that both the the left till it rests firmly.

  • Page 43: Periodical Maintenance

    OR if the motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnant water etc., Contact a nearest Royal Enfield Authorized Dealer for expert advice and to carry out the periodical maintenance.
  • Page 44 PERIODICAL MAINTENANCE DESCRIPTION SCHEDULE Kms (x 1000) Miles (x 1000) 3.75 9.5 11.25 13 17 18.75 1 Engine Oil Check level every 500 Kms or earlier as required 2 Engine oil filter element 3 Engine sump filter (oil strainer) Magnetic drain plug under gear box and secondary drain plug under crankshaft in crankcase right 5 Spark plug 6 HT lead...
  • Page 45 PERIODICAL MAINTENANCE DESCRIPTION SCHEDULE Kms (x 1000) Miles (x 1000) 3.75 9.5 11.25 13 17 18.75 11 Rubber hose, Inlet manifold / Adaptor 12 Air filter paper element 13 Inlet/Exhaust valve seating (compression/vaccum test) 14 Cylinder head 15 Exhaust system 16 Clutch free play Adjust every 1000 Kms or earlier as required 17 Rear brake pedal pivot...
  • Page 46 C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace NOTE : For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in consultation with a Royal Enfield Authorized Dealer.

  • Page 47: Tools Kit

    TOOLS KIT Qty. Description Tool Wallet Tommy bar Tubular spanner (21 × 24mm) Screw driver Double end spanners : (10 × 13 mm) (8 × 10 mm) (14 × 15 mm) (¼ ” X 5/16”) Allen Keys : (5 mm) (3 mm) (6 mm)

  • Page 48: Minor Maintenance Tips

    , we recomm end that the motorc yc le be taken to a nearest Royal Enfield Authorized Warm up engine for a few minutes & switch off ...
  • Page 49 MINOR MAINTENANCE TIPS Engine - Oil Change NOTE : (R efer P erio d ic al M a in te n an ce C h art fo r - Replace oil filter whenever oil is replaced. frequency) - Do not reuse “O” ring and Copper Washers. Place motorcycle on its center on a firm flat ...
  • Page 50 MINOR MAINTENANCE TIPS Spark Plug Brake Fluid Cleaning and adjusting gap (Refer Periodical Check brake fluid level in the reservoirs of front and Maintenance Chart for frequency) rear brakes. Top up if necessary with DOT 4 or higher Remove HT Lead and the spark plug from the ...
  • Page 51 MINOR MAINTENANCE TIPS Inspection of tyres and wheels Tyre pressure Front Inspect the tyres periodically for tread wear,  cracks and cuts. Solo 1.27 kg/cm (18 PSI) Minimum tread depth : With Pillion 1.41 kg/cm (20 PSI) Front tyre : 1mm Rear tyre : 2 mm Check and remove stone, splinters, nails or other ...
  • Page 52 MINOR MAINTENANCE TIPS Front Wheel Removal Remove the axle nut and washer.  Place the motorcycle on its center stand on a  firm and flat surface. Provide a suitable support below the front end  of the engine such that the front wheel is about 4 inches (10 cms) above the ground.
  • Page 53 MINOR MAINTENANCE TIPS Caution : Ensure the peg in  Do not depress the front brake lever when wheel the speedo drive is removed as this will result in the brake pads correctly coming too far out of the brake caliper. positioned in the slot in the right Place a 4 mm thick wooden piece or cardboard...
  • Page 54 MINOR MAINTENANCE TIPS Rear Wheel Removal Hold the pinch bolt and tighten the nylock nut on  the right side fork end. Place the motorcycle  on its center stand, on a firm and flat surface such that the rear wheel is about 4 inches (10 cms) above the ground.
  • Page 55 Remove the caliper  CAUTION : assembly by gently Do not press the rear brake pedal when wheel is pulling out from the removed as this will result in the brake pads coming swing arm slot and too far out of the brake caliper. support the caliper Place a 4 mm thick wooden piece or cardboard sheet suitably.
  • Page 56 MINOR MAINTENANCE TIPS Rear Wheel Reassembly Align the caliper bracket, spacer, hub and chain  tensioner holes. Remove the wooden piece / card board sheet  Insert the wheel spindle from left side fully. placed between the brake pads.  Ensure that chain tensioner stopper plate is firmly Ensure the four Cush rubbers are in position in ...
  • Page 57 MINOR MAINTENANCE TIPS Adjustments Drive Chain Tension Adjustment Clutch cable (play 2-3 mm) Place motorcycle on its center stand on a firm a. Clutch Play Adjustment surface. Ensure gears are in neutral and the rear wheel rotates freely. Check the drive chain tension at the bottom run of the chain.
  • Page 58 MINOR MAINTENANCE TIPS Loosen the locknuts at both ends of the swing Wheels Alighnment arm. Note the matching reference marks of the chain To reduce the free play: tensioner and the swing arm on the right side. Tighten the adjuster Tighten / Loosen nut on the right side adjuster nut on the...
  • Page 59 MINOR MAINTENANCE TIPS Drive Chain Lock Fitment Holding the adjuster  nuts, tighten the lock If for any reason the chain link lock is removed, it nuts against the should be fitted such that the closed end of the lock adjuster nuts on both is towards the direction of the chain rotation.
  • Page 60 MINOR MAINTENANCE TIPS Pre load spring tension adjustment of tension and “anticlockwise” to reduce spring tension. rear shock absorber Ensure the spring tension is the same in both  the left and right side shock absorbers After adjustment, ensure the adjuster notches ...
  • Page 61 MINOR MAINTENANCE TIPS Battery Maintenance Removal of Battery from the Motorcycle The battery is located on  Care Maintenance : the left side of the Clean the battery well using a soft and wet cloth.  motorcycle near the Inspect the battery carefully for any deformation ...
  • Page 62 MINOR MAINTENANCE TIPS Care during long duration storage: WARNING In the event the motorcycle is not used for a long  Always disconnect the -ve terminal first and  duration, the battery must be disconnected from then the +ve terminal, while removing the the motorcycle and connected to a suitable cable connections automatic battery charger.
  • Page 63 MINOR MAINTENANCE TIPS KEEP BATTERIES AND ELECTROLYTES OUT  Failure to adhere to the above warnings can  OF REACH OF CHILDREN. result in an explosion of the battery, causing Always charge the battery ONLY in a well- serious Injury or loss of life. ...
  • Page 64 MINOR MAINTENANCE TIPS Reassembly of Battery on Motorcycle Changing Electrical Components Head Lamp Bulb Locate the battery in the carrier with the terminals  facing inside. Loosen the rim holding screw on top and take  out the head lamp. Connect the +VE terminal wire first ...
  • Page 65 MINOR MAINTENANCE TIPS Position new bulb inside the reflector such that Twist the bulb holder anticlockwise and remove.   the three projections on the bulb align with the Remove the old bulb and replace with a new bulb.  slot on the reflector.
  • Page 66 MINOR MAINTENANCE TIPS Fuse Blade Fuse Usage List The fuse box is  Fuse No. Colour Remarks located inside the W hite Charging Fuse (25A) left side electrical box. W hite Main Fuse (25A) Gently remove the  Blue Ignition - EFI Fuse (15A) fuse box from the Signalling / Horn Fuse (10A) rubber...
  • Page 67 MINOR MAINTENANCE TIPS Air Filter Cleaning WARNING Compressed air can pierce the skin and Unlock and open the right filter box.  cause injury. Never direct compressed air on your Remove the nut and take out the lid.  hand or any part fo your body to check for air flow pressure.

  • Page 68: Long Trip Precautions

     Proper functioning of all lights, horn etc.,  Tightness of all fasteners.  NOTE : It is recommended that the motorcycle be checked and serviced by an authorized Royal Enfield service center prior to embarking on a long ride.

  • Page 69: Washing Procedure

    WASHING PROCEDURE Precautions Remove all plastic bags and adhesive tapes.  Lubricate control cables, pivot and rear chain.   Wash motorcycle when the engine is cold.  Polish the painted and plated surfaces using polishing  Cover the silencer tail end and control switches with wax.

  • Page 70: Storage Precautions

    STORAGE PRECAUTIONS Maintain electrolyte level between “max” or “min” Incase your Motorcycle is not going to be used for a  mark. prolonged period of time, the following precautions should be taken. Store the battery in a cool, dry and well ventilated ...
  • Page 71 STORAGE PRECAUTIONS Preparing the motorcycle for reuse NOTE : Do not raise the engine RPM the moment it is Remove the anti rust solution from all plated parts  started, but allow the engine to run at idling and clean the motorcycle well. speed.

  • Page 72: Wiring Diagram

    WIRING DIAGRAM...

  • Page 73: Abs Wiring Diagram

    WIRING DIAGRAM...

  • Page 74: Trouble Shooting

    EURO IV...
  • Page 75 EURO IV...
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  • Page 77 EURO IV...
  • Page 78 Carefully read the appropriate sections of this manual before performing any work. Repair and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield Authorized Dealer only. Improper repair and/or maintenance could result in the motorcycle not functioning properly, serious injury or death.

  • Page 79: Warranty

    Brakes adjusted too tight ..........* Re-adjust properly Rear chain adjusted too tight ........* Re-adjust properly Clutch Slipping ............* Adjust clutch cable free play Under inflated tyres ............Inflate to correct pressure * Contact Royal Enfield Authorized Dealer...
  • Page 80 Check & Correct Brake Fluid leaking/Air in brake system ...... Check & Correct, Bleed Brake System Linings worn / Uneven wear ......... Replace linings Brake Pads / Disc Uneven wear ........Check & replace * Contact Royal Enfield Authorized Dealer...
  • Page 81 Bulbs do not light Loose / improper connection ........* Check and correct Bulb fused ..............* Replace bulb Fuse blown ..............* Check and Replace fuse Horn not working Loose connections ............* Check and correct * Contact Royal Enfield Authorized Dealer...
  • Page 82 XI. Electronic Fuel Injection Engine MIL ON continuously Sensor Loose Connection .......... * Check & Correct XII. ABS (Anti lock Braking system) ABS lamp continuously ON......... Take the vehicle to service center for diagnosis * Contact Royal Enfield Authorized Dealer...

  • Page 83: Service Maintenance Record

    During the warranty period, Royal Enfield’s obligation is limited to repair or replacing free of charge, such part or parts of the motorcycle, which in examination shall be deemed defective in the opinion of Royal enfield and/or their distributors/authorized dealers.
  • Page 84 13. To the fullest extent allowed by law, Royal Enfield and its authorized distributors and/or dealers shall not be liable for loss of use, inconvenience, loss of time, commercial losses or other incidental or consequential damages.

  • Page 85: Evaporative Emission Control

    WARRANTY, EMISSION CONTROL SYSTEM WARRANTY & NOISE CONTROL SYSTEM WARRANTY. Royal Enfield Motors warrants the first owner and each subsequent owner, that this motorcycle is designed and built so as to conform, at the time of sale, with applicable regulations specified by the evaporative emission...
  • Page 86 IT IS RECOMMENDED THAT THE ROUTINE MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED INTERVALS AND ANY MAINTENANCE TO THE EVAPORATIVE EMISSION CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USING ONLY GENUINE ROYAL ENFIELD SPARE PARTS.
  • Page 87 SERVICE MAINTENANCE RECORD Job Card KMS / Royal Enfield Date Brief details of work / service Miles Authorized Dealer...
  • Page 88 SERVICE MAINTENANCE RECORD Job Card KMS / Royal Enfield Date Brief details of work / service Miles Authorized Dealer...

  • Page 89: Notes

    NOTES...
  • Page 90 Part No. 1010221/A ROYALENFIELD.COM...

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