Royal Enfield BULLET TRIALS 500 Owner's Manual
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Royal Enfield BULLET TRIALS 500 Owner's Manual

Euro iv
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BULLET TRIALS 500 - EURO IV

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  • Page 1 BULLET TRIALS 500 - EURO IV...
  • Page 2 Bullet, introduced in 1932, the world’s oldest motorcycle model in continuous production, is at the heart of the Royal Enfield’s storied heritage. The Bullet Trials Works, arriving at 1948 Colmore Cup Trials with their rear swinging arm suspension, dominated the Trials competitions across Europe for the next decade and changed the way motorcycles were designed since.
  • Page 3 Technical specifications are subject to change without prior notice. “© Copyright 2019 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: Table Of Contents

    CONTENTS Personal and Motorcycle Information Parking Safe Operating Rules Periodical Maintenance Chart Rules of the Road Tools kit Technical Specifications Wheel Removal & Assembly Recommended Lubricants Minor Maintenance Tips Safety Definitions Long Trip Precautions Motorcycle Identification Numbers Washing Procedure Location of Key Parts Storage Precautions Operation of Controls Trouble Shooting...

  • Page 5: Personal And Motorcycle Information

    PERSONAL & MOTORCYCLE INFORMATION Name Door No./Street Locality City State 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...

  • Page 6: Safe Operating Rules

    W A R N I N G motorcycle, when refuelling OR servicing the fuel system. Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom Switch OFF mobile phones and other hand made extended front forks or suspensions, which may held electronic devices.
  • Page 7 SAFE OPERATING RULES DO NOT fill the tank to its brim. Please fill fuel  Operate motorcycle only at moderate speeds and only till the bottom of the filler neck insert, so as out of traffic until you have become thoroughly to leave air space in the fuel tank to allow for familiar with its operation and handling fuel expansion.
  • Page 8 SAFE OPERATING RULES Operate your motorcycle defensively. Remember,  W A R N I N G a motorcycle does not afford the same protection as an automobile in an accident. One of the most Avoid overspeeding and never travel over the speed common accident situations occurs when the limit.
  • Page 9  condition in accordance with the Maintenance Royal Enfield recommends replacement of any tyre i nte r val s ch a r t i n t h i s O w ner ’ s M a n ua l .
  • Page 10 The exhaust system gets very hot when the engine is rear suspension system. Contact your Royal Enfield running and remains too hot, even after the engine is Authorized Dealer for repair of steering or suspension turned off.
  • Page 11 Use only genuine Royal Enfield replacement fasteners to the force of the towline. If a disabled motorcycle must be tightened to the proper torque (See your Royal Enfield Work transported, use a truck or a trailer. Towing a motorcycle Shop Manual). We caution you against the use of certain...

  • Page 12: Rules Of The Road

    RULES OF THE ROAD increases the influence of any other condition  Be sure all equipment required by Federal, State, affecting stability and increases the possibility of and local law is installed and are in good loss of control. condition. Be sure your license plate is installed in the position ...
  • Page 13 RULES OF THE ROAD  DO NOT leave the curb or parking area without  Always signal when preparing to stop, turn or signaling. Be sure your way is clear to enter pass. moving traffic. A moving line of traffic always has While turning either right or left, watch for ...

  • Page 14: Technical Specifications

    TECHNICAL SPECIFICATIONS ENGINE IGNITION SYSTEM Engine Type .... Single Cylinder 4 Stroke, Spark Ignition system ..Digital Electronic Ignition ....... Ignition, Air cooled, Fuel injection Spark plug Electrode gap 0.80 to 0.90 mm Bore ......84mm Spark plug ....WQR8DC (Bosch) Stroke ......
  • Page 15 TECHNICAL SPECIFICATIONS Tyre Pressure CHASSIS Front ....20 psi/1.41 kg/cm Frame ....... Single Down Tube, using Rear ....30 psi/2.11 kg/cm ......engine as stressed member Steering lock ... In built Suspension Fuel tank capacity . 13.5 litres approx.* Front ....Telescopic, 35mm forks, Low fuel warning ...
  • Page 16 92 Kgs. Modifications on the motorcycle which are not approved by Luggage load carrier ..should not be more Royal Enfield may not only disqualify for warranty, but also ........than 15 Kgs. affects performance of the motorcycle.  Values / Dimensions given above are for your guidance only.

  • Page 17: Recommended Lubricants

    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 B ra ke F l ui d Front Fork Oil used oils to prevent Environmental pollution.

  • Page 18: Safety Definitions

    SAFETY DEFINITIONS 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.

  • Page 19: Motorcycle Identification Numbers

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

  • Page 20: Location Of Key Parts

    LOCATION OF KEY PARTS 1. Horn Button 2. Turn Signal Switch 3. Cluth Lever 4. Day Flash 5. Head Lamp Dip Switch 6. Ignition Switch 7. Speedo Meter 8. Warning Indicator 9. Engine Kill Switch 10. Brake Lever 11. E-Start Switch Button 12.
  • Page 21 LOCATION OF KEY PARTS 1. Mudgaurd Reflector Rear 2. Right Trafficator Rear 3. Tail Lamp 4. Shockabsorber (gas filled) 5. Air filter box 6. Lid Cover 7. Throttle body 8. Pilot Lamp Right 9. Head Light 10. Number Plate Front 11.
  • Page 22 LOCATION OF KEY PARTS 1. Left Trafficator Front 2. Pilot Lamp Left 3. Fuel Tank 4. Fuel Tap 5. Battery Box Cover 6. Seat - Rider 7. Electricals & Tool Box Left 8. Left Trafficator Rear 9. Number Plate Rear 10.

  • Page 23: Operation Of Controls

    OPERATION OF CONTROLS STEERING LOCK IGNITION SWITCH  Turn Clockwise to lock  Turn Anticlockwise to Unlock FILTER / ELECTRICAL / BOXES FUEL TANK CAP  Turn anti clockwise to open. O P E N  Turn Key Clockwise & lift the lid. C L O S E BATTERY BOX Gently press lid till it “click”...
  • Page 24 OPERATION OF CONTROLS FUEL TANK W A R N I N G Do not overfill the fuel tank. Fill upto maximum fuel level & stop filling when the fuel reaches the bottom of Splash Arrestor. Failure to do so will lead to canister damage Or can cause fuel spill out of fuel tank.
  • Page 25 OPERATION OF CONTROLS NOTE E-START SWITCH  Key is common for ignition, petrol tank cap, steering Depress & hold till engine lock, battery cover and tool boxes. starts.  Key can be removed only in locked position from fuel tank, Filter box, Electrical boxes locks in “OFF” position from Ignition switch.
  • Page 26 OPERATION OF CONTROLS C A U T I O N DAY FLASH Choke should be used only to start engine in cold Press for Head Light Flash.  climates (less than 20 C) 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.

  • Page 27: Pre-Operational Checks

    PRE OPERATIONAL CHECKS CHECK FOR Petrol level in the tank and leakage if any. M AX Smooth operation and free play in Front and Rear M AX Brake levers. Front Brake Rear Brake FRONT BRAKE REAR BRAKE Brake Fluid level is above the “MIN”...

  • Page 28: Safe & Happy Riding

    SAFE & HAPPY RIDING RIDING DRESS SITTING POSTURE Correct sitting posture is a must for stable and safe  A proper riding apparel. riding.  Proper Riding Boots.  Sit Straight with your shoulders completely relaxed.  Keep your elbows close to your body. ...

  • Page 29: Running In Period

    RUNNING IN PERIOD The Royal Enfield Motorcycle as you would be Warm up the engine for a few minutes at idling experiencing, is capable of consistent high speeds. speed to allow engine oil to lubricate all the However as with any new motorcycle, a “RUNNING- moving parts in the engine before riding the IN”...
  • Page 30 MIL will glow continuously. It is recommended to take motorcycle running out of the motorcycle to a nearest Royal Enfield Authorized fuel. BUT will also cause service station for a detailed inspection and correction serious damage to the fuel pump.
  • Page 31 WARNING INDICATIONS & SAFETY SYSTEMS continously reduce the hydraulic pressure and 3. ANTI-LOCK BRAKING SYSTEM (ABS) thereby prevent the brakes from locking the wheels Anti-Lock Braking System while reducing the speed of the vehicle. This will help (ABS) will help prevent the the rider to control the motorcycle.
  • Page 32 WARNING INDICATIONS & SAFETY SYSTEMS Always ensure that you ride well within the legal speed CAUTION : (ABS) limits. ABS is a safety feature to help prevent locking of wheels Failure to adhere to the above can cause an accident during sudden application of brakes.
  • Page 33 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.
  • Page 34 WARNING INDICATIONS & SAFETY SYSTEMS Switch OFF both ignition & stop switches, wait for a  4. ROLL OVER SENSOR few seconds and switch ON the Ignition and stop In the event of motorcycle falling over on eitherof its switch again, to start the engine. sides with the engine running and the gears engaged the Roll over sensor will "disable"...

  • Page 35: Starting

    STARTING  Ensure Gear is in Neutral position and the Neutral USING THE KICK START LEVER lamp is glowing in the speedometer. To shift into neutral, move the motorcycle back and forth gently,  Slowly Crank Engine with the Kickstarter lever till a while simultaneously shifting the gear.

  • Page 36: Gear Shifting, Riding & Stopping

    GEAR SHIFTING, RIDING & STOPPING NOTE To stop the motorcycle, close throttle, apply front and rear  Release the Starter button as soon as the Engine starts. brakes. Simultaneously, shift If Engine does not start, wait for 30 seconds before ...

  • Page 37: Parking

    PARKING PARKING MOTORCYCLE ON CENTER STAND PARKING MOTORCYCLE ON SIDE STAND Select a firm, flat surface.  Select a firm, flat surface.   Hold handle bar straight. Extend side stand. Tilt the   motorcycle to the left, till it Lower center stand, such that, both the legs of the ...

  • Page 38: Periodical Maintenance Chart

    The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorised Dealer / Service Center for expert advice and to carry out the required maintenance.
  • Page 39 PERIODICAL MAINTENANCE S l . D E S C R I P T I O N S C H E D U L E Kms (x 1000) 27 30 Miles (x 1000) 3.75 9.5 11.25 13 17 18.75 Months 27 30 10 Rubber hose, Air filter to Throttle body 11 Rubber hose, Inlet manifold / Adaptor 12 Evaporative Emission Equipment rubber hoses...
  • Page 40 A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace NOTE For Maintenance after 30,000 Kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorised Dealer / Service Center.

  • Page 41: Tools Kit

    TOOLS KIT The tool kit is located in the left side Electrical box of * Please familiarise yourself with the minor the motorcycle. maintenance of the motorcycle before attempting to carry out the same. 6 7 8 S.No. Description Qty. Tool bag Box spanner 21 X 24 Screw driver O6 X 160...

  • Page 42: Wheel Removal & Assembly

    WHEEL REMOVAL / ASSEMBLY Slide out the wheel from the fork legs along with  FRONT WHEEL REMOVAL the speedo drive, and spacer on the left side. Place the motorcycle on its center stand on a firm  Remove the speedo drive, small spacer on the ...
  • Page 43 WHEEL REMOVAL / ASSEMBLY Locate stepped spacer in the left side of the hub   Hold the axle from the right with its larger face outside. side and tighten nut on left side to a torque of 7 KgM Locate front wheel between the fork ends duly ...
  • Page 44 WHEEL REMOVAL / ASSEMBLY REAR WHEEL REMOVAL REAR WHEEL REASSEMBLY Ensure the four Cush rubbers Place the motorcycle on center   Index mark are in position inside the rear stand on a firm and flat surface. wheel hub. Note the alignment index marks ...
  • Page 45 WHEEL REMOVAL / ASSEMBLY Fix the brake hose pipe in  NOTE swing arm clips properly. Ensure the brake disc is located in between the brake pads.  Align the caliper bracket, wheel and swing arm holes all are in one line. C A U T I O N Insert and tap the rear wheel ...

  • Page 46: Minor Maintenance Tips

    However for an elaborate maintenance, we recommend you to get in Clean the drive chain carefully. Apply chain lubricant touch with a Royal Enfield Authorised Dealer / Service Center. while simultaneously rotating the rear wheel. Wipe off the excess lubricant.
  • Page 47 MINOR MAINTENANCE TIPS SPARK PLUG INSPECTION OF TYRES AND WHEELS  Inspect the tyres periodically for tread wear, cracks CLEANING AND ADJUSTING PLUG GAP and cuts. Remove the spark plug cap from the spark plug. Minimum tread depth :  Remove spark plug using the plug spanner and ...
  • Page 48 MINOR MAINTENANCE TIPS BRAKE FLUID C A U T I O N Brake fluid is highly corrosive and can cause damage Check if oil is below ‘MIN’ level. To top Up, remove cover and diaphragm, then top up with DOT 4 as to painted parts.
  • Page 49 MINOR MAINTENANCE TIPS To adjust the free play:  Note the matching index marks on right swing  arm and chain adjuster and tighten / loosen  Ensure the ground level & firm and place the adjuster nut on left swing arm side, to ensure the motorcycle in its centre stand.
  • Page 50 MINOR MAINTENANCE TIPS Remove the battery cover  BATTERY & MAINTENANCE outwards while releasing the The Motorcycle is provided with  cover from the lock peg on top. 12V-12Ah MF Battery. Disconnect the -VE Terminal first  and then +VE terminal. Periodically check the battery for ...
  • Page 51 MINOR MAINTENANCE TIPS  Turn the key anticlockwise and push the lock into W A R N I N G the locator and turn the key clockwise such that the Battery terminals and internals contain lead and lead cover is locked in position. components, known to cause cancer and birth defects ...
  • Page 52 MINOR MAINTENANCE TIPS CHANGING ELECTRICAL COMPONENTS ASSEMBLING THE HEAD LAMP BULB 1. Refix the new halogen HEADLAMP BULB REPLACEMENT bulb into reflector unit of the headlamp.  Make sure the Ignition switch is in OFF position when replacing the 2. Gently press the bulb bulb.
  • Page 53 MINOR MAINTENANCE TIPS TAIL LAMP BULB TRAFFICATOR BULB  Remove the screws & take out  Remove the tail light glass by trafficator glass cover. unscrewing its mounting screw.  Press bulb gently & Turn anti- clockwise to take out the bulb. ...
  • Page 54 Replace both pad is worn to the wear indicator mark. Replace both pads as set. Visit royal enfield dealer for this service. pads as set. Visit royal enfield dealer for this service.
  • Page 55 MINOR MAINTENANCE TIPS RELAY STARTER - FUSE BOX FUSE & CARRIER  Open the left side Tool box.  The fuse holder is located inside with 9+3 fuses.  Replace the required fuse with the spare fuse available in the fuse carrier. NOTE F0 - Main Fuse - 40A Please ensure to replace a spare fuse in the holder at...
  • Page 56 MINOR MAINTENANCE TIPS HARNESS MAIN CABLE FUSE BOX Fu s e I D D e s c r p t i o n R a t i n g CHARGING FUSE TAIL LAMP FUSE IGNITION FUSE (EFI) SIGNALLING FUSE SPARE FUSE LIGHTING FUSE ABS MAIN 1 ABS MAIN 2...

  • Page 57: Long Trip Precautions

    LONG TRIP PRECAUTIONS Checks prior to the commencement of long journey Items to be carried  Service the motorcycle at a Royal Enfield Authorised  Tool kit. Dealer / Service Center.  Bulbs for headlight,trafficator light, rear tail lamp  Ensure sufficient quantity of petrol in the fuel tank and Mini blade fuse (25, 15, 10 &...

  • Page 58: Washing Procedure

    WASHING PROCEDURE Once the motorcycle has been ridden in salty conditions or  PRECAUTIONS near coastal areas it is recommended to wash your Wash motorcycle when the engine is cold.  motorcycle with cold water. Please do not use warm water for washing as it may damage the motorcycle due to Cover the silencer, tail pipe, carburetor, horn and control ...

  • Page 59: Storage Precautions

    / battery dealer.  Get the motorcycle service through a Royal Enfield  Store the battery in a cool, dry and well ventilated Authorised Dealer / Service Center. place.

  • Page 60: Trouble Shooting

    We have listed below a few basic checks in case your motorcycle is not functioning. If in case the problem is not rectified after these checks, it is necessary to get the motorcycle checked by a Royal Enfield Authorised Dealer / Service Center to rectify the problem and to ensure trouble free performance.
  • Page 61 TROUBLE SHOOTING S y m p t o m O b s e r v a t i o n s C h e ck f o r / R e me d y E n g i n e 1.

  • Page 62: Warranty Terms & Conditions

    Engine & VIN numbers, must be provided to the Distributor’s service facility OR their Authorized dealership’s service facility. 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 63 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 64: Evap

    The following warranty applies to the evaporative emission control system. 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 65 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 66: Environment Care

    BE AN ENVIRONMENTALLY CONSCIOUS RIDER You’ve ridden through some beautiful places on your Royal Enfield. Won’t you like to keep them that way? Here are some tips to help you keep those places unspoilt so that others can enjoy them too:...
  • Page 67 If your Royal Enfield’s tyre(s)/plastic/electrical/electronic part(s)/oil filter need to be replaced make sure you hand them over to an authorised recycling agent or a Royal Enfield service centre. They will follow the local authority’s guidelines to get rid of them in an environmentally friendly manner.

  • Page 68: Service Maintenance Record

    SERVICE MAINTENANCE RECORD KMS / Job Card S.No. Date Brief details of work / service Royal Enfield Authorized Dealer Miles...
  • Page 69 SERVICE MAINTENANCE RECORD KMS / Job Card S.No. Date Brief details of work / service Royal Enfield Authorized Dealer Miles...
  • Page 70 SERVICE MAINTENANCE RECORD KMS / Job Card S.No. Date Brief details of work / service Royal Enfield Authorized Dealer Miles...
  • Page 71 SERVICE MAINTENANCE RECORD KMS / Job Card S.No. Date Brief details of work / service Royal Enfield Authorized Dealer Miles...

  • Page 72: Notes

    NOTES...
  • Page 73 NOTES...
  • Page 74 Part No. RAM00069/A...

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