Royal Enfield Bullet 500 Owner's Manual

Royal Enfield Bullet 500 Owner's Manual

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Summary of Contents for Royal Enfield Bullet 500

  • Page 2 Congratulations on becoming the proud owner of a legendary Royal Enfield motorcycle. The new Bullet 500 is a motorcycle with the timeless handcrafted design of the legendary Bullet, now fitted with a solid 500cc Unit Contruction Engine with twin-spark ignition for better combustion, superior power delivery and improved fuel economy.
  • Page 3: Important Notice

    “© Copyright 2014 Eicher Limited, Royal Enfield Unit. All Rights Reserved. No part of this manual shall be copied, distributed or otherwise dealt without the express permission in writing of Eicher Motor Limited, Royal Enfield Unit.”...
  • Page 4 SERVICE HEAD QUARTERS NOTE Royal Enfield, A Unit of Eicher Motors Limited, Indicates important and useful messages for clearer Thiruvottiyur High Road, Thiruvottiyur, understanding. Chennai - 600 019.
  • Page 5: Table Of Contents

    CONTENTS PERSONAL & VEHICLE INFORMATION ......7 OPERATION OF CONTROLS ..........26 - Ignition Switch ............26 FREE SERVICE RECORD ............. 8 - Steering lock ............. 26 SAFE OPERATING RULES ..........9 RULES OF THE ROAD ............15 - Fuel tank cap ............27 - Side Box ..............
  • Page 6 CONTENTS - Rear wheel removal ..........49 GEAR SHIFTING ..............35 - Rear wheel assembly ........... 50 PA RKING ................36 - Adjustment - Clutch ..........51 - Center Stand ............36 Drive Chain tension ......... 51 - Side Stand ..............36 Checking Rear Brake Pedal height ...
  • Page 7 A LL INDIA ROA D SIGNS ........83 CARING FOR MILEAGE ........... 66 FREE SERVICE COUPONS ..........84 COMPLETE WIRING DIAGRAM - BULLET 500 ... 68 PAID SERVICE / MAINTENANCE RECORD ....93 TROUBLE SHOOTI NG ............69 LOG BOOK ............... 101 - Engine fails to start ..........
  • Page 8: Personal & Vehicle Information

    PERSONAL & VEHICLE 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 Dealer Code...
  • Page 9: Free Service Record

    FREE SERVICE RECORD It is our endeavour to provide excellent service to your Bullet 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 Authorised Dealer / Service Point 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.
  • Page 10: Safe Operating Rules

    SAFE OPERATING RULES Before operating your new motorcycle, it is your Use only genuine Royal Enfield spare parts and responsibility to carefully read and follow the approved accessories. Use of other manufacturer’s performance parts may affect the performance of operating and maintenance instructions detailed...
  • Page 11 SAFE OPERATING RULES DO NOT fill the tank to its brim. Please fill fuel A new motorcycle must be operated according to only till the bottom of the filler neck insert, so the special break-in-procedure. See BREAK-IN-THE as to leave air space in the fuel tank to allow FIRST 500KM section.
  • Page 12 SAFE OPERATING RULES WARNING Ope rat e yo ur m otor cycl e de fens ivel y. Avoid overspeeding and never travel over the Remember, a motorcycle does no t af ford the speed limit. Excessive speed may cause loss of control same protection as an automobile in an accident.
  • Page 13 Royal Enfield pressure, tread condition. Pay strict attention to dealer.
  • Page 14 SAFE OPERATING RULES WARNING WARNING Avoid any contact with the exhaust system. Wear DO NOT operate motorcycle with a loose, worn clothing that will completely cover the legs while or damaged steering system, including the front and riding. The exhaust system gets very hot when the rear sus pensio n system.
  • Page 15 Down tube. (GVWR is the sum of the wei ght of the m otor cycle, acces so ries, and the Consult your Royal Enfield Dealer regarding any maximum weight of the rider, passenger and cargo questions or problems that occur in the operation of that may be safely carried.) Exceeding GVWR may...
  • Page 16: Rules Of The Road

    RULES OF THE ROAD Be sure front & rear number plates is installed in may cause loss of control of vehicle, which could result in death or serious injury. the position specified by law and is clearly visible at all times. Keep to the correct side of the road centre line Ride at a safe speed that is consistent with the type when meeting oncoming vehicle.
  • Page 17 RULES OF THE ROAD When intending to turn, signal at least 100 feet SIDE VIEW MIRRORS (30.5 meters) before reaching the turning. Be close to the center line (unles s l ocal r ul es requir e otherwise), slow down and then turn carefully. Never jump a traffic light.
  • Page 18: Technical Specifications

    Engine Start ..........Electric / Kick Engine Oil Capacity ........2.75 Litres. Lubrication ........... Wet Sump, Forced Lubrication Engine Oil Grade ........Royal Enfield 15W50 API SL Grade Engine Oil (JASO MA) Cooling system ..........Natural Air Flow Carburetor ........... UCD 33...
  • Page 19: Ignition System

    TECHNICAL SPECIFICATIONS IGNITION SYSTEM Ignition system ........... TCI Unit, Multi Curve (Variable Ignition Timing) Spark plug ........... WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10 Spark plug Electrode gap ...... WQR8DC 0.80 to 0.90 mm ..............UR6DC 0.70 to 0.80 mm TRANSMISSION Clutch ............
  • Page 20: Electricals

    12V, 60/55 W, Halogen Modifications on the bike which are Position lamp ..........12V, 4W not approved by Royal Enfield may not only disqualify for warranty, but Brake / Tail lamp ........12V, 21/5 W also affects performance of the bike.
  • Page 21: Chassis

    Rear: Twin gas charged shock absorbers, 80mm travel Front fork oil capacity ......195 ml per leg Front 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 ........
  • Page 22: Dimensions

    TECHNICAL SPECIFICATIONS DIMENSIONS Length ............2140 mm N O TE : B S I I I This vehicle meets Emission Norms - Width .............. 810 mm (Without Mirror) Bharat (Trem) Stage - III Height ............1110 mm (Without Mirror) Wheel base ..........1370 mm Saddle height ..........
  • Page 23: Vehicle Identification Number

    VEHICLE IDENTIFICATION NUMBER - DETAILS FRAME NUMBER ENGINE NUMBER Punched on steering head tube RH side. Punched on top of the engine LH side.
  • Page 24: Key Parts Location

    KEY PARTS LOCATION TOP VIEW 1. Turn signal switch 2. Horn button 3. Clutch lever 4. Day flash switch 5. Head lamp dip switch 6. Ignition switch 7. Speedometer 8. Front brake lever 9. Accelerator 10. E-Start Switch 11. Fuel tank cap 12.
  • Page 25: Right Side View

    KEY PARTS LOCATION RIGHT SIDE VIEW 1. RH Trafficator Front 2. Starter Motor 3. Brake Pedal 4. Kick Starter Lever 5. Air Filter Box 6. RH Trafficator Rear...
  • Page 26: Left Side View

    KEY PARTS LOCATION LEFT SIDE VIEW 1. Trafficator Front LH 2. Spark Plug 3. Battery Cover 4. Electricals Box LH 5. Rear Shock Absorber 6. Trafficator Rear LH 7. Side Stand 8. Centre Stand 9. Gear Change Lever 10. Horn...
  • Page 27: Operation Of Controls

    OPERATION OF CONTROLS IGNITION SWITCH STEERING LOCK Turn key clockwise to lock. Lock the steering when leaving bike parked. Turn key anti clockwise to unlock. CAUTION Protect your motorcycle against theft. After parking your motorcycle, remove the ignition key from switch and lock the steering head.
  • Page 28: Fuel Tank Cap

    OPERATION OF CONTROLS FUEL TANK CAP SIDE BOX AIR FILTER BOX RH Turn key clockwise Turn Key anti-clockwise to open to open SIDE BOX LH Turn Key anti-clockwise to open, Press cap to lock with key in position it contains Tools Kit & Fuse NOTE Key is common for ignition, petrol tank cap, steering lock, NOTE...
  • Page 29: Head Lamp Switch

    OPERATION OF CONTROLS HEAD LAMP SWITCH DIP SWITCH Low beam High Beam Pilot Light ON Head Light ON HEAD LAMP DAY FLASH Press for Headlight Flash...
  • Page 30: Engine Kill Switch

    OPERATION OF CONTROLS ENGINE KILL SWITCH TURN SIGNAL SWITCH Left Stop OFF (Push to off) Right HORN Press...
  • Page 31: Engine Start Switch

    OPERATION OF CONTROLS ENGINE START SWITCH FUEL TAP Press Turn knob to horizontal position Main ON Turn knob downward position BATTERY BOX Turn anti clockwise to open Reserve ON Turn knob upward position...
  • Page 32: Pre Operational Checks

    PRE OPERATIONAL CHECKS A careful check of the following must be carried out 5. Engine oil level. every time before riding and specially after long per io ds o f sto r age to d eter m ine if addi ti on al maintenance is necessary.
  • Page 33: Running In Period

    RUNNING IN PERIOD Avoid driving the motorcycle with full throttle Proper running-in is very important for obtaining maximum life and performance of a new motorcycle. o peni ng. Var y the s pe ed o f th e m otor cycl e regularly but avoid using the motorcycle above The following guidelines explain proper running-in procedures.
  • Page 34: Starting

    STARTING Ens ur e Engi ne s to p STARTING PROCESS (KS / ES) swi tch is i n “R UN” position Turn fuel tap to ‘ON’ Ensur e the side and m ai n st ands ar e in released position Ensure that gears are in neutral and neutral...
  • Page 35 STARTING Pres s Star ter B utto n USING KICK START and release as soon as engine starts. Sl i ghtl y cr ank the Release the choke, if en gine fur the r ti ll applied com pres s ion eas es over.
  • Page 36: Gear Shifting

    GEAR SHIFTING Warm up engine Pre ss th e gear pedal with heel to for 2 minutes - till eng age 2 nd and idling is consistent/ higher gear. stable GEA R SH IF T PATT ERN Follow the same procedure for 3rd, 4th Press clutch lever towards the hand grip.
  • Page 37: Parking

    PARKING PARKING VEHICLE ON CENTER STAND PARKING VEHICLE ON SIDE STAND Select a firm, flat surface Select a firm, flat surface Hold handle bar straight Lower Side Stand and gently tilt motorcycle to the left till it rests firmly. Lower center stand, and ensure that both the legs of the stand are resting evenly on firm ground.
  • Page 38 TOOLS & FIRST AID KIT S.No. Description Qty. S.No. Description Qty. Antiseptic cream 5 gms Tool bag Gauze bandage 5 cm x 2 cm Screw driver O6 X 160 Elastic Gauze bandage 8 cm x 1 mtr. Wash proof plaster 1.9 cm x 7.2 cm Tommy bar Sterilized Gauze Swab 5 cm x 5 cm Sterilized elastic plaster 7 cm x 6 cm...
  • Page 39: Recommended Lubricants

    RECOMMENDED LUBRICANTS Engine Oil Front Fork Oil Brake Fluid Grade Royal Enfield Grade Royal Enfield 15 W 50 API SL Grade Front Fork Oil Engine Oil Grade DOT 3 or DOT 4 (or 1F Grade (JASO MA) Endurance) Capacity 195 ml/leg Capacity 60ml ISO 14001 –...
  • Page 40: 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 Authorised Dealer / Service Point for expert advice and to carry out the periodical maintenance.
  • Page 41 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPTION PAID SERVICE whichever is earlier Kms (x 1000) Months Engine Oil Check level at every 1000 Kms or earlier as required Engine oil filter element Engine sump filter (oil strainer) Magnetic drain plug under gear box and secon- dary drain plug under crankshaft in crankcase RH Spark plugs (2 nos.) C ,A C,A C,A C,A C,A...
  • Page 42 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPTION PAID SERVICE whichever is earlier Kms (x 1000) Months 13 Rubber hose, Adaptor 14 Exhaust system 15 Air filter paper element 16 Inlet / Exhaust valve seating 17 Clutch lever free play Check & Adjust every 1000 Kms or earlier as required 18 Cylinder head (Combustion chamber) 19 Hand levers &...
  • Page 43 D : De-carbonise I : Inspect L : Lubricate R : Replace NOTE For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultation with a Royal Enfield Authorised Dealer / Service Point. * Refer Service Manual.
  • Page 44: Minor Maintenance Tips

    However, In case, if it is felt that the adjustments are best done by an expert, we recommend that the motorcycle be taken to a nearest Royal Enfield Authorised Dealer / Service Point. CONTROL CABLES, HANDLE LEVER, PIVOTS, CENTER / SIDE STAND PIVOTS Main &...
  • Page 45: Engine Oil Change

    MINOR MAINTENANCE TIPS ENGINE OIL CHANGE TILT VEHICLE RH & LH Secondary Primary Drain Plug Drain Bolt Primary Drain Cap (Refer Periodical Maintenance Chart for frequency) Place motorcycle on its center stand on a firm flat surface. Start engine and warm up for 2 minutes. Keep a clean tray below the engine.
  • Page 46: Spark Plug

    MINOR MAINTENANCE TIPS Soak a new oil filter element in the oil and refit SPARK PLUG on the Crankcase Cover RH. Assembly 3 bolts and tighten them. Ensure ‘O’ Ring C l eani ng a nd a djus ti ng gap (Refer Peri odic al and gaskets are taken seat properly.
  • Page 47: Brake Fluid

    MINOR MAINTENANCE TIPS BRAKE FLUID INSPECTION OF TYRES AND WHEELS Inspect the tyr e peri odically fo r tread wear, Check if oil is above ‘min’ level. To top up, remove cracks and cuts. cover with diaphragm and top up with either DOT 3 or DOT 4 as specified.
  • Page 48: Tyre Pressure

    WARNING Tyres, rims and air valves must be correctly matched to wheel rims. See your Royal Enfield Dealer. Mismatching tyre, tubes, rims and air valves may result in damage to the tyre bead during mounting, allow tyre slippage on the rim and cause tyre failure.
  • Page 49: Front Wheel Assembly

    MINOR MAINTENANCE TIPS Tap and remove the front wheel spindle FRONT WHEEL ASSEMBLY Tilt the vehicle to RH Side and take out the wheel along with speedo drive with bush & LH side spacer. Remove the wooden piece / card board sheet placed between the brake pads.
  • Page 50: Rear Wheel Removal

    MINOR MAINTENANCE TIPS REAR WHEEL REMOVAL Place the vehicle on center stand on a firm and flat surface. Note and mark the position of the chain adjuster bu ttin g wi th t he stopper on the right side. Remove split pin and castle nut on the RH side.
  • Page 51: Rear Wheel Assembly

    MINOR MAINTENANCE TIPS Ensure that the chain adjuster knotch butts with REAR WHEEL ASSEMBLY the stopper as appropriate when both the front & rear wheels are aligned. Ensure the four cush rubbers are in position inside Tig hten the cas tle the rear wheel hub.
  • Page 52: Adjustment - Clutch

    MINOR MAINTENANCE TIPS ADJUSTMENTS - CLUTCH DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM) 2 to 3 mm Remove rear wheel split pin. Loo sen castle nut, spindle nut, anchor Clutch Lever (free play 2 to 3 mm) nut and brake rod nut.
  • Page 53: Checking Rear Brake Pedal Height

    MINOR MAINTENANCE TIPS Check brake pedal free play, If necessary adjust. CHECKING REAR BRAKE PEDAL HEIGHT Check that the front and rear wheels are correctly aligned. Turn the LH adjuster cam appropriately, to ali g n bo th t he wheels.
  • Page 54: Chain Lock Fitment

    MINOR MAINTENANCE TIPS CHAIN LOCK FITMENT REAR BRAKE PEDAL PLAY ADJUSTMENT 20 - 30 mm Turn in or out the adjuster nut at the brake rod end. The recommended brake pedal travel is 20-30 mm. Check that the brake is not binding and the rear The open end of the chain link master lock to face wheel rotates freely.
  • Page 55: Adjustment Of Gas Filled Shockabsorber

    MINOR MAINTENANCE TIPS Turn the adjuster such that the adjuster moves ADJUSTMENT OF GAS FILLED SHOCKABSORBER up to increase the spring tension and vice versa to reduce the spring tension. A djus t both left hand and ri ght hand s hock absorbers so that the same knotch rests on the pin in both sides.
  • Page 56: Removal Of Battery On Vehicle

    MINOR MAINTENANCE TIPS BATTERY MAINTENANCE REMOVAL OF BATTERY ON VEHICLE T he veh icle The battery must be provided with 12V - periodically checked 14 AH battery. Unlock (turn the key C l eanl i ne ss a nd cor ro si o n f r ee anti clockwise) and terminals.
  • Page 57: Assembly Of Battery On Vehicle

    Ensure ignition switch is in ‘OFF’ condition. For checking the battery voltage and electrolyte Connect the positive terminal (Red wire) first. specific gravity, contact authorised Royal Enfield Connect the negative terminal (Black wire) next. service or battery service centre. Smear the terminals with petroleum jelly. (Do not use grease).
  • Page 58: Changing Electrical Components

    MINOR MAINTENANCE TIPS Remove rubber grommet CHANGING ELECTRICAL COMPONENTS fr om the r ef lecto r Assembly. HEAD LAMP BULB REPLACEMENT Lo o sen the hea d la m p holding top screw. Then Gen tl y pr es s th e bu l b pul l head lam p...
  • Page 59 MINOR MAINTENANCE TIPS Connect the wire couplers ASSEMBLING THE HEADLAMP as mentioned below. Refix the new head lamp TOP SIDE: GREEN COLOUR hal ogen bul b in to RIGHT SIDE: B LUE C OLOUR reflector unit by locating LEFT SIDE: ORANGE COLOUR the wide protrude on top side mounting.
  • Page 60: Tail Lamp Bulb Replacement

    MINOR MAINTENANCE TIPS TAIL LAMP BULB REPLACEMENT TRAFFICATOR BULB REPLACEMENT Remo ve the 2 screws & Remove the two nuts each from RH & LH side of the take out trafficator glass rear number plate holder. cover. Pul l ou t Ta il Lamp Press bulb gently &...
  • Page 61: Fuse

    MINOR MAINTENANCE TIPS Replace the required fuse with the spare fuse FUSE available in the fuse carrier. Open the LH tool box. NOTE Take out tool kit. Please ensure to replace a spare fuse in the holder at the earliest opportunity. Remove fuse holder rub ber &...
  • Page 62: Air Filter Element Cleaning / Replacement

    MINOR MAINTENANCE TIPS Tap the filter element AIR FILTER PAPER ELEMENT CLEANING/REPLACEMENT to r em o ve d ust as sh o wn and cle an Insert the key, turn tho ro ug hl y befo r e an ti c l okw ise assembly.
  • Page 63: Washing Procedure

    WASHING PROCEDURE PRECAUTIONS AFTER WASHING Wash vehicle when the engine is cold. Ensure, the vehicle is thoroughly dry by wiping with Cover the silencer tail end and control switches with a clean soft absorbent cloth or chamois leather. suitable plastic bags and tie it firmly to prevent Remove all plastic bags and adhesive tapes.
  • Page 64: Storage Precaut Ion

    STORAGE PRECAUTIONS Rem o ve bat ter y f ro m t he b ike. C le an t he Incase your Motorcycle is not going to be used for a terminals free of corrosion. month or more, we advise the following precautions to the taken.
  • Page 65: Preparing The Motorcycle For Reuse

    STORAGE PRECAUTIONS Remove spark plug on cylinder head and pour PREPARING THE MOTORCYCLE FOR RE USE in a few drops of engine oil. Crank engine a few Remove anti rust solution from all chrome plated ti mes to lubricate cylinder walls and piston. parts and clean the motorcycle.
  • Page 66: Long Trip Precautions

    LONG TRIP PRECAUTIONS CHECKS PRIOR TO THE COMMENCEMENT OF ITEMS TO BE CARRIED LONG JOURNEY Tool kit. Ser vice the m otor cycle tho ro ughly at Ro yal Enfield Authorised Dealer / Service Point as per First aid kit. periodical maintenance chart.
  • Page 67: Caring For Mileage

    CARING FOR MILEAGE Both lower and higher road speeds cause low STOP THE DROP THAT LEAKS kilometers per litre of petrol. Petrol leak at a rate of one drop per m inute PERFORM PREVENTIVE MAINTENANCE AS PER accumulates to 5,25,600 drops a YEAR! That is, 35 RECOMMENDATIONS ltrs of Petrol.
  • Page 68 CARING FOR MILEAGE Sudden acceleration : Ten sudden accelerations For better mileage, use front and rear brakes wastes 100 ml. of petrol. simultaneously when absolutely needed. Control vehicle speed with throttle and gear like smart STOP BRAKE RIDING riders always do. Brake riding pushes the brake shoes to come in AVOID OVER LOADING contact with revolving drum.
  • Page 69 COMPLETE WIRING DIAGRAM - BULLET 500 NOTE : Complete Wiring Diagram is attached on this page. VEHICLE STARTING PROCEDURE BASIC GUIDELINES TO BE FOLLOWED “FOR ALL ELECTRIC START VEHICLES” In cold condition of the engine or for initial start, it is advised to use electric start (ES) only.
  • Page 70: Complete Wiring Diagram - Bullet 500

    C O M P L E T E W I R I N G D I A G R A M COMPLETE WIRING DIAGRAM - BULLET 500 BLADE FUSE LIST Fuse 1 TCI FUSE Fuse 2 IGNITION LOADS Fuse 3...
  • Page 71: Trouble Shooting

    TROUBLE SHOOTING CAUSES REMEDIES I. ENGINE FAILS TO START Ignition switch in ‘OFF’ Position ..........Switch on ignition. Engine Stop switch in ‘OFF’ Position ........Push stop switch to ‘ON’ position. Clogged fuel line / tap .............. Clean the fuel line / tap. Vent hole clogged in fuel tank cap ........
  • Page 72: Engine Misfiring

    TROUBLE SHOOTING CAUSES REMEDIES 13) Poor compression - Auto Decompressor not working .......... *Ensure free motion of flyweight in exhaust ......................cam gear assembly - Loose spark plug ..............*Tighten spark plug. 14) Clutch slipping ................*Adjust clutch cable free play II.
  • Page 73: Engine Starts, But Runs Irregularly & Stops

    TROUBLE SHOOTING CAUSES REMEDIES III. ENGINE STARTS, BUT RUNS IRREGULARLY & STOPS Faulty fuel supply ..............Clean the fuel line / tap / vent hole Very low idling speed ..............Increase idling speed IV. POOR PICKUP Accelerator cable free play excessive ........Adjust cable free play Faulty fuel supply ...............
  • Page 74: White/Blue Smoke

    TROUBLE SHOOTING CAUSES REMEDIES V. WHITE/BLUE SMOKE Oil level in tank above the middle line in the ....*Check and drain excess oil oil level window Worn out valve oil seal .............. *Check / Replace Worn out piston ring / cylinder ..........*Check / Replace VI.
  • Page 75: Ignition Knock

    TROUBLE SHOOTING CAUSES REMEDIES Worn out carburetor jets ............*Change the defective jets Incorrect carburetor adjustments .......... *Check and adjust correctly Choked air filter ................Clean / Replace Poor compression ............... *Auto decompressor sticky or ......................not working properly Under inflated tyres ..............Inflate to correct pressure VIII.
  • Page 76: Vehicle Wobbles

    TROUBLE SHOOTING CAUSES REMEDIES Linings worn / Uneven wear ............ *Replace linings Drum scored / Uneven wear ............ *Rectify or Replace drums X. VEHICLE WOBBLES Wheel rim runout ................ *Rectify Loose / Broken spokes ..............*Tighten / Replace spokes Tyres not fitted correctly ............*Refit tyres correctly Wheels misaligned ..............
  • Page 77: Trouble Shooting

    TROUBLE SHOOTING CAUSES REMEDIES Horn not working Loose connections ..............*Check and correct Requires tuning ................*Tune horn Switch Defective ................*Replace Fuse blown ..................Replace fuse Trafficators not working Loose / improper connections ..........Check and correct Bulb fused / Fuse blown ............Replace Switch defective ................
  • Page 78: Electric Start

    TROUBLE SHOOTING CAUSES REMEDIES XII. ELECTRIC START VEHICLE NOT STARTING (1) Neutral indicator not glowing ..........Bring the vehicle in neutral (2) If vehicle is without neutral indicator ........Press the clutch lever & start switch together (3) Loose Connection ............... *Check &...
  • Page 79: Warranty Terms & Conditions

    Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material and workmanship. Royal Enfield (RE) warrants Bullet 500 Motorcycle to be free from manufacturing and material defect under normal use subject to following conditions.
  • Page 80 WARRANTY TERMS & CONDITIONS (b) Components like fuel filter, oil filter paper element, control cables, brake shoes / brake pads, clutch plates, drive chain & sprocket kit, which are subjected to normal wear and tear. (c) Damages due to use of lubricant / oil / grease etc. other than specified by RE. (d) Damages due to use of non-genuine parts.
  • Page 81: Emission Warranty

    The method/s of examination to determine the warranty conditions of the emission warranty related components will be at the sole discretion of Royal Enfield and / or our Authorised Dealer / Service Point and results of such examination will be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royal enfield will have the right to charge all, or part of the cost of such examination to the customer in addition to the cost of the components.
  • Page 82: Emission Warranty

    All parts removed for replacement under warranty will become the property of Royal Enfield. Royal Enfield will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised Dealer / Service Point OR for any loss due to non availability of the motorcycle during the period of examination and repairs by Royal Enfield and / or their Authorised Dealer / Service Point.
  • Page 83 The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records. On examination by Royal Enfield or its Authorised Dealer / Service Point, if the motorcycle shows that any of the conditions stipulated in the Owner’s manual with regard to use and maintenance have been violated.
  • Page 84 EMISSION WARRANTY The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by Royal Enfield in the Owner’s manual or any other document given to the customer at the time of sale of the motorcycle. The emission related components are tampered with.
  • Page 85: All India Road Signs

    ALL INDIA ROAD SIGNS MANDATORY SIGNS CAUTIONARY SIGNS INFORMATION SIGNS...
  • Page 86: Free Service Coupons

    FREE SERVICE COUPONS It is our endeavour to provide excellent service to your Royal Enfield Motor Cycle at all times. Towards this we provide four free services at specific Intervals. Please avail these services at the specified time, in any of the Royal Enfield Authorised Dealer / Service Point nearest to you and as a token of satisfactory service, kindly return the free service coupon duly filled in and signed, to the service outlet.
  • Page 87 1ST FREE SERVICE 500 KMS OR 45+8 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE FREE Customer Name : Dealer Code : SERVICE Address : Regn. No: Frame No: 500 Kms Sale Date: Engine No: 45+8 days whichever is Serviced Date: Vehicle Installation Form No.
  • Page 88 1ST FREE SERVICE ACTIVITIES CUSTOMER Water wash the vehicle and dry it with a clean cloth Electrolyte ............Check level & top-up COPY Battery terminals ......... Clean and apply petroleum jelly Drive chain free play ......... Check, clean, lubricate & adjust Job Card No: Rear brake pedal pivot ......
  • Page 89 2ND FREE SERVICE 3000 KMS OR 90+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE FREE Customer Name : Dealer Code : SERVICE Address : Regn. No: 3000 Kms Frame No: Sale Date: Engine No: 90+15 days whichever is Serviced Date: Vehicle Installation Form No.
  • Page 90 2ND FREE SERVICE ACTIVITIES Water wash the vehicle and dry it with a clean cloth CUSTOMER Electrolyte ............Check level & top-up COPY Battery terminals ......... Clean and apply petroleum jelly Drive chain free play ......... Check, clean, lubricate & adjust Job Card No: Rear brake pedal pivot ......
  • Page 91 3RD FREE SERVICE 6000 KMS OR 180+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE FREE Customer Name : Dealer Code : SERVICE Address : Regn. No: 6000 Kms Frame No: Sale Date: Engine No: 180+15 days whichever is Serviced Date: Vehicle Installation Form No.
  • Page 92 3RD FREE SERVICE ACTIVITIES Water wash the vehicle and dry it with a clean cloth CUSTOMER Electrolyte ............Check level & top-up COPY Battery terminals ......... Clean and apply petroleum jelly Drive chain free play ......... Check, clean, lubricate & adjust Job Card No: Rear brake pedal pivot ......
  • Page 93 4TH FREE SERVICE 9000 KMS OR 270+15 DAYS WHICHEVER IS EARLIER FROM DATE OF SALE FREE Customer Name : Dealer Code : SERVICE Address : Regn. No: 9000 Kms Frame No: Sale Date: Engine No: 270+15 days whichever is Serviced Date: Vehicle Installation Form No.
  • Page 94 4TH FREE SERVICE ACTIVITIES CUSTOMER Water wash the vehicle and dry it with a clean cloth Electrolyte ............Check level & top-up COPY Battery terminals ......... Clean and apply petroleum jelly Drive chain free play ......... Check, clean, lubricate & adjust Job Card No: Rear brake pedal pivot ......
  • Page 95: Paid Service / Maintenance Record

    PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 12,000 + 250 Kms. Service 12,000 + 250 Kms. Service Job Card No :....Date : ......Job Card No :....Date : ......Odo Reading : ....Dealer Code : ..... Odo Reading : ....
  • Page 96 PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 12,000 + 250 Kms. Service 12,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 15,000 + 250 Kms.
  • Page 97 PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 18,000 + 250 Kms. Service 18,000 + 250 Kms. Service Job Card No :....Date : ......Job Card No :....Date : ......Odo Reading : ....Dealer Code : ..... Odo Reading : ....
  • Page 98 PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 18,000 + 250 Kms. Service 18,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 21,000 + 250 Kms.
  • Page 99 PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 24,000 + 250 Kms. Service 24,000 + 250 Kms. Service Job Card No :....Date : ......Job Card No :....Date : ......Odo Reading : ....Dealer Code : ..... Odo Reading : ....
  • Page 100 PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 24,000 + 250 Kms. Service 24,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 27,000 + 250 Kms.
  • Page 101 PAID SERVICE / MAINTENANCE RECORD CUSTOMER COPY DEALER / ASP COPY 30,000 + 250 Kms. Service 30,000 + 250 Kms. Service Job Card No :....Date : ......Job Card No :....Date : ......Odo Reading : ....Dealer Code : ..... Odo Reading : ....
  • Page 102 PAID SERVICE / MAINTENANCE RECORD DEALER / ASP COPY CUSTOMER COPY 30,000 + 250 Kms. Service 30,000 + 250 Kms. Service Brief Work Done : Brief Work Done : Dealer’s Stamp & Signature Dealer’s Stamp & Signature DEALER / ASP COPY CUSTOMER COPY 33,000 + 250 Kms.
  • Page 103: Log Book

    LOG BOOK Authorised Dealer / Service Point Idling Date Kms. Details Stamp & Job Card No. Signature...
  • Page 104 LOG BOOK Authorised Dealer / Service Point Idling Date Kms. Details Stamp & Job Card No. Signature...
  • Page 105 LOG BOOK Authorised Dealer / Service Point Idling Date Kms. Details Stamp & Job Card No. Signature...
  • Page 106 LOG BOOK Authorised Dealer / Service Point Idling Date Kms. Details Stamp & Job Card No. Signature...
  • Page 107 LOG BOOK Authorised Dealer / Service Point Idling Date Kms. Details Stamp & Job Card No. Signature...
  • Page 108: Notes

    NOTES...
  • Page 109 NOTES...
  • Page 110 NOTES...
  • Page 111 Telephone Residence Bike Regn. No. Telephone Office Invoice No. Delivery Note / Advice No. Sales Representative Have you visited Royal Enfield website?
  • Page 113 PRE DELIVERY INSPECTION LIST MODEL: BULLET 350 / ELECTRA / CLASSIC 350 / CLASSIC 500 / BULLET 500 Model : Engine No: Dealer's Name : Location: Colour : Key Number : Battery Make : Battery Number : Tyre Number :...
  • Page 114 SC / PD / R / No Defects (Mudguards / 36 Mudguards - Paint / Plating Related Fuel Tank / Tool Box SC / PD / R / 37 Fuel Tank - Paint Related No Defects SC / PD / R / 38 Tool Box LH, Air Filter Box, Battery Cover - No Defects Paint / Plating Related...
  • Page 115: Bike Installation Confirmation By Customer

    BIKE INSTALLATION CONFIRMATION BY CUSTOMER We congratulate you on becoming a proud owner of Royal Enfield bike. We request you to give this feedback after completion of the delivery process. 1 Bike Documents explained (Invoice, Insurance, RC / Road Tax Receipt) 2 Owner’s Manual received...
  • Page 116 13 Control Switches & Disc Brake System usage explained 14 Fuse Box location shown and explained 15 Recommended Tyre Pressure explained 16 Bike starting & Gear shifting procedure explained 17 Quantity of Fuel in Fuel Tank informed 18 Bike orientation & short distance drive provided 19 Date and Time of Installation 20 Name of Person who did Installation Suggestions If Any:...
  • Page 117: Form 22

    STANDARDS OF COMPONENTS AND ROAD WORTHINESS Certified that the following vehicle complies with the provisions of the Motor Vehicles Act, 1988, and the rules made there under, including the following mass emission norms: Bullet 500 Brand name of the vehicle Chassis number...

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