Royal Enfield Bullet 500 2018 Owner'S Manual Download Page 62 | Manualshive

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61

MINOR MAINTENANCE TIPS

Caution :

Brake fluid is highly corrosive and can cause
damage to painted parts. Please ensure that brake
fluid does not spill on any part of the motorcycle. In
the event of a spill, please clean the area
immediately with a soft cloth (preferably a wet cloth)
to avoid damage.

Check if oil is below ‘MIN’ level. To top Up, remove
cover and diaphragm, then top up with DOT 4 as
specified.

Brake Fluid

FRONT BRAKE

REAR BRAKE

M AX

MIN

M AX
MIN

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Summary of Contents for Bullet 500 2018

Page 1: ......

Page 2: ... major repairs require the attention of a skilled technician and use of special tools and techniques Your Royal Enfield Authorised Dealer has the facilities experience and genuine Royal Enfield spare parts necessary to render those valuable services in a correct procedure We have also provided several vital safety information for the rider and for the care and safety of the motorcycle Please read ...

Page 3: ...manual may differ from those found on the vehicle However the technical information found within this manual was correct at the time it was approved for publication Royal Enfield Chennai India Copyright 2018 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 T...

Page 4: ...ns given here Keep this manual in a convenient place for easy reference DO NOT use the motorcycle until you have become familiar with this motorcycle and after reading and understanding this manual completely In case you need any further clarifications please contact a Royal Enfield Authorised Dealer nearest to you for assistance If your motorcycle is being used by a friend relative or any other p...

Page 5: ...it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you and your dealer or Royal Enfield North America Limited To contact NHTSA you may call the Auto Safety Hotline toll free within the United States on 1 800 424 9393 or write to NHTSA 400 Se...

Page 6: ...ntially hazardous situation which if not avoided may result in minor or moderate injury leading to disability Caution Caution without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in damage to the motorcycle and its rider property etc All images in this manual are only for reference and to explain the relevance They may not be exactly the same ...

Page 7: ...S 34 SAFE HAPPY RIDING 35 RUNNINGIN 36 EVAPORATIVE EMISSION IMPORTANT NOTE 38 WARNING INDICATIONS SAFETY SYSTEMS 39 STARTING 43 GEAR SHIFTING 46 PARKING 47 PERIODICAL MAINTENANCE 48 TOOLS KIT 52 WHEEL REMOVAL ASSEMBLY 53 MINOR MAINTENANCE TIPS 57 LONG TRIP PRECAUTIONS 76 WASHINGPROCEDURE 77 STORAGE PRECAUTIONS 78 WIRING DIAGRAM 80 TROUBLESHOOTING 81 WARRANTY 86 EMISSION CONTROL SYSTEM WARRANTY 88 ...

Page 8: ...E INFORMATION Name Door No Street Locality City Country Contact Res Off Mobile Email Licence No Valid till Model Color Engine No VIN No Tire make Front Rear Tire Nos Front Rear Battery make Battery No Sold by Date of Sale ...

Page 9: ...ols tire pressures fuel and oil levels Know and respect the rules of the road Be a safe rider for your own safety and for other road users FUEL REFUELING Royal Enfield motorcycles are designed to perform best with unleaded gasoline only Use a good quality unleaded gasoline of 87 RON or higher If knocking or pinging occurs at a steady engine speed under normal load use a different brand of gasoline...

Page 10: ...ile telephones and any other electrical and electronic devices including any appliances with a pilot light DO NOT fill the fuel tank to its brim Please fill fuel only till the bottom of the filler neck insert so as to leave air space for fuel expansion inside the fuel tank Overfilling the tank can lead to fuel spillage Avoid filling the tank in rainy or dusty conditions where airborne material can...

Page 11: ...oor stability poor handling and abnormal tread wear Please replace tires which are punctured or damaged Small punctures in the tread area may be repaired from within the tire The motorcycle should not be driven over 40 MPH 60 Kmph for the first 24 hours and over 55 MPH 90 Kmph thereafter with a repaired tire WARNING In emergency situations please ride slowly with least possible load until the tire...

Page 12: ...g techniques and become thoroughly familiar with the operation of your particular motorcycle New riders should gain experience under various conditions while driving at moderate speeds WARNING Avoid over speeding and never travel over the speed limit Excessive speed may cause loss of control and could result in an accident causing serious injury or loss of life DO NOT exceed 70 MPH 110 Kmph riding...

Page 13: ...ited for riding a motorcycle Bright OR light colors are best for greater visibility in traffic especially at night Avoid loose flowing garments and scarves When carrying a pillion rider it is your responsibility to instruct them on proper riding procedures DO NOT allow other individuals under any circumstances to operate your motorcycle unless you know they are experienced licensed riders and are ...

Page 14: ...T INHALE exhaust gases Do not stay inside a closed garage after parking the motorcycle as the residual fumes from the exhaust can contain WARNING Motorcycle batteries contain lead and lead components acids and chemicals known to cause cancer birth defects or other reproductive harm Exercise extreme caution while handling a battery Wash hands thoroughly whenever a battery is handled This motorcycle...

Page 15: ...f the motorcycle leading to an accident and result in serious injury or loss of life WARNING Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom made extended front forks or suspensions which may adversely affect performance and handling Removing or altering original parts may adversely affect performance and could result in an accident causing se...

Page 16: ...als and exercise utmost caution when passing other vehicles going in the same direction Never try to pass another vehicle going in the same direction at street intersections on curves or when going up or down a hill While turning either right or left watch out for pedestrians animals as well as vehicles At street intersections always allow vehicles from your right and left to pass before turning D...

Page 17: ...o fast for existing conditions Always reduce speed when poor driving conditions exist High speed increases the influence of any other condition affecting stability and increases the possibility of loss of control WARNING Avoid excessive speed and never travel at a speed faster than the speed limit Excessive speed may cause loss of control of motorcycle which could result in loss of life or serious...

Page 18: ...rcycle DO NOT load bulky items too far behind the rider or add weight to the handlebars or front forks DO NOT exceed 5 pounds 2 3 kgs maximum hanging load on either side of the motorcycle at the rear end Recheck the cargo periodically to be sure it is secured and will not shift while riding Accessories secured loosely may affect the riding of the motorcycle and affect the stability of the motorcyc...

Page 19: ... use of nonstandard parts such as aftermarket and custom made extended front forks which may adversely affect the performance and handling of the motorcycle Removing or altering original parts may adversely affect the performance of the motorcycle causing an accident which could result in serious injury or loss of life WARNING DO NOT ignore model design specifications Doing so constitutes to motor...

Page 20: ...ngine Oil Grade 15 W 50 API SL Grade JASO MA ESTER Semi Synthetic oil Fuel Supply Electronic Fuel Injection TECHNICAL SPECIFICATIONS Ignition system Ignition system Digital Electronic Ignition Spark plug gap 0 7 mm Spark plug WQR8DC Transmission Clutch Wet Multiplate Drive Chain links 102 pitch Primary drive Duplex Chain drive 3 8 pitch Gear box 5 Speed Constant Mesh Gear Ratios I 3 063 1 II 2 013...

Page 21: ...5 Amp Max Warning Indicator lamps 12V 2W X 3 Nos Starter motor 12V 0 9 KW TECHNICAL SPECIFICATIONS Chassis Frame Tubular Frame Tire size Front 90 90 19 52 V Rear 110 80 18 58 V Tire pressure Front Solo 18 PSI Pillion 20 PSI Rear Solo 28 PSI Pillion 30 PSI Fuel tank capacity 3 8 Gallons approx Suspension Front Telescopic Hydraulic Damping Rear Swing arm with gas filled shockabsorbers with adjustabl...

Page 22: ...t 1090 mm Wheel base 1380 mm Saddle height 800 mm Ground clearance 135 mm TECHNICAL SPECIFICATIONS Weights Kerb weight 90 fuel oil 196 kg Max pay load 169 Kg Max technical permissible mass 365 Kg Performance Maximum Speed 82 kmph NOTE 1 Values given above are for your guidelines only 2 In view of continuous improvements being done on our products the specifications are likely to change without pri...

Page 23: ...Use of inferior oils or non detergent oils can damage the engine Engine oil 15 W 50 API SL Grade Grade JASO MA ESTER Semi Synthetic oil Capacity 2 75 Ltrs First Fill only 2 30 Ltrs during oil filter element replacement in periodical maintenance Front Fork Fork oil Capacity 200 ml leg Brake Fluid DOT 3 or DOT 4 Capacity 60 ml ...

Page 24: ...plate riveted to the frame down tube MOTORCYCLE IDENTIFICATION NUMBER DETAILS Sample VIN ME3 FSV XX X X X X XXXXXX World manufacturing Identification Engine Details Engine output Power Check Digit Model Year Manufacturing Plant Engine Capacity Production Serial Number G 2016 H 2017 J 2018 0 TVT 1 ORG ...

Page 25: ...ution It is illegal of tamper with the VIN information plate as it is the only means of identification of the motorcycle VIN Punched on the steering head tube VIN INFORMATION PLATE Riveted on the frame down tube VEHICLE EMISSION CONTROL INFORMATION ...

Page 26: ...the Engine and its production details Please do not tamper with the engine number as it is prohibited by law Engine Family Engine Capacity Type of start Type of Transmission Fuel Feed Manufacturing Plant Year of Manufacture Month of Manufacture Production Serial Number U 5 S 5 F X X X X X X X X X A Jan H Aug K Sep N Dec G 2016 H 2017 J 2018 0 TVT 1 ORG ...

Page 27: ... 2 1 KEY PARTS LOCATION Right Side View 7 Evaporative Emission Canister 8 Tail lamp 9 Head lamp 1 Right Trafficator Rear 2 Air Filter Box 3 ABS Cover 4 Right Trafficator Front 5 Starter Motor 6 Brake Pedal 7 8 9 ...

Page 28: ... 9 8 6 7 5 4 3 7 Gear Change Lever 8 Spark plug 9 Horn 2 1 Left Trafficator Front 2 Electrical Tool Box 3 Left Trafficator Rear 4 Center stand 5 Side Stand 6 Battery Cover Left Side View KEY PARTS LOCATION ...

Page 29: ...ch lever 4 Day flash switch 5 Head lamp dip switch 6 Manual Bistarter 7 Rear View Mirrors 8 Ignition switch 9 Speedometer 10 Warning Indicator 11 Engine Kill switch 12 Front Brake Lever 13 E Start Switch 14 Fuel tank cap 1 2 5 4 8 9 11 14 6 10 13 3 12 Top View 7 7 ...

Page 30: ...e steering when leaving motorcycle parked OPERATION OF CONTROLS Fuel tank cap With Key locking feature To Open Insert Key and Turn anti clockwise Cap will springup To Close Press cap down with key in position Key will return to locked position Remove Key Fuel tank cap To Open Turn cap anticlockwise To Close Locate cap and turn clockwise till click Sound is heard NOTE Key can be removed only in loc...

Page 31: ...30 OPERATION OF CONTROLS DIP switch Low beam High Beam Head Lamp Day Flash Depress for Day Flash ...

Page 32: ...31 Supplementary Engine Stop Horn Turn Signal Switch Left OFF Push to off Right OPERATION OF CONTROLS ON OFF Depress ...

Page 33: ...32 Engine Start Switch Manual Bi Starter Depress OPERATION OF CONTROLS ...

Page 34: ...ot overfill 6 Rear chain for proper tension 7 Brakes steering and throttle for responsiveness 8 Wheel spoke for proper tightness no breakage 9 Headlamp tail lamp brake lamp and directional lamps for proper operation 10 Check ABS lamp glows as soon as ignition switch kill switch are ON and goes OFF as soon as vehicle reaches a speed of 5 Km h 3 mph WARNING For your personal welfare and safety all t...

Page 35: ...or distance of objects seen in these mirrors WARNING Objects in mirrors are closer than they appear Always use caution when judging distances of objects in mirrors Failure to judge correctly when seeing the objects on mirrors could cause an accident resulting in serious injury or loss of life NOTE To help you establish the relative distance of vehicles behind your motorcycle adjust each mirror in ...

Page 36: ... Keep your elbows close to your body Keep your toes in straight ahead direction Slightly grip the petrol tank with both knees Hold the handle bar grips close to its inner end Look extensively ahead including rear view mirrors without turning the head Braking Apply front and rear brakes gently and simultaneously for maximum braking efficiency WARNING Applying any one of the brakes suddenly may caus...

Page 37: ...n or any high speed conditions might result in excessive heating of the engine and cause abnormal wear of the moving parts and hence must be avoided 1 0 300Miles 0 500 Kms The recommended speed for the first 300 Miles 500 Kms is 35 40 MPH 50 60 Kmph During this period avoid riding the motorcycle with full throttle opening Stop the motorcycle for about 5 to 10 minutes to let it cool down after ever...

Page 38: ...occasionally Caution Royal Enfield engines are air cooled and consequently require forced air cooling of the cylinder head and barrel to maintain proper operating temperature Extended periods of idling may over heat the engine resulting in serious engine damage DO NOT run the engine at extremely high RPM with clutch disengaged or transmission in neutral as it can cause serious engine damage An eng...

Page 39: ...nsure that the motorcycle is taken to the nearest Royal Enfield Authorised Dealer to carry out the required maintenance listed in the Owner s Manual Royal Enfield recommends that you retain all receipts covering maintenance on your motorcycle It is also your responsibility to present take your motorcycle to a Royal Enfield Authorised Dealer if a problem in the evaporative emission system As the ve...

Page 40: ...serious damage to the fuel pump Please refuel as soon as the low fuel indication comes ON 2 Engine Malfunction indicator lamp A Malfunctioning Indicator Lamp MIL is provided in the small meter When both the Ignition Engine kill switch is ON and after vehicle is started the MIL will glow for few seconds and switch OFF this indicates that all the functions of Electronic fuel injection EFI system is ...

Page 41: ...heels while reducing the speed of the vehicle This will help the rider to control the motorcycle An ABS indicator lamp is provided in the console as shown in adjacent image to warn the rider in the event of any malfunction of the ABS When the ignition and kill switch are switched ON the ABS sign light up and remain ON till the motorcycle attains a speed of 5 Kmph 3MPH and switch OFF This indicates...

Page 42: ... a corner and therefore prevent skidding due to loss of traction Please anticipate the stopping distance required for the speed of travel and apply brakes well in advance so as to bring the motorcycle to a safe stop Please apply both brakes to stop front brake momentarily earlier followed by rear brake to have better traction and control of the motorcycle Always ensure that you ride well within th...

Page 43: ... the Ignition and stop switch again to start the engine Don ts DO NOT RELEASE the brake lever pedal when pulsations are felt during hard application of the brakes in an emergency situation The pulsations only indicate that the ABS is activated DO NOT APPLY only the front OR rear brake as it can lead to inefficient braking Do s While starting the engine do check the ABS indicator comes ON and switc...

Page 44: ...lutch safety switch is provided in the system for the safety of the rider This will prevent the engine from starting if the gears are engaged To start the engine always ensure the gear is shifted to neutral before starting However if the engine has stalled and has to be started when the gears are engaged pull in the clutch lever depress starter button to start the engine in gear A side stand ON sa...

Page 45: ...ne immediately after a cold start The engine should be allowed to run slowly for 15 30 seconds This will allow the engine to warm up and let oil reach all surfaces needing lubrication Failure to adhere may result in damage to the Engine Depress Starter Button and release as soon as engine starts Manual Bi Starter ...

Page 46: ...nt Prior to riding check to see if the low fuel indicator is glowing continuously The low fuel indicator will glow continuously if the fuel level in the tank in below 0 93 US Gallon Caution Please ensure the motorcycle is not used with the low fuel indicator lamp ON continuously It may not only result in the motorcycle running out of fuel BUT will also cause serious damage to the fuel pump Please ...

Page 47: ...amaged by shifting gears while engine is stopped WARNING Shifting to lower gears when motorcycle speed is too high can severely damage the transmission or cause the rear wheel to lose traction resulting in possible loss of vehicle control and loss of life or serious injury CAUTION The clutch must be fully disengaged before attempting to shift gears Failure to fully disengage the clutch may cause a...

Page 48: ...e motorcycle parts Parking Motorcycle on Center Stand Parking Motorcycle on Side Stand Select a firm flat surface Lower side stand and gently tilt motorcycle to the left till it rests firmly A Safety switch is provided in the side stand If the side stand is in extended position and rider engages gear to ride the motorcycle this switch will cut off ignition and stop the engine Please ensure side st...

Page 49: ...he driving condition 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 for expert advice and to carry out the periodical maintenance WARNING For your personal welfare all the listed service and maintenance recommendations should be performed Lack of regular maintenance at t...

Page 50: ...ngine sump filter oil strainer C C C C C C 4 Magnetic drain plug under gear box and secondary C C C C C C drain plug under crankshaft in crankcase right 5 Spark plug C A C A C A C A C A R C A C A C A C A R 6 HT lead I I I I I I I I I I I 7 Fuel hose I I I I R I I I R I I 8 Fuel Pump Check for screw tightness in all services 9 Fuel filter in fuel pump C R R 10 Accelerator cable play A A A A A A A A...

Page 51: ...16 Exhaust system D 17 Clutch free play Adjust every 1000 Kms or earlier as required 18 Rear brake pedal pivot L L L L L L L L L L L 19 Battery terminals apply petroleum jelly C C C C C C C C C C C 20 Earth wire eyelet I I 21 Rear Wheel Cush Rubbers I R I R 22 Rear Wheel Drive Chain Lubricate Adjust every 1000 Kms Clean Lubricate Adjust every 3000 Kms or earlier as required 23 Front Fork oil R R R...

Page 52: ...okes tightness Wheel rim run out front rear I I I I I I 28 Pivot Side Stand Center Stand Pillion Foot Rest L L L L L L L L L L L 29 Tire wear pattern Front Rear I I I I I I I I I I I 30 Hand levers pivot Lubricate every 1000 Kms or earlier as required 31 Front Disc Brake Oil level check I I I I I R I I I I R 32 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I 33 Wiring harness I I...

Page 53: ...ription Qty No 1 Tommy bar 1 2 Tubular spanner 21 24mm 1 3 Screw driver 1 4 Double end spanners 10 13 mm 2 8 10 mm 1 14 15 mm 1 5 Allen Keys 5 mm 1 3 mm 1 6 Tire Lever 2 7 Single end ring spanner 24mm 1 8 Extension tube 1 ...

Page 54: ...e front brake lever is accidently depressed Front Wheel Reassembly Remove the wooden piece card board sheet placed between the brake pads Locate small spacer and speedo drive over the wheel hub on the right side Front Wheel removal 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 in...

Page 55: ...ght side and tighten nut on left side to a torque of 7 KgM 70 Nm Ensure the peg in the speedo drive is correctly positioned in the slot in the right side fork end Insert axle through the right side fork end and gently tap it in fully Locate washer and nut on the left side Locate stepped spacer in the left side of the hub with its larger face outside Locate front wheel between the fork ends duly en...

Page 56: ...ke pads Remove the left side spacer from rear wheel hub Tilt motorcycle to right side and slide out rear wheel Rear wheel reassembly Ensure the four Cush rubbers are in position inside the rear wheel hub Tilt motorcycle to right side and insert the wheel assembly between the swing arms Position the rear wheel with cush rubber on the rear chain sprocket Fix the left side spacer in rear wheel hub Re...

Page 57: ...line Insert and tap the rear wheel axle gently from left side Caution Do not force the spindle into the wheel as the threads may get damaged Tap it through the wheel gently Caution Please check the brake hose pipe routing from Reservoir to Master cylinder Master cylinder to Rear wheel caliper There should not be any twist or pinch in routing which may affect braking performance Fix the brake hose ...

Page 58: ... middle or slightly over the middle level in the oil window in the right Crank case cover Top up with recommended oil if required Control Cables Handle bar lever pivots Center Side Stand Pivots Lubricate after using the motorcycle in rain after waterwash or if used in dusty conditions Wipe the area free of dirt grease Apply a few drops of oil on the pivots Caution Do not fill oil over MAX mark It ...

Page 59: ...l to drain out by tilting the motorcycle to both sides Wash the drain plug and the suction filter thoroughly and refit on the crankcase Soak a new filter element in oil and refit on the right Crankcase cover Fill recommended oil till the oil level is between the MAX and MIN marks in the oil level window in the right Crank case cover Start the engine warm up for a few minutes switch off Check the o...

Page 60: ...ous situation which if not avoided could result in severe damage to the engine parts and cause the engine to lock up and stop the motorcycle abruptly which may result in an accident and cause serious injury or loss of life Cleaning and adjusting gap Refer Periodical Maintenance Chart for frequency Remove the spark plug cap from the spark plug Remove the spark plug from the cylinder head using a su...

Page 61: ... this warning could result in serious injury or loss of life Please inspect and ensure tires are seated evenly properly in the rims Check proper seating of the tire beading on the rim Inspect the tires periodically for tread wear cracks and cuts Maintain the recommended tire pressures as it is very important for riding stability Pay strict attention to loose and or broken spokes Check spokes for c...

Page 62: ...rake fluid does not spill on any part of the motorcycle In the event of a spill please clean the area immediately with a soft cloth preferably a wet cloth to avoid damage Check if oil is below MIN level To top Up remove cover and diaphragm then top up with DOT 4 as specified Brake Fluid FRONT BRAKE REAR BRAKE MAX MIN MAX MIN ...

Page 63: ...stment l Place motorcycle on its center stand on a firm surface Ensure gears are in neutral and the rear wheel rotates freely l Check the drive chain tension at the bottom run of the chain It must be 25 30 mm To adjust proceed as follows l Hold the rear wheel axle on the left side and loosen rear wheel axle nut and sprocket nut on the right side Adjuster Lock nut Swing arm reference mark Index mar...

Page 64: ...en or loosen adjuster nut on right side chain tensioner slowly to achieve the desired chain tension Wheels Alignment l Note the matching reference marks of the chain tensioner and the swing arm on the right side l Hold the handle bar straight and visually also check for proper alignment of the front and rear wheels l Tighten Loosen adjuster nut on the left side chain tensioner such that the same r...

Page 65: ...ous injury or loss of life Drive Chain Lock Fitment If for any reason the chain link lock is removed it should be fitted such that the closed end of the lock is towards the direction of the chain rotation Please ensure the chain lock is located properly in the chain link and is locked in place Holding the adjuster nuts tighten the lock nuts against the adjuster nuts on both the left and right side...

Page 66: ...hockabsorbers After adjustment ensure the adjuster notches are seated correctly against the peg in the shockabsorber Pre load spring tension adjustment of rear shockabsorber WARNING Riding the motorcycle with the notches adjusted in different positions can cause loss of control and may lead to an accident In case of fitting any luggage rack or tying cargo to the rear end of the motorcycle please e...

Page 67: ...ng the battery to the battery carrier Pull the battery out slightly from the carrier and Disconnect the VE terminal FIRST and the VE terminal next Remove the battery from the carrier Battery Maintenance Care Maintenance Clean the battery well using a soft and wet cloth Inspect the battery carefully for any deformation of its housing If found deformed replace the battery immediately Clean the termi...

Page 68: ...y from an internal damage WARNING Always disconnect the ve terminal first and then the ve terminal while removing the cable connections Batteries contain lead sulphuric acids and other chemicals which are known to cause cancer and birth defects or reproductive harm Battery electrolytes are highly acidic and corrosive in nature Avoid contact with eyes skin clothing etc as it causes excessive burnin...

Page 69: ...are no open flames sparks and inflammable material near the battery charger or the battery during charging In the event the battery becomes excessively hot or the electrolyte boils over stop charging the battery as overheating or electrolyte boiling over can result in an explosion Always ensure the battery charger is in OFF mode while connecting it to the battery for charging Failure to adhere to ...

Page 70: ...prevent any metal coming in contact with the terminals and causing a short circuit Position the battery correctly and fully inside the carrier and strap the battery securely using the two rubber straps Locate the battery cover over the battery and lock it in place Changing Electrical Components Head Lamp Bulb Loosen the rim holding screw on top and take out the head lamp Disconnect electrical conn...

Page 71: ...R MAINTENANCE TIPS Slightly rotate and takeout the fused headlight unit assembly Replace and position the new headlight assembly and align with the slot on the inner rim Assemble back the Headlight unit assembly in the reverse order of dismantling process Caution Never touch the bulb glass with bare fingers as it leave finger prints on the glass and reduce the lighting intensity Hold the bulb only...

Page 72: ...Turn anti clockwise to take out the bulb Position the new bulb inside holder ensuring that the pins in the bulb match with the slots in the holder Gently press the bulb and turn clockwise to lock the bulb in the holder Refit the trafficator glass and screws ensuring the lens slot cut mark is at the bottom NOTE Do not over tighten the screw Make sure the Ignition switch is in OFF position when repl...

Page 73: ...er pad is worn to the wear indicator mark replace both pads as set Visit royal enfield dealer for this service Check the wear indicator mark on each pad if either pad is worn to the wear indicator mark replace both pads as set Visit royal enfield dealer for this service Wear indicator mark Front Brake Rear Brake Wear indicator mark MINOR MAINTENANCE TIPS ...

Page 74: ...d to access the fuses For easy reference the individual fuse ratings and its function is mentioned inside the lid of the fuse box Whenever a spare fuse is used please ensure it is replenished at the earliest opportunity Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing frequently NOTE Do not use a fuse different rating from that specified ...

Page 75: ...se 25A 3 Blue Ignition EFI Fuse 15A 4 Red Signalling Fuse 10A 5 Brown Spare Fuse 5A 6 Blue Lighting Fuse 15A 7 White ABS Main Fuse 1 25A 8 Red ABS Main Fuse 2 10A 9 Brown ABS ECU 5A SF1 White Spare fuse 25A SF2 Blue Spare fuse 15A SF3 Red Spare fuse 10A MINOR MAINTENANCE TIPS 3 4 5 6 7 8 9 SF2 SF3 ...

Page 76: ...lter Cleaning Unlock and open the right filter box Remove the nut and take out the lid Remove the metal plate Remove the Air filter Element Tap off the dirt Blow compressed air on the Filter element from inside out Replace element if it is cracked or punctured Place element inside air filter box Fix the air filter cover plate Fix the Air filter lid and tighten the nut Close the filter box lid and ...

Page 77: ...oper functioning of all lights horn etc Checks after every 930 miles 1500 kms of run Tightness of all fasteners Tire treads condition and wear of tires Battery condition Correct level of oil in engine brake fluid Working of all lights and horn Proper chain tension Items to be carried Tool kit Bulbs for headlight trafficator light rear tail lamp and fuse Accelerator clutch and Bi starter cables Rea...

Page 78: ...tore to remove dirt or grease from the engine external parts if required Follow the directions in the label carefully before using the degreaser Use low pressure jet of water to clean the entire motorcycle Never spray water with great force on head lamp speedometer flasher lights front and rear wheel hubs electrical connections and wires control cables Throttle body sparkplug battery etc Use Luke ...

Page 79: ...lean the terminals free of corrosion and apply petroleum jelly to terminals Store the battery in a cool dry and well ventilated place Do not place the battery in direct sun light near open flame or where temperature is above 40o C or below 0o C Cover the silencer with plastic bags to prevent moisture entry Set the motorcycle on its center stand Apply anti rust solutions on all plated parts Take ca...

Page 80: ... any cracks or cuts Clean the air filter Remove plastic covering from the silencer Remove spark plug on cylinder head and pour in a few drops of engine oil Crank engine a few times to lubricate cylinder walls and piston Clean spark plug and refit Switch on ignition switch Start motorcycle and warm up engine for a few minutes before riding the motorcycle NOTE Do not raise the engine rpm the moment ...

Page 81: ......

Page 82: ...pair and or maintenance could result in the motorcycle not functioning properly serious injury or loss of life Causes Remedies I Engine fails to start 1 Stop switch in OFF Position Push stop switch to ON position 2 Side stand not retrieved Retrieve side stand 3 Vent hole clogged in fuel tank cap Clean vent hole 4 Spark plug cap lead not connected Fix cap lead firmly 5 Spark plug electrode dirty fo...

Page 83: ... irregularly stops 1 Faulty fuel supply Remove fuel pump clean fuel pump filter blocked IV Poor pickup 1 Accelerator cable free play excessive Adjust cable free play 2 Faulty fuel supply Remove fuel pump clean Fuel pump filter blocked 3 Choked air filter Clean Replace air filter 4 Brakes adjusted too tight Re adjust properly Contact Royal Enfield Authorised Dealer TROUBLE SHOOTING Causes Remedies ...

Page 84: ...line in the Check and drain excess oil oil level window VI Engine overheating 1 Cylinder fins not clean Clean the cylinder fins at regular intervals 2 Clutch slipping Check and correct VII Excessive fuel consumption 1 Fuel leakage Check and rectify 2 Choked air filter Clean Replace 3 Under inflated tires Inflate to correct pressure Contact Royal Enfield Authorised Dealer TROUBLE SHOOTING Causes Re...

Page 85: ...1 Wheel rim runout Rectify 2 Loose Broken spokes Tighten Replace spokes 3 Tires not fitted correctly Refit tires correctly 4 Wheels misaligned Ensure proper alignment 5 Under inflated tires Inflate to correct pressure X Electricals Bulbs do not light 1 Loose improper connection Check and correct 2 Bulb fused Replace bulb 3 Fuse blown Check and Replace fuse Contact Royal Enfield Authorised Dealer T...

Page 86: ...1 Switch link not adjusted properly Adjust connecting links properly 2 Switch sticky Replace switch XI Electronic Fuel Injection MIL Blinking continuously 1 Sensor Loose Connection Check Correct XII ABS Anti lock Braking system 1 ABS lamp continuously ON Take the vehicle to service center for diagnosis Contact Royal Enfield Authorised Dealer TROUBLE SHOOTING Causes Remedies ...

Page 87: ...ch part or parts of the vehicle which in examination shall be deemed defective in opinion of Royal Enfield and or their distributors authorised dealers Such defective part s which have been replaced shall become the property of Royal Enfield 4 Cost of consumables like fuel Oils etc Labour shipping charges of replacement parts for any warranty replacement are chargeable to the customer 5 Warranty i...

Page 88: ...serves the right to make changes in the motorcycle without any obligation to install these changes on previously sold motorcycles 9 Royal Enfield authorised distributors and or their dealers are independently owned and operated They may hence deal with other aftermarket products for which Royal Enfield is not responsible for the performance safety quality reliability and suitability of such produc...

Page 89: ...h may cause this motorcycle not to meet the U S Federal Environmental Protection Agency standards for a period of 5 years OR 18 641 Miles 30 000 Kms whichever occurs first from the date of first use of the motorcycle The Warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser OR from the first date the motorcycle is used as a demonstrator OR as a display a...

Page 90: ...TENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED INTERVALS AND ANY MAINTENANCE TO THE EMISSION CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USING ONLY GENUINE ROYAL ENFIELD SPARE PARTS REPAIRS TO THE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE OUTLET OR INDIVIDUAL AND USE OF PARTS OTHER THAN GENUINE ROYAL ENFIELD SUPPLI...

Page 91: ...rkmanship which may cause this motorcycle not to meet the U S Federal Environmental Protection Agency standards for a period of 5 years OR 18 641 Miles 30 000 Kms whichever occurs first from the date of first use of the motorcycle The Warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser OR from the first date the motorcycle is used as a demonstrator OR ...

Page 92: ... MAINTENANCE OF THE MOTORCYCLE BE CARRIED OUT AT SPECIFIED INTERVALS AND ANY MAINTENANCE TO THE NOISE CONTROL SYSTEMS SHOULD BE PERFORMED ONLY BY AN AUTHORISED ROYAL ENFIELD SERVICE DEALER AND USING ONLY GENUINE ROYAL ENFIELD SPARE PARTS REPAIRS TO THE NOISE CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE OUTLET OR INDIVIDUAL AND USE OF PARTS OTHER THAN GENUINE ROYAL ENFIELD SUPPLIE...

Page 93: ...Resources Board standards for a period of 5 years OR 18 641 Miles 30 000 Kms whichever occurs first from the date of first use of the motorcycle The Warranty period shall begin either on the date the motorcycle is delivered to the first retail purchaser OR from the first date the motorcycle is used as a demonstrator OR as a display and or trial motorcycle THE FOLLOWING ITEMS ARE NOT COVERED BY THE...

Page 94: ...COMMENDED 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 REPAIRS TO THE EVAPORATIVE EMISSION CONTROL SYSTEM MAY BE PERFORMED BY ANY OTHER QUALIFIED SERVICE OUTLET OR INDIVIDUAL A...

Page 95: ...94 SERVICE MAINTENANCE RECORD S No Date Brief details of work service Royal Enfield Authorised Dealer 1 2 3 4 5 6 7 8 Job Card No KMS Miles ...

Page 96: ...95 SERVICE MAINTENANCE RECORD S No Date Brief details of work service Royal Enfield Authorised Dealer 9 10 11 12 13 14 15 16 Job Card No KMS Miles ...

Page 97: ...96 NOTES ...

Page 98: ...Part No RAM00103 A ...

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