Royal Enfield Bullet 500 Owner'S Manual Download Page 53

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CHECKING REAR BRAKE PEDAL HEIGHT

Loosen the lock nut.

Turn in or out the pedal stop pin bolt till the brake
pedal and front footrest are in the same height /
level as shown in above pic.

Tighten the lock nut

Check for free rotation of rear wheel.

MINOR MAINTENANCE TIPS

Check that the front
and rear wheels are
correctly aligned.

Turn the LH adjuster
cam appropriately,
to align bo th t he
wheels.

Check  and  ensure
that the knotches on
the  cam  are  resting
on  the  pin  in  t he
swing  arm  on  both
sides.

Apply brake and
tighten all nuts.

Finally Torque the
anchor Nut.

Check brake pedal free play, If necessary adjust.

Summary of Contents for Bullet 500

Page 1: ......

Page 2: ...re that you operate your motorcycle the right way are aware of the terms and conditions of warranty and know how to maintain it properly We urge you to avail of the four free services we offer at the right time at any of our Authorised Dealer Service Point to keep your motorcycle in peak condition Please log on to www royalenfield com to know more about the history of the world s oldest motorcycle...

Page 3: ...e manual along with the motorcycle and it s documents 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 Because of continous improvements in the product and changes that may occur in the manufacturing process subsequent to pri...

Page 4: ...or or moderate injury NOTE Indicates important and useful messages for clearer understanding All Images shown are for reference to explain and need not to be exactly the same on the model you own However if you have any queries clarification suggestions feedback please write to us or e mail at customerservice royalenfield com SERVICE HEAD QUARTERS Royal Enfield A Unit of Eicher Motors Limited Thir...

Page 5: ...1 VEHICLE IDENTIFICATION NUMBER 22 KEY PARTS LOCATION 23 Top View 23 Right Side View 24 Left Side View 25 OPERATION OF CONTROLS 26 Ignition Switch 26 Steering lock 26 Fuel tank cap 27 Side Box 27 Head lamp switch 28 Dip Switch 28 Head lamp Day flash 28 Engine Kill Switch 29 Horn 29 Turn Signal Switch 29 Engine Start Switch 30 Battery Box 30 Fuel Tap 30 PRE OPERATIONAL CHECKS 31 RUNNING IN PERIOD 3...

Page 6: ...e 47 Front Wheel removal 47 Front Wheel assembly 48 Rear wheel removal 49 Rear wheel assembly 50 Adjustment Clutch 51 Drive Chain tension 51 Checking Rear Brake Pedal height 52 Rear Brake Pedal height Adjustment 53 Chain Lock Fitment 53 Adjustment of Gas Filled Shockabsorber 54 Removal of Battery on Vehicle 55 Battery Maintenance 55 Assembly of Battery on Vehicle 56 Changing Electrical Components ...

Page 7: ...ils to start 69 Engine misfiring 70 Engine starts but runs irregularly stops 71 Poor pickup 71 White blue smoke 72 Engine over heating 72 Excessive fuel consumption 72 Ignition knock 73 Brakes poor 73 Vehicle wobbles 74 Electricals 74 Electric Start 76 WARRANTY TERMS CONDITIONS 77 EMISSION WARRANTY 79 ALL INDIA ROAD SIGNS 83 FREE SERVICE COUPONS 84 PAID SERVICE MAINTENANCE RECORD 93 LOG BOOK 101 N...

Page 8: ... Installation Form VIF No Name Door No Street Locality City State Pin Contact Nos Res Off Mobile Email Engine No Battery No Frame No Battery make Reg No Licence No Date of Sale Valid till dt Model Key No Tyre make Colour Sold by Dealer Code ...

Page 9: ...upon duly filled in and signed to the service outlet Availing the free services in the specified time is a prerequisite for warranty consideration The cost of fuel oil grease etc used for all free services are chargeable to the customer NOTE Please ensure that the free service details are recorded in this sheet immediately after the service is carried out Date of Service Kms Covered Servicing Deal...

Page 10: ... affect performance and handling Removing or altering original parts may adversely affect performance and could result in an accident causing serious injury Use only genuine Royal Enfield spare parts and approved accessories Use of other manufacturer s performance parts may affect the performance of your motorcycle and render the motorcycle void of warranty See your Royal Enfield dealer for detail...

Page 11: ...ry A new motorcycle must be operated according to the special break in procedure See BREAK IN THE FIRST 500KM section Operate motorcycle only at moderate speeds and out of traffic until you have become thoroughly familiar with its operation and handling characteristics under all conditions DO NOT exceed the legal speed limit or drive too fast for existing conditions Always reduce speed when poor d...

Page 12: ...ptly or force the handlebar Operate your motorcycle defensively Remember a motorcycle does not afford the same protection as an automobile in an accident One of the most common accident situations occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns into the oncoming motorcyclist Wear an approved helmet clothing and foot gear suited for riding a motorcycle B...

Page 13: ...ceed 60 km h for the first 24 hours after repair and the repaired tyre should Never be used over 90 km h applicable tube less tyre SAFE OPERATING RULES In emergency situations if a temporary repair is made ride slowly with as light a load as possible until the tyre is permanently repaired or replaced Failure to heed this warning could result in serious injury Safe motorcycle operation requires ale...

Page 14: ...t the suggested intervals may affect the safe operation of your motorcycle which could result in serious injury WARNING Avoid any contact with the exhaust system Wear clothing that will completely cover the legs while riding The exhaust system gets very hot when the engine is running and remains too hot even after the engine is turned off due to catalic converter Failure to wear proper or protecti...

Page 15: ...to do so may aggravate an initial problem cause costly repairs jeopardize your personal safety and could result in serious injury WARNING Use only genuine Royal Enfield replacement fasteners tightened to the proper torque We caution you against the use of certain non standard parts such as aftermarket and custom made fasteners which may not have specific strength finish and type requirements to pe...

Page 16: ...tre line when meeting oncoming vehicle Always sound your horn actuate your turn signals and exercise 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 At street intersection give the right of way to the vehicle on your left or right DO NOT presume you have t...

Page 17: ...and flat surface to prevent it from falling over Protect your motorcycle against theft After parking your motorcycle remove Ignition key from switch and lock the steering head NOTE To help you establish the relative distance of vehicles behind your motorcycle adjust each mirror in such a way that a small portion of your shoulder is visible and a large portion behind your motorcycle is seen clearly...

Page 18: ...r RPM 26 1 BHP 5100 rpm Max Torque RPM 40 9 Nm 3800 rpm Air Filter Element Corrugated Paper Element Fuel Supply Carburetor with Throttle Position Sensor TPS 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: ... to 0 90 mm UR6DC 0 70 to 0 80 mm TRANSMISSION Clutch Wet Multiplate 7 Plates Clutch Primary drive Duplex Chain Primary Drive Ratio 2 15 1 Gear box 5 Speed Constant Mesh Gear shift pattern 1 N 2 3 4 5 Gear Ratios 1st 3 06 1 2nd 2 01 1 3rd 1 52 1 4th 1 21 1 5th 1 1 Secondary Drive F D Sprocket 18 Teeth Final Ratio 2 11 1 Drive Chain links 102 links TECHNICAL SPECIFICATIONS ...

Page 20: ...igh beam indicator 12V 1 7 W 2 nos Neutral Indicator 12V 1 7 W 1 no Horn Dual 12V 2 5 Amp Max X2 Starter Motor 12V 0 9 KW TECHNICAL SPECIFICATIONS WARNING Using bulbs other electrical gadgets other than specified rating may lead to over loading erratic behaviour premature failure of electrical system Modifications on the bike which are not approved by Royal Enfield may not only disqualify for warr...

Page 21: ...usable fuel 0 75 Litres approx Suspension Front Telescopic 130mm Travel 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 60 ml Brake oil grade DOT 3 or DOT 4 TECHNICAL SPECIFICATIONS Fu...

Page 22: ...135 mm WEIGHTS Kerb Weight with 90 Fuel 193 Kg Max pay load 172 Kg NOTE 1 Values Dimensions given above are for your guidelines only 2 In view of continuous improvements being done on our products the specifications are subject to change without notice TECHNICAL SPECIFICATIONS NOTE BS III This vehicle meets Emission Norms Bharat Trem Stage III ...

Page 23: ...22 VEHICLE IDENTIFICATION NUMBER DETAILS FRAME NUMBER Punched on steering head tube RH side ENGINE NUMBER Punched on top of the engine LH side ...

Page 24: ...n 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 Rear View Mirror 1 2 5 4 11 10 3 7 8 6 9 12 12 ...

Page 25: ...24 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 6 2 3 4 5 1 ...

Page 26: ...OCATION 1 3 4 5 2 6 7 8 9 10 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: ...our motorcycle against theft After parking your motorcycle remove the ignition key from switch and lock the steering head Turn handle bar to extreme left before attempting to lock steering Do NOT lubricate barrel locks with petroleum based lubricants or graphite Inoperative locks may result in damage to your vehicle Turn key anti clockwise to unlock ...

Page 28: ...TROLS Turn key clockwise to open NOTE Key is common for ignition petrol tank cap steering lock side boxes and battery cover Key for fuel tank and tool boxes can be removed from the lock only in locked position AIR FILTER BOX RH Turn Key anti clockwise to open SIDE BOX LH Turn Key anti clockwise to open it contains Tools Kit Fuse ...

Page 29: ...28 Low beam Press for Headlight Flash OPERATION OF CONTROLS HEAD LAMP SWITCH Pilot Light ON OFF Head Light ON High Beam DIP SWITCH HEAD LAMP DAY FLASH ...

Page 30: ...29 ENGINE KILL SWITCH HORN OPERATION OF CONTROLS Stop Run Press TURN SIGNAL SWITCH Left OFF Push to off Right ...

Page 31: ...PERATION OF CONTROLS ENGINE START SWITCH FUEL TAP Turn anti clockwise to open BATTERY BOX Press OFF Turn knob to horizontal position Main ON Turn knob downward position Reserve ON Turn knob upward position ...

Page 32: ... i ng and thro tt l e fo r responsiveness 4 Cable for fraying or crimping and free operation 5 Engine oil level WARNING For your personal welfare and safety all the points mentioned above should be performed periodically Failure to do so may affect safe operation and damage your motorcycle and could result in an accident causing serious injury 7 Headlamp tail lamp brake lamp and indicator lamps fo...

Page 33: ... of running Vary the speed of the motorcycle regularly during running but avoid using the motorcycle above throttle opening position 2 501 2000 Kms The recommended speed is below 80 Kmph Avoid driving the motorcycle with full throttle opening Vary the speed of the motorcycle regularly but avoid using the motorcycle above 3 4 throttle opening position 3 2 001 kms and above Avoid prolonged full thro...

Page 34: ... to shift to neutral Move the motorcycle back forth and simultaneously press gear lever to come to neutral Ensure neutral indicator light comes ON in the Speedometer WARNING Before starting engine always shift gears into neutral Switch on ignition N Ensure the side and main stands are in released position Ensure that gears are in neutral and neutral lamp is glowing in cluster box ...

Page 35: ...s Press starter button and release starter switch once the engine starts If the engine does not start on the first attempt in cold climate release the starter button wait for 30 seconds before pressing the starter button again USING ELECTRIC START Press Clutch Lever Press Starter Button and release as soon as engine starts Release the choke if applied Slightly crank the engine further till compres...

Page 36: ...edal with toe to engage 1st gear Gently open throttle and release clutch simultaneously If clutch is released suddenly the engine may stall and cause a jerky start NOTE Always move the motorcycle in first gear position only When engine speed decreases while climbing a gradient or running at a reduced speed shift to the appropriate lower gear to prevent the engine from stalling or straining to pull...

Page 37: ...pull vehicle backwards gently as shown in pic Select a firm flat surface Lower Side Stand and gently tilt motorcycle to the left till it rests firmly PARKING VEHICLE ON CENTER STAND PARKING VEHICLE ON SIDE STAND WARNING Always park the motor cycle on a firm and flat surface Parking in a soft ground may cause stand to sink and the motorcycle to fall causing injury to you or to others and damage to ...

Page 38: ...ner 10 X 12 2 1 4 5 6 7 3 2 1 2 3 4 5 6 S No Description Qty 1 Antiseptic cream 5 gms 1 2 Gauze bandage 5 cm x 2 cm 1 3 Elastic Gauze bandage 8 cm x 1 mtr 1 4 Wash proof plaster 1 9 cm x 7 2 cm 2 5 Sterilized Gauze Swab 5 cm x 5 cm 2 6 Sterilized elastic plaster 7 cm x 6 cm 1 7 First aid kit pouch 1 NOTE This Tool Kit is kept in Tool box Refer Page No 27 ...

Page 39: ...res as mentioned in above point No 1 Engine Oil Grade Royal Enfield 15 W 50 API SL Grade Engine Oil JASO MA Front Fork Oil Grade Royal Enfield Front Fork Oil or 1F Grade Endurance Capacity 195 ml leg Brake Fluid Grade DOT 3 or DOT 4 Capacity 60ml Capacity 2 75 Ltrs with oil filter 2 50 Ltrs during oil filter element replacement WARNING DO NOT switch oil brands indiscriminately because some oil int...

Page 40: ...on the severity of the 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 Service Point for expert advice and to carry out the periodical maintenance WARNING For your personal welfare all the listed service and maintenance recommendations should be performe...

Page 41: ...R R R R 3 Engine sump filter oil strainer C C C C C C C 4 Magnetic drain plug under gear box and secon C C C C C C C dary drain plug under crankshaft in crankcase RH 5 Spark plugs 2 nos C A C A C A C A C A R C A C A C A C A R 6 HT leads for crack I I I I I I I I I I I 7 Carburetor C V Type Clean Inspect and Tune 8 Fuel Tap Filter C C C C C C 9 Fuel tank C C C C C 10 Fuel hose pipe I I I R I I I R ...

Page 42: ... 16 Inlet Exhaust valve seating I I 17 Clutch lever free play Check Adjust every 1000 Kms or earlier as required 18 Cylinder head Combustion chamber D 19 Hand levers kick starter lever pivot Lubricate every 1000 Kms or earlier as required 20 PAV pipes hose clip I I C I C I C I C I C 21 Rear brake pedal pivot L L L L L L L L L L L 22 Battery terminals apply petroleum jelly C C C C C C C C C C C 23 ...

Page 43: ... Months 1 5 3 6 9 26 Rear wheel drive chain Adjust for every 1000 Kms Clean Lubricate Adjustevery 3000 kms or earlier as required 27 Rear brake pedal free play Adjust every 1000 Kms or earlier as required 28 Rear brake cam L L L L L 29 Steering ball races play adjustment A L A R A L A R A L 30 Spokes tightness Wheel rim run out I I I I I I 31 Rear wheel cush rubbers I R I R 32 Swing Arm pivot bush...

Page 44: ...TER SIDE STAND PIVOTS ENGINE OIL LEVEL INSPECTION MINOR MAINTENANCE TIPS Lubricate after using the motorcycle in rain after water wash or if used in dusty conditions Wipe the area free of dirt grease Apply a few drops of oil on the pivots Lever Pivot Main Side Stand Pivot MAX MIN Place motorcycle on its center stand on a firm surface Warm up engine for a few minutes switch off The level is correct...

Page 45: ...tion filter magnet Then remove secondary drain plug to drain oil clean the magnet Finally remove primay drain bolt to drain the complete oil Remove the oil filter element on the Crankcase Cover RH Allow the oil to drain by tilting the motorcycle to both sides Wash the primary and secondary drain plugs along with suction filter thoroughly and refit on the crankcase after all the oil is drained out ...

Page 46: ...lfuncton Max Min Fill recommendedoil to engine till the oil level is upto MAX level mark in the oil window in Crank case Cover RH SPARK PLUG Cleaning and adjusting gap Refer Periodical Maintenance Chart for frequency MINOR MAINTENANCE TIPS Remove HT Lead and the spark plug from the cylinder head using the plug spanner and tommy bar as shown in pic Clean the insulator tip and electrodes of the plug...

Page 47: ...INSPECTION OF TYRES AND WHEELS Inspect the tyre periodically for tread wear cracks and cuts MIN MAX Check and remove stone splinters nails or other particles embedded in the tyre treads Bald spots swelling may be caused by internal damage Replace the tyres if defective Replace tyres when the tread depth has reached the minimum as specified Periodically inspect wheels for spokes breakage and wheel ...

Page 48: ... the tyre bead during mounting allow tyre slippage on the rim and cause tyre failure Place the vehicle on center stand Place a wooden block the front end of engine to support the vehicle Disconnect speedo cable Loosen the pinch bolt on the RH fork guide Hold front axle by spanner and loosen axle nut then remove nut along with washer MINOR MAINTENANCE TIPS Solo 1 41 kg cm2 2 11 kg cm2 20 PSI 30 PSI...

Page 49: ...th bush LH side spacer MINOR MAINTENANCE TIPS CAUTION Do not press the front brake lever when wheel is removed as this will result in the brake pads coming too far out of the brake caliper Take out Speedo drive and bush on the RH side as shown in pic Place the bush speedo drive in position and place speedo drive over it Insert the wheel along with speedo drive assembly and LH spacer between the fr...

Page 50: ...eedo meter Press brake lever 2 or 3 times to check front brake efficiency REAR WHEEL REMOVAL Place the vehicle on center stand on a firm and flat surface Note and mark the position of the chain adjuster butting with the stopper on the right side Remove split pin and castle nut on the RH side Remove wheel spindle from LH side along with chain adjuster taking care not to drop the wheel collar and sp...

Page 51: ...t the chain adjuster knotch butts with the stopper as appropriate when both the front rear wheels are aligned Fix the split pin Tilt vehicle to right and insert wheel assembly between the swing arms Position the rear wheel with cush rubber on the rear chain sprocket Hold wheel collar and spacer in position Assemble the wheel spindle along with chain adjuster from the LH side of vehicle and gently ...

Page 52: ... play or Anticlockwise to increase the free play Check free play 2 to 3 mm at Clutch lever pivot on handle bar end Tighten lock nut A after adjustment is done Remove rear wheel split pin B A 2 to 3 mm MINOR MAINTENANCE TIPS Turn the RH adjuster cam as appro priately till 25 to 30 mm slackness is achieved on the top run of the chain Loosen castle nut spindle nut anchor nut and brake rod nut ...

Page 53: ...ck nut Check for free rotation of rear wheel MINOR MAINTENANCE TIPS Check that the front and rear wheels are correctly aligned Turn the LH adjuster cam appropriately to align both the wheels Check and ensure that the knotches on the cam are resting on the pin in the swing arm on both sides Apply brake and tighten all nuts Finally Torque the anchor Nut Check brake pedal free play If necessary adjus...

Page 54: ...ms If you ride under adverse conditions steep hills heavy traffic etc a more frequent inspection at 1600 Kms or less is required 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 wheel rotates freely The open end of the chain link master lock to face opposite to normal direction of chain rotation as ...

Page 55: ...r provided on the bottom of the spring has five knotches Insert special C spanner on the bottom adjuster and rotate to change knotch position RH WARNING Riding the motorcycle with the knotches adjusted in different positions can cause loss of control and may lead to an accident Regularly inspect shock absorbers and front forks for leaks Replace worn parts Worn parts can adversely affect stability ...

Page 56: ...ll out the battery and turn then disconnect both the terminal wires negative and positive respectively Take out the battery The battery must be periodically checked for Cleanliness and corrosion free terminals Electrolyte level must be above MIN level If electrolyte level is low remove caps and top up with distilled water only Apply petroleum jelly over the battery terminals to avoid sulphation MI...

Page 57: ...s to avoid damage to battery Electrolyte should not be filled when the level is between minimum maximum levels indicated in battery as MIN MAX MINOR MAINTENANCE TIPS NOTE Clean the wire terminals free of corrosion and keep the terminals coated with petroleum jelly CAUTION Connect the ve and ve cables to the respective battery terminals Failure to do so may result in damage to the motorcycle electr...

Page 58: ...TION Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with paper or clean dry cloth during handling Remove rubber grommet from the reflector Assembly Gently press the bulb holding U clip from both the sides downwards and release it from reflector slot as shown Pull out head lamp bulb and inspect its filament for fuse MINOR MAINTEN...

Page 59: ...rs as mentioned below TOP SIDE GREEN COLOUR RIGHT SIDE BLUE COLOUR LEFT SIDE ORANGE COLOUR NOTE After connecting above said procedure turn ignition switch to ON condition and then check ensure that flash light working in HIGH BEAM mode If you use the bulb other than specified rating 12V 55 60W may result in over loading electrical system lead to premature failure or frequent battery discharge Posi...

Page 60: ... turn clockwise to lock the bulb in the holder Refit the trafficator cover cut slot mark facing downwards and tighten the 2 screws Remove the two nuts each from RH LH side of the rear number plate holder Pull out Tail Lamp assembly along with bracket and twist the bulb holder in anticlockwise to remove bulb holder assembly Turn old bulb to remove and replace with a new bulb Refit the bulb holder a...

Page 61: ...e ensure to replace a spare fuse in the holder at the earliest opportunity BLADE FUSE USAGE LIST 1 Blue Main Fuse 15A 2 Red Ignition Fuse 10A 3 Red Spare Fuse 10A 4 Blue Spare Fuse 15A Fuse No Color Remarks Replace the required fuse with the spare fuse available in the fuse carrier MINOR MAINTENANCE TIPS 1 2 3 4 ...

Page 62: ... shown and clean thoroughly before assembly Loosen the filter holding nut by 10mm spanner as shown in pic Assemble the filter element and cover in the reverse order of dismantling process Please ensure proper sealing of cover plate against air filter element Remove the nut washer and cover air filter to take out air filter element Clean both intake adaptors and duct as shown in pic ...

Page 63: ...lencer tail end and control switches with suitable plastic bags and tie it firmly to prevent water entry into them Remove ignition key and seal key hole using adhesive tape Use a suitable engine degreaser available with your local parts store 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 ...

Page 64: ...kplug Clean rear chain thoroughly and apply a thin film of lube oil Remove battery from the bike Clean the terminals free of corrosion Maintain electrolyte level between max or min mark by adding distilled water and wipe the battery dry Store the battery in a cool dr y and well ventilated place Do not place the battery in direct sun light near open flame or where temperature is above 40o C or belo...

Page 65: ...tyre pressure Ensure battery is fully charged and proper electrolyte level is maintained Connect the battery Lubricate all control cables and pivots Check proper level of oil in engine Fill fuel tank with fresh petrol Check fuel line hose for 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 Cr...

Page 66: ...CKS AFTER EVERY 1500 KMS OF RUN Tightness of all fasteners Tyre tread condition and wear of tyres Battery condition and electrolyte level Correct oil level in engine Working of all lights and horn Proper drive chain tension ITEMS TO BE CARRIED Tool kit First aid kit Bulbs for Headlight Trafficator light Rear Tail Lamp and Fuse 10 15 Amps Accelerator Clutch and Speedo Cable Rear chain master link l...

Page 67: ... fuel unleaded 87 octane petrol and oils only RIDE AT COST EFFECTIVE SPEED Cost effective speed in top gear is 45 to 50 Km per hour Both lower and higher road speeds cause low kilometers per litre of petrol PERFORM PREVENTIVE MAINTENANCE AS PER RECOMMENDATIONS REGULAR PREVENTIVE MAINTENANCE ENSURES Correctly inflated tyres Fasteners tightened to correct torques Freely moving engine transmission co...

Page 68: ...e overheating AVOID FREQUENT BRAKING Braking arrests the road speed Motorcycle momentum is reduced Additional fuel is burnt for subsequent acceleration For better mileage use front and rear brakes simultaneously when absolutely needed Control vehicle speed with throttle and gear like smart riders always do AVOID OVER LOADING Over loading tyres the engine wears the parts faster and reduces mileage ...

Page 69: ... in cold start condition ambient temperature 25 C 3 DO NOT ATTEMPT HALF START BY CASUALLY PRESSING ELECTRIC START BUTTON 4 PLEASE PRESS AND HOLD ELECTRIC START BUTTON FOR ATLEAST 3 SECONDS CONTINUOUSLY FOR THE CRANKING OR UNTIL THE ENGINE FIRES AND SUSTAINS WHICHEVER IS EARLIER 5 If engine doesn t start in the first attempt release the ES button and repeat the above Procedure 6 It is advised not t...

Page 70: ...MMETER ASSEMBLY TRAFFICATOR REAR RH 10W TRAFFICATOR REAR LH 10W STOP TAIL LIGHT 21 5W THREE PHASE MAGNETO 1 T PULSER COIL RED RED YELLOW BLUE WHITE GREEN WHITE LIGHT GREEN 4x6 3 COUPLER RED YELLOW YELLOW YELLOW RED 2x6 3 COUPLER 3x6 3 COUPLER RECTIFIER REGULATOR UNIT THREE PHASE RED BROWN BLACK 2x2 3 WATER PROOF COUPLER NATURAL 3x2 8 COUPLER 2x2 3 WATER PROOF COUPLER 3x2 3 WATER PROOF COUPLER 2x2 ...

Page 71: ...and Replace Ref Page No 60 6 Carburetor passage jets blocked Dismantle carburetor clean jets passages 7 Carburetor float stuck in closed position Ensure correct movement of float 8 Spark plug cap lead not connected Fix cap lead firmly 9 Loose HT connections Fix connections firmly 10 HT Lead Damaged Replace HT Lead 11 Spark plug electrode dirty fouled Clean spark plug Reset gap 12 Spark plug insula...

Page 72: ...an carburetor petrol tank Fill tank with fresh petrol 2 Leak through intake hose Tighten rubber hose suitably Replace if necessary 3 Loose spark plug cap Fix cap lead firmly 4 Spark plug fouled insulation broken Clean reset gap or replace 5 Poor Compression Auto decompressor sticky or not working 6 Loose electrical connections coupler Battery cable fuse carrier coils TCI unit Switch TROUBLE SHOOTI...

Page 73: ...play 2 Faulty fuel supply Clean the fuel line tap vent hole 3 Choked air filter Clean Replace air filter 4 Loose carburetor mounting Tighten clamps firmly 5 Brakes adjusted too tight Re adjust properly 6 Rear chain adjusted too tight Re adjust properly 7 Clutch Slipping Adjust clutch cable free play 8 Under inflated tyres Inflate to correct pressure TROUBLE SHOOTING Contact Authorised Dealer Servi...

Page 74: ... cylinder Check Replace VI ENGINE OVERHEATING 1 Cylinder fins not clean Clean the cylinder fins at regular intervals 2 Clutch slipping Check and correct 3 Suction leakage Check and correct 4 Incorrect carburetor adjustments Check and correct VII EXCESSIVE FUEL CONSUMPTION 1 Fuel leakage Check and rectify TROUBLE SHOOTING Contact Authorised Dealer Service Point CAUSES REMEDIES ...

Page 75: ...or sticky or not working properly 6 Under inflated tyres Inflate to correct pressure VIII IGNITION KNOCK 1 Carburetor adjusted too lean Check and readjust 2 Suction intake system leakage Check and correct IX BRAKES POOR 1 Not adjusted properly Adjust properly 2 Oil grease on lining or drum or disc Clean and refit TROUBLE SHOOTING Contact Authorised Dealer Service Point CAUSES REMEDIES ...

Page 76: ...es 3 Tyres not fitted correctly Refit tyres correctly 4 Wheels misaligned Ensure proper alignment 5 Under inflated tyres Inflate to correct pressure XI ELECTRICALS Bulbs do not glow 1 Loose improper connection Check and correct 2 Bulb fused Replace bulb 3 Fuse blown Replace fuse 4 Switch defective Replace switch TROUBLE SHOOTING Contact Authorised Dealer Service Point CAUSES REMEDIES ...

Page 77: ...rafficators not working 1 Loose improper connections Check and correct 2 Bulb fused Fuse blown Replace 3 Switch defective Replace 4 I C Flasher defective Replace Brake light remains ON 1 Switch not adjusted properly Adjust switch properly 2 Switch sticky Replace switch TROUBLE SHOOTING Contact Authorised Dealer Service Point CAUSES REMEDIES ...

Page 78: ... Loose Connection Check Correct 4 Starter relay not working Check Replace 5 Malfunctioning of clutch switch Check Replace 6 Malfunctioning of Starter switch Check Replace 7 Battery discharge Check Recharge 8 Motor not working Check Replace 9 Battery not fully charged Check charge 10 Failure of sprag clutch Check replace TROUBLE SHOOTING Contact Authorised Dealer Service Point CAUSES REMEDIES ...

Page 79: ...per the schedule given in the owner s manual from Authorised Dealer Service Point 4 During the warranty period RE s obligations shall be limited to repairing replacing free of charge such part or parts of the vehicle which on examination to have manufacturing defect Such defective part parts which have been replaced becomes property of RE 5 Cost of oil oil filter fuel and other consumables are cha...

Page 80: ...nized as affecting the quality or function of the vehicle such as slight vibration oil leakage discoloration of exhaust bent pipe silencer soft hard shock absorber etc i Defects arising from fitment of unauthorised additional Electrical loads j Vehicle serviced repaired at unauthorised service points k Vehicle used for competition racing l Electrical component like bulbs fuses etc m Normal mainten...

Page 81: ...he 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 i...

Page 82: ...ocument are met from the date of original sale of the motorcycle THE WARRANTY SHALL APPLY IF THE CUSTOMER Observes all the important instructions and any other precautions listed in the owner s manual Under all circumstances uses lubricants and fuel as recommended by Royal Enfield Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the details in th...

Page 83: ...n the maintenance chart The motorcycle has been subjected to abnormal use abuse neglect and improper maintenance or has met with an accident Replacement parts not specified and approved by Royal Enfield have been used The motorcycle or parts thereof has been altered tampered with or modified or replaced in an unauthorised manner The odometer is not functioning or the odometer and or its reading ha...

Page 84: ...HT SIDE OF LAW Always get your vehicle checked to meet the emission regulations through and authorised emission checking center Always carry a valid Pollution Under Control certificate with you at all times during the validity of the emission warranty 30 000 Kms 3 years from the date of first sale TIPS TO REDUCE POLLUTION 1 Ensure that the periodical maintenance is carried out as stipulated in the...

Page 85: ...83 ALL INDIA ROAD SIGNS MANDATORY SIGNS INFORMATION SIGNS CAUTIONARY SIGNS ...

Page 86: ... 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 Availing the free services in the specified time is a prerequisite to warranty consideration FREE SERVICE COUPONS ...

Page 87: ...e Record Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer s Name Address 1ST FREE SERVICE Cost of oil oil filter element and other consumables used are chargeable to ...

Page 88: ...oil leak Check for leakage 10 Air filter element Clean 11 Spark plugs 2 Nos Check clean adjust gap 12 H T Leads Inspect for cracks 13 Carburetor Drain Tune 14 Fuel filter Clean 15 Fuel hose Inspect for cracks 16 Rubber hose Air filter to carburetor Inspect for cracks 17 Accelerator cable Check adjust play 18 Clutch cable Adjust play 19 Engine oil sump strainer Clean 20 Engine oil Replace 21 Engine...

Page 89: ...ice Record Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer s Name Address 2ND FREE SERVICE Cost of oil oil filter element and other consumables used are chargeable t...

Page 90: ... leakage 10 Air filter element Clean 11 Spark plugs 2 Nos Check clean adjust gap 12 H T Leads Inspect for cracks 13 Carburetor Drain Tune 14 Fuel filter Clean 15 Fuel hose Inspect for cracks 16 Rubber hose Air filter to carburetor Inspect for cracks 17 Accelerator cable Check adjust play 18 Clutch cable Adjust play 19 Steering free play Check Adjust 20 Engine oil Check level top up 21 Hand levers ...

Page 91: ...vice Record Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer s Name Address 3RD FREE SERVICE Cost of oil oil filter element and other consumables used are chargeable ...

Page 92: ...ar and tread depth 11 Air filter element Clean 12 Spark plugs 2 Nos Check clean adjust gap 13 H T Leads Inspect for cracks 14 Carburetor Clean O H Tune 15 Fuel filter Clean 16 Fuel hose Inspect for cracks 17 Rubber hose Air filter to carburetor Inspect for cracks 18 Accelerator cable Check adjust play 19 Clutch cable Adjust play 20 Engine oil sump strainer Clean 21 Engine oil Replace 22 Engine oil...

Page 93: ...vice Record Received the above vehicle after the service having been done to my entire satisfaction Customer s Signature Date Contact Phone Mobile No Regn No Sale Date Serviced Date Serviced by Dealer s ASP Name Address Frame No Engine No Vehicle Installation Form No ODO Reading Sold by Dealer s Name Address 4TH FREE SERVICE Cost of oil oil filter element and other consumables used are chargeable ...

Page 94: ...rake Check Adjust 9 Front fork oil leak Check level replace oil 10 Air filter element Clean 11 Spark plugs 2 Nos Check clean adjust gap 12 H T Leads Inspect for cracks 13 Carburetor Drain Tune 14 Fuel filter Clean 15 Fuel hose Inspect for cracks 16 Rubber hose Air filter to carburetor Inspect for cracks 17 Accelerator cable Check adjust play 18 Clutch cable Adjust play 19 Engine oil strainer Clean...

Page 95: ...ALER ASP COPY 12 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 15 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 15 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature ...

Page 96: ...Kms Service Brief Work Done Dealer s Stamp Signature 12 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 15 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 15 000 250 Kms Service Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 97: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 21 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 21 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 98: ...Kms Service Brief Work Done Dealer s Stamp Signature 18 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 21 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 21 000 250 Kms Service Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 99: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 27 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 27 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 100: ...Kms Service Brief Work Done Dealer s Stamp Signature 24 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 27 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 27 000 250 Kms Service Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 101: ...vice Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature CUSTOMER COPY 33 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature DEALER ASP COPY 33 000 250 Kms Service Job Card No Date Odo Reading Dealer Code Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 102: ...Kms Service Brief Work Done Dealer s Stamp Signature 30 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 33 000 250 Kms Service Brief Work Done Dealer s Stamp Signature 33 000 250 Kms Service Brief Work Done Dealer s Stamp Signature PAID SERVICE MAINTENANCE RECORD ...

Page 103: ...101 LOG BOOK Sl No Date Kms Details Idling Co Authorised Dealer Service Point Job Card No Stamp Signature ...

Page 104: ...102 LOG BOOK Sl No Date Kms Details Idling Co Authorised Dealer Service Point Job Card No Stamp Signature ...

Page 105: ...103 LOG BOOK Sl No Date Kms Details Idling Co Authorised Dealer Service Point Job Card No Stamp Signature ...

Page 106: ...104 LOG BOOK Sl No Date Kms Details Idling Co Authorised Dealer Service Point Job Card No Stamp Signature ...

Page 107: ...105 LOG BOOK Sl No Date Kms Details Idling Co Authorised Dealer Service Point Job Card No Stamp Signature ...

Page 108: ...106 NOTES ...

Page 109: ...107 NOTES ...

Page 110: ...108 NOTES ...

Page 111: ...Telephone Residence Invoice No Delivery Note Advice No Have you visited Royal Enfield website Yes No Bike Regn No Telephone Office E Sales Representative or ...

Page 112: ......

Page 113: ...V T 2 3 mm Accelerator Operation T SY Smooth Lever Brackets Tightness LF Tight Switch Modules Tightness LF Tight Steering Movement T Free Handle Bar Positioning WF W r to Dot Punch Lock Nut T Stem LF 4 5 to 5 5 Kgm Electrical Switch Operation NW F No Defects Neutral Lamp NW F No Defects Fuel Tap Operation H NW Smooth Main Reserve Fuel Leak L No Leak Tank Tap Carburetor Fuel Tank Alignment M Straig...

Page 114: ...hifting TPS Setting N ST J H Smooth 56 Any Rattling Squeaking Noise N Nil Silencer Accessories Body Parts Suspension 57 Easy Start Hot Condition ST NW Smooth 58 Leak L No Leak Oil Fuel Hydraulic Acid Leakage 59 Smoke Oil Droplets in Silencer SK EO No Smoke 60 Cam Noise Top End Noise N Smooth ANY OTHER Note Any Abnormal Noise or Engine Open cases during PDI Inform to Plant Factory STATIC CHECK AFTE...

Page 115: ...al received 3 Recommended Lubricants explained 4 Maintenance Schedule sheet in Owner s Manual shown and explained 5 Next Free Service due explained 6 All Free Paid Services explained 7 Warranty Guidelines explained 8 Running in period details shown in the manual explained 9 Service Station Address given and Location explained 10 Service Incharge Name Mobile No given 11 Bike delivered in neat and c...

Page 116: ...for you KEEP RIDINGP 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 NO YES ...

Page 117: ...plies with the provisions of the Motor Vehicles Act 1988 and the rules made there under including the following mass emission norms Brand name of the vehicle Chassis number Engine number motor number in case of battery operated vehicles Sub rule No of rule 115 2 i 115 14 F Emission norms Bharat Stage III Bharat Stage I II III Bharat Trem Stage III etc Date Bullet 500 For ROYAL ENFIELD Quality Assu...

Page 118: ......

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