Bullet Classic 500 Owners Manual

1

We congratulate you on your choice of the legendary Bullet motorcycle and welcome you to the exciting worldof motorcycling on a Royal Enfield.This manual will help you to operate your Classic 500cc motorcycle, the right wayand guide you to maintain your motorcycle meticulously. We have also provided tips on safe riding and on minoradjustments for the care of your motorcycle. Please avail the four free services at the nearest Authorised Servicecentre, at the appropriate time to maintain your Bullet motorcycle in top riding condition.Log on to the exciting worldof Royal Enfield website: www.royalenfield.com to get to know more about the company, its products and excitingnews from time to time. We request you to carefully read the terms and conditions of warranty and other usefulinformation given in this manual before starting to use your Bullet Motorcycle.

Foreword

Service HeadquartersRoyal Enfield, A Unit of Eicher Motors Limited,Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019.Phone : 044 - 4223 0400, Fax : 044 - 4201 1719E-mail : [email protected] : www.royalenfield.com Part No. 591822 / b / Qty. 500 / April ‘11

2Notice

All information in this manual is based on the latest product information available at the time of publication.Due to continues improvements or other changes, there may be discrepancies between information in thismanual and your vehicle. Royal Enfield reserves the right to make production changes at any time without priornotice and without incurring any obligation to make same or similar changes to vehicles previously built or sold.

All images shown are for reference to explain and need not to be exactly the same on the model you own.Technical specification are subject to change without prior notice.

“© Copyright 2011 Royal Enfield. All Rights Reserved. No part of this manual shall be copied, distributed orotherwise dealt without the express permission in writing of Royal Enfield.

3

PERSONAL & VEHICLE INFORMATION... 6

FREE SERVICE RECORD........................ 7

TECHNICAL SPECIFICATIONS................ 8

Engine................................................ 8

Ignition System................................... 9

Transmission...................................... 9

Electricals........................................... 10

Chassis .............................................. 11

Dimensions......................................... 12

Weights.............................................. 12

SAFETY DEFINITIONS ............................ 13

SAFE DRIVING TIPS/GUIDELINES........... 14

SAFE & HAPPY RIDING........................... 18

RULES OF THE ROAD............................. 19

VEHICLE IDENTIFICATION...................... 21

Chassis Number.................................. 21

Engine Number................................... 21

KEY PARTS LOCATION........................... 22

Top View............................................ 22

Right Side View .................................. 23

Left Side View .................................... 24

OPERATION OF CONTROLS ................... 25

Ignition Switch .................................... 25

Steering Lock...................................... 25

Fuel tank cap ..................................... 26

Side Box ............................................ 26

Battery Carrier ................................... 27

Utility Box .......................................... 27

Head lamp switch ............................... 28

Head lamp Day flash .......................... 28

Dip Switch ......................................... 28

Engine Start Switch ............................ 29

Engine Stop Switch ............................ 29

Turn Signal Switch ............................. 29

Horn .................................................. 30

Manual Bi Starter (choke) ................... 30

PRE OPERATIONAL CHECKS ................. 31

RUNNING IN ........................................... 32

Contents

4Contents

ELECTRONIC FUEL INJECTION & MIL..... 33

EFI .................................................... 33

The Advantages of EFI ....................... 33

Malfunction Indicator Lamp (MIL) ......... 33

ROLL OVER SENSOR ............................. 34

STARTING ............................................. 35

GEAR SHIFTING ..................................... 38

PARKING ............................................... 39

Center Stand ...................................... 39

Side Stand ......................................... 39

TOOLS & FIRST AID KIT .......................... 40

RECOMMENDED LUBRICANTS ............... 41

PERIODICAL MAINTENANCE .................. 42

MINOR MAINTENANCE TIPS .................. 46

Control Cables, Hand lever, Pivots,Center / Side Stand Pivots .................. 46

Oil Level Inspection ............................ 46

Engine oil change ............................... 47

Spark Plug ......................................... 48

Brake fluid ......................................... 49

Inspection of tyres and wheels............. 49

Tyre pressure ..................................... 50

Front Wheel removal .......................... 50

Front Wheel reassembly ..................... 51

Rear wheel removal ........................... 52

Rear wheel reassembly....................... 53

Adjustments-Clutch............................. 54

Drive Chain free play .......................... 54

Rear Brake Pedal Height .................... 55

Rear Brake free play adjustment.......... 56

Chain lock fitment .............................. 56

Adjustment of gas shockabsorber ........ 57

Removal of Battery from the Vehicle.... 58

Battery Maintenance........................... 58

Reassembly of Battery on Vehicle ....... 59

CHANGING ELECTRICAL COMPONENTS.... 60

Head Lamp Bulb Replacement .......... 60

Reassembling the Head Lamp............. 61

5Contents

Tail Lamp bulb Replacement................ 62

Trafficator bulb Replacement .............. 62

Fuse .................................................. 63

Blade fuse usage list........................... 63

PILLION(REAR)SEAT REMOVAL & REFITTING 64

Pillion (Rear) seat removal .................. 64

Pillion (Rear) seat refitting................... 65

WASHING PROCEDURE ......................... 66

Precautions ....................................... 66

After washing ..................................... 66

STORAGE PRECAUTION ........................ 67

Preparing the motorcycle for re-use...... 68

LONG TRIP PRECAUTIONS .................... 69

COMPLETE WIRING DIAGRAM ............... 70

TROUBLE SHOOTING ............................ 71

Engine fails to start ............................ 71

Engine misfiring ................................. 72

Poor pickup ....................................... 72

White / Blue smoke ............................ 73

Engine overheating ............................ 73

Excessive fuel consumption ................ 73

Brakes Poor ........................................ 74

Vehicle wobbles ................................. 74

Electricals .......................................... 75

Electronic Fuel Injection (EFI) ............ 75

WARRANTY ............................................ 76

EMISSION WARRANTY ........................... 78

REGIONAL & AREA OFFICES ................. 82

ALL INDIA ROAD SIGNS ......................... 83

6Personal & Vehicle Information

Vehicle 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

7Free Service Record

It is our endeavour to provide excellent service to your Classic 500 at all times. Towards this we provide 4 free servicesat specific Intervals.

Please avail these services at the specified time, in any of the Royal Enfield Dealerships / Authorised service centresnearest to you and as a token of satisfactory services, kindly return the free service coupon duly filled in and signed, tothe service outlet.

Availing the free services in the specified time is a prerequisite for warranty consideration. The cost of fuel, oil, greaseetc. 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 ServiceKms CoveredServicing ASP /Dealer’s NameAddress

1st Service 4th Service2nd Service 3rd Service

8Technical Specification

ENGINE

Engine ........................................................ 4 Stroke, air cooled, single cylinder, OHV, SI & FI Engine

Capacity ..................................................... 499 cc (Displacement)

Bore ........................................................... 84 mm

Stroke ........................................................ 90 mm

Compression ratio ..................................... 8.5 : 1

Max. Power @ RPM .................................. 27.2 BHP @ 5250 rpm

Max. Torque @ RPM................................. 41.3 Nm @ 4000 rpm

Air Filter Element ....................................... Corrugated Paper Element

Engine Oil Capacity ................................... 2.75 Litres.

Lubrication ................................................. Forced Lubrication, Wet Sump

Engine Oil Grade ....................................... MOTUL 3000 4T Plus 15W50 API SL JASO MA

Cooling system .......................................... Natural Air Flow

Fuel Supply ............................................... Electronic Fuel Injection Programmed (PGM-EFI)

9

IGNITION SYSTEM

Ignition system .......................................... Electronic Ignition (ECU / Variable)

Spark plug Electrode gap ........................ 0.7 to 0.8 mm

Spark plug ................................................. WQR8DC (Bosch Super) M14 & UR6DC (Bosch Super) M10

TRANSMISSION

Clutch ........................................................ Wet Multiplate (7 Plates)

Primary drive ............................................. Duplex Chain

Primary Drive Ratio .................................. 2.15 : 1

Gear box .................................................... Constant Mesh 5 Speed

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. Sproket) .............. 18 Teeth

Final ratio ................................................. 2. 11 : 1

Drive Chain links ...................................... 102 links

Technical Specification

10

ELECTRICALS

Generation ................................................ Alternator

System ....................................................... 12V DC

Battery ....................................................... 12V - 14 AH MF

Head lamp ................................................. 12V, 60/55 W, Halogen

Brake / Tail lamp ...................................... 12V, 21/5 W

Turn signal ................................................ 12V, 10W - 4 nos.

Pilot lamp .................................................. 12V, 2 W - 2 nos. & 12V, 4 W - 1 no.

Speedometer lamp ................................... 12V, 3.4 W - 1 no.

Turn signal / High beam indicator ........... 12V, 2 W - 2 nos.

Neutral Indicator ....................................... 12V, 2 W - 1 no.

Horn (Dual) ............................................... 12V, 2.5 Amp (Max.) X2

Starter Motor ............................................. 12V, 0.9 KW


11

CHASSIS

Frame ........................................................ Tubular Frame

Tyre size .................................................... Front: 90 / 90 - 19” - 52 P Rear: 120 / 80 - 18” - 62 P

Tyre pressure ............................................ Front- Solo: 1.41 Kg/cm2 (20 PSI) Pillion: 1.55 Kg/cm2 (22 PSI)

............................................................ Rear- Solo: 2.11 Kg/cm2 (30 PSI) Pillion: 2.25 Kg/cm2 (32 PSI)

Fuel tank capacity .................................... 13.5 Litres (MIN)

Low fuel warning ....................................... 2.5 Litres

Dead stock of petrol (unusable fuel) ....... 0.75 Litres

Suspension ............................................... Front: Telescopic (Dia 35mm), Hydraulic Damping Stroke 130mm

............................................................ Rear: Swing arm with gas filled shock absorbers Stroke 80 mm

Front fork oil capacity ............................... 195 ml per leg

Fron 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


12

DIMENSIONS

Length ........................................................ 2170 mm

Width ......................................................... 800 mm

Height ........................................................ 1070 mm

Wheel base ............................................... 1370 mm

Saddle height ............................................ 800 mm

Ground clearance ..................................... 135 mm

WEIGHTSKerb Weight (with 90% Fuel) .................. 190 Kg

Max pay load ............................................ 178 Kg

NOTE :

1. Values 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.


13

The information given under the titles : Warning, Caution and Note are for your safety and for the care and safety toyour motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others anddamages to the motorcycle.

Warning

Indicates a potentially hazardous situation. Disregarding this message may result in injury to rider or other persons.

CAUTION :

This message if disregarded may result in damage to the vehicle.

NOTE :

Indicates important and useful messages for clear understanding.

Safety Definitions

14Safe Riding Tips / Guidelines

Before operating your new motorcycle, it is yourresponsibility to carefully read and follow theoperating and maintenance instructions detailedin this manual for your own safety, yourmotorcycle and that of others.

Know and respect the rules of the road. Be asafe rider for your own safety and for other roadusers.

Before starting the motorcycle, check for properoperation of brakes, clutch, gear shifter, handlebar controls, tyre pressures, fuel and oil levels.

Use only genuine Royal Enfield spare parts andapproved accessories. Use of other manu-facturer’s performance parts may affect theperformance of your motorcycle and render themotorcycle void of warranty. See your RoyalEnfield dealer for details.

Whenever refuelling your motorcycle, pleaseexercise utmost caution and carefully observethe following rules :

DO NOT smoke and please ensure thatthere are no open flames or sparks near themotorcycle, when refuelling OR servicingthe fuel system.Switch OFF mobile phones and other handheld electronic devices.Open the fuel filler cap slowly.Refuel in a well ventilated area with theengine turned off.DO NOT fill the tank to its brim. Please fillfuel only till the bottom of the filler neckinsert, so as to leave air space in the fueltank to allow for fuel expansion.

Warning

Royal Enfield cautions you against the use of certainnonstandard parts such as aftermarket and custommade extended front forks or suspensions, which mayadversely affect performance and handling. Removingor altering original parts may adversely affectperformance and could result in an accident.


A new motorcycle must be operated accordingto the special running-in-procedure. Seerunning-in-procedure mentioned in Page No. 32.

Operate motorcycle only at moderate speedsand out of traff ic unti l you have becomethoroughly familiar with its operation andhandling characteristics under all conditions.

DO NOT exceed the legal speed limit or drivetoo fast for existing conditions. Always reducespeed when poor driving conditions exist. Highspeed increases the influence of any othercondition affecting stability and increases thepossibility of loss of control.

NOTE :

If you are an inexperienced rider we recommend thatyou obtain formal training on correct motorcycle ridingtechniques and become thoroughly familiar with theoperation of your particular motorcycle. New ridersshould gain experience under various conditions whiledriving at moderate speeds.

Pay strict attention to road surfaces and windconditions. Any two wheeled vehicle may be subjectto the following upsetting forces :

Wind blasts from passing trucks.

Rough uneven road surfaces.

Slippery road surfaces.

These forces may affect the handl ingcharacteristics of your motorcycle. If this happens,reduce speed and guide the motorcycle with arelaxed grip to a controlled condition. Do not brakeabruptly or force the handlebar.

Operate your motorcycle defensively.Remember, a motorcycle does not afford thesame protect ion as an automobile in anaccident. One of the most common accidentsituations occurs when the driver of the othervehicle fails to see or recognize a motorcycleand turns into the oncoming motorcyclist.


Wear an approved helmet, clothing, and footgear suited for riding a motorcycle. Bright ORlight colors are best for greater visibility intraffic, especially at night. Avoid loose, flowinggarments and scarves.

When carrying a pi l l ion r ider, i t is yourresponsibility to instruct them on proper ridingprocedures.

DO NOT allow other individuals, under anycircumstances, to operate your motorcycleunless you know they are experienced, licensedriders and are thoroughly familiar with theoperating conditions of your motorcycle.

Warning

Regularly inspect shock absorbers and front forksand look for leaks. Replace worn parts. Worn partscan adversely affect stability and handling.

Warning

For your personal welfare, all the listed service andmaintenance recommendations should beperformed. Lack of regular maintenance at thesuggested intervals may affect the safe operationof your motorcycle.

Warning

Avoid any contact with the exhaust system. Wearclothing that will completely cover the legs whileriding. The exhaust system gets very hot when theengine is running and remains too hot, even afterthe engine is turned off. Failure to wear proper orprotective clothing could result in serious injury.

Warning

Exhaust gases contains poisonous carbonmonoxide and chemicals, known to cause Cancer,Birth Defects or other reproductive defects.


Warning

Motorcycle batter ies contain lead and leadcomponents, acids and chemicals known to causecancer, birth defects or other reproductive harm.Exercise extreme caution while handling a battery.Wash hands thoroughly whenever a battery ishandled.

Warning

Consult your Royal Enfield Dealer regarding anyquestions or problems that occur in the operationof your motorcycle. Failure to do so may aggravatean initial problem, cause costly repairs & jeopardizeyour personal safety.

Warning

DO NOT tow a disabled motorcycle. The steeringand handling of the disabled motorcycle will beimpaired due to the force of the towline. If adisabled motorcycle must be transported, use atruck or a trailer. Towing a motorcycle may causeloss of control of the motorcycle in the front, leadingto an accident.

Warning

DO NOT pull a trailer behind a motorcycle. Towinga trailer may cause reduced braking efficiency, tyreoverloading and unstable handling. Towing a trailermay cause loss of control of the motorcycle in thefront, leading to an accident.

18Safe & Happy Riding

RIDING DRESS

Please wear a proper riding apparel.A pair of riding boots or shoes.Soft leather gloves.Goggles or spectacles to safe guard eyes.A certified helmet. Affix light reflecting strips ofstickers at the front and rear.

NOTE :A light coloured shirt enables greater visibility to otherroad users especially during nights.

CAUTION :Loose clothing may get caught on moving parts of yourmotorcycle.

SITTING POSTURECorrect sitting posture is a pre-requisite for stableand safe riding

Sit Straight with your shoulders completely relaxed.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 viewmirrors, without turning the head.

BRAKINGApply front and rear brakes gent ly andsimultaneously for maximum braking efficiency.

WARNING

Applying any one of the brakes suddenly may causethe vehicle to skid. The hydraulic disc brake fitted onyour motorcycle requires very less effort. High effortor sudden application may lock the wheel. Please useutmost caution while applying the brakes.

While riding on wet or bad road conditions usebrakes cautiously.

Avoid excessive banking, otherwise footrestmay touch the ground and cause instability.

19Rules of the Road

Be sure your number plate is installed in theposition specified by law and is clearly visibleat all times.

Ride at a safe speed that is consistent with thetype of road surface you are on. Pay strictattention to whether the surface is :

Dry

Oily

Icy

Wet

Watch for loose debris, such as leaves, slipperysubstances or loose gravel that can hamper thestability of your vehicle.

DO NOT exceed the legal speed limit or drivetoo fast for existing conditions. Always reducespeed when poor driving conditions exist. Highspeed increases the influence of any othercondition affecting stability and increases thepossibility of loss of control.

Keep to the correct side of the road centre linewhen meeting oncoming vehicle.

Always sound your horn, actuate your turnsignals, and exercise caution when passingother vehicles going in the same direction.Never try to pass another vehicle going in thesame direction at street intersections, oncurves, or when going up/or down a hill.

At street intersection give the right-of-way tothe vehicle on your left or right. DO NOTpresume you have the right-of-way.

Always signal when preparing to stop, turn orpass.

While turning either right or left, watch forpedestrians, animals, as well as vehicles.

All traffic signs, including manual controls atintersections, should be obeyed promptly.SLOW DOWN at traffic signs near schools andCAUTION signs at railroad crossings.

20

When intending to turn, signal at least 100 feet(30.5 meters) before reaching the turning. Beclose to the center line (unless local rules requireotherwise), slow down and then turn carefully.

Never jump a traffic light. When achange is imminent from GO toSTOP (or vice versa) atintersections, slow down and waitfor the light to change to green.Never run through a yellow or redtraffic light.

DO NOT leave the curb or parking area withoutsignaling. Be sure your way is clear to entermoving traffic. A moving line of traffic alwayshas the right-of-way.

Park your motorcycle on a firm and flat surfaceto prevent it from falling over.

Protect your motorcycle against theft. Afterparking your motorcycle, remove Ignition keyfrom switch and lock the steering head.

Rules of the Road

NOTE :

To help you establish the relative distance of vehiclesbehind your motorcycle, adjust each mirror in such away, that a small portion of your shoulder is visible anda large portion behind your motorcycle is seen clearly.

SIDE VIEW MIRRORS

Your motorcycle is equipped with convex mirrorsand have a curved surface. This type of mirror isdesigned to give a much wider view to the rear thana flat mirror; however, cars and other objects seenin this type of mirror will look smaller and fartheraway than when seen in a flat mirror.

Use care when judging the size or distance ofobjects seen in these mirrors.

Red

Yellow

Green

21Vehicle Identification

CHASSIS NUMBER

Punched on the streering head tube

ENGINE NUMBER

Punched on top of the engine LH side.

22Key Parts Location

1. Turn signal switch2. Horn button3. Clutch lever4. Day flash switch5. Head lamp dip switch

TOP VIEW

6. Manual Bistarter / Choke7. Ignition switch8. Speedometer9. Malfunction / Low fuel Indicator10. Engine Kill switch

11. Pilot head light switch12. E-Start Switch13. Fuel tank cap

12

3 4 5 6 7 8 9 10

1112

13

23Key Parts Location1. RH Trafficator front

2. Brake Pedal

3. Starter Motor

4. Utility Box

5. Air Filter Box

6. RH Trafficator Rear

1

45

6

RIGHT SIDE VIEW

23

24Key Parts Location

LEFT SIDE VIEW

8

1

2 3 4 56

7

1. Trafficator front LH

2. Horn

3. Spark plug

4. Gear Change Pedal

5. Battery Cover

6. Side Stand

7. Centre stand

8. Trafficator rear LH

25Operation of Controls

IGNITION SWITCH

OFF

ON

STEERING LOCK

CAUTION :

Protect your motorcycle against theft. After parking your motorcycle,remove the ignition key from switch and lock the steering head.

DO NOT lubricate barrel locks with petroleum based lubricants orgraphite. Inoperative locks may result in damage to your vehicle.

Turn key clockwise to lock.

Lock the steering whenleaving bike parked.


FUEL TANK CAP SIDE BOX

Turn key clockwise to open.Press cap to lock with key inposition.

NOTE :Key can be removed only inlocked position.

Use high quality unleadedhigh octane petrol (91octane and above) forenhanced performance.

SIDE BOX LH AIR FILTER BOX RH

Turn Key anti-clockwise to open Turn Key anti-clockwise to open

NOTE :

Key is common for ignition, petrol tank cap, steering lock, sideboxes and battery cover.

Key for fuel tank and tool boxes can be removed from the lockonly in locked


BATTERY CARRIER UTILITY BOX

Battery Box Cover

Turn Key clockwise & lift the battery box covergently

To remove cover turn key anti clock-wise and pullthe oval cover by applying finger pressure

28

DIP SWITCHHEAD LAMP DAY FLASH

PRESS FOR HEAD LIGHT FLASH LOW BEAM HIGH BEAM

Operation of ControlsHEAD LAMP SWITCH

ON PILOT LIGHT ON OFF


ENGINE STOP SWITCH

ENGINE ON ENGINE OFF

TURN SIGNAL SWITCH

LEFT RIGHTOFF (PUSH TO OFF)

ENGINE START SWITCH

PRESS

30

MANUAL BI STARTER (CHOKE)

Operation of Controls

HORN

31Pre Operational Checks

A careful check of the following must be carried out every time before riding and specially after long periods ofstorage to determine if additional maintenance is necessary.

1. Tyres for correct pressure, abrasions or cuts.

2. Rear chain for proper tension.

3. Brakes, steering and throttle for responsiveness.

4. Cable for fraying or crimping and free operation.

5. Engine oil level.

6. Wheel spoke for proper tightness, no breakage,

7. Headlamp, tail lamp, brake lamp and indicator lamps for proper operation.

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.

32Running In

Proper running-in is very important for obtainingmaximum life and performance of a new motorcycle.The following guidelines explain proper running-inprocedures.

Since the engine is brand new, it should not be loadedexcessively for the first 2,000 kms. During the first fewhundred kms, the various parts in the engine wear andpolish themselves to the correct operating clearances.Driving with prolonged full throttle operation, or any highspeed conditions might result in excessive heating ofthe engine and cause abnormal wear of the moving partsand hence must be avoided.

1. 0 - 500 Kms :

The recommended speeds for the first 500 Kms isbelow 50 Kmph. During this period avoid operatingthe motorcycle with full throttle opening. Stop themotorcycle for about 5 to 10 minutes to let it cooldown, after every hour of running. Vary the speed ofthe motorcycle regularly during running but avoidusing the motorcycle above ½ throttle openingposition.

2. 501 - 2000 Kms.

The recommended speed is below 80 Kmph. Avoid

driving the motorcycle with full throttle opening. Varythe speed of the motorcycle regularly but avoid usingthe motorcycle above 3/4 throttle opening position.

3. 2,001 kms and above

Avoid prolonged full-throttle operation. Vary speedoccasionally.

CAUTION :

After covering the first 500 kms. please replace theengine oil and oil filter element.

Royal Enfield engines are air-cooled and consequentlyrequire forced air cooling over the cylinders and headsto maintain proper operating temperature. Extendedperiods of idling may over heat the engine, resultingin serious engine damage.

DO NOT run the engine at extremely high RPM withclutch disengaged or transmission in neutral as it cancause serious engine damage.

An engine running long distances at high speed mustbe given close attention to avoid over heating andpossible engine damage.

33Electronic Fuel Injection & MIL

ELECTRONIC FUEL INJECTION (EFI)

An electronic control unit (ECU) monitors engineperformance and provides exact requirement of Air/ Fuel mixture to the engine, through the fuel injectorby taking inputs from various sensors provided inthe motorcycle.

THE ADVANTAGES OF EFI ARE

Faster response of the engine to suit road/loadconditions.

Better power output

Lower emission

Better reliability

Excellent cold startability

Engine Diagnostic capabilities

Maintenance free

MALFUNCTION INDICATOR LAMP (MIL)

A Malfunctioning IndicatorLamp (MIL) is provided inthe small meter located onthe right side of the headlamp casing.

There are two indicationsin this unit.

Low fuel indication & EFI Mal-function Indicator Lamp(MIL). When both the Ignition & Engine kill switch is“ON”, the MIL will glow for few seconds and will go“OFF”. This indicates that all the functions ofElectronic Control Unit (ECU) and other sensors areworking perfectly and the motorcycle can be used.

Incase of any malfunctioning of the ECU or othersensors etc., the MIL will glow continuously. In theevent of any such phenomenon, it is recommendedto take the vehicle to a nearest Royal Enfieldauthorized service station for inspection and furthernecessary action.

34Rollover Sensor

ROLLOVER SENSOR Your motorcycle is fitted with a unique “Roll OverSensor” under rider seat. This is a safety feature.

In the event of an accident OR if the motorcyclefalls over on its side with the engine running.

The “Roll Over Sensor” will switch off Ignition andcut off fuel supply to prevent the motorcycle frommoving suddenly, if it is in gear.

To re-activate the system after the motorcycle hasbeen made upright, please switch off both theIgnition & Engine kill switch, wait for a few secondsand switch “ON” again.

This will help to RESET the “Roll Over Sensor” andthe engine can be started / run.

35Starting

Warning

Before starting engine, always shift gears into neutral.

CAUTION :Do not force the gear lever while attempting to shift toneutral. Move the motorcycle back & forth andsimultaneously press gear lever to come to neutral.Ensure neutral indicator light comes “ON”’ in theSpeedometer.

NOTE :If the engine does not start on the first attempt incold climate, release the starter button, wait for 30seconds before pressing the starter button again.

Press starter button and release starter switch oncethe engine starts.

A clutch switch is provided in the system for thesafety of the rider. This is to prevent the vehicle fromstarting when the vehicle is in gear. To start theengine when it is in gear, pull clutch lever, pressstarter button and release as soon as the engine starts.

Turn igni t ionswitch ‘ON’

Ensure the sideand main standsare in releasedposition

Ensure that gearsare in neutral andneutral lamp isglowing

N

36

Ensure Enginestop switch is in“RUN” position

Starting

Press ClutchLever.

Press StarterButton andrelease assoon as enginestarts

CAUTION :

Never accelerate the engine immediately after a coldstart. The engine should be allowed to run slowly for15-30 seconds. This will allow the engine to warm upand let oil reach all surfaces needing lubrication.Failure to adhere may result in damage to the Engine.

Manual bi(choke) Starter

NOTE:It may be necessary to operate and hold the manualbi starter, when starting the engine for the first time incold mornings, temperatures below 100C or at highaltitudes, to prevent the stalling and to keep the idlingRPM steady.

37Starting

As soon as the engine attains the operatingtemperature, the RPM will raise, at which time themanual Bi Starter should be released.

Warm up engine for 2 minutes - till idling isconsistent.

Prior to starting, check to see if the low fuel indicatoris glowing continuously.

CAUTION :

Please ensure the motorcycle is not used with the lowfuel indicator lamp “ON” continuously. It may not onlyresult in the motorcycle running out of fuel. But will alsocause serious damage to the fuel pump. Please ensurefuel is filled up as soon as the low fuel lamp comes“ON”.

This will glow continuously, if the fuel level in tankis below 2.5 litres.

38Gear Shifting

CAUTION :The clutch must be fully disengaged before attemptinga gear shift. Failure to fully disengage the clutch maycause a jerky start and / OR stalling the enginebesides causing damage to transmission parts.

Warm up enginefor 2 minutes -t i l l id l ing isconsistent/stable

GEAR SHIFT PATTERN1 N 2 3 4 5

Press clutch lever towards the hand grip.Press gear pedal with toe to engage 1st gear.Gently open thrott le and release clutchsimultaneously. If clutch is released suddenly,the engine may stall and cause a jerky start.

NOTE :

Always start motorcycle with gear in neutral position.

Always move the motorcycle in first gear position only.

When engine speed decreases, while climbing agradient or running at a reduced speed, shift to theappropriate lower gear to prevent the engine fromstalling or straining to pull.

Press the gearpedal with heel toengage 2nd andhigher gear.

Follow the sameprocedure for3rd, 4th and 5thgear.

39Parking

PARKING VEHICLE ON CENTRE STAND

Select a firm, flat surfaceHold handle bar straightLower center stand, and ensure that both thelegs of the stand are resting evenly on firm ground.Apply pressure on the fulcrum lever on thecenter stand and pull vehicle backwards, gently.

PARKING VEHICLE ON SIDE STAND

Select a firm, flat surface

Lower Side Stand and gently tilt motorcycle tothe left till it rests firmly.

Warning

Always park the motor cycle on a firm and flat surface. Parking in a soft ground may cause stand to sink and themotorcycle to fall, causing injury to you or to others and damage to the motorcycle parts.

40Tools & First Aid Kit

S.No. Description Qty.

1. Tool bag 1 2. Box spanner 21x24 1 3. Screwdriver 1 4. Double end spanner 1/4 x 5/16 1 5. Double end spanner 10x12 2 6. Tool- Spark plug 1 7. Tomy bar 1 8. Tubular spanner 12x13 1 9. Single end ring spanner - 17 110. Extension tube 1

1 2 3 4 5 6 7 8 109

1

4

5 6 7

3

NOTE :This Tool Kit is kept in Utility box. Refer Page No. 27

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

2

41Recommended Lubricants

Engine oil MOTUL 3000 4T Plus 15W50 API SL JASO MA (Royal Enfield Engine Oil)

Capacity 2.75 Litres

Front Fork 1F Grade Endurance (or Royal Enfield )Fork Oil

Capacity 195 ml / leg.

Brake Fluid DOT 3 or DOT 4

Capacity 60 ml.

Warning

DO NOT switch oil brands indiscriminately because some oil interact chemically when mixed. Use of inferior oils or non-detergent oils can damage the engine.

42Periodical Maintenance

The maintenance schedule detailed here will help you to maintain your Royal Enfield motorcycle meticulouslyand to get a long trouble free service. The schedule provided herein is based upon average riding conditions andindicates the mileage at which regular inspections, adjustments, replacements and lubrications must be carriedout.

The frequency of the maintenance must be shortened depending upon the severity of the driving condition OR ifthe motorcycle is used in a very dusty environment, severe climatic cold and hot conditions, bad roads, stagnantwater etc., Contact a nearest Royal Enfield 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 ofregular maintenance at the suggested intervals may affect the safe operation of your motorcycle causing the motorcycleto malfunction and stall abruptly resulting in an accident and cause serious injury.


DESCRIPTION FREE SERVICEwhichever is earlier PAID SERVICE

S.No.

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

1 Engine Oil R I R I R I R I R I R

Check level every 1000 Kms or earlier as required

2 Engine oil filter paper element R R R R R R

3 Engine suction filter & secondary drain magnetic plug

4 Spark plugs (2 nos.) C,A C,A C,A C,A C,A R C,A C,A C,A C,A R

5 HT leads for crack I I I I I I I I I I I

6 Fuel hose & clip / Injector ‘O’ Ring / Seal Ring I I I I R I I I R I I

7 Fuel Pump (under tank) Check for screw tightness in all services

8 Accelerator & Throttle pully cable free play A A A A A A A A A A A

9 Rubber hose, Air filter to Throttle body I I I I R I I I R I I

10 Rubber hose, Inlet manifold / Adaptor I I I I R I I I R I I

44


S.No.

Periodical Maintenance

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

11 Air filter element C C C C R C C C R C C

12 Inlet / Exhaust valve seating I I

13 Cylinder head (Combustion chamber) D

14 Clutch lever free play Adjust every 1000 Kms or earlier as required

15 PAV pipes & hose clip I I I I I I I I I I I

16 Rear brake pedal pivot L L L L L L L L L L L

17 Battery terminals (apply petroleum jelly) C C C C C C C C C C C

18 Battery Electrolyte level I I I I I I I I I I I

19 Earth wire eyelet (behind battery carrier) I I

20 Rear Wheel Drive ChainAdjust for every 1000 Kms / Clean, Lubricate & adjust

every 3000 kms or earlier as required



S.No.

NOTE :For maintenance after 30,000 Kms, please repeat the same frequency levels specified above, in consultationwith a Royal Enfield authorised Dealer/Service Station

A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace

Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30

Months 1.5 3 6 9

21 Front Fork oil I R I R I

22 Rear brake pedal free play Adjust every 1000 Kms or earlier as required

23 Rear brake cam L L L L L

24 Steering ball races / play adjustment L L

25 Spokes tightness & Wheel rim run out I I I I I I

26 Swing Arm pivot bush & spacer L L L R L

27 Tyre wear (Front & Rear) I I I I I I I I I I

28 Hand levers & kick starter lever pivot Lubricate every 1000 Kms or earlier as

46Minor Maintenance Tips

The following minor maintenance can be carriedout easily with simple tools. However, In case, if itis felt that the adjustments are best done by anexpert, we recommend that the motorcycle be takento a nearest Authorized Royal Enfield Dealer/Service Station.

CONTROL CABLES, HANDLE BAR LEVER, PIVOTS,CENTRE / 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.

OIL LEVEL INSPECTION

Place motorcycle on its centre stand on a firmsurface.

Warm up engine for a few minutes & switch off

The level is correct if the oil level is in themiddle of the oil level window.

Top up with recommended oil if required.

MAX

MIN

Lever PivotMain & SideStand Pivot


ENGINE - OIL CHANGE

SecondaryDrain Plug

PrimaryDrain Cap

Remove the oil filter element on the CrankcaseCover RH.Allow the oil to drain by tilting the motorcycleto both sides.Wash the drain plug and the suction filterthoroughly and refit on the crankcase after allthe oil is drained out.Soak a new oil filter element in the oil and refiton the Crankcase Cover RH.

(Refer Periodical Maintenance Chart for frequency)

Place motorcycle on its centre stand on a firmflat surface.

Start engine and warmup for 2 minutes.

Keep a clean tray below the engine

Remove primary drain cap, to drain oil & cleansuction filter, magnet.

Then remove secondary drain plug to drain oil& clean the magnet.

TILT VEHICLERH & LH


NOTE :

Replace oil filter element whenever oil is beingreplaced.

CAUTION :

Filling up oil over MAX mark may cause smoke and /or loss of power. Do NOT allow oil level to fall belowMIN mark. Doing so may result in engine internaldamage or malfuncton.

Max

Min

Fill recommendedoil to engine tillthe oil level isupto “MAX” levelmark in the oilwindow in Crank-case Cover RH.

SPARK PLUG

Cleaning and adjusting gap (Refer PeriodicalMaintenance Chart for frequency)

Remove HT Lead and the spark plug from thecylinder head using the plug spanner andtommy bar.

Clean the insulator tip and electrodes of theplug carefully using a pointed scraper or sparkplug cleaner.

Set the gap between 0.7 to 0.8 mm.

Refit the spark plug on the cylinder head andconnect H.T. Lead.

49

CAUTION :

Please take care that it does not spill over any otherparts of the motorcycle. Please wipe the spilledbrake fluid immediately, if there is any spill over,using a soft cloth (preferably a wet cloth) to avoiddamage to paint work or other parts.

Minor Maintenance Tips

Check if oil is above ‘min’ level. To top up, removecover and diaphragm and top up with either DOT 3or DOT 4 as specified.

BRAKE FLUID INSPECTION OF TYRES AND WHEELS

Inspect the tyre periodically for tread wear,cracks and cuts.

Minimum tread depth :

Front tyre : 1mm Rear tyre : 2 mm

Check and remove stone, splinters, nails orother particles embedded in the tyre treads.

Bald spots / swelling may be caused by internaldamage. Replace the tyres, if defective.

Replace tyres when the tread depth hasreached the minimum as specified.

Periodical ly inspect wheels for spokesbreakage and wheel rim run out.

Check proper seating of the tyre beading onthe rim whenever the tyre is reassembled.

Whenever a new tyre is installed, ensure rimand spokes do not get damaged on account ofusing wrong levers.

MIN

MAXMinimum tread depth :


FRONT WHEEL REMOVAL

Place the vehicle on center stand

Place a wooden block the front end of engineto support the vehicle.Disconnect speedo cable.Loosen the pinch bolt on the RH fork guide.Remove the axle nut along with washer.Tap and remove the front wheel spindle

Tilt the vehicle to RH Side and take out thewheel along with speedo drive and RH sidespacer.

Use only standard tyres & tubes inflated tocorrect pressure.

TYRE PRESSURE

Front Rear

Solo 1.41 kg/cm2 2.11 kg/cm2(20 PSI) (30 PSI)

With Pillion 1.55 kg/cm2 2.25 kg/cm2(22 PSI) (32 PSI)

Warning

Tyres, rims and air valves must be correctly matchedto wheel r ims. See your Royal Enfield Dealer.Mismatching tyre, tubes, rims and air valves mayresult in damage to the tyre bead during mounting,allow tyre slippage on the rim and cause tyre failure.

Frontt Rear


Take out Speedo drive and bush on the RHside.

CAUTION :

Do not press the front brake lever when wheel isremoved as this will result in the brake pads comingtoo far out of the brake caliper.

Place a 4 mm thick wooden piece or cardboardsheet between the brake pads to avoid padsactivation in the event the front brake lever isaccidently pressed.

FRONT WHEEL REASSEMBLY

Remove the wooden piece / card board sheetplaced between the brake pads

Place the speedo drive bush in position andplace speedo drive over it.

Insert the wheel along with speedo drive andRH spacer between the front fork endsensuring the brake disc is located between thebrake pads.

Insert and tap the front wheel axle gently inside.

Refit the washer and tighten the nut firmly.

52

Tilt vehicle to RH side and slide out rear wheel.

NOTE :

Ensure that the speedo drive is correctly located suchthat the cable can be connected without difficulty.

Tighten the pinch bolt on the RH fork guide.

Rotate the wheel and check for smoothrotation.

Connect the speedo cable to speedo drive andcheck for proper working of speedo meter.

Press brake lever 2 or 3 times to check frontbrake efficiency

REAR WHEEL REMOVAL


Remove split pin and castle nut on the RH side.

Place the vehicle oncenter stand on afirm and flat surface.

Remove wheelspindle from LH sidealong with chainadjuster, takingcare not to drop thewheel col lar andspacer from the LHside of the wheel.

Note and mark theposition of the chainadjuster butting withthe stopper on theright side.

53

REAR WHEEL REASSEMBLY

Position the rear wheel with cush rubber on therear chain sprocket.

Hold wheel collar and spacer in position.

Assemble the wheel spindle along with chainadjuster from the LH side of vehicle and gentlytap it through the wheel

. Ensure that the chain adjuster notch butts withthe stopper as appropriate when both the front& rear wheels are aligned.


CAUTION :Do not force the spindle into the wheel as the threadsmay get damaged. Tap it through the wheel gently.

WarningEnsure the vehicle does not come off centre stand whileassembling / disassembling the wheel assembly. Failureto adhere could result in damage or serious injury.

Ensure the fourcush rubbers arein position insidethe rear wheelhub.

Tilt vehicle toright and insertwheel assemblybetween theswing arms.

Tighten the castle nut firmly and ensure thatthe hole on axle shaft and the slot on castlenut are aligned to enable split pin fitment.

Fit the splitpin.

54

DRIVE CHAIN FREE PLAY (PLAY 25 - 30 MM)

Remove rear wheel split pin.

Loosen castle nut, spindle nut, anchor nut andbrake rod nut.

Turn the RH adjuster cam as appropriately, till25 to 30 mm slackness is achieved on the toprun of the chain.

Check that the front and rear wheels arecorrectly aligned.

ADJUSTMENTS - CLUTCH

Clutch Lever (free play 2 to 3 mm)


Clutch Free Play Adjustment

Loosen the cable outer lock nut (A).

Turn the Nut (B) Clockwise to reduce the playor Anticlockwise to increase the free play.

Check free play 2 to 3 mm at Clutch lever pivoton handle bar end.

Tighten lock nut ( A) after adjustment is done.

BA2 to 3 mm

55

Turn the LH adjuster cam appropriately, to alignboth the wheels.

Check and ensure that the notches on the camare resting on the pin in the swing arm on bothsides.

Apply brake and tighten all nuts.

Finaly Torque the anchor Nut.

Check brake pedal free play, If nessasary.adjust.


REAR BRAKE PEDAL HEIGHT

Loosen the lock nut.

Turn in or out the pdeal stop pin bolt till thebrake pedal and front footrest are in the sameheight / level as shown in above fig.

Tighten the lock nut

Check for free rotation of rear wheel.

56

CHAIN LOCK FITMENT


REAR BRAKE FREE PLAY ADJUSTMENT

WarningPlease ensure brakes are adjusted to their maximumefficiency. Inefficient brakes can cause an accident.Please ensure adequate caution while applying brakes. Suddenapplication OR pressing the levers fully can caused the wheelsto lock. This may cause the motorcycle to skid with possibleloss of control and result in an accident causing. Brake shoesmust be inspected for wear every 4000 Kms. If you ride underadverse conditions, (steep hills, heavy traffic, etc.) a morefrequent 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 rearwheel rotates freely.

20 - 30 mm

The open end of the chain lock to face opposite tonormal direction of chain rotation

Warning

The fitment in wrong direction can lead to falling offof chain link thus disengaging the drive. This willlead to potentially hazardous situation which, if notavoided, could result in serious injury.


ADJUSTMENT OF GAS SHOCKABSORBER

The rear gas shock absorber is of adjustable typei.e., the spring tension can be increased orreduced.

Increase the spring tension for high load operation.

Reduce the spring tension for low load operation.

The adjuster provided on the bottom of thespring has five notches.

Insert 4 mm tommy bar into the eyelet providedon the adjuster.

Turn the adjuster such that the adjuster movesup to increase the spring tension and vice versato reduce the spring tension.

Adjust both left hand and right hand shockabsorbers so that the same notch rests on thepin in both sides.

Warning

Riding the motorcycle with the notches adjusted indifferent positions can cause loss of control and maylead to an accident.

Regularly inspect shock absorbers and front forks forleaks. Replace worn parts. Worn parts can adverselyaffect stability and handling.

NOTE :Ensure no fouling of any accessories with rear shockabsorber. Check for sufficient gap availability betweenthe shock absorber and the attachments when the rearend of the motorcycle is fully loaded and the shockabsorbers are fully compressed.

58

BATTERY MAINTENANCE

The vehicle is provided with 12V - 14 AHbattery.The battery must be periodically checked for

Cleanliness and corrosion free terminals.Electrolyte level.If electrolyte level is low, top up withdistilled water only.

NOTE :Incase of poor contact or loose fitment of Batteryterminals may cause the failure of ECU.


REMOVAL OF BATTERY FROM THE VEHICLE

Unlock (turn the key clockwise) and remove thebattery cover.

Remove the battery holding two rubber strapsgently.

Pull out the battery and turn, then disconnectboth the terminal wires (negative and positiverespectively)

Take out the battery.


REASSEMBLY OF BATTERY ON VEHICLE

Position the battery in the battery carrier suchthat the negative terminal of the battery istowards fuel tap.Ensure ignitiion switch is in ‘OFF’ condition.Connect the positive terminal (Red wire) first.Connect the negative terminal (Black wire) last.Smear the terminals with petroleum jelly. (Donot use grease).Refit the rubber strap bracket to hold thebattery.Refit LH side panel.

NOTE :Clean the wire terminals free of corrosion and keepthe terminals coated with petroleum jelly.

CAUTION :Connect the +ve and -ve cables to the respectivebattery terminals. Failure to do so may result indamage to the motorcycle electrical system.

WarningAlways disconnect the negative (-) battery cable firstand then the Red positive (+) cable while removingthe battery connections.

NOTE :For checking the battery voltage and electrolytespecific gravity, contact authorised Royal Enfieldservice or battery service centre.

CAUTION :Do not use battery with low electrolyte level asthe battery internals will get damaged.

Do not overfill the battery electrolyte level as itwill spill out through the overflow pipe and causecorrosion to vehicle parts.

Use only distilled water meant for use in batteriesto avoid damage to battery.

Electrolyte should be filled only between minimum& maximum levels indicated in battery as “MIN” &“MAX”.

60

CHANGING ELECTRICAL COMPONENTSHEADLAMP BULB REPLACEMENT


Loosen the head lampholding top screw. Thenpull out head lampassembly.

Detach bottom lug fromthe head lamp housingbody.

Disconnect head lampwire connectors Green,orange and blue colorterminals.

CCCCCAUTION :AUTION :AUTION :AUTION :AUTION :Never touch the bulb with your fingers, Finger printswith etch the glass and decrease bulb life. Always grabthe bulb with paper or clean dry cloth during handling.

Remove rubber grommetf r o m t h e r e f l e c t o rassembly

Gently press the bulbholding U clip from boththe sides downwardsand release i t f romreflector slot as shown.

Pull out head lamp bulband inspect its filamentfor fuse

61

REASSEMBLING THE HEADLAMP


Refix the new head lamphalogen bulb intoreflector unit by locatingthe wide protrude on topside mounting.

Fix bulb holding U clipinto ref lector bodyknotch,then press theboth ends of clip andlock in its slot.

Fit the rubber grommet.

Connect the wire couplersas mentioned below

TOP SIDE: GREEN COLOUR RIGHT SIDE: BLUE COLOUR

LEFT SIDE:ORANGE COLOUR

NONONONONOTE :TE :TE :TE :TE :

After connecting above said procedure,turn ignitionswitch to “ON” condition and then check,ensure thatflash light working in HIGH BEAM mode.

Position the reflector ringbottom lug into head lampcasing slot and slide it,then t idhten the topmounting screw.

62

TAIL LAMP BULB REPLACEMENT

Remove the two nuts holding the rear numberplate of RH & LH side.Remove the three screws holding the tail lampto the bracket.Twist the bulb holder anticlockwise and remove.Remove the old bulb and replace with a new bulb.Refit the bulb holder and turn clockwise to lockthe bulb holder.Refit the tail lamp on the bracket and rearnumber plate in the reverse order of removal.


TRAFFICATOR BULB REPLACEMENT

Remove the 2screws & takeout trafficatorglass cover.

Press bulb gently & Turn anticlockwise to takeout the bulb.

Position the new bulb inside the holder,ensuring that the pins in the bulb, match withthe slots in the holder.

Press the bulb and turn clockwise to lock thebulb in the holder.

Refit the trafficator cover cut slot mark facingdownwards and tighten the 2 screws.

63

1 Spare Fuse (20A)

2 Spare Fuse (20A)

3 Spare Fuse (20A)

4 Main Fuse (20A)

5 RR Unit Fuse (20A)

6 EFI Fuse (20A)


FUSE

Fuse No. Remarks

BLADE FUSE USAGE LIST

1 2 3 4 5 6

Open the LH tool boxThe fuse holder is located inside with 3 fusesof 20 Amps each - One for Charging circuit,One for Other electrical loads and one for theEFI System.Replace the required fuse with the spare fuseavailable in the fuse carrier.

Please ensure to replace a spare fuse in the holderat the earliest oppurtunity.

E C U

Warning

Electronic Control Unit (ECU) may get failure due to

a. In case of loose electrical / sensors wire connectors /couplers or Battery terminals.

b. While doing Arc welding on Motorcycle, its isrecommended to “SWITCH OFF” ignit ion,disconnect the Battery terminals & ECU from MainWiring Harness.

64

(E)

(D)(A) Loosen frontmounting nut of therear seat under therider seat with12mm tubularspanner.

(B) Loosen both LH andRH shock-absorbertop mounting nuts byholding the bolt with3/8” x 15/16” doubleend spanner andturning the doom nutwith 17mm eyeletspanner

(C) Pull out the frontmounting bolt ofthe rear seat fromthe bracket underthe rider’s seat.

(D) Pull the rear seatwith its sub frametowards back sothat it will becomefree from the shockabsorber mountingbolts.

(E) Take out the rearseat sub assembly

(F) Re-t ighten theshock absorbermounting bolts &nuts before usingthe vehicle.

PILLION (REAR) SEAT REMOVAL

Pillion Seat Removal & Refitting

(B)

(A)

(C)

65

(E)

Pillion Seat Removal & Refitting

PILLION (REAR) SEAT REFITTING

(A) Loosen shockabsorber uppermounting nuts andplace the pillion seatin the position overthe rear mudguard,inserting the front endof its sub frame goesto its mounting underthe rider’s seat.

(B) Ensure the slit ofrear mountingbrackets are seatedproperly in the LH &RH shock absorbermounting bolts.

(C) Insert the frontmounting boltthrough thebracket under therider seat.

(D) Tighten the frontmounting nut with12mm tubularspanner holdingthe bolt with 13mmdouble end spannerfrom other side.

(E) Tighten both LH &RH rear shockabsorber topmounting bolt andnuts.

(A)

(B)

(C)

(D)

66Washing Procedure

PRECAUTIONS

Wash vehicle when the engine is cold.Cover the silencer tail end and control switches withsuitable plastic bags and tie it firmly to prevent waterentry into them.Remove ignition key and seal key hole usingadhesive tape.Use a suitable engine degreaser, available with yourlocal parts store, to remove dirt or grease from theengine external parts if required. Follow thedirections in the label carefully before using thedegreaser.Use low pressure jet of water to clean the entire vehicle.Never spray water with great force on head lamp,speedometer, flasher lights, front and rear wheelhubs, electrical connections and wires, controlcables, EFI components, sparkplug, battery, etc.Use luke warm water and mild detergent on thepainted components to remove dirt, etc.Rinse vehicle thoroughly with plain water to removethe detergent and wipe vehicle dry.If possible, use compressed air and blow off waterparticles from the obscure areas of the vehicle,electrical connections, EFI components etc.

AFTER WASHING

Ensure, the vehicle is throughly dry by wiping witha clean soft absorbent cloth or chamois leather.Remove all plastic bags and adhesive tapes.Lubricate control cables, pivot and rear chain withlube oilPolish the painted and plated surfaces usingpolishing wax.Start engine and allow to run at idling speed for afew minutes to warm up engine.Drive the motorcycle slowly, applying both brakesintermittently to dry up the brake shoes.Test brakes for full efficiency.

WarningObserve warnings and cautions given on labels ofcleaning compounds.

When washing your motorcycle, be careful not to getthe brakes, engine, mufflers or air cleaner etc., too wet.Wet brake shoe and / or drum can affect braking. Enginecan be started after washing. Ensure brakes and engineare operating properly before riding in traffic.

67Storage Precautions

Incase your Motorcycle is not going to be used fora month or more, we advice the fol lowingprecautions to the taken.

Carryout required repair / adjustments on themotorcycle.

Wash the motorcycle thoroughly and lubricateas per the maintenance chart.

Start the engine, warm up for a few minutesand switch off.

Drain out the fuel completely from the fuel tankand fuel lines.

Remove spark plug. Pour in about 30ml ofclean engine oil through spark plug hole. Closethe hole and crank engine several times andrefit sparkplug.

Clean rear chain thoroughly and apply a thinfilm of lub oil.

Remove battery from the bike. Clean theterminals free of corrosion.

Maintain electrolyte level between max or minmark, by adding distilled water and wipe thebattery dry.

Store the battery in a cool, dry and wellventilated place.

Do not place the battery in direct sun light, nearopen flame or where temperature is above 40oCor below 0oC

Cover the silencer with plastic bags to preventmoisture entry. Set the motorcycle on its centerstand.

Apply anti rust solution on all chrome platedparts. Take care not to apply this solution onrubber or painted parts.

Store motorcycle in a clean covered area free- of moisture and keep it covered to preventdust settling on it.

68

PREPARING THE MOTORCYCLE FOR REUSE

Remove anti rust solution from all chromeplated parts and clean the motorcycle.

Inflate the tyres to the correct tyre pressure.

Ensure battery is fully charged and properelectrolyte 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 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. Crank engine afew times to lubricate cylinder walls and piston.Clean spark plug and refit.

Switch on ignition switch.

Start vehicle and warm up engine for a fewminutes before riding the vehicle.

NOTE :

Do not raise the engine rpm the moment it is started,but allow the engine to run at idling speed.

CAUTION :

Proper long-term storage is important for the safe,trouble-free operat ion of your Royal Enf ieldmotorcycle.

Storage Precautions

69

CHECKS PRIOR TO THE COMMENCEMENT OF LONGJOURNEY

Service the motorcycle throughly at RoyalEnfield Dealer / Authorised Service Centre asper periodical maintenance chart. (Ref. PageNo. 43, 44 & 45)

Sufficient quantity of petrol in the fuel tank forthe journey planned.

Check and correct tyre pressure if necessary.

CHECKS 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

Tools kit.

First aid kit.

Bulbs for Headlight, Trafficator light, Rear Tail

Lamp and Blade Fuse (20 Amps).

Accelerator, Choke, Clutch and Speedo Cable.

Rear chain master link lock assembly.

Spare tube, tyre, puncture repair kit - cold

vulcanising type.

Foot operated Air Pump.

Insulation tape.

Spark plugs (M14 & M10), Fuel hose.

Long Trip Precautions

70Complete Wiring Diagram

NOTE :

Complete Wiring Diagram is attached along with this page.

VEHICLE STARTING PROCEDURE

Basic Guidelines to be followed “FOR ALL ELECTRIC START VEHICLES”

1. When ignition key is switched “ON”, please wait until the malfunction indicator lamp(MIL) goesoff, (EFI models only) before attempting to start.

2. In cold condition of the engine or for initial start, it is advised to use electric start (ES) only.

3. Apply choke in cold start condition. (ambient temperature <25°C)

4. DO NOT ATTEMPT – “HALF START” BY CASUALLY PRESSING ELECTRIC START BUTTON.

5. PLEASE PRESS AND HOLD ELECTRIC START BUTTON FOR ATLEAST 3 SECONDSCONTINUOUSLY FOR THE CRANKING OR UNTIL THE ENGINE FIRES AND SUSTAINS,WHICHEVER IS EARLIER.

6. If engine doesn’t start in the first attempt, release the ES button and repeat the above procedure.

7. It is advised not to apply excessive throttle during starting.

71Trouble ShootingWarning

The trouble shooting section of this Owner’s Manual isintended solely as a guide to diagnosing problems.Carefully read the appropriate sections of this manualbefore performing any work. Repair and maintenanceoperations not listed in this Owner’s Manual should beperformed by your Royal Enfield Dealer only. Improperrepair and/or maintenance could result in the motorcyclenot functioning properly or serious injury.

I. ENGINE FAILS TO START

1) Stop switch in ‘OFF’ Position ........... Push stop switch to ‘ON’ position.

2) Vent hole clogged in fuel tank cap ... Clean vent hole.

3) Spark plug cap / lead not connected Fix cap / lead firmly

4) Spark plug electrode dirty / fouled ... Clean spark plug

5) Spark plug insulation cracked .......... Replace spark plug

6) Clutch slipping ................................... * Adjust clutch cable free play

CAUSES REMEDIES

* Contact Dealer / Authorised Service Point

Warning

Electronic Control Unit (ECU) may get failure due to

a. In case of loose electr ical / sensors wireconnectors / couplers or Battery terminals.

b. While doing Arc welding on Motorcycle, its isrecommended to “SWITCH OFF” ignit ion,disconnect the Battery terminals & ECU from MainWiring Harness.

72Trouble Shooting

II. ENGINE MISFIRING

1) Water in petrol tank ........................... * Clean petrol tank. Fill tank with fresh petrol.

2) Loose spark plug cap ........................ Fix cap / lead firmly

3) Spark plug fouled .............................. Clean spark plug or non specified heat range plug.

4) Any sensor loose connections .......... * Check MAP or TPS sensor wiring/coupler loose connections

III. POOR PICKUP

1) Accelerator cable free play excessive Adjust cable free play

2) Choked air filter ................................. Clean / Replace air filter

3) Brakes adjusted too tight .................. * Re-adjust properly

4) Rear chain adjusted too tight ........... * Re-adjust properly

5) Clutch Slipping .................................. * Adjust clutch cable free play

6) Under inflated tyres ........................... * Inflate to correct pressure

CAUSES REMEDIES


73Trouble Shooting

IV. WHITE/BLUE SMOKE

1) Oil level in sump above the Top line. * Check and drain excess oilin the oil level window ....................... * Worn out valve stem, oil seal

V. ENGINE OVERHEATING

1) Cylinder fins not clean ...................... Clean the cylinder fins at regular intervals

2) Clutch slipping ................................... * Check and correct

3) Low engine oil level ........................... Check and top-up if necessary

VI. EXCESSIVE FUEL CONSUMPTION

1) Fuel leakage ...................................... * Check and rectify

2) Choked air filter ................................. Clean / Replace

3) Under inflated tyres ........................... Inflate to correct pressure

CAUSES REMEDIES


74Trouble Shooting

VII. BRAKES POOR

1) Not adjusted properly ........................ * Adjust properly

2) Oil/grease on lining or drum or disc. * Clean and refit

3) Linings worn / Uneven wear ............. * Replace linings

4) Drums scored / Uneven wear ........... * Rectify or Replace drums

VIII. VEHICLE WOBBLES

1) Wheel rim runout ............................... * Rectify

2) Loose / Broken spokes ..................... * Tighten / Replace spokes

3) Tyres not fitted correctly ................... * Refit tyres correctly

4) Wheels misaligned ............................ * Ensure proper alignment

5) Under inflated tyres ........................... Inflate to correct pressure

CAUSES REMEDIES


75

IX. ELECTRICALSBulbs do not light1) Loose / improper connection ............ * Check and correct2) Bulb fused .......................................... * Replace bulb3) Fuse blown ......................................... * Check and Replace fuseHorn not working1) Loose connections ............................ * Check and correctTrafficators not working1) Loose / improper connections .......... Check and correct2) Bulb fused .......................................... ReplaceBrake light remains on(1) Switch link not adjusted properly ..... * Adjust connecting links properly(2) Switch sticky ...................................... * Replace switch

X. ELECTRONIC FUEL INJECTION (EFI)Malfunctioning Indicator Lamp (MIL) glowing continuously(1) Sensor Coupler Loose Connection .. * Check for any EFI sensor coupler loose connection and correct them(2) Any EFI Sensor Failure ....................... * Check & replace the same

Trouble Shooting

CAUSES REMEDIES


76Warranty

Royal Enfield Motor Cycles are manufactured by following best Quality practices in respect of the material andworkmanship.

Royal Enfield (RE) warrants Classic 500 EFI Motor Cycle to be free from manufacturing and material defectunder normal use subject to following conditions.

1. RE will replace or repair defective part / parts at their authorised Dealers, Service point, free of charge withina period of 12 months from the date of sale (date of Installation) or 10,000 kms whichever occurs earlier.

2. The warranty is applicable only to first registered owner.

3. The warranty shall be applicable only if all the free services are availed at the respective period / kilometerrange as per the schedule given in the owner’s manual from RE Dealers/ authorised service points.

4. During the warranty period, RE’s obligations shall be limited to repairing / replacing free of charge such partor parts of the vehicle, which on examination to have manufacturing defect. Such defective part / parts whichhave been replaced become property of RE.

5. Cost of oil, oil filter, fuel and other consumables are chargeable to the customer.

6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken up with respectivemanufacturer or their authorised agents in the area directly by customer. RE shall not be liable in any mannerto replace them though their Dealers will provide assistance in preferring such claims on their manufacturer.

7. Warranty shall not apply to:

(a) Normal ageing, detoriation or rusting of plated parts paints coat, rubber parts, soft items, glass items,plastic parts etc.

77Warranty

(b) Components like fuel filter, oil filter element, control cables, brake shoes, clutch plates, which are subjectedto 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.

(e) Damages due to lack of proper maintenance of the vehicle.

(f) Damages due to incorrect driving or riding habits.

(g) Parts damaged due to accidents, collision, abuse etc.

(h) Irregularities not recognized as affecting the quality or function of the vehicle such as slight vibration, oilleakage, blue discoloration of exhaust bent pipe / silencer / soft or 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 likes bulbs, fuses etc. & Electronic components failure due to repairs by arc welding.

(m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine tune up andother such adjustments

8. RE reserves the right to finally decide on all warranty claims

9. RE reserves the right to make changes in Design of the vehicle without any obligation to install thesechanges on previously supplied vehicles.

78Emission Warranty

In compliance with the provisions of Rule 115(2) of the Central Motor Vehicle Rules, 1989, Royal Enfield certifiesthat the following warranty is applicable to those components liable to affect the emission of the gaseous pollutantsin its range of motorcycles, in normal use to which it may be subjected to.

This emission warranty comes into force from 01st July 2001 and is valid for a period of 30,000 Kms. or 36months, whichever occurs earlier, from the date of sale to the first customer and is in addition to and parallel tothe warranty policy, conditions and obligations laid down in the Owner’s Manual.

Royal Enfield further warranty that if on examination by its authorised service center, the motorcycle fail to meetthe specified emission standards, then the authorised service center shall take necessary corrective measuresand shall at its sole discretion, repair or replace free of charge such components of the emission control systemto meet the required emission standards.

The method/s of examination to determine the warranty conditions of the emission warranty related componentswill be at the sole discretion of Royal Enfield and / or our authorised service centers and results of such examinationwill be final and binding. If on examination the warranty conditions of the part/s is/are not established, Royalenfield will have the right to charge all, or part of the cost of such examination to the customer in addition to thecost of the components.

In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge,the component/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeableto the customer as per actuals.

In case any of the components covered under emission warranty or the associated parts, are not independentlyreplaceable, Royal Enfield will have the sole discretion to replace either the entire assembly or parts of theassembly, through suitable repairs.

79Emission Warranty

Royal Enfield reserves the right to carry out necessary consequential repairs to the motorcycle or replace anypart, in addition to the repair or replacement of the components covered under emission warranty, to establishcompliance to in-use emission standards. Such repairs / replacements will be chargeable to the customer.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 authorisedservice center OR for any loss due to non availability of the motorcycle during the period of examination andrepairs by Royal Enfield and / or their Authorised Service centres.Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on accountof failure to comply with the in-use emission standards.That cost/s incurred to check emission of the motorcycle will have to be borne by the customer.Emission warranty will be applicable irrespective of the change of ownership of the vehicle provided all theconditions as laid down in this document are met from the date of original sale of the motorcycle.

THE WARRANTY SHALL APPLY IF THE CUSTOMERObserves 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 thedetails in the Log book.Immediately approaches the nearest authorised service centre upon discovery of failure to comply with theIN-USE emission standard inspite of having maintained and used the vehicle in accordance with theinstructions in the owner’s manual and having carried out such repairs and adjustments as may be requiredwith a view to establish such compliance.

80Emission Warranty

Produce the ‘Pollution Under Control’ certificate valid for the period immediately preceding the test duringwhich the failure is discovered, the test having been carried out either for obtaining a new certificate orpursuant upon being directed by an officer as referred to in sub rule (2) of rule 116 of the Central MotorVehicles Rules (CMVR).Produce the Owner’s Manual and Log book for verification details.Produce receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date oforiginal purchase of the vehicle.Produce valid certificate of Insurance and R T O registration certificate.

THE EMISSION WARRANTY SHALL NOT APPLY IF

A valid “Pollution under control” certificate is not produced.The motorcycle is not serviced by authorised service centers as per the service schedule described in themaintenance chart.The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has metwith 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 unauthorisedmanner.The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, sothat the actual distance covered cannot be readily determined.The motorcycle has been used for competitions, races, and rallies or for the purpose of establishing records.

81Emission Warranty

On examination by Royal Enfield or its authorised service centers, if the motorcycle shows that any of theconditions stipulated in the Owner’s manual with regard to use and maintenance have been violated.The motorcycle has been run on adulterated / leaded fuel or lubricant other than those specified by RoyalEnfield 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.All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced.All maintenance activities carried out on the vehicle during the tenure of the emission warranty is not enteredin the log book.

TIPS TO BE ON THE RIGHT SIDE OF LAWAlways 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 theemission warranty (30,000 Kms / 3 years from the date of first sale)

TIPS TO REDUCE POLLUTION1. Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal

Enfield authorised service center.2. Use only Unleaded petrol (> 91 octane) from reputed fuel pumps.3. Ensure the fuel used is not adulterated.4. Use correct spark plug as recommended in the owner’s manual.5. Use lubricants as per recommendations given on grade / brand in the owner’s manual.

100Regional & Area Offices

R1 : Chandigarh, H.P, J&K,Punjab

Royal EnfieldSC0-269, Second Floor, 16 Sector,PANCHKULA (Haryana)Pin Code - 134 113.Ph: 0172-5011255, 5011251

R2 : Delhi, Haryana, NCR &Rajasthan

Royal EnfieldC/o EICHER ENGG.COMPONENTSPlot No. 7, HSIDC Industrial Area,Sector 18, Palam Gurgaon Road,GURGAON (Haryana) – 122 015.Ph: 0124-4278138 / 4278139Fax: 4382148

Royal EnfieldG-5, 6, 7, Gitanjali Towers,Ajmer Road, JAIPUR – 302 006.Ph: 141-5143434 / 4034748Fax: 0141-5125657

R3 : Bihar, Uttaranchal &Uttar Pradesh

Royal Enfield

UGF-109, Cross Road Plaza,Badshaha Nagar Chauraha,Near Flyover, Faizabad Road,LUCKNOW – 226 006.Ph:0522-4004640 Fax: 4005973

R4 : Assam, N.E. & West Bengal

Royal EnfieldC/o V.E.Commercial Vehicle Ltd.1st Floor, P.S.Tower,No.13, Bondel Road,KOLKATA - 700 019.Tel: 03340060206 / 0209Mob: 09748664010 / 09830935285

R5 : Gujarat & M.P

Royal EnfieldB-306, Shapath-IV,Opp. Karnavati Club,S.G. Highway,AHMEDABAD - 380 015.Ph: 079-29086118Fax: 079-40024461

R6 : Goa & Maharastra

Royal EnfieldPlot No.16, Sector -1,

Sion Panvel Highway, Nerul,NAVI MUMBAI - 400 706.Ph: 022-27700395, 27700501

Royal Enfield203, 204 Sneh ganga,Near Vega Centre,Shankar Seth Road, Swargate,PUNE - 411 037.Ph: 020-40028090Fax: 24447174

R7 : A.P, Chattisgarh,Jharkhand & Orissa

Royal Enfield2-3-52/1 & 2-3-42/52,Unit No. 4, 2nd Floor,Maitri Arcade, M.G. Road,Ranigunj,Opp. To Hotel Plaza,SECUNDERABAD-500 003.Ph: 040-40201080, 42021080Fax: 40201090

Royal EnfieldA Unit of Eicher Motors Ltd.309, 3rd Floor, Nirmal Plaza,Forest Park,

BHUBANESWAR - 751 001.Ph: 0674 – 6540206

R8 : Karnataka, Kerala,Tamilnadu & Puducherry

Royal EnfieldDevikripa, No.9,Besant Avenue Road,Besant Nagar, Adyar,CHENNAI- 600 020.Ph:044-42607999 / 42607777Fax: 42607666

Royal EnfieldDoor no. 2067/1, 2068/2,East End “A” Main9th Block, Jayanagar,BANGALORE - 560 069.Ph: 22440588 / 41753277 /41536488

Royal Enfield25/85A, Opp. to IOC Pump,Koonamthai,Edappally Post,KOCHI - 682 024.Ph: 0484-6494990Fax: 2543616

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101All India Road Signs

MANDATORY SIGNS

INFORMATION SIGNS

CAUTIONARY SIGNS

83

Bullet Classic 500 Owners Manual

Documents

z right

z transmission

z electricals

z dimensions

z weights

z chassis number

z engine number

z ignition system